The 4th Generation

Maintenance Manual

CONTENENTS
1) GENERAL
2) SAFETY NOTICE
3) WORKING CONDITIONS AND TECHNICAL DATA
4) OPERATING FUNCTION AND DIRECTION OF ROTATION
5) ACTUATOR INSTALLATION INSTRUCTON
6) MAINTENANCE INSTRUCTION
7) STORAGE INSTRUCTION

1) GENERAL
This instruction manual contains important information regarding the installation, operation, main-
tenance and storage for AIR TORQUE rack and pinion pneumatic actuators. Please read these
instructions carefully and save them for future reference. It is important that only properly trained
personnel disassemble/assemble the actuator.

2) SAFETY NOTICE
• It is important that the actuator should only be used within pressure limits indicated in our techni-
cal specifications.
• Operating the actuator over pressure limits will damage internal parts as well as cause damage
to the housing.
• Operating the actuator over temperature limits will damage internal and external components
(disassembly of spring return actuator may become dangerous).
• Operating the actuator in corrosive environments with incorrect protection may damage the
internal and external parts.
• Do not disassemble individual spring cartridges. Disassembly may result in personal injury. For fur-
ther information contact Air Torque.
• Isolate all air lines and make sure that actuator air connection is vented before installation or ser-
vicing of the actuator.
• Do not remove end caps or disassemble the actuator while the actuator is pressurised.
• Before installing onto a valve make sure that the rotation of the valve and the actuator are the
same and that the position indicator orientation is also correct.
• If the actuator is incorporated in a system or used within safety devices or circuits, the customer
shall ensure that the national and local safety laws and regulations are observed.

3) WORKING CONDITIONS AND TECHNICAL DATA

• Operating media:
Dry or lubricated air or inert/non-corrosive gases provided they are compatible with internal actu-
ator parts and lubricant. The operating media must have a dew point equal to –20°C (-4°F) or at
least 10°C below the ambient temperature. The maximum particle size must not exceed 30 µm.
• Supply pressure:
The maximum supply pressure is 8 Bar (116 PSI).
Generally for Double Acting and Spring Return actuator the supply pressure is: from 2.5 Bar (36 PSI)
minimum to 8 Bar (116 PSI) maximum.
• Operating Temperature:
Standard product from –20oC (-4oF) to +80oC (+176oF).
Low temperature LT actuator with silicon "O'' rings from -40oC (-40oF) to +80oC (+176o F).
High temperature HT actuator with FPM "O” rings from –15oC (+5oF) to +150oC (+300oF)
Caution: For low and high temperature service, special grease is required. Please contact
AIR TORQUE for each application. High and low temperature will vary the output torque of the
actuator.

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Maintenance Manual

• Operating Time:
See Technical Data Sheet.
Caution: The operating speeds depend on several factors such as: supply pressure/supply capac-
ity (i.e. pipe diameter/flow capacity or pneumatic accessory), valve type, valve torque and char-
acteristics, what safety factor is to be applied, frequency of operation and temperature.

• Stroke:
The stroke for AIR TORQUE actuators are as follows (See technical data):
Standard construction: 90° rotation with stroke adjustment at 0° and 90° + or – 4°
Type Y 120o stroke: 120° rotation with stroke adjustment at 0° and 120° + or – 4°
Type X 180o stroke: 180° rotation with stroke adjustment at 0° and 180° + or – 4°

• Lubrication:
The actuators are factory lubricated for the life of the actuator in normal working conditions.
The standard lubricant is suitable for use from -20oC (-4oF) to +80oC (+176o F). For low (LT) and high
(HT) temperature service, where special grease is required please contact AIR TORQUE.
Recommended Air Torque actuator lubricants for standard working conditions:
- Kluber Unigear LA02
- Esso (Exxon) Beacon EP2
- Fina Marson EP L2
- Shell Alvania EP2
- Mobilux EP2

• Construction:
Rack and pinion actuator design suitable for both indoor or outdoor installations.

• Protection and Corrosion resistance:

Ensure actuators are supplied with corrosion protections for normal environments. For severe duties
select the protection required for corrosion protection. See technical data sheet before installing
actuators.

• Actuator designation and Marking:

The actuator type, size, operating pressure, output torque, direction of rotation, orientation of fail-
ure mode, operating temperature and drive type are determined by actuator designation.
AIR TORQUE actuators are supplied with a label showing all of this information: type, model (includ-
ing protection and if applicable the LT or HT for operating temperature), stroke, maximum permis-
sible supply pressure, direction of rotation, output torque, ancillary attachment, pressure connec-
tion, valve actuator attachment and serial number.

4) OPERATING FUNCTION AND DIRECTION OF ROTATION

The actuator is a pneumatic operator for remote actuation of valves. The operation (90° – 120° or
180° rotation) may be connected by different methods:
- Direct mounting of solenoid valves (5/2 for double acting, 3/2 for spring return) to pressure
connections 2 and 4.
- Screwed connection (to pressure connections 2 and 4) with air lines from separate control cabi-
net.

The standard rotation is clockwise to close, counter-clockwise rotation is obtained when port 2 is
pressurised. For actuator marked LF the rotation is counter-clockwise to close, clockwise rotation
is obtained when port 2 is pressurised.

Modifications reserved. Date 02.2000. 09e Maintence 02

No guarantee for accuracy.
Older data sheets are invalid.
 The 4th Generation

Maintenance Manual

• Double Acting operation function (standard rotation) Top View

Air supplied to Port 2 forces the pistons apart and Air supplied to Port 4 forces the pistons together
toward end positions, with exhaust air exiting at Port with exhaust air exiting at port 2, a clockwise rota-
4, a counter-clockwise is obtained. tion is obtained.

• Single Acting operation function (standard rotation)Top View

Air supplied to Port 2 forces the pistons apart and On loss of air pressure (air or electric failure) at
toward end positions, compressing the springs with Port 2 allow the springs to force the pistons to the
exhaust air existing at Port 4, a counter clockwise centre position with exhaust air exiting at Port 2, a
rotation is obtained. clockwise rotation is obtained.

5) ACTUATOR INSTALLATION INSTRUCTIONS

The AT actuator is a pneumatic device for the remote operation of industrial valves. The AT actu-
ator will operate through 90°, the option is available for 120° or 180° of rotation permitting the
opening and closing of many types of 1/4 turn valves.
All the necessary technical information to install the actuator correctly and safely onto a valve
i.e. Dimensions, Output torque, Air volume, Stroke Adjustment, Operating time, Operating temper-
ature, Direction of rotation and Weight is stated clearly on the Actuator label, in the catalogue
and technical data sheets. Please read this technical information carefully before proceeding
with the actuator installation.

5.1) Important Safety Notice :

• The actuator must not be pressurized at any time during installation as injury may result.
• The utmost cleanliness is required during air supply connection to the actuator i.e. the connect-
ing pipe thread, fittings and seals must be clean and dirt-free.
• When fitting accessories onto the actuator assemble them in such a way that the top of the drive
shaft is easily accessible should manual operation of the actuator be required.
• Before fitting onto the valve make sure that the actuator / valve are correctly orientated,
depending upon which direction of rotation is required.

Modifications reserved. Date 02.2000. 09e Maintenance 03

No guarantee for accuracy.
Older data sheets are invalid.
 The 4th Generation

Maintenance Manual

5.2) Controls and connections, Figure A :

5.3) Assembly of accessories : Solenoid valves and Switchboxes Figure B :

• Solenoid valve mounting:
Before mounting a Solenoid valve ensure that the actuator is in its normal position (closed posi-
tion) pistons together :
- For Standard assembly and rotation (Clockwise to close): the groove on the indicator 2 must be
diagonal to the longitudinal axis of the actuator in the closed position.
Fit the solenoid valve 4 onto the actuator 3 using the screws provided (max. tightening torque
see the table below).

• Switchbox mounting:
Fit the switchbox and bracket 1 onto the actuator 3, using four screws provided (max. tightening
torque see the table below).

Tightening torque table:

M.. Nm
M5 5 -> 6
M6 10 -> 11
M8 23 -> 25
M10 48 -> 52
M12 82 -> 86
M14 132 -> 138
M16 200 -> 210
M20 390 -> 410
M24 675 -> 705

Modifications reserved. Date 02.2000. 09e Maintenance 04

No guarantee for accuracy.
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Maintenance Manual

5.4) Assembly of Valve Figure C:

Before proceeding with the assembly of a valve onto an actuator be sure that the actuator
operates in the desired direction of rotation and both actuator / valve are correctly orientated.
Important : When using a spring return actuator for a fail safe operation, ensure that when air or
electricity failure occurs the direction of rotation is correct for your application.
Fit the valve 5 onto the actuator 3. Ensure that the actuator is in normal position (closed posi-
tion). There are two types of valve assembly onto the actuator :
- Direct-mount : Fit the square of the valve 5 directly into the square of the actuator 3 and bolt
together through the valve ISO pad (max. tightening torque see table above).
- Bracket-mount : Mounting with a bracket 6 and coupling 7, the bracket is bolted to the actua-
tor / valve to join them together and the coupling is used to connect the actuator output drive
to the valve stem (max. tightening torque see table).

5.4.1) Mounting alternatives :

5.4.2) Valve mounting with Actuator Type STANDARD (Clockwise to close) Figure D :
5.4.3) Valve mounting with Actuator Type LF (Clockwise to open) Figure E :

Modifications reserved. Date 02.2000. 09e Maintenance 05

No guarantee for accuracy.
Older data sheets are invalid.
 the 4th Generation

Maintenance Manual

6) MAINTENANCE INSTRUCTION
With the information given below, AIR TORQUE provides the end user with all the required infor-
mation necessary for maintenance. Under normal operating conditions the actuator requires only
periodic observation to ensure proper adjustment.
Rebuilding of the AIR TORQUE actuators is allowed only to the personnel of AIR TORQUE or to
personnel which are properly instructed. By contravention the guarantees expires!
Spare kits for maintenance are available to replace all seals and bearings (Soft components list-
ed in table) that may be necessary between 500,000 and 1,000,000 cycles depending on operat-
ing and/or environmental conditions.

6.1) Drawing with itemised component and recommended spare parts

Pos. Pcs Part Description Material Specification Protection

(1) (1)
01 1 Octi-Cam (Stop Arrangement)
1.4021/GS400-15 EN 10088-3/ISO 1083
02 2 Stop Cap Screw B8 CI.2 ASTM A193 EX1 EX2 ød
03 2 Washer (Stop Cap Screw) A2 ISO 3506
04 2 Nut (Stop Cap Screw) A2-70 ISO 3506
mm mm mm
05* 2 Bearing (Piston Back) PPA Amodel ET1001HS
06* 1 Bearing (Pinion Top) PA46 Stanyl TW300
07* 1 Bearing (Pinion Bottom) PA46 Stanyl TW300 AT 050 10 8 14
08* 2 Thrust Bearing( P i n i o n ) PPA Amodel ET1001HS
09* 2 Plug (Transfer Port) NBR NBR 70Shore
AT 100 10 10 16
10 1 Thrust Washer( P i n i o n ) 1.4301 EN 10088-3 AT 200 13 10 22
11* 2 O' Ring (Stop Cap Screw Seal)
NBR NBR 70Shore
12 2 Piston Guide PPA+45%GF Amodel AS1145 AT 250 13 10 25
13 8 / 1 2 / 1(2)
6 Cap Screw (End Cap) A"-70 ISO 3506
14* 2 O' Ring (End Cap) NBR NBR 70Shore
AT 300 17 13 26
15* 2 Bearing (Piston Head) PPA Amodel ET1001HS AT 350 19 13 36
16* 2 O' Ring ( P i s t o n ) NBR NBR 70Shore
17 min.4/max.12 Spring (Cartridge) SiCr Spring Alloy Steel
DIN 17223 Part 2 Epoxy coated AT 400 19 17 38
18 1 Spring Clip ( P i n i o n ) C75 DIN 17223 ENP
19 1 Position Indicator PP+30%GF Hostalen PPN VP7790 GV 2/30
AT 450 22 17 45
20* 1 O' Ring (Pinion Bottom) NBR NBR 70Shore AT 500 22 19 48
21* 1 O' Ring (Pinion Top) NBR NBR 70Shore
30 1(3) Right End Cap GD-AlSi8.5Cu3.5Fe UNI 5075 A, B, C, D, E, P AT 550 24 19 52
31 1(3) Left End Cap GD-AlSi8.5Cu3.5Fe UNI 5075 A, B, C, D, E, P
39 1 Cap Screw (Indicator) A2-70 ISO 3506
AT 600 30 22 58
40 2 Pistons GD-AlSi8.5Cu3.5Fe UNI 5075 anodized AT 650 30 24 68
41 1 Identification Label Polyester Aluminium
42 2 Label (End Cap) Polyester Aluminium AT 700 36 22 80
43 1 Spigot Alloy 6082 ASTM B221 Alodur
50 1 Body Alloy 6083 ASTM B221 A, B, C, D, E, P
AT 800
60 1 Drive Shaft A105 ASTM A105 ENP
(1)
*Spare Part AlSi420 Type DR/DL, SC/SO 15-150; GS400-15 Type DR/DL, SC/SO 220-4000
(2)
8 pcs. Type DR/DL, SC/SO 15-1200; 12 pcs. Typ DR/DL, SC/SO 3000
(3)
Type DR/DL, SC/SO 600-3000 End Caps are symmetric

Modifications reserved. Date 02.2000. 09e Maintenance 06

No guarantee for accuracy.
Older data sheets are invalid.
 The 4th Generation

Maintenance Manual

6.2) Disassembly
When disassembly of actuator is required for maintenance, firstly remove
the actuator from the valve. Before performing any disassembly operations
it is important to verify that the actuator is not pressurised. Always use cau-
tion and double check that the ports 2 and 4 are vented and are free
from any accessory and/or device. When the actuator is a spring return
unit, make sure that the actuator is in the failed
position before disassembling.

A) Removal of position indicator (Part No. 19), figure 01:

• Remove cap screw (39) if fitted
• Lift position indicator (19) off shaft, it may be necessary to pry gently with
a screwdriver.

B) Removal of stop cap screws (Part No. 02), figure 02:

• Remove both stop cap screws together with nut (04) and washer (03)
• Remove stop screw O-rings (11) and discard if replacing all soft parts.

C) End Caps disassembly (Part No 30 right and 31 left) For model DR/SR900
to DR/SC3000 the 2 end caps
(30) are symmetric, figure 03:
• Remove cap screw (End cap 13) in the sequence shown in the fig-
ure 03. Caution: when disassembling a spring return actuator, the end cap
(30 and 31) should be loose after unscrewing end cap bolts (13) 4-5 turns.
If there is still force on the end cap after 4-5 turns of the end cap bolts, this
may indicate a damaged spring cartridge and any further disassem-
bly should be discontinued. Further disassembly of the end caps may
result in injury. Return actuator to AIR TORQUE for further maintenance.
• For spring return actuators, always remove spring cartridge.
• Remove end cap O-rings (14) and discard if replacing all soft components.

D) Pistons disassembly (Part No. 40), figure 04:

• Holding the body (50) in a vice or similar device, rotate the drive shaft (60)
until the pistons (40) are released.
Caution: Air pressure should not be used to remove the pistons from the
body.
• Remove piston ‘O’ rings (16) using a small screwdriver; remove the piston
back (05) and piston head (15) bearings. Discard bearings when
replacing all soft components.

E) Pinion shaft disassembling (Part No 60), figure 05:

• Remove spring clip (18) carefully, using nap-ring pliers, remove external
thrust bearing (08) and thrust washer (10).
• Apply downward force to top of drive shaft (60) until it is partially out of
the bottom of the body when it is possible to remove the octi-cam 01) and
internal thrust bearing (08), then push the pinion (60) completely out of
the bottom of the body. If pinion does not remove freely gently tap the
top of the shaft with a plastic mallet.
• Remove top and bottom pinion bearings (06)and (07) and top and bot-
tom pinion O-rings (21) and (22).
• Discard bearings (06) and (07), internal and external thrust washer (08) and
O-rings (21) and (22) if replacing all soft components.

Modifications reserved. Date 02.2000. 09e Maintenance 07

No guarantee for accuracy.
Older data sheets are invalid.
 The 4th Generation

Maintenance Manual

When all component are disassembled, those not being replaced

should be properly cleaned and inspected for wear prior to being
greased and re-assembled.

6.3) Assembly :
Prior to assembly, ensure all components are perfectly clean and free
from damage. Please see point 3 for recommended lubricants.

A) Drive shaft assembly (Part No. 60), figures 06 and 07:

• Install top and bottom pinion bearings (06) and (07) and top and bottom
pinion O-rings (21) and (22) onto the shaft.
• Grease the outside surface of the drive shaft on
top and bottom as shown in figure 06.
• Insert partially the drive shaft (60) in the body
(50), install octi–cam (01) in the correct position as
shown in figure 07 related to the bottom and top
of the drive shaft and the rotation of the actu-
ator when energised and install internal thrust
bearing (08). Insert completely the drive shaft in
the body.
• Fit external thrust bearing (08), thrust washer (10)
and then external circlip (18) using snap ring pliers.

B) Pistons assembly (Part No. 40), figures 08, 09, 10 and 11:
• Install piston O-rings (16), the Piston skirt (05) and piston head (15) bear-
ings.
• Grease the internal surface of the body (50) and the piston (40) rack
teeth.
• Hold the body (50) in a horizontal position by inserting the top of the
shaft into a vice or the bottom of the shaft connection into a male drive
fitted in a vice as shown in figure 08.
• Ensure that the octi-cam is in the right position as shown in figure 09.
• For standard rotation assembly (clockwise to close) rotate the body (50)
about 40-45° counter-clockwise from bottom view or clockwise from
top view depending on which way the shaft has been linked as shown
in figure 10.
• Press the two pistons (40) simultaneously inside the body (50) until the pis-
tons are engaged and rotate the body clockwise from bottom view or
counter clockwise from top view until the stroke is completed.
• Ensure that when the pistons are inserted that they both mesh at the
same time. Check fully closed and open positions as shown in figure 11.

Modifications reserved. Date 02.2000. 09e Maintenance 08

No guarantee for accuracy.
Older data sheets are invalid.
 The 4th Generation

Maintenance Manual

C) End cap (part 30 right and 31 left) and spring

cartridge (17) assembly (For model DR/SC2000 to
DR/SC3000 the 2 end caps 30 are symmetric), fig-
ures 12, 13 and 14:
• Lubricate the body.
• For spring return actuator insert the proper quan-
tity of spring cartridge according to the pattern
shown in figure 12 (referring to the total number of
springs). Insert spring cartridge (17) as shown in fig-
ure 13.

• Fit end cap O-ring seal (14) into the groove in the end cap, on both end
caps.
• Fit end caps onto the body (50), verifying that the O-ring remains in the
groove.
• Insert all the cap screws (13) and tighten each only partially. Complete
tightening by following the sequence indicated in figure 14.

D) Assembly of stop cap screws (Parts 02), and stroke adjustment figure15:
• Insert on both the stop cap screw (02), the nut (04), the washer (03), and
the O-ring in (11)
• Fit the stop cap screw (02) in the body.

Stroke adjustment for standard rotation actuator (Clockwise to close):

• 0° (Close) position stoke adjustment with actuator in close position,
screw or unscrew the right (from top view) stop cap screw (02) until the
desired stop position is achieved. Then tighten the stop adjustment nut
(04) to lock it in place
• 90° (open) position stroke adjustment with actuator in open position,
screw or unscrew the left (from top view) stop cap screw (02) until the
desired stop position is achieved, then tighten the
stop adjustment nut (04) and lock it in place.

E) Assembly of position indicator (Parts No 19 and 39), figure 16:

• Fit position indicator (19) on the shaft verifying that it indicates the correct
actuator position.
• Then fit cap screw (39) where fitted.

7) STORAGE INSTRUCTIONS
If the actuators are not for immediate use, the following precaution must
be taken for storage :
• Store in a dry environment at ambient temperature.
• It is recommended that the actuator be stored in its original box.
• Do not remove the plastic plugs on air supply ports.

Modifications reserved. Date 02.2000. 09e Maintenance 09

No guarantee for accuracy.
Older data sheets are invalid.