Workshop and Spare Parts Manual

IQ, IQM and IQML Mk 2 Range Actuators

Module 1G Hand/Auto Lever
All mechanical sizes

Module 1G consists of the following

components:-

Hand/Auto Lever.
Cam.
Spring.
‘O’ Ring Seals (2).
Stop Bolt Screw.
Driver Tool for Stop Bolt Screw.
Loctite for Stop Bolt.
Pic 60

Module 1G Components
Sizes 10, 12, 18, 20, 25, 35

Pic 193

Module 1G Components
Sizes 40, 70, 90, 91, 95

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
Module 1G Hand/Auto Lever
IQ, IQM, IQML 10,12,18,20,25,35

Removing Actuator Removal of Actuator

from Valve from Valve Gearbox

Before dismantling the Take the weightof the actuator

actuator, isolate and on the sling before removing the
disconnect incoming electrical Pic 26 actuator to gearbox fixings,
Pic 74
supply to actuator. Remove actuator should slide off
and retain any adaptors or gearbox input shaft, ensure
reducers from the threaded sling is holding weight of
cable entries. Actuator can be actuator at all times.
removed from its base leaving
this to maintain the valve
position. In this case the base
must be protected from the
environment by placing a
plastic bag over it. 1 4
Oil Plugs
Alternatively, the actuator and
base can be removed as one
piece. To drain the oil, remove one of
the two plugs situated in the
Pic 27 gearcase. Pic 13

Removing Actuator
from Valve or Gearbox
2 5
Only persons competent by Remove Top Handwheel
virtue of their training and
experience should be allowed To remove top handwheel,
to remove the actuator from the locate and remove the large cap
valve or gearbox. As the head screw located in gearcase
actuator may be installed at Pic 75
below handwheel. Pic 14
any angle, correct slinging of
this unit must be judged in each
individual case.

Actuator Weights
10,12,18= 32kgs 72lbs
20,25 = 52kgs 115lbs
35 = 75kgs 165lbs
3 6
Actuator Direct
The nylon retainer can be pulled
Mounted onto Rising out using tapered pliers and
Stem Valves rotating the handwheel
clockwise. The handwheel can
Ensure pressure is removed now be lifted off
Pic 15
from pipeline, move valve
‘open’ a short distance to Keep handwheel and nylon
eliminate any locked in retainer in a safe place for
pressure, close the valve fully. refitting to new gearcase.
Take the weight of the actuator
on the sling before removing
the actuator to valve fixings,
wind the handwheel in the close
direction when actuator will
move up the valve stem, ensure
sling is holding the weight at all 7
times.

2
Module 1G Hand/Auto Lever
IQ, IQM, IQML 10,12,18,20,25,35

Side Handwheel Remove Clutch Yoke

(Size 20, 25,& 35 only)
To remove side handwheel and Pic 42
its associated worm gearbox, Simply lift out the yoke from its
locate and remove the four cap pivot pin. Retain this item for Pic 46
head screws, gearbox must be reassembly.
lifted off straight. Retain this
module in a safe place for
refitting to new gearcase.

8 12
To Remove the Clutch Motor Stator
Spring
Before removing motor stator
Locate the ‘O’ ring on top of the cover mark its position relative
centre column, press down on to the top of the gearcase. Pic 16
the steel washer beneath the
Pic 43 Remove and retain the four cap
‘O’ ring and roll the ‘O’ ring up head screws, slide the stator off
off the centre column. the gearcase.
TAKE GREAT CARE WHEN
RELEASING THE SPRING

9 13
To make the job safer the Motor Rotor
appropriate clutch spring
compression tool can be
purchased direct from Rotork Using an allen key (hex wrench)
or via your local agent. and a spanner remove and
Pic 44 retain the bolt and nut securing
the rotor shaft to the worm shaft,
slide the rotor shaft off and
Pic 49
retain in a safe place for
refitting.

10 14
Remove Clutch Ring DO NOT MISLAY THE COIL
SPRING AT THE OUTBOARD
Using a pair of pliers pull the END OF THE ROTOR SHAFT.
clutch ring up and off the RETAIN FOR REFITTING.
centre column. Depression of Pic 45
the hand/auto lever will raise Pic 109
the clutch ring and assist in its
removal.

11 15

3
Module 1G Hand/Auto Lever
IQ, IQM, IQML 10,12,18,20,25,35

Disconnect Torque The centre column, wormwheel

and bevel gear can now be
Transducer P.C.B pulled from the top of the
gearcase, rotate actuator back
This P.C.B is situated in the onto its base.
motor compartment and fitted Pic 50 Pic 53
to the wormshaft thrust plate, it
must be disconnected before
the wormshaft is removed.

Remove and retain the ‘horse

shoe’ shaped flange. Turn the
drive end of the wormshaft anti
clockwise as it is pulled out,
this will also force out the
wormshaft thrust plate.
16
16 20
Remove Worm Shaft Remove Hand/Auto (H/
A) Lever
Retain the wormshaft and
bronze bushing, also the thrust The adjoining sketch shows the
plates, do not separate the two H/A components when fitted
thrust plates. Pic 52 into gearcase.

Refit the motor stator back in

position temporarily to avoid
damaging the cables when the
actuator is turned over.

17 21
Remove Lower Centre Using the special tool provided
in the module remove the lever
Column Circlip
stop bolt.

Turn actuator onto its terminal

compartment. Using the
Pic 48 Pic 61
correct size circlip pliers
remove the smaller circlip
securing the shaft to the
bearing.

18 22
Remove Centre Column Rotate the hand/auto lever to
the vertical (12oclock) position.
Looking into the top of the
gearcase, ensure that the hand/
auto cam is not resting on the Pic 127
Pic 116
top face of the wormwheel, if it
is then push it into the position
shown.

19 23

4
Module 1G Hand/Auto Lever
IQ, IQM, IQML 10,12,18,20,25,35

Holding the hand/auto cam in Place cam on the end of shaft

the vertical position the lever with spring loaded finger in the
can now be pulled out of the vertical position. With the spring
gearcase. held hook uppermost insert
lever fully through spring.
Pic 62 Rotate shaft anti clockwise to Pic 64
the 9 o clock position. Fit new
stop bolt after applying a small
quantity of Loctite 242
(supplied) onto its thread.
Tighten down to 6.8Nm (5lb/ft).

24 28
Remove the hand/auto cam Sizes 20,25,35 only
and spring from the gearcase.
Refit Wormwheel to
Centre Column
Pic 128 With its four drive pins facing up Pic 124
slide the wormwheel onto the
drive (lower) end of the centre
column.

25 29
Reassemble Hand/Auto Sizes 20,25,35 only
Assembly Using New Refit Original Resolver
Components Bevel Gear

Before fitting lever ensure that Pic 126 Pic 120

Slide original bevel gear onto the
two ‘O’ ring seals are in centre column beneath the
position on its shaft and that wormwheel with its teeth facing
they are lightly greased. towards the base.

26 30
With the lever in the 12 o clock
position insert partially into the
Refit Centre Column
gearcase. into Gearcase

Turn the actuator onto its

Pic 63 terminal compartment. Lightly
grease the lower end of the pic 53
centre column before fitting it
into the gearcase. Locate it
through the base seal and
bearing and push onto the
mechanical stop, only hand
force should be necessary.

27 31

5
Module 1G Hand/Auto Lever
IQ, IQM, IQML 10,12,18,20,25,35

Using the correct size of circlip Press down on the steel spacer
pliers fit the circlip onto the to compress the spring. Slide
lower end of the centre column. the ‘O’ ring over the centre
column and down into its
Turn the actuator back onto its groove.
base. Pic 48 TAKE GREAT CARE WHEN Pic 44
FITTING THIS SPRING.
To make this job safer the
appropriate clutch spring
compression tool can be
purchased direct from Rotork or
via your local agent.

Remove motor cover (stator)

that was temporarily refitted to
gearcase.
32 36
Fit Clutch Ring and Fit Worm Shaft and
Spring Bronze Bush

First refit the original yoke ring Before fitting check that the ‘O’
by placing it on its pivot pin Pic 47 ring seal and lip seal on the Pic 52
(not applicable to sizes 10,12 bronze bush are serviceable
and 18). and lightly greased. Slide
wormshaft into the gearcase
and rotate it clockwise so as to
engage into the wormwheel.

33 37
Slide clutch ring down the Reconnect the Torque
centre column with drive pins
down towards the wormwheel. Transducer

Reconnect the grey colour multi

core cable onto the P.C.B.
Pic 45 Pic 51

34 38
Place the coil spring, steel
spacer with its chamfer
Refit Torque
uppermost onto the centre Transducer
column in that order.
Locate the torque transducer
Pic 43 assembly over the drive end of
the wormshaft, position the
Pic 107
locating hole in the flange over
the dowel pin in the gearcase.

35 39

6
Module 1G Hand/Auto Lever
IQ, IQM, IQML 10,12,18,20,25,35

Locate the ‘horseshoe’ shaped Fit Motor Stator to

flange over the torque Gearcase (WT Only)
transducer with its open ends
around the P.C.B. This will also
Slide stator over rotor shaft, do
align a ‘cut out’ around the
motor cables. Fit the three Pic 50 not damage the windings, feed
countersunk screws and
the motor cables through into Pic 111
the electrical compartment.
tighten down to 6.8nm.
ENSURE THAT NO CABLES
ARE TRAPPED BETWEEN
FLANGE AND GEARCASE.

Fit Motor Stator to

40 Gearcase (Explosion 44
Explosion Proof Units Proof Only)
Only
On these units the motor loom
remainsin the motor
The black plastic cable retainer
compartment. To prevent it
can now be clicked into Pic 110
being damaged it must be
position on the flange, ensure Pic 108 positioned correctly in its plastic
that the ‘cut out’ aligns with the
retainer as follows:-
motor cables.
Position the stator onto the rotor
shaft, do not damage the
windings, whilst rotating the
stator anti clockwise feed the
cables into the plastic retainer.
Ensure that the cables are
correctly positioned before
finally bolting stator casting onto
41 the gearcase.Tighten screws to 45
Fit Rotor to Wormshaft 16.5Nm (12lb/ft).

Slide the rotor shaft onto the Fill Gearcase with Oil
end of the wormshaft, align the
bolt hole and fit shouldered Use gear oil type SAE 80/90 EP,
bolt and Nyloc nut. Tighten to Pic 49 alternatively a food grade Pic 102
6.8nm. lubricant can be used namely
Hydra Lube GB Heavy.

Oil Capacities
Sizes IQ
10,12,18 = 0.3 litre
20,25 = 0.8 litre
35 = 1.1 litres
If the gearcase is filled via the
42 handwheel aperture first ensure 46
Fit coil spring onto outboard
that the clutch is down in ‘motor
end of rotor shaft.
drive’ position and bring oil level
up to the top face of clutch ring
and no higher.

Pic 109 Pic 41

Fit Handwheel

Before fitting the handwheel

ensure that the top of gearcase
and handwheel hub are clean
and lightly greased and that the
seals and ‘O’ ring are
serviceable.

43 47

7
Module 1G Hand/Auto Lever
IQ, IQM, IQML 10,12,18,20,25,35

Insert the handwheel nylon Disconnect the existing battery

retaining rod into its position in and using the strap provided
the gearcase. pull out of its plastic holder. Fit
new battery into strap and push
into its holder. Reconnect.
Refit and tighten threaded plug
Pic 15 after lightly greasing thread and
Pic 76
checking sealing ‘O’ ring is
serviceable.

Light Run

Before returning the actuator to

the valve connect it to an
electricity supply of the correct
voltage and check that it is both
48 electrically and mechanically 52
Refit sealing plug. serviceable.

Refit actuator to valve or

gearbox and fully bolt down.
Pic 14 Pic 27

49 53
Replace Battery
Tighten down torque for Mounting Studs/Bolts
Whilst the actuator is down for using ISO Class 8.8
maintenance it is
recommended that its battery IQ Flange Bolt Dia: Torque
be changed. The battery as Pic 115 Act. Size ISO/USA Metric/Inches
fitted by Rotork is Pp3 9volt Nm/Lb/ft
Ultralife Lithium Cell, this exact
type of battery MUST be fitted 10,12,18 F10/FA10 M10 - 3/8 47/35
to all explosion proof units 20,25 F14/FA14 M16 - 5/8
CENELEC/FM/CSA.
230/170
35 F16/FA16 M20 - 3/4 230/170
40 F25/FA25 M16 - 5/8 230/170
70,91 F25/FA25 M16 - 5/8 230/170
90 ‘A’
50 Coupling F30/FA30 M20 - 3/4 407/300
The battery is situated in its
own compartment located in the 90 ‘B’
gearcase. Using an 8mm allen Coupling F25/FA25 M16 - 5/8 230/170
key (hex wrench) remove the 95 F30/FA30 M20 - 3/4 407/300
access plug.
Pic 25

51

8
Module 1G Hand/Auto Lever
IQ, IQM, IQML 10,12,18,20,25,35

Electrically Reconnect
Actuator
Recommission the actuator
using Publication E170E2 and Pic 28
Rotork Infra Red Setting Tool.

54

9
Module 1G Hand/Auto Lever
IQ, IQM, IQML 40, 70, 90, 91, 95

The actuator may remain in - Remove Side Geared

situ on the valve if required Handwheel
when changing out this
module. To remove side handwheel and
its associated worm gearbox Pic 171
Pic 193 remove the securing bolts and
FIRST ISOLATE THE retain. Gearbox must now be
ACTUATOR FROM ALL lifted off straight. Retain this
ELECTRICAL SUPPLIES. module for refitting to new
gearcase.

55 59
Drain Oil Remove the Clutch
To drain oil remove the two
Spring
plugs situated in the gearcase,
retain these plugs. Pic 13 Locate the ‘O’ ring on top of the
centre column, press down on Pic 43
the steel washer beneath the
‘O’ ring and roll the ‘O’ ring up
off the centre column.
TAKE GREAT CARE WHEN
RELEASING THE SPRING.

56 60
Remove Top To make the job safer the
Handwheel appropriate clutch spring
compression tool can be
To remove top handwheel, purchased direct from Rotork or
locate and remove the large via your local agent.
cap head screw located in Pic 14 Pic 44
gearcase below handwheel.

57 61
The nylon retainer can be
Remove Clutch Ring
pulled out using tapered pliers
and rotating the handwheel
Using a pair of pliers pull the
clockwise. The handwheel can
clutch ring up and off the centre
now be lifted off.
column. Depression of the
Pic 170 hand/auto lever will raise the Pic 45
clutch ring and assist in its
removal.
Keep handwheel and nylon
retainer in a safe place for
refitting to new gearcase.

58 62

10
Module 1G Hand/Auto Lever
IQ, IQM, IQML 40, 70, 90, 91, 95

Slide the jack assembly along

Remove Clutch Yoke the shaft to the right, remove
the key from the shaft. Pull the
Noting its position, lift yoke out
lever from the gearcase
from its pivot point, retain this
retrieiving the following
item for reassembly. Pic 46 components from it as you do Pic 192
so:-
Spring, Circlip, Jack and
Spacer.

63 67
Using the special tool bit
provided in the module remove Fit New Items
the lever stop bolt.
Replace the hand/auto lever
seal in the gearcase with the
Pic 61 new item supplied. Pic 244

64 68
Rotate the hand/auto (H/A) Lightly grease the hand/auto
lever to the 11 o’clock position. lever shaft before fitting it into
the gearcase, slide the spacer
onto the shaft.

Pic 249 Pic 245

65 69
Using a pair of 90o circlip pliers Fit the hand/auto jack assembly
open up the circlip on the shaft onto the shaft behind the
and slide it along the shaft to spacer, finger towards the
the right. actuator centre column.
Pic 246
Pic 191

66 70

11
Module 1G Hand/Auto Lever
IQ, IQM, IQML 40, 70, 90, 91, 95

Position circlip on the shaft at Slide the jack to the left so that
approximately 12mm (1/2”) it is positioned over the key and
from the end, allowing enough retain in position by sliding the
space for the spring to fit onto circlip along the shaft into its
the end of the shaft. groove.
Pic 247
Pic 191

71 75
Rotate the hand/auto lever to Rotate the hand/auto lever anti-
the clockwise and fit special stop
11 o’clock position. bolt into gearcase using tool bit
provided.
Pic 249 Pic 61

72 76
Slide return spring onto shaft Refit original yoke by placing it
locating the finger at its inside into its pivot pin.
diameter onto the slot on the
shaft and finally the hook end
onto the shaft in the gearcase.
Pic 248 Pic 173

73 77
Push H/A lever in fully so that
keyway is fully visible and fit
Refit Clutch Ring
key.
Slide the clutch ring down the
centre column with its smallest
diameter towards the
Pic 192 wormwheel, the yoke may have Pic 45
to be moved slightly so that
clutch ring engages onto the
wormwheel drive pins.

74 78

12
Module 1G Hand/Auto Lever
IQ, IQM, IQML 40, 70, 90, 91, 95

Insert the handwheel nylon

Refit Clutch Spring retaining rod into its position in
the gearcase. Refit the retaining
Place the coil spring, steel
plug.
spacer with its chamfer
uppermost onto the centre Pic 43
column in that order. Pic 15

79 82
Press down on the steel
spacer to compress the spring,
Refit Geared Side
slide the ‘O’ ring over the Handwheel
centre column and down into All sizes
its groove.
Pic 44 Lower the hand gearbox onto Pic 171
TAKE GREAT CARE WHEN the actuator output shaft taking
FITTING THIS SPRING. care not to damage the oil seal.
Secure with cap head screws or
To make this job safer the hex heads as supplied.
appropriate clutch spring
compression tool can be
purchased direct from Rotork
or via your local agent.

Check for correct operation of

the hand/auto mechanism by 80 83
pressing down on the H/A Fill Gearcase with Oil
lever, clutch should be seen to
rise up the centre column into First ensure that drain plug is in
the hand drive position and position, sealed and tight. Fill
remain there. The mechanism gearcase through top plug.
will only return to motor drive
position by starting the motor.
Pic 102
Use gear oil SAE 80/90 EP,
alternatively a food grade
lubricant can be used namely
HydraLube GB Heavy.

Oil capacities
Size Litres US Pints
40 = 7.5 15.8
70,90,91,95= 7.0 14.7 84
Refit Top Handwheel
Size 40 only Replace Battery
Before fitting the handwheel Whilst the actuator is down for
ensure that top of gearcase and maintenance it is recommended
handwheel hub are clean and Pic 115
Pic 41 that its battery be changed. The
lightly greased and that the seal battery as fitted by Rotork is
and ‘O’ ring are serviceable. Pp3 9volt Ultralife Lithium Cell,
this exact type of battery MUST
be fitted to all explosion proof
units CENELEC/FM/CSA.

81 85

13
Module 1G Hand/Auto Lever
IQ, IQM, IQML 40, 70, 90, 91, 95

The battery is situated in its

own compartment located in
the gearcase. Using an 8mm
allen key (hex wrench) remove
the access plug.
Pic 25

86
Disconnect the existing battery
and using the strap provided
pull out of its plastic holder. Fit
new battery into strap and push
into its holder. Reconnect.
Refit and tighten threaded plug Pic 76
after lightly greasing thread
and checking sealing ‘O’ ring is
serviceable.

87
Recommission the actuator
using Publication E170E2 and
Rotork Infra Red Setting Tool.
Pic 28

88

14