Actuators TR 104884

Technical Repair Guide for Rotork Valve
Actuators NA Range Models
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Leadership in Science
EPRI and Technology REPORT SUMMARY
Technical Repair Guide for Rotork

Valve Actuators "NA" Range Models
This guide provides comprehensive technical information on Rotork
valve actuator operation, maintenance, testing, and troubleshooting.
Its design provides the user with a uniform methodology to reduce
human errors and increase actuator reliability.
BACKGROUND A number of valves in nuclear power plants are equipped with

electric motor actuators. Some of these valves are installed in systems critical
to plant safety. Reliable operation of these motor-operated valves plays a major
role in ensuring that these systems can meet their safety function. Proper
maintenance, repair, and refurbishment of these actuators directly affects power
plant operation. NMAC has published a number of documents providing mainte-
INTEREST CATEGORIES nance and repair guidelines for Limitorque valve actuators. These documents
have proven to be extremely popular with utility personnel. NMAC member
utilities using Rotork actuators requested that similar guidelines for Rotork
Maintenance practices actuators be developed.
Nuclear plant operations
and maintenance OBJECTIVE To elaborate on the manufacturer's technical instructions and
Engineering and technical provide uniform guidance for the operation, testing, maintenance, and trouble-
support shooting of Rotork valve actuators.
KEYWORDS
APPROACH NMAC surveyed all member utilities to identify the type and model
of valve actuators to be included in this guide. A detailed outline of the guide was
Maintenance developed based on the results. A project team with expertise in operating and
Valves maintaining Rotork actuators developed an initial draft of this guide using informa-
Valve actuators tion from the manufacturer's operating, maintenance, testing, and troubleshooting
Maintainability procedures. Manufacturer information updates, actual utility practices, and
Motor-operated valves regulatory information were also included in the guide.
The draft was reviewed by a number of utilities experienced with Rotork actua-
tors in the United States and overseas and by engineering and technical per-
sonnel of Rotork, Inc. The final publication includes substantial additions and
changes suggested by reviewers.
RESULTS This guide covers Rotork actuator models A, AZ, NA1, NA2, NA4,
NA5, NAX, NAT, and NAZT in sizes 7 through 90. It contains consistent and
accurate repair, routine maintenance, adjustment, testing, and troubleshooting
methodologies for engineering, operations, and maintenance personnel. Basic
actuator descriptions and the major differences between various models are
given in detail. Also included is the theory of operation of the actuator and major
subassemblies and a description of actuator electric controls. Environmental
qualification, torque bench testing, and certification of actuators are also dis-
cussed. The guide also includes numerous tables of actuator performance data
and detailed drawings of the actuator, its major subassemblies, and special
maintenance tools, as well as a discussion of design upgrades.
EPRI 104884s Electric Power Research Institute December 1995

Actuator maintenance is discussed extensively in this guide. Included
are preventive maintenance recommendations and troubleshooting
methods, along with a discussion of problems that can cause actuator
failure. Complete disassembly and reassembly instructions are pro-
vided for the basic NA1 model.
EPRI PERSPECTIVE This document provides a guideline for utility

personnel to use as a detailed supplement to the manufacturer's techni-
cal instructions. Utility personnel who use this guide will reduce potential
error during Rotork actuator repair, testing, maintenance, and trouble-
shooting, leading to improved actuator performance and reliability.
PROJECT
WO 2814-94
EPRI Project Manager: Vic Varma
Nuclear Power Group/Nuclear Maintenance Applications Center
Contractor: Duke Engineering & Services, Inc.
For further information on EPRI research programs, call EPRI
Technical Information Specialists, (415) 855-2411.
Technical Repair Guide for Rotork
Valve Actuators "NA" Range Models
TR-104884
Work Order 2814-94

Final Report, December 1995
Prepared by
Duke Engineering & Services, Inc.
230 South Tryon Street
Charlotte, North Carolina 28201
Principal Investigator
C.W. Hendrix
Prepared for
Nuclear Maintenance Applications Center
1300 Harris Boulevard
Charlotte, North Carolina 28262
Operated by
Electric Power Research Institute
3412 Hiliview Avenue
Palo Alto, California 94304
EPRI Project Manager

Vic Varma
Nuclear Power Group
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES
THIS REPORT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK SPONSORED
OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE INC. (EPRI). NEITHER EPRI, ANY MEMBER OF
(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH RESPECT TO THE
USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS REPORT,
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OF SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR USE OF THIS REPORT OR ANY INFORMATION,
APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS REPORT.
ORGANIZATION(S) THAT PREPARED THIS REPORT:
Duke Engineering & Services, Inc.
ORDERING INFORMATION
Price: $20,000
Requests for copies of this report should be directed to the Nuclear Maintenance Applications Center
(NMAC), 1300 Harris Boulevard, Charlotte, NC 28262, 800/356-7448. There is no charge for reports
requested by NMAC-member utilities.
Electric Power Research Institute and EPRI are registered service marks of Electric Power Research Institute, Inc.
Copyright © 1995 Electric Power Research Institute, Inc. All rights reserved.
EPRI Licensed Material
Rotork Maintenance Manual
ABSTRACT
This technical repair guide (TRG) covers Rotork motor operated valve actuator models
including Models A, AZ, NA1, NA2, NA4, NA5, NAX, NAT and NAZT in sizes 7 through 90.
The TRG is aimed at supplementing manufacturer's technical instructions, providing utility
engineering, operations and maintenance personnel with comprehensive, consistent
methods for repair, maintenance, testing and troubleshooting of Rotork actuators. A
description of the electrical and mechanical operation of the actuator and the differences
between various models is provided. The TRG provides extensive listings of actuator
performance data and numerous detailed actuator/subassembly drawings. Complete
disassembly and reassembly instructions are provided for the basis NA1 Model actuator.
iii
INTRODUCTION
The purpose of this set of manuals is to provide a maintenance document aimed at

improving the long range operational reliability of Rotork motor operated valve actuators.
This Technical Repair Guide (TRG) is intended to provide the power-producing industry
with a technical methodology as a basic guideline and instructional tool for maintaining
Rotork actuator reliability and safety.
This set of manuals includes maintenance information for the following basic Rotork
models: 7A, 7AZ, 7NA1, 7NAX1, 7NAT1, 7NAZ1, 7NAZT1, 11A, 11AZ, 11NA1, 11NAX1,
11NAT1, 11NAZ1, 11NAZ1, 14A, 14AZ, 14NA1, 14NAX1, 14NAT1, 14NAZT1, 14NAZ1,
16A, 16AZ, 16NA1, 16NAX1, 16NAT1, 16NAZT1, 16NAZ1, 30A, 30AZ, 30NA1, 30NAX1,
30NAT1, 30NAZT1, 30NAZ1, 40A, 40AZ, 40NA1, 40NAX1, 40NAT1, 40NAZT1, 40NAZ1,
70A, 70AZ, 70NA1, 70NAX1, 70NAT1, 70NAZT1, 70NAZ1, 90A, 90AZ, 90NA1, 90NAX1,
90NAT1, 90NAZT1, and 90NAZ1. Other actuator model variations such as the NA2, NA4
and NA5 are similar in design to the NA1 actuator and only the differences will be
described. There are two other models of Rotork Actuators for non-thrusting applications
included in this guide. They are the Models AB and AR. These models have special
mounting bases which are not designed to accept thrust.
This TRG provides a general description of the actuator; various model differences and a
detailed mechanical operation description. Descriptions are provided for each of the
actuator sub-modules including the motor; switch mechanism; add-on-pak; syncroset
assembly; gearcase; thrust compensator and torque limiting brake. Included in the report
are basic electric control descriptions; environmental qualification summary and nameplate
data descriptions. Sections are included to describe upgrades made to the actuator over
time and a procedure for testing the actuator on a torque test bench. This TRG also
provides sections for troubleshooting actuator problems and descriptions of potential valve
problems that can lead to actuator failures.
Complete disassembly and reassembly procedures are given for each of the basic NA1
models to aid the maintenance technician during routine maintenance and actuator repair.
A section on special tools is provided to help identify the right tool for the job during the
maintenance activities.
The comprehensive approach of this set of manuals addresses the functions and needs of
plant personnel from managers to craft personnel. Since each plant has its own
administrative and management structure, the TRG is designed to provide the key
elements essential for implementation into each utility's maintenance program. These
manuals provide the technician or engineer with a single method of task performance.
Other methods exist which will accomplish these tasks, but the methods provided herein
are expected to have a minimal probability of human error consistent with providing
expedient resolution of the problem.
v
Due to the variety of valve/actuator configurations available, care should be taken to

ensure that the information and procedures presented here are consistent with the user's
plant specific organization, QA requirements and overall plant philosophy, as well as the
functional design requirements of the specific valve.
Although this document is written with the latest available information, changes in
actuator design, parts availability, etc., may supersede this document. Therefore, the user
of this document should ensure that no change has occurred since publication that might
affect the conclusions or recommendations of this document.
vi
ACKNOWLEDGMENTS
This document was created with the help and input from several sources. A major source of
information was Rotork Controls, Inc., who allowed us to use their "Rotork Maintenance
Manual", Volumes 1-3, as a source of information in the development of this manual.
Duke Power Company procedures, as well as individuals who through day-to-day
experience have become highly knowledgeable in regard to Rotork actuators, also proved to
be major sources of information. This assistance is gratefully acknowledged.
Technical Contributors include:
Tim Cline, Duke Power Company

Neal Estep, Duke Power Company
Steve Rea, Heyward & Associates
Fred Washburn, Rotork, Inc.
Detailed review of the draft was completed by:
Paul Albares, Northern States Power (Monticello)

Ken Brearley, Scottish Nuclear
Gerry Desrochers, NAESCO (Seabrook)
A.H. Jeng, Taiwan Power Company
Yoshinobu Nakanishi, Kansai Electric Power Company
Jeff Roberts, Wisconsin Electric Power Company
Keith Peterson, Northern States Power (Monticello)
Mike Wake, Nuclear Electric, England (Sizewell-B)
Mike Winter, Northern States Power (Monticello)
Len Zucker, Ontario Hydro (Pickering)
vii
TABLE OF CONTENTS
1.0 GENERAL DESCRIPTION OF THE ROTORK “NA” RANGE
ACTUATOR 1-1
1.1 Rotork Actuator Characteristics ..........................................................1-1
1.2 Drive Bushing Assembly Configurations............................................1-3
1.3 “A”and “NA”Range Actuators Differences ..............................................1-7
2.0 MECHANICAL OPERATIONS 2-1

2.1 Drive Train - Motor Operation ..............................................................2-1
2.2 Drive Train - Manual Operation ............................................................2-1
2.3 Mechanical Subcomponents Description and Functions..................2-2
2.3.1 Center Column .............................................................................2-2
2.3.2 Gearcase Assembly .....................................................................2-2
2.3.3 Worm Wheel ................................................................................2-3
2.3.4 Clutch Assembly...........................................................................2-3
2.3.5 Handwheel Module.......................................................................2-4
2.3.6 Torque Switch Shaft .....................................................................2-4
3.0 ACTUATOR MOTOR 3-1
4.0 PRIMARY SWITCH MECHANISM, ADD-ON-PAK AND

SYNCROSET FUNCTION 4-1
4.1 Primary Switch Mechanism ..................................................................4-1
4.2 Add-on-pak ............................................................................................4-5
4.3 Syncroset Assembly .............................................................................4-7
ix
5.0 THRUST COMPENSATOR AND TORQUE LIMITER FUNCTION 5-1

5.1 Thrust Compensator.............................................................................5-1
5.2 Torque Limiting Brake ..........................................................................5-2
6.0 BASIC ELECTRICAL CONTROL DESCRIPTION 6-1

6.1 Electrical Components - Motor Control Center ..................................6-1
6.1.1 Circuit Breaker/Fuses...................................................................6-1
6.1.2 Power Contactors .........................................................................6-1
6.1.3 Thermal Overload Relays.............................................................6-2
6.1.4 Control Power Transformer ..........................................................6-3
6.1.5 Control Switch and Contacts ........................................................6-3
6.1.6 Opening and Closing Coils...........................................................6-4
6.1.7 Red and Green Status Lights .......................................................6-4
6.2 Electrical Control Components............................................................6-5
6.2.1 Torque Switch ..............................................................................6-5
6.2.2 Limit Switch ..................................................................................6-6
6.2.3 Limit Switch Contact Functional Description ...............................6-6
6.3 Actuator Control Circuit for Rising Stem Type Valves ......................6-7
6.3.1 Opening Cycle..............................................................................6-8
6.3.2 Closing Cycle .............................................................................6-16
7.0 GENERAL NAMEPLATE DATA 7-1

7.1 Motor Nameplate Data ..........................................................................7-1
7.1.1 Actuator Size and Type ................................................................7-1
x
7.1.2 Revolutions per Minute (RPM) .....................................................7-2

7.1.3 Motor Horsepower ........................................................................7-3
7.1.4 Wiring Diagram Number...............................................................7-3
7.1.5 Development Chart for Basic Rotork Wiring Diagram Numbering7-4
8.0 GENERAL PRECAUTIONS FOR USE AND REPAIR OF ROTORK
“NA”RANGE ACTUATORS 8-1
8.1 General Precautions .............................................................................8-1
8.2 Electrical Precautions...........................................................................8-2
8.3 Mechanical Precautions .......................................................................8-3
9.0 ENVIRONMENTAL QUALIFICATION SUMMARY 9-1

9.1 Rotork Model NA1 Required Maintenance ..........................................9-1
9.2 Equipment/Part Replacement Intervals...............................................9-1
9.3 Electrical Termination Method .............................................................9-1
9.4 Cable Entrance Sealing ........................................................................9-2
9.5 Gearcase Breather Tubes.....................................................................9-2
9.6 Shelf Life ................................................................................................9-2
9.7 Design Environments ...........................................................................9-2
9.8 Specific Characteristics of NA1 Actuators .........................................9-3
10.0 ACTUATOR CERTIFICATION PROGRAM 10-1

10.1 Introduction .........................................................................................10-1
10.2 Torque Test Bench Requirements.....................................................10-1
10.3 Rotork Certification Procedure ..........................................................10-1
xi
11.0 ACTUATOR UPGRADE NOTES (PRE-1978 VS. POST-1978) 11-1

11.1 Gearcase Subassemblies...................................................................11-1
11.2 Switch Mechanism ..............................................................................11-2
11.3 Syncroset.............................................................................................11-4
11.4 Add-on-pack 6 & 12 Switch ................................................................11-4
11.5 Torque Limiters ...................................................................................11-5
11.6 Thrust Compensator...........................................................................11-6
11.7 Motor ...................................................................................................11-6
11.8 Handwheel ...........................................................................................11-7
12.0 ACTUATOR PERFORMANCE DATA 12-1

12.1 General Motor Performance Requirements ......................................12-1
12.2 Motor Performance Data.....................................................................12-2
12.3 Rotork Published Motor Currents......................................................12-3
12.4 Electrical Performance Data...............................................................12-3
12.5 Mechanical Performance Data ...........................................................12-3
12.6 Sizing Guide for Rotork Electric Actuators ....................................12-11
13.0 ACTUATOR MOUNTING BOLT SPECIFICATION 13-1

13.1 Bolting Material Requirements ..........................................................13-1
13.2 Torque Requirements .........................................................................13-2
14.0 PREVENTIVE MAINTENANCE INSPECTIONS 14-1

14.1 Precautions..........................................................................................14-1
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14.2 Procedure ............................................................................................14-1

14.3 Restoration ..........................................................................................14-5
15.0 ACTUATOR INTERNAL WIRING DIAGRAMS 15-1
16.0 SPECIAL TOOLS 16-1

16.1 Material.................................................................................................16-1
16.2 Dimensions & Surface Finish.............................................................16-2
17.0 ACTUATOR FAILURE MODES/TROUBLESHOOTING 17-1

17.1 Actuator Fails to Start.........................................................................17-1
17.2 Actuator Fails to Completely Close Valve ........................................17-1
17.3 Freeing a Jammed Valve Manually ....................................................17-2
17.4 Actuator Motor Trips Continually on Overload ................................17-2
17.5 Actuator Runs Without Driving Valve................................................17-3
17.6 Actuator Will Not Engage or Stay in Manual Mode ..........................17-3
17.7 Actuator is Leaking Oil .......................................................................17-3
17.8 Actuators Mounted on 90°Butterfly Valves Fall to
Take Valve to Full Travel ....................................................................17-3
17.9 Control Circuit Malfunctions ..............................................................17-4
17.10 Remote Indication Not Correct ..........................................................17-4
17.11 Computer Points are Erroneous ........................................................17-4
17.12 Actuator Hammering...........................................................................17-4
18.0 VALVE PROBLEMS AFFECTING ACTUATOR OPERABILITY 18-1

18.1 Valve Packing ......................................................................................18-1
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Nuclear Maintenance Application Center
18.2 Valve Stem ...........................................................................................18-1

18.2.1 Improperly Sized Stem Nut for Valve Stem ................................18-1
18.2.2 Valve Stem Failure .....................................................................18-2
18.2.3 Valve Stem Fouling ....................................................................18-2
18.3 Valve Thermal Binding........................................................................18-2
18.4 Valve Pressure Locking......................................................................18-3
18.5 System Pressure Induced Valve Position Change ...........................18-3
18.6 Valve Yoke Failure ..............................................................................18-4
18.7 Valve Seat Friction ..............................................................................18-4
19.0 ROOT CAUSE AND CORRECTIVE ACTION GUIDELINES 19-1

19.1 Root Cause Failure Analysis Guidelines...........................................19-2
19.2 Failure Analysis Review .....................................................................19-4
19.3 Followup Actions ................................................................................19-4
20.0 PROCEDURES FOR SETTING SWITCHES 20-1

20.1 Prerequisites .......................................................................................20-1
20.2 Precautions..........................................................................................20-2
20.3 Switch Mechanism Setup ...................................................................20-2
20.4 Add-on-pak Setup ...............................................................................20-7
20.5 Electrical Startup...............................................................................20-17
20.6 Restoration ........................................................................................20-20
21.0 7/11/13 NA1 ACTUATOR 21-1

21.1 Actuator Removal From Valves .........................................................21-1
21.2 Actuator Disassembly.........................................................................21-2
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21.2.1 Motor Assembly Removal and Inspection ..................................21-2

21.2.2 Switch Mechanism Removal and Inspection ..............................21-3
21.2.3 Add-on-pak Removal and Inspection .........................................21-5
21.2.4 Syncroset Disassembly and Inspection......................................21-7
21.2.5 Handwheel Removal and Inspection ..........................................21-8
21.5.6 Gearcase Module Removal and Inspection ...............................21-8
21.3 Actuator Assembly............................................................................21-11
21.3.1 Gearcase Module Assembly.....................................................21-11
21.3.2 Syncroset Assembly .................................................................21-12
21.3.3 Switch Mechanism Assembly ...................................................21-13
21.3.4 Add-on-pak Assembly ..............................................................21-15
21.3.5 Motor Assembly........................................................................21-16
21.3.6 Handwheel Assembly ...............................................................21-18
21.3.7 Post-maintenance Testing - Gearcase Pressure Check ..........21-18
21.3.8 Post-maintenance Testing - Requirement Matrix .....................21-19
21.3.9 Actuator Replacement ..............................................................21-19
22.0 14/16 NA1 ACTUATOR 22-1

22.1 Actuator Removal From Valve ...........................................................22-1
xv

22.3.5 Motor Assembly........................................................................22-19
22.3.8 Post-maintenance Testing - Requirements Matrix ...................22-21
23.0 30 NA1 ACTUATOR 23-1

xvi

23.3.5 Motor Assembly........................................................................23-17
23.39 Actuator Replacement ..............................................................23-20
24.0 40 NA1 ACTUATOR 24-1

24.3.5 Motor Assembly........................................................................24-17
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Nuclear Maintenance Application Center
25.0 70/90 NA ACTUATOR 25-1

25.3.5 Motor Assembly........................................................................25-17
25.3.9 Actuator Replacement..............................................................25-20
26.0 PRE-OPERATIONAL/POST-MAINTENANCE TESTING 26-1

26.1 Rotork Torque Test Bench Certification Guidelines........................26-1
26.2 Functional Verification .......................................................................26-2
26.2.1 Functional Verification of Open Torque Bypass Switch .............26-2
26.2.2 Operational Verification of Rotork Actuators ..............................26-2
xviii
26.3 Time Response ...................................................................................26-5

26.4 Diagnostic Testing..............................................................................26-6
27.0 SPARE PARTS HANDLING AND STORAGE REQUIREMENTS 27-1

27.1 Spare Parts Handling ..........................................................................27-1
27.2 Receipt of Material ..............................................................................27-1
27.3 Storage Requirements ........................................................................27-1
27.3.1 O-Rings and Seals .....................................................................27-1
27.3.2 Used Parts Control .....................................................................27-2
APPENDIX A A-1
References .................................................................................................... A-1
Regulatory Documents................................................................................... A-2
APPENDIX B B-1
Rotork General Arrangement Drawings........................................................ B-1
APPENDIX C C-1
Glossary....... ................................................................................................... C-1
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Rotork Maintenance manual
LIST OF FIGURES
Figure 1.2-1 Typical Drive Bushing ................................................................................. 1-3
Figure 1.2-2 Drive Bush Assembly - Type A ................................................................... 1-4
Figure 1.2-3 Drive Bush Assembly - Type AZ ................................................................. 1-5
Figure 1.2-4 Type AX ...................................................................................................... 1-6
Figure 2.1-1 Drive Train - Hand Operation (Size 14 and Larger) .................................... 2-5
Figure 2.1-2 Drive Train - Motor Operation (Size 14 and Larger) .................................... 2-6
Figure 4.1-1 NA1 Electrical Actuator ............................................................................... 4-1
Figure 4.1-2 Primary Switch Mechanism ......................................................................... 4-2
Figure 4.1-3 Primary Switch Mechanism Selector ........................................................... 4-3
Figure 4.1-4 Switch Mechanism ...................................................................................... 4-4
Figure 4.2-1 Post-1978 Add-on-pak Assemblies............................................................. 4-5
Figure 4.2-2 Add-on-pak ................................................................................................. 4-6
Figure 4.3-1 Syncroset Assembly ................................................................................... 4-8
Figure 5.1-1 Thrust Compensator ................................................................................... 5-1
Figure 5.2-1 Typical Torque Limited Brake Assembly ..................................................... 5-2
Figure 6.1-1 Thermal Overload Trip Indication 6-4

Modification with Overload ..........................................................................
Figure 6.3-1 Typical Electrical Component Location ....................................................... 6-8
Figure 6.3-2 Typical Opening Cycle for Fully

Closed Valve (Control Circuit De-energized)............................................... 6-9
Figure 6.3-3 Typical Opening Cycle for Fully Closed

(Control Circuit Shown at the Instant Open Signal is Given)....................... 6-10
Figure 6.3-4 Typical Opening Cycle Valve Fully Closed

(Control Circuit Shown just after the Open Signal
is Given and the Opening Coil Actuates) .................................................... 6-11
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Nuclear maintenance Application Center
Figure 6.3-5 Typical Opening cycle Valve Fully Closed

(Control Circuit Shown after the Open Cycle
is Initiated and the Control Switch is Released) .................................. 6-12
Figure 6.3-6 Typical Opening Cycle Valve Moving in the
Open Directory (Control Circuit Shown with the
Valve at the Near Closed Position)...................................................... 6-13
Figure 6.3-7 Typical opening Cycle Valve Moving in the
Open Direction (Control Circuit Shown with the
Valve at the Full Open Position)......................................................... 6-14
Figure 6.3-8 Typical Opening Cycle Valve Fully Open
(Control Circuit Shown just after the Open Position
with Opening Coil Dropped Out, Ready for
Closing Operation) .............................................................................. 6-15
Figure 6.3-9 Typical Closing Cycle Valve Fully Open
(Control Circuit Shown at the Instant the
Closed Signal is Given) ....................................................................... 6-17
Figure 6.3-10 Typical Closing Cycle Valve Fully Open
(Control Circuit Shown with the Closing Cycle Initiated
and the Control Switch Released) ....................................................... 6-18
Figure 6.3-11 Typical Closing Cycle Valve Moving in the
Closed Direction (Control Circuit Shown with the
Valve at the Near Open Position)........................................................ 6-19
Figure 6.3-12 Typical Closing Cycle Valve Moving in the
Closed Direction (Control Circuit Shown with the
Valve at the Near Closed Position)...................................................... 6-20
Figure 6.3-13 Typical Closing Cycle Valve Fully Closed
(Closed Circuit Shown with the Valve just after the
Near Closed Position-Closing Coil Drips Out,
Ready for Opening Cycle) ................................................................... 6-21
Figure 7.1-1 Nameplate Size/Type (Commercial Application) ................................. 7-1
Figure 7.1-2 Nameplate Size/Type (Nuclear Safety Related Applications).............. 7-2
Figure 7.1-3 Rotork Wiring Diagram Numbering...................................................... 7-4
Figure 10.3-1 Test Data Sheet .................................................................................. 10-7
Figure 12.1-1 Rotork Motor Speed Torque Characteristics ....................................... 12-2
Figure 13.2-1 Rotork Actuator Mounting Flange Sizes 7, 11, 13 ............................... 13-2
xxii
Figure 13.2-2 Rotork Actuator Mounting Flange Sizes 14,16 ........................................... 13-2
Figure 13.2-3 Rotork Actuator Mounting Flange Size 30 .................................................. 13-3
Figure 13.2-4 Rotork Actuator Mounting Flange
Sizes 40AR, 70AR, 90AR, 91AR................................................................ 13-3
Figure 13.2-5 Rotork Actuator Mounting Flange Sizes 40,70 ........................................... 13-4
Figure 13.2-6 Rotork Actuator Mounting Flange Size 90 .................................................. 13-4
Figure 15.0-1 Actuator Internal Wiring Diagram
(12 Switch AOP with POT, No Thermo)...................................................... 15-1
(6 Switch AOP with POT with Thermo)....................................................... 15-2
(6 Switch AOP, No POT, No Thermo) ........................................................ 15-3
(12 Switch AOP, No POT , No Thermo) ..................................................... 15-4
Figure 16.2-1 TO 24 Worm Shaft Flameproof Shroud Tool.............................................. 16-3
Figure 16.2-2 TO 25 Small Needle Bearing Tool .............................................................. 16-4
Figure 16.2-3 TO 26 Torque Shaft Seal Tool ................................................................... 16-5
Figure 16.2-4 TO 535 Worm Shaft Seal Tool ................................................................... 16-6
Figure 16.2-5 TO 537 Hand Auto Seal Tool ..................................................................... 16-7
Figure 16.2-6 TO 547 Hand Auto Seal Tool ..................................................................... 16-8
Figure 16.2-7 TO 548 Worm Shaft Needle Bearing/Flameproof Seal Tool ...................... 16-9
Figure 16.2-8 TO 549 Worm Shaft Oil Seal Tool.............................................................. 16-10
Figure 16.2-9 TO 550 Gearcase Small Bearing................................................................ 16-11
Figure 16.2-10 TO 551 Small Flameproof Shroud Gearcase ............................................. 16-12
Figure 16.2-11 TO 552 Small Seals.................................................................................... 16-13
Figure 16.2-12 TO 620 Torque Shaft.................................................................................. 16-14
Figure 16.2-13 TO 621 Worm Shaft Oil Seal...................................................................... 16-15
xxiii
Figure 16.2-14 TO 622 Hand Auto Seal Tool ........................................................... 16-16

Figure 16.2-15 TO 674 Pin Inserting Tool................................................................. 16-17
Figure 16.2-16 TO 754 Flameproof Shroud and Bearing Mandrel............................ 16-18
Figure 16.2-17 TO 864 Top Handwheel Seal Tool ................................................... 16-19
Figure 16.2-18 TO 865 Side Handwheel Seal Tool .................................................. 16-20
Figure 16.2-21 TO 869 Handwheel Seal Tool .......................................................... 16-23
Figure 16.2-23 TO 871 Worm Shaft Seals ............................................................... 16-25
Figure 16.2-24 TO 875 Worm Shaft Bearings .......................................................... 16-26
Figure 16.2-25 TO 877 Torque Shaft Seal Tool ....................................................... 16-27
Figure 16.2-26 TO 900 Handwheel Seal Tools (Top) ............................................... 16-28
Figure 16.2-28 TO 913 Flameproof Shroud (Torque Shaft End) .............................. 16-30
Figure 16.2-29 TO 914 Torque Shaft Seal Tool ....................................................... 16-31
Figure 16.2-30 TO 1099 Needle Bearing Assembly Tool ......................................... 16-32
Figure 16.2-31 TO 1100 Worm Shaft Oil Seal Tool.................................................. 16-33
Figure 16.2-32 TO 1101 Torque Plunger Shroud and Oil Seal Tool......................... 16-34
Figure 16.2-33 TO 1105 Worm Shaft Needle Bearing Tool...................................... 16-35
Figure 16.2-34 TO 1106 Worm Shaft Oil Seal Tool.................................................. 16-36
Figure 16.2-35 TO 1107 Torque Shaft/Shroud Oil Seal Tool.................................... 16-37
Figure 16.2-36 TO 1123 Torque Shaft Shroud Tool for Model 4ONA....................... 16-38
Figure 16.2-37 TO 1124 Torque Shaft Shroud Tool ................................................. 16-39
Figure 16.2-38 To 1125 Worm Shaft Oil Seal Tool................................................... 16-40
xxiv
Figure 16.2-39 TO 1126 Worm Shaft Needle Bearing/Flameproof Shroud Tool ....... 16-41
Figure 20.3-1 Clutch Nut Design Switch Mechanism ............................................... 20-3
Figure 20.3-2 New Type Switch Mechanism............................................................ 20-3
Figure 20.4-1 Add-on-pak Typical AOPI
Gear Spacer Arrangement ................................................................ 20-10
Figure 20.4-2 Switch Mechanism Position Flags ..................................................... 20-12
Figure 20.4-3 Front View Switch Mechanism Switches and Add-on-pak Wiring...... 20-13
Figure 20.4-4 Primary Switch Mechanism Selector ................................................. 20-18
Figure 21-1a 7/11/13 Gearcase Assembly ............................................................. 21-22
Figure 21-1b 7/11/13 Gearcase Assembly ............................................................. 21-23
Figure 21-2 7/11/13 Drive Bush Assembly ........................................................... 21-24
Figure 21-3 7/11/13 Motor Assembly.................................................................... 21-25
Figure 21-4 7/11/13 Handwheel Subassembly ..................................................... 21-26
Figure 21-5 Spring Pak Sheet 7/11 NA1 .............................................................. 21-27
Figure 21-6a Syncroset Assembly .......................................................................... 21-28
Figure 21-6b Syncroset Assembly .......................................................................... 21-29
Figure 21-7 Post-1978 Add-on-pak Assemblies ................................................... 21-30
Figure 21-8 Type “A” and Type “NA” Old Version Add-on-pak-
Pre- 1978........................................................................................... 21-31
Figure 21-9 Type “NA” New Version Add-on-pak - Post- 1978 ............................. 21-32
Figure 21-10 Add-on-pak Modular Replacement of Switch Banks -
Post- 1978 ......................................................................................... 21-33
Figure 21-11 Add -on-pak Modular Replacement of Switch Banks-
Pre- 1978........................................................................................... 21-34
Figure 21-12 Add-on-pak Typical AOPI Gear Arrangement.................................... 21-35
Figure 21-13 NA1 and NA2 Switch Mechanism Assembly - Pre- 1978................... 21-36
xxv
Figure 21-14 NA1 Switch Mechanism Assembly - Post - 1978 ............................... 21-37
Figure 21-15 Switch Mechanism Module (NA1) (Front View Cross Section)........... 21-38
Figure 21-16 Replacement Switch Mechanism Switch Paks................................... 21-39
Figure 21-17 Fabricated Cover Assembly for Switch Mechanism ........................... 21-40
Figure 21-18 Fabricated Cover Assembly for 6 Switch Add-on-pak 1..................... 21-41
Figure 21-19 Fabricated Cover Assembly for 12 Switch Add-on-pak 1................... 21-42
Figure 22.3-1 Yoke Assembly Installation and Adjustment ...................................... 22-13
Figure 22-1a 14/16 Gearcase Assembly................................................................. 22-24
Figure 22-1b 14/16 Gearcase Assembly................................................................. 22-25
Figure 22-2 14/16 Drive Bush Assembly............................................................... 22-26
Figure 22-3 14/16 Motor Assembly ....................................................................... 22-27
Figure 22-4 14/16 Top Handwheel Assembly ....................................................... 22-28
Figure 22-5a 14/16 Side Handwheel Assembly ...................................................... 22-30
Figure 22-5b 14/16 Side Handwheel Assembly ...................................................... 22-31
Figure 22-6 Spring Pak Sheet 14 NA1.................................................................. 22-32
Figure 22-7 Spring Pak Sheet 16 NA1.................................................................. 22-33
Figure 22-8a Syncroset Assembly .......................................................................... 22-34
Figure 22-8b Syncroset Assembly .......................................................................... 22-35
Figure 22-9 Add-on-pak Assemblies ..................................................................... 22-36
Figure 22-10 Type “A” and Type “NA” Old Version Add-on-pak- Pre- 1978 ............ 22-37
Figure 22-11 Type “NA” New Version Add-on-pak
Post- 1978 ......................................................................................... 22-38
Figure 22-12 Add-on-pak Modular Replacement of Switch Banks
Post - 1978 ........................................................................................ 22-39
Pre- 1978 ........................................................................................... 22-40
xxvi
Figure 22-14 Add-on-pak Typical AOPI Gear Arrangement............................................. 22-41

Figure 22-15 NA1 and NA2 Switch Mechanism Assembly - Pre- 1978............................ 22-42
Figure 22-16 NA1 Switch Mechanism Assembly ............................................................. 22-43
Figure 22-17 Switch Mechanism Module (NA1) (Front View Cross Section) ................... 22-44
Figure 22-18 Replacement Switch Mechanism Switch Paks ........................................... 22-45
Figure 22-19 Fabricated Cover Assembly for Switch....................................................... 22-46
Figure 22-20 Fabricated Cover Assembly for 6 Switch Add-on-pak 1 ............................. 22-47
Figure 22-21 Fabricated Cover Assembly for Add-on-pak 1............................................ 22-48
Figure 23-1a 30 Gearcase Assembly .............................................................................. 23-22
Figure 23-1b 30 Gearcase Assembly .............................................................................. 23-23
Figure 23-2 30 Drive Bush Assembly ............................................................................ 23-24
Figure 23-3 30 Motor Assembly..................................................................................... 23-25
Figure 23-4 30 Top Handwheel Assembly..................................................................... 23-26
Figure 23-5a 30 Side Handwheel Assembly.................................................................... 23-28
Figure 23-5b 30 Side Handwheel Assembly.................................................................... 23-29
Figure 23-6 Spring Pak Sheet 30 NA1 .......................................................................... 23-30
Figure 23-7a Syncroset Assembly ................................................................................... 23-32
Figure 23-7b Syncroset Assembly ................................................................................... 23-33
Figure 23-8 Add-on-pak Assemblies.............................................................................. 23-34
Figure 23-9 Type “A” and Type “NA” Old Version Add-on-pak-
Pre- 1978.................................................................................................... 23-35
Figure 23-10 Type “NA” New Version Add-on-pak - Post- 1978 ...................................... 23-36
Figure 23-11 Add-on-pak Modular Replacement of Switch Banks -
Post- 1978 .................................................................................................. 23-37
Figure 23-12 Add-on-pak Modular Replacement of Switch Banks-
Pre- 1978.................................................................................................... 23-38
xxvii

Figure 23-14 NA1 and NA2 Switch Mechanism Assembly Pre- 1978.............................. 23-40
Figure 23-17 Replacement Swtich Mechanism Switch Paks ........................................... 23-43
Figure 23-18 Fabricated Cover Assembly for Switch Mechanism.................................... 23-44
Figure 23-20 Fabricated Cover Assembly for 12 Switch Add-on-pak 1 ........................... 23-46
Figure 24-1a 40 Gearcase Assembly .............................................................................. 24-22
Figure 24-1b 40 Gearcase Assembly .............................................................................. 24-23
Figure 24-2 40 Drive Bush Assembly ............................................................................ 24-24
Figure 24-3 40 Motor Assembly..................................................................................... 24-25
Figure 24-4 40 Top Handwheel Assembly..................................................................... 24-26
Figure 24-5a 40 Side Handwheel Assembly.................................................................... 24-28
Figure 24-5b 40 Side Handwheel Assembly.................................................................... 24-29
Figure 24-9 Type “A” and Type “NA” Old Version Add-on-pak
Pre- 1978.................................................................................................... 24-35
Figure 24-10 Type “NA” New Version Add-on-pak .......................................................... 24-36
Figure 24-11 Add-on-pak Modular Replacement of Switch Banks................................... 24-37
Pre- 1978.................................................................................................... 24-38
xxviii
Figure 24-14 NA1 and NA2 Switch Mechanism Assembly .............................................. 24-40
Figure 24-18 Fabricated Cover Assembly for Switch....................................................... 24-44
Figure 25-1a 70/90 Gearcase Assembly ......................................................................... 25-22
Figure 25-1b 70/90 Gearcase Assembly ......................................................................... 25-23
Figure 25-2 70/90 Drive Bush Assembly ....................................................................... 25-24
Figure 25-3 70/90 Motor Assembly................................................................................ 25-25
Figure 25-4a 70/90 Handwheel Asembly......................................................................... 25-26
Figure 25-4b 70/90 Handwheel Assembly ....................................................................... 25-27
Figure 25-9 Type “A” and Type “NA” Old Version Add-on-pak
Pre- 1978.................................................................................................... 25-33
Figure 25-10 Type “NA” New Version Add-on-pak Post- 1978 ........................................ 25-34
Post- 1978 .................................................................................................. 25-35
Figure 25-12 Add-on-Pak Modular Replacement of Switch Banks .................................. 25-36
xxix
Figure 25-14 NA1 and NA2 Switch Mechanism Assembly .............................................. 25-38
Figure 25-18 Fabricated Cover Assembly for Switch Mechanism.................................... 25-42
Figure B-1 Nuclear Range Drive .................................................................................. B-2
Figure B-2 Nuclear 12 Switch AOPI Cover................................................................... B-3
Figure B-3 7, 11 NA1,4,5 & NAT1,4,5 Gearcase Assembly ......................................... B-4
Figure B-4 7,11 NA1,4,5 & NAT1,4,5 Handwheel Assembly........................................ B-5
Figure B-5 7,11 NA1,4,5 & NAT1,4,5 Motor Module .................................................... B-6
Figure B-6 7,11 NA Thrust Compensator..................................................................... B-7
Figure B-7 14,16 NA1,4,5 & NAT1,4,5 Gearcase Assembly ........................................ B-8
Figure B-8 14,16 NA1,4,5 & NAT1,4,5 Handwheel Assembly...................................... B-9
Figure B-9 14/16 NA1,4,5 & NAT1,4,5 Motor Module .................................................. B-10
Figure B-10 14/16 NA1,4,5 Thrust Compresator............................................................ B-11
Figure B-11 30 NA1,4,5 & NAT1,4,5 Gearcase Assembly ............................................. B-12
Figure B-12 30 NA1,4,5 & NAT1,4,5 Handwheel Assembly........................................... B-13
Figure B-13 30 NA1,4,5 & NAT1,4,5 Motor Module ....................................................... B-14
Figure B-14 30 NA1,4,5 Thrust Compensator................................................................ B-15
Figure B-15 40 NA1,4,5 & NAT1,4,5 Gearcase Assembly ............................................. B-16
Figure B-16 40 NA1,4,5 & NAT1,4,5 Handwheel Assembly........................................... B-17
Figure B-17 40 NA1,4,5 & NAT1,4,5 Motor Module ....................................................... B-18
Figure B-18 40 NA1,4,5 Thrust Compensator................................................................ B-19
XXX
Figure B-19 70/90 NA1,4,5 & NAT1,4,5 Gearcase Assembly ........................................ B-20
Figure B-20 70/90 NA1,4,5 & NAT1,4,5 Handwheel Assembly...................................... B-21
Figure B-21 70/90 NA1,4,5 & NAT1,4,5 Motor Module .................................................. B-22
Figure B-22 70/90 NA1,4,5 Thrust Compensator........................................................... B-23
Figure B-23 NA Range Switch Mechanism .................................................................... B-24
Figure B-24 NA1,4,5 Syncroset ..................................................................................... B-25
Figure B-25 Nuclear AOP1 Potentiometer Assembly..................................................... B-26
Figure B-26 Nuclear AOP1 Assembly ............................................................................ B-27
Figure B-27 Switch Mechanism and NA Range AOP1 Cover ........................................ B-28
xxxi
List of Tables
Table 1.3-1 “A” / “NA1” Mechanical Construction................................................... 1-7
Table 1.3-2 “A” / “NA1” Electrical Construction ...................................................... 1-7
Table 3.0-1 Torque Rating..................................................................................... 3-1
Table 9.8-1 Actuator Construction Details ............................................................. 9-4
Table 10.3-1 Post-1978 Stall Tloque Ratings .......................................................... 10-8
Table 10.3-2 Post-1978 Ratings for U.S. Manufacturer........................................... 10-9
Table 10.3-7 Cofmmercial, Pre-1978 NA and U.K.Manufactured Post-1978

Ratings ............................................................................................... 10-14
Table 11.1-1 Gearcase Comparison........................................................................ 11-2
Table 11.2-1 Rotork Actuator Switch Mechanism Variations ................................... 11-3
Table 11.3-1 Rotork Actuator Syncroset Variations ................................................. 11-4
Table 11.4-1 Rotork Actuator Add-on-pak Variations .............................................. 11-5
Table 11.5-1 Rotork Actuator Torque Limiter Variations.......................................... 11-6
Table 11.6-1 Rotork Actuator Thrust Compensator Variations ................................ 11-6
Table 11.7-1 Rotork Actuator Motor Variations........................................................ 11-6
Table 11.8-1 Rotork Actuator Handwheel Variations ............................................... 11-7
Table 12.4-1 Performance Summary for Rotork Electric Actuators Electrical Data
Commercial, Pre-1978 and U.K. Manufactured Post-1978
Actuators 575AC 60 HZ...................................................................... 12-4
Table 12.4-2 Performance Summary for Rotork Electric Actuators Electrical Data
US Manufactured Post-1978 575VAC 60 HZ ..................................... 12-7
xxxiii
Table 12.5-1a Performance Summary for Rotork Electric Actuators

Mechanical Data......................................................................................... 12-10
Table 12.5-1b Rotork Mounting Flange Data..................................................................... 12-11
Table 13.1-1 Acceptable Bolting Materials ...................................................................... 13-1
Table 13.2-2 Torque Requirements................................................................................. 13-5
Table 14.3-1 Capscrew Torque Guide............................................................................. 14-5
Table 16.1-1 Recommended Materials for Special Tools ................................................ 16-1
Table 20.4-1a Post- 1978 NA1 Add-on-pak Gear Selection Chart
(Forged Metal Gears) ................................................................................. 20-8
Table 20.4-1b Pre- 1978 NA1, NA2 and Commercial Add-on-pak Gear Selection
Chart (Plastic and Machined Brass Gears)................................................. 20-9
Table 26.0-1 Post-maintenance/Pre-operation Testing ................................................... 26-1
xxxiv
1.0 GENERAL DESCRIPTION OF THE ROTORK "NA" RANGE

ACTUATOR
1.1 Rotork Actuator Characteristics
T he R oto r k actu ato r is an ele ctr om ech ani cal de vic e t hat p osit ion s a v alv e up on r ece ipt o f
c om m an d s f ro m pl an t per s o nn el o r pl an t c on tr ol s y s tem s . T h is de vic e is u s ed i n s y st em
a pp licat ion s w h ere is o lati on an d/ or co n tro l o f a system 's fl ow is r equ ir ed. A ct uat ion m ay be
a cco m pl ishe d eith er r em o tely by el ectr ical sig na l o r b y op er atin g m an u ally u s in g the
h an d w h eel .
R o to rk act ua to rs ar e de sig ne d to ex clu d e m o is tu re t hr o ug h t he u s e o f th re e in ne r seal ed

c om p ar tm e nt s . T h es e i nc lu de t he e lec tr ica l co m p ar tm en t, t he g ea re d ( oi l) c om pa rt m en t,
a n d th e e lec tr ic al te rm in at io n c om p ar tm en t.
R o to rk actu at or s a re u s ed i n bo th cr itic al an d n on cr iti cal ap p lic atio n s . T h e "N A " r an ge

a ctu at or i s d esi gn ed and test ed f o r us e i n n uc lear ap pl icat io ns w it h th e let ter " N " d en ot in g
a ccep tan ce f or u s e as C lass 1E o r Q A co n dit io n 1 ap pli cati on s . T h e a ctu ato rs ar e q ua lif ied
i n ac co rd an ce w i th S t an da rd IE E E 3 82 issu ed i n 1 98 0 . T h e le tte r "A " de no te s t he ty p e of
d riv e bu sh ing .
R o to r k d ef in es ac tu ato r s a bl e to op er at e in a n u cl ear re act or ha rs h acc id en t en v ir on m en t

(a n ac tiv e d ut y ac tu ato r ), as "N A 1 " w h er e th e n um b er " 1" de no te s t he a ctu at or 's act iv e
du ty . T hi s c la s s o f a ctu at or m a y b e us e d i n ei th er a n ac tiv e o r p as s i ve r o le ( s tr u ctu r all y
s ou n d) in s id e or o u ts id e co n tai nm en t. T he " N A 1 " act ua to rs u nd er g o s tr in g en t de s ig n an d
qu al if ica tio n r eq u ir em e n ts to e ns u r e th ey c an w ith s ta nd ex tr em e e nv i ro n m en ta l co nd it io n s
s uc h a s h ig h vi br a tio n , h ig h t em pe r atu r es , hi gh m o is t u re l ev el s a n d h ig h r ad ia ti on
exp o su r e. T h is c lass o f ac tua tor a lso r eceiv es a c oat in g of C ar bo n ic I I u nd er coa t w i th a
P hen o lin e 30 5 t op co at to w i th s tan d n uc lear en vir o nm en tal co n di tio ns an d an im p r ov ed
m ot or w i nd in g ins u lat ion .
T w o o th er T y pe "N " act uat or s ar e a vai lab le. T h ese are th e " N A 4" an d "N A 5 ". T h e " N A 4"
ac tu at or s ar e d es i gn ed to m ai n tai n s t ru ct ur a l in teg r it y d u ri ng an d i m m ed ia tel y f o llo w in g a
L O C A b ut ar e n o t d esig ned t o op era te du rin g or afte r accid en t c on dit ion s . T h e " N A 5 "
ac tu at or s ar e th e sa m e a s " N A 1 " ex c ep t th e te m p er at u re a nd r ad iat io n l im its a re r ed u ce d.
T h e " N A 2 " actu ator s ar e t he sam e as "N A 5 " e xcep t t he seis m ic qu alif icatio n lev els ar e
r ed uc ed . T hi s a ctu a to r m o d el h as n ot b ee n m an uf ac tu r ed s i nc e 19 7 8 . T a bl e 9.8 - 1 p ro v id es
d esi gn d etails f or R oto rk ty pe "N " actu ator s . Se ction 7 .1 .1 p ro vid es a dis cu s si on of R ot ork
ac tua to r s ize /ty pe d es ig n atio n s .
R ot or k a ctu at or s ize s a re d en o ted by nu m b er s w hi ch i nd ic ate t he t or q ue o u tp ut c ap ab ili ty

o f t h e ac tu a to r . T h e lo w e r t he n um b er , th e lo w e r t h e to r q u e o u tp u t ca p ab il it y. R o to r k
ac tu ato r to rq u e o u tp uts r ang e f ro m a 15 f o ot p ou n d ou tp u t f o r s ize 7 , to a m axi m u m 16 5 0
fo ot po un d out put fo r the siz e 90 . T he fo llow in g "s ize" g ro up s w ill b e d is cus s ed in d etail in
th is m an ual: 7/ 11/ 13, 1 4/1 6, 3 0, 40 , 70 /90 .
1-1
T ab les 10 .3- 2 th ro ug h 1 0.3 -8 p ro v id e t or qu e ou tp ut s f or t he act ua tor s d is cu s s ed in thi s

m a n u al .
N O T E : A ctu ator s s iz e 6, 1 2, 35, 4 5 a nd 16 0 m ay be ins talled in s om e o lder pla nts .

Th es e actu ator s a re no long er m anu factu red by R otor k. dep ar ts or tech nical
assistance pertaining to these sizes is necessary, co ntact Ro to rk C o rpor ation.
T h e R o to rk a ctu ato r s p eed is b as ed o n th e cen ter c ol um n re vo lu tio ns pe r m in u te (R P M ) . B y

in ter cha ng in g m o to r & w or m gea r co m b ina tio ns , v ar io us s pee ds can b e ach iev ed . T h e
m o to r an d w o r m g ea r a re ch an g ed as a m atc h ed s et. T h er e a re s ix ge ar ra ti os : 80 : 1, 6 0: 1 ,
40:1 , 3 0:1 , 2 0:1, 15 :1, and tw o ind uctio n m o tors w ith no load s peeds o f 1 800 , 3 600 R PM
cu rr en tl y av a ila bl e. S p ee d o pt io ns f or sm a lle r siz e act ua to rs ar e li m it ed b ase d o n th e g ea r
ra tio s p ar ti cu lar t o th e size o f m o to r . C e nt er c olu m n spe ed s av ai lab le at 6 0 H z ar e 2 1, 2 9 ,
43 , 5 7, 86, 1 16, 17 3, and 23 0 R P M (1 8, 24, 36 , 4 8, 72 , 9 6, 14 4, 192 R PM for 50 H z). A
R o to rk a ctu ato r is c lassif ied as "h ig h spee d" if t he cen ter c olu m n i s 8 6 R P M or gr eate r. I n
the electr ic op eratin g m o de, R oto rk actu ator s ar e g ener ally co ns id ered to h ave "lo ckin g"
ge ar s e ts if t he y h av e an 8 0 :1 g ea r r ati o. T h is lo ck in g r ati o is n ot g u ar an tee d; t he re fo r e,
valv e s tem lock ing m u st be achiev ed..
T he R o to r k g ea r t ra in op er a tes in an o il b ath . In o rd er to m ai n tai n t he R o to r k 4 0 y e ar l if e

q uali ficati on , o il levels m us t be chec ked p erio dica lly to ens u re the leve l is m ainta ined
w i thi n o ne in ch o f th e u pp er m os t f ille r ho le b ot to m t hr ead . R eco m m en de d m ai nt ena nc e
i nc lu de s : s te m lu br ic ati on , O -r in g i ns p e cti on an d r elu b r ica tio n w h en m e ch an ica l jo in ts ar e
d is as s e m b led . M ai nt en an ce tas k s w ill b e dis c us s e d fu r th er in S ect io n 14 .0 o f th is m an u al.
R ot ork a ctua tor s co ns is t of s ev en bas ic as s em b lies : the g earca se , dr ive bu s hin g, m oto r,
h an d w h eel , s y nc ro s et , t or q ue s w i tch , an d ad d -o n - pa k. F or th is r eas o n a m od u la r ap p ro ac h
t o m a in ten an ce i s u ti liz ed . W he n an in teg r al p ar t of a m o d ul e fa ils , th e en tir e m o d ul e is
rep laced .
A ssem bl ies t ha t d o n ot ef fe ct the a ctu ato r to rq ue o ut pu t are cl assifi ed b y R o to rk as

c ust om er r ep lac eab le . R ep air /r ep lac em e nt o f th ese a ssem b li es r eq u ir es no sp ec ial t ra in ing
o r ce rti fic atio n o f m a int ena nc e p er s on n el to in s tal l o r r ep lace . C u s to m er r ep lac eab le
m od ules include:
• D ri ve bu s h i ng an d bu s h i ng r et ain e r
• H a nd w h eel a s s em b ly
• S y ncro s et
• A dd- on-pak
1-2
If th e m od ule to b e r ep aire d or r epl aced is no t cl assifie d as cu stom er rep lace able , (i.e.
af fe cts ac tu ato r t or q ue o u tp ut ), m ai n ten an ce p er s o nn el m us t b e q u ali fi ed u n de r a s it e
s pe ci fi c tr a in in g pr o g ra m f o r R o to r k a ct ua to r s . T h is s te p e n s ur e s t h at t he ac tu at or 's o u tp u t
tor q ue cer tif ica tio n is m ain tai ned . M o du les in th is cate go ry i ncl ud e:
• S w itch m ech anis m (to rqu e s w itch)

• M o to r an d w o rm g ea r
• G e arca se
R ot or k ac tu ato r s r ead il y ad ap t to a v ar ie ty o f v alv es. P ra cti cal ap p lic ati on s i nc lu de

o pe rat io n o f b ut ter f ly ( q ua rt er -tu r n) , d ia ph r ag m , g at e, g lo b e, a nd pl ug va lv es . T h e
act ua to rs bo lt d ir ect ly to th e yo ke o r g ear ca s e of t he s e v al ve s . In or d er to en s ur e a pr op er
m at ch of t he actu ato r to th e val ve, sp ecif ic in fo rm atio n abo u t th e va lve's resp on se tim e,
th r u s t/ to r q u e r eq u i re m e n ts a n d y o k e/ g ea rb o x b ol ti n g p a tt er n s m u s t be d et er m i n ed . In
add itio n, th e sei sm ic q ua lific ation o f the v alve/ actua tor co m b inati on m u s t b e co ns id ere d.
1.2 Drive Bushing Assembly Configurations

F or r is in g no n ro t ati ng s te m ap p li cat io n s , th e R o to r k ac tu at or 's to r qu e o u tp u t is co n ve r ted
to v alv e stem th ru st by th e d r ive b u sh in g ( s ee F ig ur e 1.2 -1 ). T hi s in te rf ace o f stem to dr iv e
bus hi ng m ust b e p rop erly lub ricated to ensur e an accep table coeff icient of fr iction is
m ai n tai n ed . T he d r iv e b u s hi n g is i ns e r ted in to th e th r u s t b as e s i de of th e ce n ter co lu m n
and is h eld i n pl ace b y a dr iv e b u sh in g r etai ner .
F i g u r e 1 .2 - 1
T yp ic a l D r ive B u sh in g
1-3
T he d r iv e b u s h in g r et ai ne r p er f o rm s a d ua l r ol e in th e R o to r k ac tu at o r. I t no t o n ly re ta in s
th e dr iv e bu shi ng in th e cen ter col um n ag ain s t th e c en ter co lu m n dr iv e d o gs, b u t i t also
ti gh te ns ag ain s t th e be ar in g s to p r in g to k ee p th e cen te r co lu m n i n th e pr o pe r po s it io n.
T h e r etai ner is loc ked in to p lace us in g on e o r tw o set sc rew s ( ba se d on act uato r size) set
ag ai ns t t he ce nt er c ol um n.
T h er e ar e th r ee d riv e sle ev e co nf ig u ra tio n s u s ed in n u cle ar a pp lic ati on s . T he y ar e

described as follow s:
• "A " T y pe (s ee Fi gur e 1 .2 -2 ) S lo tted on th e f lang e sid e to en gag e cen ter colu m n
slo ts (do g s)
- A lu m in u m b r on ze m ate rial
- C on vertible po sition s:
- P os iti on 1 in s er ts in to cen ter c olu m n
- P os i tio n 2 ex ten d s o u t o f t he c en ter c ol um n . (A n ad ap ter pl ate o r la rg er
yo ke bo re betw ee n yo ke and actu ato r m ay be ne eded if p os itio n 2 is
utilized .)
S h o w n p o sitio n fo r P o s itio n 1
F i g u r e 1 .2 - 2
D riv e B u sh A ss em b ly - T y p e A
1-4
• "A Z " T ype ( see F ig ure 1.2-3)

- N on co nv ert ibl e s tr aig ht cy lin der w it h no f lan ge o r s ho uld er an d
no ncon verti ble
- A lu m in um br o n ze m ate r ial
- S lott ed on o ne end t o eng age cen ter co lum n slo ts ( do gs)
- D ri ve s leev e re tain er is lo ng er in len gth and e xte nd s o u t o f th e cen ter co lu m n
F i g u r e 1 .2 - 3
D riv e B us h A s sem b ly - T y p e A Z
1-5
• "A X " Ty pe (s ee Fig ure 1.2-4)

- U s e d o nl y o n act ua to rs w it h th ru st co m p en sat or assem bl ies
- S i m ila r to A Z i n ap pe ar an ce bu t ha s a sh ou ld er
- A lum in um bro nze m ater ial
- S lotted on on e end to engag e center colu m n slo ts (do gs)
- R eq uir es a lo ng er d riv e s l eeve r etain er th an "A " ty pe
- N o nco nve rtib le ( w o rk s w ith sl otted en d tow ard cen ter colu m n )
F i g u r e 1 .2 - 4
T y pe A X
1-6
1.3 "A" and "NA" Range Actuators Differences
T he R o tor k "A " R an ge actu ator w as in itiall y dev elop ed fo r op erati on of cr itical va lves in
haz ard o us en vir o nm e nt s. T yp e "N A " ac tua tor s w e re s p ecif ica lly d ev elo pe d, q u alif ied a nd
su p pli ed fo r s af ety r ela ted d ut y in n ucl ear p ow e r pla nts .
T ables 1.3 -1 and 1.3 -2 prov ide a com par iso n o f "A " an d " N A 1" actuator con stru ction.
T a b le 1 .3 - 1
" A " /" N A 1 " M e c h a n ic a l C o n s t r u c t io n
C om ponent A R an ge N A 1 R ange
G earcase N o s n a p r in g m a c h in i n g S n a p r i n g m a c h in in g fo r s e a l b a c k u p
w a s he rs
D ynam ic O il Seals M e d ium nitrile V ito n w ith b ack up w a sh ers to pro vide
be tter res ilien ce a nd im p rov ed
du rab ility
O -ring for B earing N itrile O -rin g V iton O -ring to prov ide b e tter
S to p R in g resilie nc e an d im pro ve d d ura bility
P a in t S y ste m C hrom atic p rim er, A c rylic C a rbo nic II u nd e rcoat, P hen olin e 30 5
re in forced syn th etic alky d to p c o a t to w ithsta nd n uc le a r
env iro nm en ta l co nd ition s
L ub ric an t SA E 80 E P oil R a diation re sis ta nt o il
M otor H o using A lum inu m w ith alach rom e G ra y cast iron d ue to n uc le a r
co atin g en viron m e ntal co nd ition s
S yn c roset H o using A lu m in um w ith a la c hro m e G ra y cast iron d ue to n uc le a r
co ating en viron m e ntal con ditio ns
T a b le 1 .3 -2
" A " /" N A 1 " E l e c t r ic a l C o n s t r u c t io n
C o m p o n en t A R ang e N A 1 R ange
P rim a ry S w itch B u rgess T K -5 B u rgess V -1 2, ch ang e d c a sin g m a te rial to
M e cha nism D A P plastic
S w itc h e s
A O P S w itc h e s H o ne y w e ll s ta nd a rd H o ne y w e ll nu c le a r w h ic h re p la c e s the
ph en olic resin sw itch case w ith a h igh
tem pe rature ph en olic re sin sw itc h c a se
C a b le Insu latio n H igh T e m pe ra tu re P V C R a diation re sistant B IC C (T ersil) - C lass H
P o te n tio m e ter C o lve rn stan da rd O h m ite n u c lea r
Local P osition S ta n d a rd p oin te r a nd d ia l N ot a v a il a b l e
Ind icato r
O ve r loa d T h e r m o s ta t C u s t o m e r 's r e l a y
P rotection
M oto r Insu lation C la s s F C la ss H
1-7
2.0 MECHANICAL OPERATIONS

R o to r k a ctu at or s pr o vi de a c ap ab il ity fo r b o th e lec tr ic a nd m an u al v alv e o p er ati on . I n
m an y cas e s , m an ua l o p era tio n of a v alv e is pr ef err ed o r n eces s ar y .
E le ctr ica l o p er atio n o f a v alv e is t he p r inc ip al du ty of a n ele ctr ic v alv e act uat or . R em o te
elec tri c o p er atio n is pa rti cul ar ly u se fu l in lo cat io ns w her e acc es s to val ve s is lim ited ( i.e.,
ex tr em e en v ir on m e n tal c on d it io ns , h ig h r ad ia tio n l ev el ). E le ct ri cal o p er at io n a dd r es s e s
pe rs o nn el s af ety co n cer ns an d s up p or ts c en tra liza tio n of v al ve o per ati on s .
T h e fo llo w in g p ar ag rap h s e xp lai n th e in ter fa ce o f act ua tor co m p on en ts du r ing th e e lec tri c

an d m an u al m o d es o f o p er ati o n. F ig u re s 2 .1 -1 an d 2 .1- 2 ill us t r ate t he s e m o d es an d
s up po rt the d is cus s io n of co m p on en ts .
2.1 Drive Train - Motor Operation
W h il e in m an u al o p er at io n , th e a ctu at o r cl ut ch is m a in ta in ed i n t he u p po s i tio n , e ng ag i ng
th e h an d w hee l dr iv e do gs . T h e h an d au to jack (s iz e 7 /1 1 ) or han d a uto fi ng er o f th e yo k e
(s iz es 1 4 an d lar g er) is r ot ated d o w n an d res t ing on t op o f th e w or m w h eel ho ld in g th e
clut ch eng ag ed w ith th e h and w hee l d riv e d og s . (S ee F igu re 2 .1- 1)
T o s w i tch to t he m o to r op e rat io n m od e, th e re m o te m o to r p u s h b ut to n is d ep re s s ed a nd th e
m o t o r i s en e rg i ze d . T h e m o to r w o r m s h a ft an d w o r m w h e el th e n r o ta te . A s th e w o r m
w he el r ota tes , th e han d a ut o ja ck o r h an d- au to fi ng er w i ll m o v e s lig h tly i n th e d ire cti on th e
w o rm w h ee l is t u rn i n g. C lu t ch s p ri n g p r es s u re fo r ce s th e c lu t ch ri n g a n d k e ys d o w n th e
cen ter co lum n aw a y fr o m the h an d w hee l do gs . C l utc h k ey s n ow en g age t he w o rm w h eel
do g s w h ich al lo w s th e m ot o r to tu r n t he c en te r c ol u m n . T he dr iv e b u s h in g t u rn s w it h t he
cen ter c olu m n a nd r ep os it io ns the v alv e.
T h e m o to r dr iv e m a y be o v er rid d en b y n o t a llo w in g th e h an d au to l ev er to s pr in g r etu r n to

au to p o s iti on . T hi s is ac co m p lis h ed by ho ld in g t he h an d a ut o lev er in t he m an ua l po s it io n,
kee pin g th e c lut ch aw ay f ro m the w or m w hee l.
2.2 Drive Train - Manual Operation
T o op er a te th e a ct ua to r i n th e m an u al m od e , p o s iti o n th e h an d au to lev e r to w a rd h an d .
T h e ha nd a ut o jac k ( 7/ 11 ) o r h an d au to f in g er ( s ize 1 4 an d la rg er ) r ais e s th e y ok e an d th e
clu tc h ri ng w ith t he k ey s . T h e cl ut ch , no w di s en ga ged fr o m th e w or m w he el, en ga ges th e
ha n dw h e el d ri v e do g s . A s t he h an d w h ee l is tu r ne d, th e h an d w h eel d r iv e d og s co n ta ct
clu tc h k ey s p o s iti on ed 18 0 d eg r ees ap ar t. T he c lu tch ke ys , ri di ng in t he c en ter c ol um n
slo ts , t ur n th e ce n te r c ol u m n . T h e d ri v e b us hi n g, at ta ch ed to th e c en te r c o lu m n r ot at es,
rep os itio nin g the valv e. (S ee F igu re 2.1-2 )
In so m e ca ses, th e c lu tch k ey s m ay co nt act th e top of t he h an dw h eel d riv e do g s p re ven ti ng

m an u al e ng ag em en t. R o t ati ng th e ha n dw h ee l s li gh tl y w il l o ff s et t he k ey s an d d o g s ,
all ow in g m an ua l eng ag em en t.
2-1
2.3 Mechanical Subcomponents Description and Functions

2.3.1 Center Column
T h e cen ter co lu m n is t he o u tp ut d r iv e sha ft f o r th e ac tu ato r . A ctu at or spe ed i s c on tr o lle d

by th e ce nt er co lu m n R P M . I t tu r ns t he d r iv e b u s hi ng p ro d u cin g t h e to rq u e r eq u ir ed t o
op erat e th e valv e. T h e cent er col um n i s a ho llo w tu be, slo tted d ow n o pp o si te sid es t o allo w
clu tch k ey s t o b e i ns er te d. I t is kn ur led on the o u ts id e t o all ow th e lim i t sw i tch w o r m to f it
s nu g ly to t he s ha ft . T h e l im i t s w it ch w or m m es h es w it h th e p r im a ry s w it ch m ec ha n is m
gea r. T he l ow er en d of th e c en ter c olu m n is t hr ea ded on the o u ts id e to ac cep t th e d r iv e
bu sh in g re tain er fo r A , A Z , an d A X ty pe d riv e bu s hin gs . T he lo w e r end o f th e c ent er
colu m n also has d riv e d og s , 1 80 d egr ees ap art, to en gag e th e A , A Z , an d A X dri ve bu sh ing
slo ts .
M ajo r C en te r C o lu m n A tta ch ing P a rts in clu de :
• O il S eal
T h e oil seal u s ed o n th e 7 /1 1 actu ato r s is a m ech ani cal seal w ith a cu p ped si de
h ou si ng a sp ri ng . T he cu pp ed side of th e se al ( dy na m ic si de) f aces t he oil or
d irect ion to be s ealed . T he o il s ea l f its b elo w th e s h ou lde r of th e c ente r colu m n
an d a b ov e th e m ain be ar in g . S iz e 1 4 an d l ar g er h av e O - r in gs lo ca te d in th e
th r ust b ase to ke ep t he o il in th e ge ar case .
• M a in T hr u s t B ea ri n g
T he m a in th r u s t b e ar in g is a s ea le d b ea r in g an d ca nn o t b e gr e as e d . I t i s p re s s e d
o n the lo w er end o f cen ter co lu m n, f itti ng b etw een t he oil s eal an d the d riv e
b u s h in g r et ai n er . T h e m a in t hr u s t b ea r in g s u p p or t s th e ce n te r c o lu m n .
• L im i t S w itch W o rm G ear
T h e lim i t s w it ch w o rm g ear d riv es the li m it s w itch w hee l o n th e pr im ar y s w itc h

m e ch an is m . It i s p r essed on to kn u rl s a bo v e th e cen te r co lu m n sh ou ld er . T he
li m it s w i tch w o rm g ea r is av ai lab le i n d if fe re nt g ea r r ati os an d m us t m at ch t he
p ri m ar y sw it ch m ech an is m g ear .
2.3.2 Gearcase Assembly
T h e 14 a nd lar ge r ge arc ase assem bli es h o use th e cen ter co lum n, assoc iate d ge ar s, clu tch
as s em b ly , an d ac ts as an o il r es er v oi r. T h e c en ter co lu m n , O - ri ng , m ain b ea ri ng , a nd lim it
sw it ch w o rm ge ar in ser t th r ou g h th e cen te r o f th e g ear case f r om t he b o tto m . T h e 7/ 11
ac tu at o rs a re as s e m b l ed s lig h t ly di ff e re n t. T h e t hr u s t b as e is p ar t o f th e g ea rc as e an d n o t
re m o vab le. T he th r us t be ari ng i s n ot im m er s ed in o il as it is lo ca ted b elo w t he oi l s e al (n o
O - rin g s o n c en ter c ol um n) . T he t hr u s t b ea ri ng is hel d in pl ace b y th e b ear in g s to p r in g
w hic h is s ecu re d by a s hea r pin .
2-2
T h e assem b ly se rv es as th e sup p or t fo r th e m o tor , p rim ar y sw itch m ech an is m , sy n cro set,

an d h an dw h eel a s s em b lie s .
2.3.3 Worm Wheel
T h e w o rm w he el m a tes w it h th e m o to r w or m s h af t to t ra ns m it m o to r t or q ue a nd is
av ai lab l e in v ar io u s g e ar r at io s t o al ter act ua to r sp ee d. T h e w o rm w h e el is m a de o f
al u m i nu m b r o n ze m at er ia l. It w he el fi ts ar o u n d t he up p er ce nt er co l um n a n d r es t s o n a
m a ch ine d sur f ace o f th e g ea rca se. T h e w or m w h eel h as t w o dr iv e pi ns , 1 8 0 de gr ees ap ar t,
o n the u pp er s id e t o eng ag e t he clu tch k ey s du r ing m oto r o per atio n .
T h e w o r m w h eel e ng a ge s a nd ro t ate s w i th th e ro ta tio n of th e m o to r w o r m s h af t. I t i s

av ai lab le i n d if fer en t g ear ra tio s w hi ch d et er m in e ac tu ato r sp eed an d to r qu e o ut pu t.
2.3.4 Clutch Assembly
2.3.4.1 Size 7/11/13 Clutch Assembly
T h e clu tch a s se m b ly m e cha nis m s al low shi fti ng a ctu ato r op er ati on b etw e en ele ctr ical an d
m a nu al op era tion . T h e 7/1 1/ 13 cl utc h as s em b ly is c om p r is ed of a clu tch rin g an d tw o clu tch
k eys , sp ace d 18 0 d eg ree s ap ar t. T h e clu tch k ey an d w o rm w h eel spa cin g allo w the m oto r to
r each t he co rr ec t sp eed b ef or e th e k ey s a nd d og s eng ag e. T h is pr ov id es a h am m er b lo w
ef fe ct to e ns u re th at th e m o to r is up t o s pe ed b ef or e th e t or qu e lo ad i s ap p lied . T h is
h am m e r bl ow pr ov id es a n im p act lo ad to a s si s t in ov er com ing ini tial v alv e/act uat or s ta tic
fric tio n.
T he clutch as sem bly W ilts d ow n over th e cen ter co lu m n. T he clutch k ey s fit into slots
p ro vid ed o n th e o ut si de of the cen ter c olu m n . T he ta per ed ( sh o rt) s id e of th e clu tch k eys
ar e p os iti on ed do w n, in th e dir ectio n of th e w or m w h eel. T h e c lutc h as se m bly i s he ld do w n
in th e m oto r dr ive po s itio n us in g a co il s pr ing , flat m eta l w as h er and ci rclip .
I n m o to r dr iv e, th e bo tto m o f th e c lut ch k ey s en g age th e w or m w h eel dr iv e pin s . I n

h and w he el o p erat ion , th e to p o f the clu tch k ey s en ga ge the d riv e do gs of th e han d w h eel
assem bly.
2.3.4.2 Size 14/16 and Larger Clutch Assembly

T h e 14 /1 6 and larg er c lutc h as s em b lies s ho w n in F ig u res 2.1.1 an d 2.1 .2 f un cti on in t he
sam e m an ner as the 7/1 1/ 13 assem b ly w i th the fo llo w i ng ex cept ion s:
• T h e 14 /1 6 a nd lar g er cl ut ch a ssem b li es ut ili ze a th r ust p ad t ha t is bo lt ed i nsi de

the g ear case ho us i ng d ir ectly abo ve th e w or m w hee l u s in g fo ur c ap scr ew s . T h e
th ru st pa d p rev en ts th e w or m w h eel f ro m r isin g u p th e cen te r co lu m n ( ca usi ng
bin din g) du rin g hig h tor qu e co nd ition s .
2-3
• A yo ke as s em bl y is p o si tio ned jus t ab o ve th e t hr us t p ad an d ju s t b elo w the cl utc h

r ing a nd k ey s. T he yo k e as s em bly tran s fe rs o p erat ion f ro m m o tor ( au to) t o
m an ua l ( ha nd w h ee l) w he n th e h an d lev el i s m an u al ly o p er at ed . T he y o k e
as s em b ly w ill o nly s w itch f ro m m a nua l to m o tor w h en the m o tor is en er gized .
• A h an d a u to cam , a tt ach e d t o th e h a nd au to le v er , r o tat es a nd r ais e s th e y o ke
f or m anu al op er atio n.
• T h e ta per ed s ides of clu tch key s ar c p os iti on in th e u p dir ectio n.
• T h e clu tch s pr in g is hel d in p lac e us in g a tap er ed w a sh er a nd an O - rin g .
2.3.5 Handwheel Module
T he h an dw h eel m od u le pr o vi des a m e ans f or m an ua l op er ati on o f th e asso cia ted v al ve .
• T o p M ou nted H an dw h eel
T he t op m o u nt ed ha nd w h ee l is av ai la bl e on al l size s ex cep t si ze 7 0 a nd la rg er .
T he ri m o f t he ha n dw h e el i s s m o o th on th e 7 / 11 /1 3 . T h e h an d w h ee l on s i zes
1 4 /1 6 a n d l a rg e r h av e s p ok e s p r o tr u d i ng f r o m t h e r i m . T h e h a nd w h ee l a tt ac h es
t o th e g e ar ca s e u s in g a re ta in er . T w o s ea ls h av e b ee n p r o vi d ed a t th e c o nn e cti o n
p o in t o f t he ha nd w h e el t o en s u r e th a t o il is r et ai ne d i n t he ho u s in g an d t o
p r ev en t o il co n tam in a tio n .
T h e t op m o u nt ed h a nd w h ee l att ach es t o th e g ea rc as e u s in g a n y lo n o r f le xi b le
m e ta l r e ta in e r.
• S id e M o un ted H and w heel
T h e s id e m o un te d ha nd w h eel is o pti on al o n s iz e 1 4 a nd l ar ge r act uat or s and is

s t an d ar d o n s iz e 7 0 a n d l ar g er . T h e s id e m o u n te d h a nd w h e el as s e m b l y i s
a tta ch ed to th e g e ar ca se w it h se v en so ck et -h e ad cap scr e w s . T h e h an d w h eel
o pe rat es us in g it s o w n g ear d r ive c on s is ti ng o f a w o rm s h af t a nd w or m w he el
m uc h li ke t he m o to r d ri ve . T he s i de m o un te d h an dw he el in cr ea s es th e
m e ch an ica l a dv an ta ge f or m an u al op er at io n.
2.3.6 Torque Switch Shaft
T h e tor qu e s w it ch s haf t ( als o cal led a tor qu e p lu ng er) co n ver ts lin ear m otio n of t he m o tor 's
r oto r, t o rad ial m o tio n via a hel ix ge ar on th e bac k of th e tor qu e sw it ch m ech an is m (s izes 7
- 4 0 ) and a r ati o pl ate (s iz es 7 0 /90 ) . T he to r qu e sw i tch sh af t a lso fu n ctio ns to is o lat e t he
r ot atin g m o tio n o f th e m ot or s h af t f ro m th e pr im ar y s w it ch m ec ha nis m h elic al gea r.
T he m ot or en d o f th e sh af t ha s a c ase h ar de ne d al len cap scr ew th at in te rf ac es w ith a

h ar d en ed s tee l ba ll b ea ri ng on th e en d o f t he m o to r s h af t. T h e to rq u e s w it ch m ec ha ni s m
e nd of th e s ha ft h as an ad ju s tab le c ap s c re w u s ed fo r l en gt he ni ng an d s h or te ni ng du r in g
ac tu ato r to rq ue ce rti fic atio n tes t ing to b alan ce to rq ue o ut pu t be tw een o p en an d clo s e s ide o f
to rq ue s w i tch.
2-4
F igu r e 2.1- 1
D r i v e T r a i n - H a n d O p e r a t io n
S iz e 1 4 an d L a rg e r
2-5
F i g u r e 2 .1 - 2
D r i v e T r a i n - M o t o r O p e r a ti o n
S ize 1 4 a n d L a rg er
2-6
3.0 ACTUATOR MOTOR
T h e A C m o to r s c ur r en tly su p pl ied w ith R o to r k ac tua to rs ar e sin g le vo lt ag e, t hr ee- p ha s e,

s qu ir re l c ag e, in d uct io n ty pe , to tall y en clo s ed n on v en tila ted ( T E N V ) m o to rs . T hes e m oto r s
are g ener ally w o un d fo r eith er 4 60 o r 57 5 V A C (o ther v ol tage s an d fr equ en cies a re
av ai la b le i n o t he r c o un t ri es) . T h e y h av e h i g h st ar ti n g t or q u e c ha r act er i s ti cs an d ar e si ze d
to p r o vi de th e ra ted to r qu e o f t he a ct ua to r as s em b ly . A ll m ot or s ar e p ro v id ed w it h
ou t bo ar d b al l b ear in g s lu br ic ate d a t th e fa cto r y f o r li fe tim e o pe ra ti on . T he ou tb o ar d
be ar in g s ar e f itt ed be tw e en t h e op e n an d clo s e s p r in g p a ck s . A n ee dl e b ear in g is us ed a t
th e in b o ar d m ot or en d t o a llo w th e m ot o r r ot o r to tr an s l ate a x ial ly . T hi s ne ed le b ea r in g is
lu b ri cat ed b y t h e ge ar case o i l. A n oi l sea l be tw ee n t he n ee dl e b ear in g a nd ro t or pr ev en t s
ge ar case o il fr o m ent er in g th e m o to r assem bl y. R o to rk A C m o to rs ar e fr act io na l a nd lo w
h or s e p ow er ra te d m o to r s . T h e m o t o rs n o r m a ll y h av e a n in te r m it te n t d u ty ra ti n g o f 1 5
m inu tes an d hav e a no lo ad op erati ng s peed o f 18 00 or 3 60 0 R P M f or 4- po le an d 2- po le
m o tor s , re s pec tiv ely . T h e a ctu al f u ll loa d op er atin g s pe ed is s lig htl y les s f o r A C m o tor s .
D C m o to r s ar e no t av ail ab le fo r n u clea r ser vi ce. M o to r le ad ou ts ar e m ad e of T er s il 18 H i
T ° N C . T he r e ar e no m o to r t he r m o stat s em b ed d ed in t h e w in di n gs o f N A 1 m o to r s ;
ext ern al ov er loa d pr ot ectio n is typ ica lly p ro vid ed a t th e m o tor c on tro l cen ter .
A ct ua to r s s ho u ld b e s iz ed s uc h t ha t to r qu e s w itc h w i ll t ri p a ft er th e r eq u ir ed to rq u e h as
bee n de live red . T h e actu ato r size sho ul d acco un t fo r w or s t c ase c on dit ion s o f v olt age,
te m p er at ur e a nd m e ch an i cal e f fi cie n cy . O n c e th e r eq u ir ed to rq u e t o o p er ate th e v alv e h as
be en d eter m i ned safe ty f acto r s f or v o ltag e d ro p, t em p er atu re a nd m ech an ical e ff icie nc y
m u s t b e in clu d ed . T a bl es 10 .3 -3 th ro u gh 10 .3- 7 p r o vi de u n it m a xi m u m to r qu e r ati ng s fo r
var io us vo ltag e d ro ps .
F or te m p erat ur es a bo ve 1 63 °F ( 70 °C ), m ult ipl y the r equ ir ed to rq ue b y th e f ol low in g

co rr ec tio n f act or s to p ro v id e ad eq ua te m a rg in f o r h ig he r tem pe ra tu re m ot or o p er ati on .
T a b le 3 . 0 - 1
T o r q ue R a tin g
T e m p e r a tu r e M u ltip lie r
1 6 3 ° F (7 0 ° C ) to 2 5 0° F (1 24 ° C ) 1 .1
2 5 0 °F (1 2 4 ° C ) to 3 0 0 ° F ( 1 4 9° C ) 1.13
3 0 0 °F (1 4 9 ° C ) to 3 7 0 ° F ( 1 8 8° C ) 1.17
A s n o te d ab o ve , ac tu ato r m o to rs ar e n ot r at ed f o r c on ti nu o us d ut y a nd ge ne ra lly ha ve s ho r t
du ty cy cle s . S in ce th e m o to r s a re to ta lly en clo s ed w ith o ut ex te rn al f an co ol ing , t he h ea t
g en er at ed b y t he m o to r d oe s n ot r e ad il y e s ca p e, an d t em p er at u re s th at c an d am ag e t he
m o to r in s u lat io n m a y d ev elo p q u ick ly un d er s e ve re l oa di ng co nd it io ns . T h e ra ted du ty
cy cle o f the m oto r is b ased o n th e tim e t he m o to r m a y be o pe rat ed at it s av er ag e l oa d
to rq u e in a o n e h o ur pe ri od w ith o ut e xc eed in g th e m o to r 's d es i gn tem pe rat ur e li m it s .
O p er ati on fo r lo ng er p er io ds o f t im e a t av er ag e l oa d to r q ue b u ild s u p te m p er at ur e s t ha t
ca n d a m a ge th e m o to r s ta to r or r o to r . F re q u en t s t ar t s ( p l ug g i ng ) m a y a ls o d a m a ge th e
m ot or eve n tho ug h the du ty cycl e tim e is n ot ex ceede d.
3-1
A ct ua tor m ot or s h av e th e fo llo w in g ge ner al d es ig n attr ib ute s :
• R ate d to rq u e i s v ar iab le ac cor d ing to th e act ua tor size an d R P M

• A v er ag e l oa d to rq u e i s es t im a ted a t a pp ro x im a tely 33 % o f th e rat ed to r qu e
• R ated d uty c ycle is n or m all y 15 m in u tes /ho ur f or th ree -p has e A C
• L o cke d rot or cur ren t l ast s fo r app ro xim at ely on e an d on e h alf cycle s of th e
s u pply f req uen cy (les s th an 30 m illi sec ond s ) b efo re the m ot or reach es f ull sp eed
R o tor k m o to rs are sp ecial ly d esign ed w i th sm al l d iam eter r ot or s to red uc e i ner tia l l oad in g
e ff ects fo llo w in g co nt ro l sw i tch tr ip . T h e m ot or h ou s in g an d en d cap b ear the th r ust lo ads
d eve lop ed w hen th e w o rm an d w o rm w hee l "c raw l" du rin g th e to rq uin g op erat ion .
C A U T IO N : N ever o pera te th e m o tor w ith th e m o tor e nd cap rem o ved. S eriou s

m o tor da m a ge a nd per s onn el in jur y m ay o ccur . M oto r hold ing bo ats an d end cap
b olts s hou ld b e m ad e of qua lified m ater ials a nd tor qued to pr oper va lues to
p r ovid e s tr uctu ra l a s w ell as en vir onm en tal integ rit y.
T he m o to r sh aft h as a har d en ed stee l bal l p r ess f itt ed in to the w o rm e nd t o p ro vi de a lo w

f r icti on co nta ct su rf ace w h er e th e m o to r sha ft m eet s th e to rq u e pl un g er sh af t.
A re pl acem ent m oto r an d w o rm w h eel ar e sup p lied a s a m a tch ed set sin ce th e m ot or w o r m

a nd w or m w h ee l pr o vi de t he o n ly ge ar r ed u cti on in t he t or q ue p a th o f t he a ctu at or . T he
m o to r a nd w o rm w he el m u s t b e in s ta lle d a s a s et w h en th e a ctu a to r s p ee d i s c h an g ed . I t is
ac ceptab le to r eplace a d am ag ed w o rm w heel, if th e m o tor is i n p ro per w or kin g con ditio n.
N O T E : See S ection 12.0 for specific m o tor perfor m ance data .
3-2
4.0 PRIMARY SWITCH MECHANISM, ADD-ON-PAK AND

SYNCROSET FUNCTION
B o th t he N R C an d I N P O h av e i de nt ifi ed th e lea din g c aus e o f ac tua to r/v al ve f ailu r e a s

im p r op er act ua to r s et u p. S pe cif ic all y, nu m e ro u s fa ilu r es ha ve b ee n ex p er ie nc ed d u e to
s etu p pr o b le m s w it h p r im ar y s w itc h es an d ad d -o n - pa ks . I m p r o pe r s e tu p t ec hn i qu e s o n ce
ov erl oo ke d or co n si der ed i nsig ni fica nt ar e n o w b ein g an alyz ed u si ng so ph is tic ated t est
eq ui pm en t. T hi s s e ctio n pr o vi de s a d is cu s s io n o n t he d es i gn /o p er ati on of th e pr im ar y
s w it ch m e ch an is m , ad d -o n - p ak a n d s y n cr o s e t. B e tt er u n d er s t an d in g o f th e
des i gn /o pe ra tio n o f th es e m ec han is m s s h ou ld res u lt in im p ro v ed s et up p r oc ed ur es .
4.1 Primary Switch Mechanism
T h e R o to rk actu at or sw i tch m ec han is m f u nc tio n is to a cti vat e/d ea ctiv at e sw i tch es to

con tro l valv e po si tion o r pr ov id e in di catio n/i nter lo cks at s p ecif ic valv e po si tion s . T h e m o to r
con tr ol p or tio n o f th e sw i tch m ech an is m can b e us e d to sto p th e actu at or a t a sp ecif ic
po s iti on e s tab lis h ed d u rin g l im it s w i tch s et up (w it h to rq u e sw i tch b ac ku p ) or at a sp ec ifi c .
m o to r to r qu e e s tab li s he d f r om t or q ue s ele cto r s e tti ng s . T h e de s ir ed o p er at io n is s el ec ted

via th e to rq ue /lim it s elec to r kn ob on t he s w itc h m ec ha nis m .
T o s to p th e actu ato r at a s pe cif ic po s iti on , th e sw i tch m ech an is m lim i t s w i tch ( po s iti on

se ns i ng ) o pe ra tio n u tili zes a pi ni on g ea r o n th e lim i t s w itch s ha ft d ri ven by a w or m on th e
cen ter co lu m n ( s ee F ig ur e 4.1- 1 ). T he lea d s cr ew o r s cr ew ed s h af t i s d ri ven fr om th e pi ni on
thr o ug h an ov er lo ad cl ut ch w h ich c au s es t he tr av eli ng nu t to m o v e axi all y alo n g th e
s cr ew e d s h a ft . T h e tr av e lin g nu t m o ve s al on g th e s h af t u n ti l it c o nt ac ts th e l u g o n t h e
back s to p (g oin g clo s ed) o r th e l ug o n th e lo ck nu t ( go in g op en ). C on tact w ith e ithe r lug
cau s es th e o v er tr av el g u id e b ar t o r ot at e an d co n ta ct th e s t ri ke r p lat e w h ich m o v es to
eng age a m ic ros w itch , s top pin g t he m oto r (s ee F ig ur e 4 .1 -2 ).
F i g u r e 4 .1 - 1
N A T E lec trical A c tua tor
4-1
F ig u r e 4 .1 - 2
P rim ar y S w itc h M ec h a n ism
T o sto p th e m o to r a t a pr ed et er m i ne d to r qu e, th e sw itc h m ech an is m r ec eiv es a li ne ar

m o tio n m ech an ica l in pu t fr o m th e t or q ue s w i tch s h af t as to rq u e i s a pp lie d to th e m ot or
(d u rin g o ve rlo ad o r at th e en d of val ve m o v em en t) . T h e lin ear m ot ion is c on ve rte d to a
ro t ati ng m o ti on b y a h el ica l ge ar (h el ix ). T h e r ot at in g m ot io n o p er ate s a s tr ik er p l ate
w hich m ov es to co nta ct a m icr os w itch an d s top th e m oto r.
F i gu r e 4 .1- 3 s h o w s t he f ace p la te o f th e s w itc h m e ch an is m . T o rq ue a dj us t m en t s cr ew s fo r

clo s e and op en o pe rat ion are sh ow n ( I tem s A a nd B ). Ite m s C and D al low th e m ot or t o be
stop ped at a p rese lected tor qu e o r po sit ion fo r clos e and o pen o per ation .
4-2
F i g u r e 4 .1 - 3
P rim a r y S w itch M e ch an is m S e lec to r
T he re ar e si x m ic ro sw i tch es o n th e sw itc h m ec han is m ( s ee F igu r e 4 .1- 4) . T h r ee are f or the

o pe n dir ecti on an d th ree fo r th e c los e dir ect ion . T h e cl os e sw i tche s ar e t he clo se to rq ue
lim it sw itch ( C T /L S ), clos e auxiliar y s w itch on e (C A S 1) and clos e aux iliary sw itch tw o
( C A S 2) . T he op en sw itch es ar e o pen to rq ue l im it s w itch ( O T /L S ), op en aux iliar y s w itch 1
( O A S1 ) and o pe n a ux iliar y sw it ch 2 (O A S 2) . T he tor qu e l im it sw it ches are us ed f or m o tor
co nt rol w hil e th e au xil iary s w itch es are u sed f or p os itio n ind icatio n or in terlo cks .
T he au x ilia ry sw i tch es (C A S 1 ,2 & O A S 1 ,2 ) ar e act ua ted f r om a s ep ar ate s tr ik er p late a nd

o pe rate s lig ht ly bef or e the to rq ue lim it s w itc hes (C T /L S or O T / L S ). T h is s li gh t d if fer ent ial
i s im po r tan t in t hat i t e ns u r es r em ot e p o s itio n s i gn ali ng bef o re th e v alv e m o to r re ceiv es th e
stop sign al.
A s view e d fr om the s w itch c ov er s ide lo ok ing i nto t he actu ato r, th e r ig ht s ide o f t he pr im ar y

s w itc h m o d ul e co n ta in s th e c lo s e s w itc h es . C T /L S is t he fr o n t s w i tch . It is n o rm al ly
c lo se d an d o pe ns to s to p a ctu ato r /va lv e m ov em en t a t the e nd o f c los i ng t ra ve l. I t i s a
co m bin ation tor que "or " lim it sw itch depe ndin g o n w h ich is s elected .
or
C A S 1 is the m i dd le sw itch . It is no r m ally op en an d clo s es w h en t he v alv e f ul ly clo s es. I t is

so m etim es u s ed fo r a sh or t op en tor qu e sw i tch by p ass.
C A S 2 is th e re ar s w i tch . I t is no r m a lly clo s ed w he n th e v alv e is in th e in ter m e di ate a nd

o pe n po s itio n and o pe ns w h en th e v alv e f ul ly clo s es . It is u s ed fo r rem ote in dic atio ns
( com p uter, rem o te in dication s, etc.) .
4-3
A s v iew e d fr om th e sw i tch co ve r si de lo ok in g int o the ac tua tor , th e l eft s id e o f th e p r im ar y

s w i tch m o d u le co n ta in s t he op en s w it ch . T he O T /L S is th e fr o n t s w it ch . I t is n or m all y
c lo se d a n d o p e n s w h e n th e v a lv e re ac h e s th e o p e n en d p o s itio n o f tra v e l to p ro v id e th e
m o to r s top si gn al. A s w i th th e C T /L S , the O T /L S is a c om bin atio n to rq u e " or " lim it s w itc h
d epen din g on w hi ch is s elected .
O A S 1 is the m id d le s w it ch. I t is n or m al ly clo s ed in th e op en va lve p os iti on , an d clo se s

w h en t he v al ve r ea ch es t he f u ll o pe n p os i tio n . It i s s o m e tim es us e d fo r a s h o rt c lo s ed
to r qu e s w itch by pa s s.
O A S 2 is th e r ea r s w i tch . It i s no r m a lly cl os e d w h en th e v al ve i s i n t he in ter m ed iat e an d

cl os ed po sitio n , an d o pen s w h en t he v alv e re ach es t he f ull y op en po sitio n . It is us e d fo r
r em o te i nd icati on s (c om p u ter, r em o te ind icat ion s , etc.).
T he sw i tch m e ch an is m is f itt ed w ith a sm al l he at er ( 1 2 w at t m ax ) t o r ed u ce m o is t u re

co n d en s ati on in s id e th e act ua to r el ect ri cal e nc lo s ur e w h ich m i gh t r es u lt f ro m am bi en t
t em p er a tu r e c h an g e s . L a te r v e r s io n s o f th e R ot o r k a ct u at o r ha v e t h is h e at er a tt ac h ed to
th e g ea rc as e ju s t b eh in d t he s y n cr o s et h ou s in g i n s tea d o f at tac hi ng it t o th e b ack of th e
sw it ch m e ch ani s m .
F i g u r e 4 .1 - 4
S w itc h M e c h a n ism
4-4
4.2 Add-on-pak
T he bas ic fu nc tion o f a R oto rk ac tuato r ad d-o n- pa k is to pr ov id e ad dit ion al co nt ro l s w itch

fu nc tio n s ( i.e., ex ten de d to r qu e s w itc h by p as s ) . F ig ur e 4.2 -1 s ho w s 6 an d 12 s w itc h ad d-
on-p aks .
F ig u r e 4 .2 - l
P o st-1 9 7 8 A d d -o n -p ak A s sem b lies
T h e ad d- on - pa k co n tai ns ad ju s tab le c am s to s et th e s w itc h b an k li m it ac tu ati on po in ts ( s ee

F ig ur e 4 .2- 2 ). M ic ro s w i tch es a re a dj us ted w ith s et s c re w s s o th a t th e en ti re b an k of
s w itc he s o p er ate t og e th er . T h e ad d -o n -p ak s et s c re w s a re f ac to ry s et an d s h o u ld n o t
re q ui re ad ju st m e nt s in th e f ie ld . T h e ad d - on - p ak at tac h es to th e f r o nt o f th e p r im ar y
sw i tch m ech an is m u s ing po sts an d alle n set scr ew s. A d d- o n- pa ks can be a six sw i tch
4-5
v ers io n w ith th ree clo s ed and th re e o pen m icr os w itch es o r a t w e lve s w itch v ers io n w ith 6
o pen an d 6 clo s ed m icr os w itch es. T h e tw elv e sw it ch pac k has fo ur cam s to allo w th e sw it ch
b an k s t o b e s e t at v ar i ou s v alv e p o s it io ns . T h e s i x s w i tc h p ac k h as tw o ca m s to s et t h e
s w itch b ank s at tw o s pec ific p os itio ns . O ld er ver s ion a dd -o n- pak s h ave pu s h on ( app lian ce)
te rm in al s w h il e ne w er v er s i on s ha ve r in g t er m i na ls w ith lo ck w as h er s a nd s cr ew s .
F i g u r e 4 .2 - 2
A dd -on -pa k
S w itch es desig nat ed as "clo se" sw itch es ar e o n the rig ht side of the add -o n- pak as v iew ed
f ro m t he en d o f t he a ssem bl y f ar th es t aw ay f ro m t he d r iv e g ear en d . S w i tch e s a ctu a te as
th e c am r o tat es ov e r th e to p an d d ep r es s e s t he s tr ik er p l ate . S w i tch es d es i gn a ted as "o p en "
ar e o n the lef t sid e.
T h e ad d- on -p ak co m es o ptio na lly equ ip ped w ith a po ten tiom eter fo r rem ote ana log v alve
po sitio n in dication .
T h e a dd - o n- p ak ca n b e ad ju st ed t o a ctu a te at an y p o in t d ur i ng va lv e tr a ve l. T h is is
d if fe re nt f r om t he p r im a ry s w itc h m e ch an is m s in ce t he p r im a ry s w itc he s m us t b e s et a t th e
en d o f v alv e tra ve l t o co nt ro l th e v al ve p os it io n. T he ad d -o n- p ak , ho w ev er , m u s t be s et to
ac tu at e p ri o r to th e p r im ar y s w i tc h m ech a ni s m . T h is " en d o f s tr o ke " li m i tat io n r e qu i re s
th at t he ad d -o n -p ak be s et t o ac tu ate at a pp r ox im ate ly 1 0% of va lv e tra ve l pr io r to th e
sw it ch m e ch ani s m actu at io n to e nsu re th at o th er d ev ice s ac tu ate ju st pr io r to m o tor cu tof f .
T h e ad d- on - pak is ac tu ated b y m ov em e nt o f th e c ent er co lu m n th r ou gh the sw it ch

m ech an i s m scr ew e d sh af t a nd ge ar dr iv e . T h e a dd - o n- p ak att ach e s t o t he sw itc h
m ech a ni s m s h a ft . T he ad d -o n - pa k i n pu t d r iv e s h a ft ro t ate s w it h t he s w it ch m e ch an is m
sh af t. S in ce th e ad d - on - pa k sw i tch act ua tin g cam s r o ta te le ss t ha n o n e re vo lu ti o n f or
n or m al o pe ra tio n , r ed uc tio n g e ar s a re u s ed to o b tai n th e co r re ct g ea r r ati os . D ep en di ng o n
th e va lv e st ro k e, th e ad d- o n- pa k h as a v ar yi ng n u m b er o f sp acer s/g ear s to p ro v ide t he b est
s w itc h act ua tio n r es ol ut ion . E ach s et o r p air o f r ed uc tio n g ear s p ro v ide s a 2 t o 1 s tep do w n
in sha ft r o tat io n. O ld v er s io n sw i tch es us e h ig h t em p er at ur e p ol y g ear s/sp ac er s, w h ile
n ew e r a dd -on -p aks us e b ras s ( s ee F ig ur e 4 .2 -2 ).
4-6
4.3 Syncroset Assembly
T h e s yn cro s et as s em b ly (s ee F ig ur e 4 .3- 1) is the f ield ca ble ter m in ati on b loc k. T h e

sy ncr o se t h o usin g p ro vid es an en vi ro nm ent ally sea led en clo s ur e fo r ter m in ati ng th e fi eld
c ab les. T h e act ua to r u s er m u st sup p ly t he q u ali fi ed c ab le en t ra nc e seal in g d ev ice m eet in g
sit e spe cif ic r eq u ir em e nt s. T h er e ar e 4 4 te rm in als av ai lab le f o r co nn e ctin g v ar io u s i nt er na l
a ctu at o r o pt io n s . T he t er m i n al lu g s pa s s th ro u g h an el ect r ica l in s u lat in g b l oc k ( te rm in al
b un g) to th e i nsid e of th e elec tri cal enc los u re w h ere th e m o tor l ead s an d sw itch lead s ar e
at tac he d. T h e ter m i na l bu n g is al s o s ea led w ith an O - r in g to pr o vi de a s e co nd ba rr ie r to
p re ve nt m oi s tu re f ro m en te ri ng th e i nn er m o s t el ect ric al en cl os u re . E a rl y s y nc ro s et m o d els
h ad b ra s s t er m i n al p os ts fi tt ed w ith s p eci al " ba r re l nu t s ". L at er ve rs io ns h av e s t eel p o s ts
a nd us e t he s am e b ar r el n u ts fo r s e cu ri n g th e w ir e te rm in al s t o th e p o s t.
T h e sy nc ro set te rm in al bu n g h as a lar ge n u m b er o f te rm in al po sts en cl os ed in a sm all

s p ac e. S p eci al c ar e m u s t b e t ak en in fi tti n g th e t er m i na ls an d ro u ti n g th e i nd i vi du a l w ir es
to en su re t ha t ele ctr ica l sho r tin g to a dj ace nt t erm in al s d o es no t o ccu r . T h e ty p e an d siz e of
r in g ter m i na ls u ti lize d by th e i nd iv id ua l uti lit y w ill d ete rm ine t he n eed fo r ad di tio n al car e
i n te r m i n a l a r ra n g e m e n t.
4-7
F i g u r e 4 .3 - 1
S y n cr o se t A sse m b ly
4-8
5.0 THRUST COMPENSATOR AND TORQUE LIMITER FUNCTION
5.1 Thrust Compensator
T h e th r us t co m p e ns a to r is u s ed on h ig h s p e ed v a lv e s te m s a nd ac tu at o rs to p re v en t r ap id
v a lv e th r u s t b u i ld u p in t o t h e s e a t ( s e e F i g ur e 5 .1 - l ) . T h e t h ru s t co m p en s a to r a ct s as a
sp ri ng cu shi on o r sho ck ab sor be r to p ro tect th e v alv e and a ctu ato r fr om ex cessiv e f o rce d ue
.
t o i ne rt ia . T h e th r u st co m p en sa to r w i ll p ro v id e n o m ech a ni cal i n er tia p r o tec tio n on ce th e
s pr in g s ar e f ul ly co m p r es s e d . T h e t h ru s t c om p en s at or m a y p r o vi de th e ad d it io na l
a d va nt ag e o f im p ro v ed to rq u e s w it ch re pe ata b ili ty s i n ce th e s l ow e r t hr u s t bu i ld up r ate
d u r in g s p r in g c om p re s s io n s im u l ate s m o re clo s e ly t h e th ru s t b u il du p ra tes s e en du r in g
h igh v alve load ing p erio ds .
.
F ig u re 6.1-1
T h ru s t C o m p en s at or
T h e th r u s t c om p en s a to r r e qu i re s n o s e tu p or ad j us tm en t, al th o u gh h ea vy a nd li g ht s p ri n g
p a ck s a re av ail ab le f o r sp ec if ic th r u st da m p en in g . T hr u st co m pe nsa to r s c on s i s t of a set o f
s pr i n g w as h e r s s im il ar to t h e m o t o r s pr i n g p a ck b u t la r g er in s i ze . T h e t h ru s t
c o m p en s at or h ou s i ng re p lac es th e th r u s t ba s e o f th e a ctu a to r an d is lo ca ted b etw e en th e
a ctu ato r g ear case an d v alv e yo ke .
5-1
5.2 Torque Limiting Brake
T he to r qu e l im it ing b r ake co ns i st s o f a m ech an ical d isc a nd p ad assem bly m uc h lik e t he

di sc b ra ke s o n a car ( s ee F ig ur e 6.2 -1 ). U nli ke ca r br ak es , th e di s c m ov es in an d o ut w i th
th e m o to r s ha f t as t h e ac tu a to r to r qu e bu i ld s u p . T he p ad s ar e s tat io n a ry o n e it h er s id e o f
th e d is c. T h e a s s em bl y f it s o n th e o ut bo a rd en d o f t h e m o to r . T hi s re qu i re s t h e ro to r s ha f t
to b e lo ng er tha n th o s e w ith ou t to rq u e lim iti ng b r ak es .
1 B rak e D isc 5 M oto r H o us ing

2 B ra ke Pa ds 6 L o ck ing Set Screw
3 L o ckin g B ack P late 7 P lat e A ssem b ly
4 B r ak e P a d M o u n tin g P la te 8 S h a ft
F i g u r e 5 .2 - 1
T y p i c a l T o r q u e L im i t i n g B r a k e A s s e m b l y
T h e to rq u e lim iti ng br ak e p er fo r m s th e sam e fu n cti on as th e th ru st co m p en sat or assem bl y ,

re du c in g th e in e rt ial t hr u s t in to th e v alv e b y s t op p in g t he m o to r r o tat io n s h o rt ly a f ter
m o to r cu to ff . T h e to rq u e lim itin g b r ake c an p ro te ct th e va lve d u rin g m ot or st all s s in ce t he
ex cess t or q ue w i ll b e ab so rb e d b y th e a ctu at or br ak e a nd no t t he v al ve s tem . T h e t or q ue
lim i tin g b ra ke is de s ign ed to li m it th e actu at or t or qu e o utp u t t o 1 50 % o f ra ted t or qu e.
S ett in g th e to rq u e l im i tin g b r ak e i s c ri tica l. I f th e p ad s a re s et t oo clo s e to t he d is c, th e

m o to r m ay s t all b ef o re t he s h af t ca n m o v e fa r en o ug h to t ri p th e to r qu e s w it ch . I f th e p ad s
ar e s e t t oo fa r fr o m the d is c, th e a ctu ato r m ay p ro d uc e e xc es s i ne rt ial to rq u e an d th e
be n ef it s o f th e b ra k e w o u ld b e l o s t. T h e to r q ue lim it in g b r ak e m us t b e ad ju s t ed u s i n g a
to rq u e tes t b en ch . A d ju s tm en t of th e t or q ue l im i tin g b r ak es s ho u ld b e p er fo r m ed by
pe rs o n n el tr a in ed i n t he p r o pe r m a in te na n ce an d ad ju s tm en t of th es e a s s em bl ie s .
5-2
6.0 BASIC ELECTRICAL CONTROL DESCRIPTION
T h is sect io n de scr ib es t he b asic e lec tri cal co n tr ol f or a R o to rk act ua tor . A l th ou gh m an y

v ar ia ti o ns a n d a rr a ng e m e nt s o f c on t ro l c ir c ui tr y ar e u s ed th r o u g ho u t t he in d u s tr y , a ll
co ntr ol sch em es m ak e u s e o f th e sam e m ajo r com po nen ts . A t yp ical 46 0/ 57 5 V A C thr ee
p has e c on tr ol s ch em ati c f o r act ua tor co ntr o l is d es c rib ed in th is ch ap ter .
N O T E : T he cont ro l co m p on ents in clud ed in th e sch em a tics ar e ref err ed to by the

con tr ol fu nctio n th at they p ro vide.
6.1 Electrical Components - Motor Control Center

6.1.1 Circuit Breaker/Fuses
A m o ld ed ca s e ci rc u it b re ak er w it h in s t an ta ne ou s m a g ne ti c tr ip un it s an d f u s es p ro v id es a
m e an s fo r b o th m a nu al an d au t om at ic d e- en er g iza ti on of th e en t ir e R o t or k a ct ua to r
46 0/ 57 5 V A C po w er circ uit an d 12 0V con tro l po w er. T h e br eake r is m a nu ally o pen ed o r
clo se d by m o vin g the han dl e m o un ted o n t he ou ts ide of th e m o to r c on tro l cen ter ( M C C )
do o r to th e o n an d o ff p os it ion s . T h e d oo r is typ ica lly eq ui pp ed w ith a s af ety i nte rlo ck to
p rev en t th e d o or f r om b ein g o pe ned w ith t he b re ake r clo s ed a nd t he ci rcu it ry e ne rg ized .
A u tom ati c de -en er g izat io n (t ri pp in g ) is pr ov id ed by t he m ag ne tic tr ip u n its fo r s h or t ci rcu it

p r ot ec ti o n. T h e m a gn e ti c tr i p u n it s ar e s o m et im es r ef e r re d t o as ci r cu it p ro t ec to r s in th at
th e p ow e r ci rc ui t a nd co nt ro l p ow er tr an s f or m e r ar e p ro te cte d f ro m th e d an ge ro u s ly h ig h
cu r r en ts t h at r es ul t f r om s h or t c ir cu i t co n d it io n s . W h en s h or t c ir c ui t cu r r en t ( u s u al ly 10 to
1 2 t im e s cir c ui t b re ak er ra ti ng ) oc cu r s , t he m ag n et ic t ri p u n it o p er at es in s t an ta ne ou s l y t o
tr i p t he ci rc u it b r ea k er . A t r ip on a ny o n e o r a ll o f th e t hr e e p h as e s op e ns a ll t h r ee b r ea k er
con tacts.
F u s es is ol ate t he 1 2 0V co nt ro l p ow e r tr an s fo r m er in t he ev en t tr an s f or m e r is o lat io n fa ils .
6.1.2 Power Contactors
T w o po w er r ever sin g con tactor s (o pen ing , clos ing ) are pr ovid ed, o ne for each d irecti on of
m o to r ro ta tio n . E ach co n ta cto r c on s i s ts o f th r ee s e ts of co n tac ts r ate d to cl os e o r in ter r u pt
th e p ow e r su p pl y to th e m o to r a t fu l l cu rr en t v alu es a nt ici pa ted fo r t h e size a nd ty pe of
m o to r . T he t h re e set s o f c on t act s a r e op er a ted as a g ro u p t o o pe n o r c lo s e a ci rc u it. T h e
co n tac to r as s em b ly is s p ri ng - lo ad ed to m ain ta in th e co nt act s in t he o p en p o s it io n. T h e
fo rce r equ ired t o c los e the co ntact s is p ro vid ed b y t he assem bl y's co ntac tor o per atin g coil .
T h e o per atin g coil is w i red in th e c on tro l ci rcu it ( s ee S ec tion 6 .1 .6 ) and , w hen en er gized ,
act iv ates th e con ta cto r to c los e th e cir cu it an d h old th e c on tac ts i n th e clo s ed p osi tio n as
lo n g as th e o p er ati ng c oi l rem ain s en erg iz ed . W h en t he o p er atin g c oi l i s d e- en er gi zed , th e
co n tac ts op en un d er s p ri ng ten s io n .
6-1
W h en o ne of the co nt acto rs is p ick ed u p an d its con tac ts cl os e, t hr ee ph ase po w er is app lied

to t he a ctu ato r m ot or , w h ich re su lt s i n m o to r r ot ati on t o m o v e th e v al ve i n th e s ele cted
di rec tio n. A s eco nd con tac tor is s u pp lie d an d s erv es to r eve rs e th e d ir ecti on o f m o to r
ro tat ion . T h is is p er fo rm ed b y the s ec on d co nt acto r s w itch in g tw o o f th e m ot or p ow e r
sup pl y's t hr ee ph ases. T h e t w o con tact or s ( lab eled " op en ing " and "clo sing ") a re in terl ock ed
elec tri cally a nd m ech ani cally t o pr ev ent b oth c on tact or s f ro m bein g cl os ed at th e sam e
tim e.
6.1.3 Thermal Overload Relays
T h er m al o ve rlo ad rel ay s ar e fo u nd in th e m o to r co nt ro l cen ter cub ic les th at po w er t he

ac tu ato r . T he s e el ect ri cal d e vi ces a re u s ed to pr o te ct th e m ot or ag ai ns t o v er h eat in g f r om a
du ty cyc le in ex ces s o f d es ign , loc ked ro to r c on ditio n or an ex ces s ive ru nn ing lo ad. T h e
pr in ci pl e o n w h ic h th ese d ev ices o pe rat e is e lec tr ical r esist an ce he ati ng w hic h ac tu ates a
b im e tall ic el em e nt o r m elt s a s o ld er d as h po t. T h e tim e fo r th es e d ev ic es to t rip is
in v er s ely pr o po r tio n al t o th e cu r re nt d r aw n by th e m o to r . I n o rd er fo r t he s e de v ice s t o
pr o vid e eff ecti ve m o to r pr ot ectio n , the y are g ene ral ly sized to tr ip at lo cke d ro to r cur re nts
in le ss th an 1 0 se con d s . M oto rs m ay b e da m ag ed af ter 1 6 s eco nd s o r les s of lo ck ed r oto r
cu r re n t. I d ea lly , th er m a l o ve r lo ad s ar e s iz ed to a d eq u ate ly pr o te ct t he l im ite d d u ty m o to r s
us e d in act uat or ap pl icat io ns . T h is o f ten in vo lv es us i ng ov er lo ad s w h ic h ar e on e to th ree
s iz es s m al le r th an th e s iz e co rr es p o n di ng to m o to r f ul l lo ad cu rr en t. In ap p lic ati on s w h er e
va lv e cy cle ti m es ar e g re ater th an 4 m in u tes (2 m in u tes to o p en o r c lo s e), ov er lo ad s a re
ty pi call y size d as if th e m o tor w ere a co n tin uo u s d ut y ap pl icat io n. R eg u lato ry co nce rn s
re lated t o ov er loa d hea ter u se ca n be fo u nd in N R C R eg ula tor y G ui de 1.10 6 an d N U R E G
12 96 . IE E E 7 41 -1 99 0 pr ov ide s a d is cu ss io n of in du s try o ver lo ad s izing p ra ctices .
It s h o uld be n o ted t ha t o ld er m ot or con tr o ls w e re d es ig n ed w it h th er m al o v erl oa d r elay s in

o nl y tw o of th e th re e ph ase s . C ar e m u st be t ak en w h en sel ecti n g th e co r rec t ov e rlo a d
h eate r s in ce t he co r re ct s iz e i s d ep en d en t on w he th er tw o or th re e ph as e p ro te cti on is u s ed .
T h e the rm a l o v erl oad rel ays p ro tect th e m o to r fr om th e da m ag in g ef fec ts o f o ver h eati ng a s

a resu lt of e xten d ed p erio d s o f ov erc ur re nt. T he ov er lo ad re lay co ns i st s o f an o ver lo ad
he ater an d re lay a s se m b ly , w ith c on tr ol ci rc uit c on tac ts f o r each of t he th r ee po w er su p ply
p ha s es . T h e ov e rl oa d h ea ter ele m e nt s m ay be w i r ed i n li n e w ith ea ch o f t he m o to r s t ato r
w i nd i n g s an d ca r ry t h e s a m e cu r r en t a s th e w in d i n g s . W h en t he cu r r en t in th e ci rc u it
ex cee ds th e m o tor fu ll lo ad c ur re nt r ati ng by a p r ede ter m in ed va lue f o r a giv en am o u nt o f
ti m e, th e he at er e lem en t p ro d uc es en o ug h h ea t to tr ip t he o v er lo ad re lay an d o p en i ts
asso ciat ed co n tact s in t he co n tro l cir cu it. W he n an y o f th e o v erl oa d co nt acts in th e co nt ro l
cir cui t o pe n, th e c on tacto r op er atin g co il d e- ener g izes a nd o pen s th e po w er sup pl y con tact s
to de- en erg ize th e m oto r po w e r c ircu it.
T he m o tor ov erlo ad relay s m u st be cor rectl y sized to p ro vid e ef fectiv e p ro tection o f the
m o tor fo r loc ked ro tor c on di tio ns . T h e the rm a l o ve rlo ad r elay s a re th e o nl y de vic es
pr o tec tin g th e m o to r d ur in g th e to rq u e by p as s p er io d . T h es e d evi ces m a y als o pr ov id e
s om e pro tection f rom ov erhe ating du rin g jo gg ing or s ever e du ty cycles .
6-2
O ne d is ad va nt ag e r es u lti ng fr om t he u s e of o v er loa d r elay s is t ha t i f th es e d evi ces ar e no t

sized pr op er ly , n ui sa nc e tri ps can occ ur . T h e m a jor co nce rn is t ha t t he s e d ev ice s c ou ld t rip
a saf et y -r el at ed ac tu at or at a tim e w h en d am ag e to th e a ct ua to r i s ir r ele v an t co m pa r ed to
en s u ri ng th at t h e ac tu ato r pe rf o r m s it s r e qu ir e d s af e ty f u n cti o n. In c lu s io n o f th e d ev ic e
do es a dd ano th er le ve l o f co m p lex ity to th e s ys te m . T o a vo id t he r is k as s o ciate d w ith a
po t en ti al t ri p o f an a ct u ato r 's o ve r lo ad re la ys , s o m e pl an ts h a ve i n s ta lle d b y p as s e s th at
cir cu m v en t ov er lo ad r el ay s w h en f u ll act ua to r cap ab il ity i s d esi red . ( S ee F i gu re 6 .1- 1 .)
A no th er p o ten tia lly n eg ati ve as p ec t w ith t he u s e of o v er loa d r elay s is t ha t o n ce a re lay

tr ip s , it g en e ra ll y m u s t b e r es e t m a n ua ll y . I n a d di ti o n, th e re m ay b e n o i n di ca ti on in th e
co nt ro l r o om th at th e r el ay s h a ve t ri pp e d, lea vi n g th e ac tu at or in an u n d ete cte d i no p er ab le
co nd i tio n . R el ay s a r e av ail ab le t ha t p ro v id e an au to m a ti c re s et c ap ab il ity pr ec lu d in g t hi s
s itu ati on . A p p lic atio n s u s in g a ut om atic r es e t sh o ul d r eco g ni ze th at th e o ve rlo ad s m ay co ol
and res e t b ef o re th e m o tor has co ol ed . L ac k of tri p in di cati on m ay al s o be p ot en tial ly
res o lv ed t hr ou g h th e d es i gn m od if ica tio n of the c on tr ol ci rcu it . In s o m e in s tan ce s it m ay b e
po ssibl e and desi rab le to m od if y th e con tr ol ci rcu it so th at w h en an ov er loa d re lay tr ip s, it
res u lt s in th e los s o f th e va lv e's i nd ica tio n li gh ts . T hi s m od if ica tio n is s h ow n in th e
T her m al O ver load T r ip In dic ation M o dif icatio n (s ee F igu re 6.1- 1) an d pr ovi des f or th e
im m edi ate in d icat io n o f an o ve rl oa d re lay t ri p. T he in d ica tio n is ev id enc ed b y b ot h th e red
an d th e g re en po s it io n in d ic ato r l ig ht s o u t at t he s a m e ti m e .
6.1.4 Control Power Transformer
T he c ontr ol pow er tran s for m er pro vid es 12 0 V A C (o r o ther co ntro l v oltag es) co ntro l p ow er
req u ir ed to op er ate th e act ua tor op en in g an d cl os in g c on tac to r co ils , a s w el l as t he r ed a nd
gr ee n p o s iti on in d ica tin g l ig h ts . T he t ra n s fo r m er p ri m ar y w in di ng s ar e co n ne ct ed f o r
460 /57 5 V A C (o r o ther s up ply vo ltages ) acro s s tw o o f the p has es o f th e p ow er circu it ju st
do w nst re am of th e c ir cui t br eak er . T h e tr an sfo rm er st eps d ow n the v o ltag e to 1 2 0 V A C .
T h e tr an s fo r m er s eco n da ry w in d in gs ar e p ro te cte d ag ai ns t s h o rt c ir cu it an d o v er lo ad
cond ition s by the con trol po w er fu s e.
6.1.5 Control Switch and Contacts
N o r m ally l oca ted in th e con tr ol ro o m , th e c on tro l sw i tch is ava ilab le in s eve ral d iff ere nt
co nf ig u ra tio n s . T h es e i nc lu d e k e y lo ck , p u s hb u tto n , s p ri ng re tu rn to c en te r, s e alin o r
th ro t tle . T he s pr i ng re tu r n t o c en ter s w i tch is o n e of th e m os t co m m o n ty p es . I t pr o v id es
m om en tar y s w itch a ctio n f or t he op en a nd c los e v alv e m ov em ent co n tacts . I f p ro vi ded , th e
s to p po s it io n is u s ed to pr ev en t o pe ra tio n o f th e v alv e o r to t er m in at e the a ctu at or
op er at io n i n m id s tr ok e . I t s h ou ld be no te d t ha t th is s w it ch co nf ig u r ati on al lo w s f a s t
re ve rs a l o f a ctu at or di re cti on . V a lv es th at h av e hi gh in er tia s h o ul d b e all ow e d to co as t
dow n be for e r evers in g d irect ion.
6-3
F i g u r e 6 .1 - 1
T h e r m a l O v e r l o a d T r i p I n d i c a t io n M o d if i c a t i o n w it h O v e r l o a d
6.1.6 Opening and Closing Coils
T he fu nc tion o f th e co nta ctor o pe ratin g co ils is to actu ate the op en ing an d clo s ing
con tact or s, ene rg izin g the ir assoc iated p ow e r su p ply c ircu it to p ow er th e actu ato r m o tor .
T he coi ls are pr ov ide d w it h a ux iliary co nta cts to p erf orm o ther co ntr ol circ uit fu nctio ns ,
such as t he sea l-i n fu n ctio n ar o un d th e co ntr o l sw i tch o pe n an d clo s e co nt acts. T he
op er atin g co il au xil iar y con tac ts a lso serv e as a n elec tri cal in ter loc k to p re ven t bo th th e
m oto r co ntact or clo s ing an d the op eni ng co ils f ro m b ein g e ner gize d at th e sam e tim e.
6.1.7 Red and Green Status Lights
G ene rall y, r ed an d gr een li gh ts ar e us ed t o ind icat e w h en th e valv e is f ul ly op en ( on ly r ed

ligh t illu m ina ted) , fu lly clo s ed (o nly g re en lig ht illu m in ated) , an d m idw ay b etw een t he tw o
(b ot h lig h ts i llu m in ate d) . O ne o f th e tw o li gh ts i s n or m a lly il lu m in ate d as l on g as co nt ro l
po w e r i s ava ilabl e.
6-4
N O T E : T hr ou gh ou t th is m a nu al, the red lig ht w ill be us ed to re fer ence the op en va lve

p os iti on in dic ation l igh t a nd g reen li gh t f or th e c los ed v alv e p os iti on in dic ation l igh t.
6.2 Electrical Control Components
E lec tri cal co ntr o l o f th e actu ati on is acc om p lis h ed u s in g lim i t a nd t or qu e s w itch es l oca ted
in th e a ctu a to r 's li m it s w it ch co m pa r tm en t. T h e l im it a nd to r q u e s w i tch e s p r o v id e t he
ne cessary o p en an d clo s e co n tact fu n ctio ns to co ntr ol th e actu ato r's o p eni ng an d clo s in g
cycle, and pr ovid e va lve p os ition ind ication.
T h e lim it an d to r qu e s w itc h fu n cti on s in th e co n tro l ci rcu it o f th e ac tu ato r ar e de s cr ib ed

bel ow .
6.2.1 Torque Switch
T h e to r qu e sw it ch i s p ar t o f th e p ri m a ry sw itc h m e ch an is m ( s ee S e cti on 4.1 ). T h is p ri m ar y

sw itch m ech anis m co n tain s a pa ck of t hr ee m icr os w it che s f or b ot h the o pen and c los e en d
of tra ve l. T w o of t he th r ee s w itc hes ar e en d po s it ion au xi liar y li m it s w it ch es f o r re m o te
in d ica tio n , in te rl oc k, or co m p u ter in di cat io n s . T h e th ir d sw i tch at t he f r on t o f ea ch se t
fu nct ion s p rim a rily a s a t or qu e s w itch ( O T /L S and C T /L S fo r op en an d clos e to rqu e/li m it
sw itc he s, r esp ect iv ely ) . O p en a nd clo s e to r qu e sw it ch se tti ng s ar e in de pe nd en t ly
ad ju s t ab le us i n g a s e p ar at e ca m . T h is t or q u e/ lim it s w it ch can al s o b e s et t o a ctu a te w h e n
th e va lv e has r eac he d its en d p o s iti on . B ot h th e o pe n an d cl os e sw i tch es can be
in de pen d ent ly s et to the " to rq ue " or " lim it" p os i tio ns . I n th e "to r qu e" p os i tio n, t he
to rq u e/l im i t s w itc h fu n cti on s as a to rq u e s w i tch . W he n s et t o th e "l im i t" p os i tio n , th e
s w itch w ill act iv ate at th e s et po s iti on o r w h en th e to rq ue s et tin g is ex ceed ed .
T h e p r im ar y s w itch m ech an is m is c on tr oll ed by tw o m ec han ic al inp ut s : 1 ) lin ea r w or m

m o ve m en t and 2) c en ter co lu m n d r ive g ear ro tat ion . T o r qu e s w itch actio n i s co n tro lle d b y
lin ear w o r m m ov em ent v ia a hel ix g ear w h ich con v ert s th e lin ear w o r m m ot ion to th e
pr im ar y sw it ch m e ch an is m r ot ary m o tio n . A ll p osi tio n sw i tch es ar e co ntr o lle d b y th e
cen ter c olu m n d r ive g ear w h ich e ss e nti ally c ou nt s th e nu m b er o f cen ter c olu m n r ev ol uti on s
an d a cti va te s s w i tc he s a t th e p os iti on es t ab lis h e d d ur in g s etu p .
T h e to r qu e s w it ch i s d es i gn e d to lim it th e to r qu e o ut p ut o f t he a ctu at or to a l ev el th at c an
b e s af el y ex e rt ed on th e v al ve an d a ctu a to r w i th o ut d a m ag e o r u n d u e w ea r. T h e to r q ue
re qu ir ed t o o pe rat e th e v al ve ca n b e aff ec ted b y m an y v ar iab les suc h as sy st em p re ssur e,
di f fe re nt ia l pr es s u r e, s ys tem t em pe ra tu r e, t yp e o f p ac k in g m ate ri al, p ack in g tig h tn es s ,
gen er al c on dit ion o f the v alv e ( e.g ., c or ro si on ), v alv e s tem lu br icat ion , and t he actu ato r's
m e ch an ica l co n di ti on . E ach o f th ese va ri ab les c an c ha n ge w i th tim e to alt er t he r e qu ir ed
to rq u e s w itc h s et tin g f o r pr o pe r v alv e o pe ra tio n . T h e m a xi m u m to rq u e s w itc h s et tin g ( 5)
ty p ica lly co rr es p o n ds to th e to r qu e r ati ng o f th e ac tu ato r . R ed u ced v ol tag e r eq ui re m e nt s
m ay c ha ng e the to r qu e rat ing at the m axi m u m s w i tch s et tin g (s ee T abl es 1 0 .3 -2 t o 10 .3- 8) .
N or m a lly , th e t or q ue s w itc h can be s et to a ny val ue w it ho ut d an ge r of exc eed in g act uat or
to r q u e o r u n d e rv o l ta ge li m i ts .
6-5
6.2.2 Limit Switch
T he lim i t s w itch i s a con tr ol/i nd icatio n d evic e w ith the ch ief fu nc tion o f tr ack ing an d
i nd icati ng th e po si tio n of th e valv e stem .
L im it sw it ch es ar e co n ta in ed in b o th t h e pr im ar y sw i tch m e ch an is m a n d th e ad d - on - pa k
m ec ha ni s m (i f p re s en t) . T w o li m it s w itc he s a re p r ov id ed in th e pr im ar y s w i tch m ec ha n is m
f or both the open (O A S 1 an d O A S2 ) an d clo se (C A S 1 an d C A S2 ) p os itions as d escr ibed in
S e ctio n 4 .1. I n ad d itio n , as di scusse d in S e ctio n 4 .2 , A d d- o n- p aks ar e av aila bl e w i th ei th er
6 o r 12 au x iliar y po si tion ac tiva ted s w itch es .
T he a dd - on - p ak c on ta in s t he i nt er m ed ia te au x ili ar y sw it ch es (I A S ) . T h ese sw i tch es

p ro vi de fo r ind icati on an d var iou s in ter loc ks .
6.2.3 Limit Switch Contact Functional Description
T he sw i tch m ech an is m an d 6 sw itch ad d- on -p ak no rm ally p erf or m t he fo llo w i ng f un ctio ns :
• C on tact IA S7
P ro vid es th e clo s ing v alve m ov em en t to rq ue s w i tch by pas s f un ction co ntr ol.
T h is o ccu rs a t t he beg in nin g o f the va lve s tr ok e r ef eren ced f ro m the f ull op en
valv e pos ition .
• C on tact O A S 1
S par e con tact s no r m ally u s ed fo r co m pu ter i nd icatio n .
• C on tact O A S 2
E n erg izes an d de- ene rgi zes th e g reen ( clo sed ) val ve po si tion in dic ator lig ht.
• C on tact O T /L S
P r ov id es th e o p en v al ve m ov em ent t ra ve l l im i t fu nc tio n . T h is s w itc h m a y be s e t
fo r tor que contr ol f or sp ecial app licatio ns (i.e., 3-w ay valves ).
• C on tact IA S5
P ro v ide s th e op en v alv e m o ve m en t tor qu e s w itch by pa s s f un ctio n co n tro l. T hi s
oc cur s at the beg in nin g of th e v alve s tro ke r efer ence d fro m the clo se d pos it ion to
s o m e de s ir ed p oi nt i n th e va lv e t ra ve l aft er u n s eati ng .
• C on tact C A S1
S pa re con tac ts n or m all y us ed f or c om p u ter in dic atio ns .
• C on tact C A S2
E n erg izes and d e-en er gize s th e r ed (o pe n) v alve po s itio n ind icat or lig ht .
• C on tact C T/L S
U s ed ei the r as a cl os in g v alv e m o vem ent t rav el lim it fu nc tio n, o r n or m al ly as a
clos e to rqu e s w itch .
• R em a in in g s w itc he s a re s p ar es .
R e fer to S ec tion 1 5.0 , f or t yp ical ene rg ized w ir ing a rra ng em en ts f or ea ch cir cuit
dev elop m en t fu nct ion.
6-6
6.3 Actuator Control Circuit for Rising Stem Type Valves
T he fol low ing is a step- by -step descr iptio n of the con tro l cir cuit op erat ion of a typ ical
R o to r k a ct ua to r . T hi s d e s cr ip ti o n an d its a s s o cia te d d ia gr am do n ot ad dr e s s o p ti o na l
con tr ol cir cui t ca pab ilit ies . It is int end ed to p ro v ide a bas ic d es cr ipti on o f on ly o ne of a
var iety of p ossib le co nt ro l sc hem es. T h e c on tr ol sch em e is p r ov id ed as an ex am p le an d is
desi gn ed to co n tr ol th e b asic o pe ra tio n o f a ri sin g stem v al ve. T h e tor q ue sw i tch es an d
lim it sw i tc he s ar e w ir ed an d ad ju ste d su ch th at th e ac tu ato r w il l to r qu e t he v a lv e o n it s
clo s ed seat a n d tr ip on lim it sw i tch ac tu ati on at th e e nd of th e o pe ni ng op e ra tio n . T o r q ue
sw i tch "O T /L S " is c on ne cted a nd ad ju s ted as a bac ku p to th e op en lim it s w itch in the
op enin g op era tion . T or qu e sw it ch by pas s l im it s w i tches "I A S 7 " and "I A S 5" are p ro vid ed to
pr ev en t s p u ri ou s to rq u e s w it ch t ri p f u nc tio n s d u r in g h ig h t or q ue c on d it io ns at t he
beginn ing of the o penin g an d clo sing cycles .
T he descri ptio n i s div ided in to tw o sect ion s; op enin g cycle and clo s ing cy cle. T he heav y
line s in ea ch of t he fig u res ref ere nce d in th is s ect ion an d S ect ion 1 5.0 in dic ate com ple te
pat hs fo r cu rr en t flo w .
T he typ ical lo cation o f each con trol circ uit com p on ent is show n in the "T y pical E lectr ical
C o m p on en t L o cat ion " ( S ee F ig ur e 6.3 -1 ). T hi s d iag r am is the b asic e lect ric al sch em a tic
us ed to de sc rib e th e o pe ratio n of th e c ircu it d ur in g i ts op en an d clos e cyc le.
6-7
EPRI Licensed Material -
F i g u r e 6 .3 - 1
T y p i c a l E l e c tr i c a l C o m p o n e n t L o c a t i o n
6.3.1 Opening Cycle
N O T E : R efer to F igu re 6 .3- 2 entitled "T yp ical O p ening C y cle for F ully C los ed V alve
(C o ntrol C ircuit D e-energized)"
6-8
Fi gu re 6 .3 -2 sh ow s th e c on tro l cir cu it c on fi gu rat ion fo r an act uat or t hat is fu lly cl os ed a nd

rea dy f o r an o pe nin g cy cle . A t thi s p oi nt, the o pe nin g an d cl os in g c on tact or s a re o pen and
th e m o to r is d e- en er g iz ed . O n ly th e g r een in d ic ato r lig h t is i llu m in at ed , i nd ic at in g t ha t th e
valv e is clos ed.
F i g u r e 6 .3 - 2
T y p ic a l O p e n i n g C y c l e f o r F u ll y C lo s e d V a l v e ( C o n t r o l C i r c u it D e -e n e r g i z e d )
N O T E : R efer to F igu re 6.3-3 entitled "T yp ical O penin g C ycle V alve Fu lly C los ed
(C o ntr ol C ircu it S ho w n at the I ns tant the O p en Sig nal is G iv en) "
F ig ur e 6 .3 - 3 il lu s tr at es th e va lv e op e ni ng op er at io n in i tia ted by m o m e nt ar ily m o v in g th e

con tr ol sw it ch to t he o pen po sitio n . T h is c aus e s th e con tr ol sw it ch's no r m all y op en c on tact
"C S -O P E N " to c lo se .
6-9
F i g u r e 6 .3 - 3
T y p i c a l O p e n i n g C y c l e f o r F u ll y C l o s e d
(C o n tro l C ir cu it S h o w n a t th e I n sta n t O p e n S ig n a l is G iv en )
A pa th fo r cu rr ent f low is co m p leted f ro m the co nt ro l p ow er t ran s fo rm er thr ou g h the fu s e,

thr ou gh th e n or m all y clos ed " C S - ST O P" co nta cts , and th ro ug h th e " C S -O P E N " co nta cts to
the " O T /L S" and "I A S5 " co ntacts . A t th is po int torq ue sw itch "O T /L S " is clos ed , b ut coul d
open if m o m ent ary hig h load is ex per ienced .
T or que by pas s li m it s w itch "I A S 5 " is clos ed , b yp as sin g the tor qu e s w itch "O T /L S " un til th e
valv e un se ats o r m ov es t o so m e ot her ex ten ded o pe n st ro ke po s itio n.
T he clo se coil interlo ck co ntact "C " is clos ed and pro vid es a path f or curr ent sin ce the clos e
coil is d e- ener gi zed. A pat h fo r cur ren t f lo w is c om p lete d thr ou gh th e op en coi l, thr ou gh t he
clos ed ov erlo ad con tacts ( O L ), an d b ack to th e co ntr ol pow er tr ansfo rm e r, allo w in g the
opening coil to pick u p.
6-10
N O TE : R efer to F igure 6.3- 4 entitled " Ty pical O pening C y cle V alue F ully C los ed
( C o ntro l C ircu it S ho w n jus t af ter the O p en S igna l is G iv en an d the O peni ng C o il
A ctuators)".
F ig u re 6 .3 -4 sho w s t hat th e o pen coi l has en er giz ed . T h e op en co n tact or a ctu ate s to clo s e
its co ntac ts in th e m ot or p ow er ci rcu it, en er gizi ng th e m ot or .
T h e o pen co il au xil iary seal-i n c ont acts "O " clos e to se al in th e cir cuit aro un d the con tro l
sw itch contact "C S- O P E N ".
T he open coil in ter lock norm ally clos ed co ntacts "O " , in line w ith the clos e coil, open to
p reven t en ergizin g the clo s e coil du ring th e op enin g cy cle.
F ig u r e 6 .3- 4
T y p i c a l O p e n i n g C y c l e V a lv e F u ll y C lo s e d
(C on t ro l C irc u it S h o w n ju st aft er th e O p en S ign a l is G ive n a n d th e O p e n in g C o il A ctu a te s)
6-11
N O T E : R efer to F igure 6.3 -S entitled "T ypical O pening C ycle V alue Fully C lo sed
(C on tro l C ir cuit S how n after th e O pen C ycle is In itiated and the C o ntro l S w itch is
R el ea s ed ) ".
Fi gu re 6.3- 5 s ho w s th e circ uit af ter th e c on tro l s w it ch is r elea se d and t he "C S -O P E N "

con tac ts r et ur n to t he o pen po siti on . T h e op en in g cy cle is no w f u lly i nit iate d an d op er ate s
to f ully op en the v alve.
F i g u r e 6 .3 - 5
T y p i c a l O p e n i n g C y c l e V a lv e F u ll y C lo s e d
(C o n tr ol C ir cu it S h o w n af ter th e O p en C y cle is In itia te d a nd th e
C o ntr ol S w itch is R elea se d )
N O T E : R efer to Fig ure 6.3-6 entitled "T ypical O penin g C y cle V alve M o ving in the
O pen D ir ectio n ( C on trol C ircuit S ho w n w ith the V alv e at the N ear C los ed
P os ition) ".
6-12
F i gu r e 6.3- 6 s h o w s th e cir cu it af te r th e va lve h as op en ed to a p oi nt w h er e i t is u n s eat ed .
" C A S 2" co ntacts hav e no w clo s ed, allo w ing cur ren t to f low t hro ug h the red in dicato r ligh t.
A t th i s po i nt b ot h t h e r ed an d g re en in d ic at o r l ig h ts a re ill u m i n ate d . B o th l ig h ts ar e
i llu m in ated w h en ev er th e v alv e is b etw ee n the o pe n and clo se d po s itio n s.
T h e torqu e byp ass lim it sw itch "IA S 5" contacts are now o pen, allow ing "O T /L S" to contr ol
t he rem ain der o f t he o pen cy cle, w ith tor qu e sw itch "O T /L S " pr ov idin g b ack up con tro l.
F i g u r e 6 .3 - 6
T y p ic a l O p e n i n g C y c l e V a l v e M o v i n g i n t h e O p e n D i r e c t i o n
(C o n tr ol C ir cu it S h o w n w ith th e V a lv e at th e N ea r C lo se d P os ition )
6-13
N O T E : R efer to F ig ure 6.3- 7 entitled "T ypical O pening C ycle V a lve M oving in th e
O pen D ir ection ( C ontr ol C ircuit Show n w ith the V a lve at the F u ll O p en P osition) ".
F ig ur e 6 .3 -7 s ho w s the v alve in th e o pen p os itio n.
T h e lim it sw i tch "O T /L S " h as o pe ned , in ter ru pt ing the cu rr en t pat h to th e o p en co il.
T he l im i t s w i tch "O A S 2 " h as op en ed , i nte rr u pt in g th e cu r ren t p ath to t he g re en i nd ic ato r

l ig ht . T he r e d li gh t i s n o w th e o nl y o n e ill u m in at ed , i nd i cat in g t ha t th e v alv e i s n e ar t he
fu ll op en Pos itio n.
"I A S 7" has cl os ed to pr ovi de t he clos e m ov em ent tor qu e s w itch by pas s f un ction d ur ing the
s u bs eq ue nt clo s ing e vo lut ion . T h is is no t a lw ays ut ilize d fo r ris in g s tem v alve co nt ro l.
F i g u r e 6 .3 - 7
T y p i c a l O p e n i n g C y c l e V a lv e M o v i n g i n t h e O p e n D i r e c t i o n
( C o n t r o l C ir c u i t S h o w n W i t h t h e V a l v e a t t h e F u l l O p e n P o s i t i o n )
6-14
N O T E : R efer to F ig ur e 6.3- 8 en titled " T ypical O p enin g C ycle V a lve F ully O pen
(C o ntr ol C ircu it Sh ow n jus t a fter th e O pen P os ition w ith O p ening C o il D ro pped
O ut, R eady for C lo sing O peration)".
F ig u re 6 .3 -8 s ho w s t hat th e op en in g m o v em en t co il ha s d ro p ped ou t and th e o p eni ng

m o v em en t m oto r po w er cir cu it c on tacts "O " hav e op ene d, d e-e ner gi zing t he m o tor . T h e
m o to r and v alv e w il l co as t to a s to p at or n ear th e f ul ly op en po s itio n.
T h e v alv e is no w fu lly o pen an d is r eady to b egi n a clo s ing cy cle w hen in itiate d u s ing th e
co ntrol sw itch.
A t th is p oi nt th e m oto r op en ing and c los in g co nt acto rs are o pen a nd th e m o tor is de -

e ne rg i zed . O nl y t he r e d in d ic ato r lig h t is il lu m i n ate d , in d ic ati ng th at th e va lv e is i n th e
o pen p osit ion . T he actu ato r is r eady f or th e clos in g cy cle.
F i g u r e 6 .3 - 8
T y p i c a l O p e n i n g C y c l e V a lv e F u l ly O p e n
( C o n t r o l C i r c u i t S h o w n j u s t a f t e r t h e O p e n P o s i t i o n w it h O p e n i n g C o i l
D r o p p e d O u t , R e a d y f o r C l o s in g O p e r a ti o n )
6-15
6.3.2 Closing Cycle
N O T E : R efer to F igu re 6 .3- 9 en titled "T ypica l C los ing C ycle V a lve F ully O pen
( C o ntr ol C ir cu it S how n at the Ins ta nt the C lo se Sig na l is G iven )"
F ig ur e 6 .3 -9 s h ow s a v alve clo s ing o p erati on in itiat ed by m om en tar ily m o vin g th e co n tro l

s w itc h to th e c los e po s itio n . T hi s cau s es t he co ntr ol s w itc h no rm ally o pe n con tac ts "C S -
C L O S E " to c lo se .
A pa th fo r cu r ren t fl ow is c om p le ted f ro m th e c on tr ol p ow er t ran s fo r m er t hr ou gh the f us e ,

th ro ug h the no rm a lly clos ed " C S -S T O P " con tacts, th ro ug h t he "C S - C L O S E " co ntact s to a
co m m on con nection , to tor que sw itch "C T /L S" and torq ue byp ass lim it sw itch "IA S 7"
co ntacts.
A t this p oin t t orq ue s w i tch "C T /L S " an d tor qu e b yp ass lim it sw itc h " IA S 7" are clo sed ,
b yp as s i ng t he to r qu e s w itc h un ti l t he v alv e clo s es to t he n ex t lim i t s w itch co nta ct
d evel op m ent po int .
A p ath fo r curr ent is co m plete d to o pen th e co il in terlo ck no rm ally clo s ed con tact "O " .
T h e o pe n coil int erlo ck co ntact "O " is cl os ed an d p ro vi des a p ath fo r cur ren t sin ce t he op en
co il is d e-e ner giz ed. A pat h fo r cur ren t flo w is com ple ted th ro ug h the clo s e c oil , t hr ou gh
th e clos ed o ve rlo ad co ntac ts (O L ), an d bac k to the co ntr ol p ow er tr ans f or m er , allo w i ng th e
clo sin g co ntacto r to pick u p.
6-16
F i g u r e 6 .3 - 9
T y p ica l C lo sin g C y cle V a lv e F u lly O p e n
(C o n tr o l C irc u it S h o w n a t th e I n sta n t th e C lo se d S ig n a l is G ive n )
N O TE : R efer to F igu re 6.3 -10 entitled "T yp ical C los ing C ycle V alve F u lly O pen
( C o ntr o l C ir cuit Sh ow n w ith th e C los ing C ycle Ini tiated a nd th e C ont ro l S w itc h
R el ea s ed .
F i gu re 6 .3 -1 0 sho w s th at th e c los e co il has en erg ize d. T h e clo s e co n tacto r act uat es to c los e
i ts co nt acts in the m o to r po w er cir cui t to ener gi ze t he m o tor .
T he clo s e co il aux iliary s eal-in co ntacts " C " clos e to s eal in ar oun d the contr ol sw itch
c o n tac ts "C S -C L O S E " .
T he clo s e coil con tactor inte rlock o pens c ontacts "C ", an d p rev ents en ergizin g the open co il
t o pr eve nt ene rg izin g the o pen d ire ctio n m o tor ci rcu it du rin g th e clo s in g valv e op era tion .
6-17
W hen th e c on tro l r oo m o pe rato r rele ases th e v alv e co ntr ol sw itch an d the "C S -C L O SE "
c on tact s r etu rn to th e op en p os i tio n, t he clo s in g cy cle is fu lly ini tiat ed an d th e actu ato r
o per ates to full y clo s e the valv e.
F ig u r e 6 .3 - 1 0
T y p i c a l C lo s i n g C y c le V a l v e F u l l y O p e n
( C o n t r o l C i r c u i t S h o w n w it h t h e C l o s i n g C y c l e I n i t i a t e d a n d t h e C o n t r o l S w i t c h R e l e a s e d )
N O T E : R efer to F ig ur e 6.3-1 1 en titled " T ypical C los ing C ycle V alve M ovin g in the
C lo sed D ir ection (C o ntr ol C ir cuit Show n w ith th e V alve a t the N ear O pen
P o sitio n )" .
F i gu re 6.3- 11 s h ow s the co ntr ol ci rcu it con fi gu rati on af ter th e val ve has m o ved s li gh tly
f rom the full op en p os ition .
6-18
T h e lim it s w itch "O A S 2 " co nta cts hav e n ow c los ed, allo w ing cu rren t t o f low thro ug h the
g re en in d ic ato r lig h t. A t th i s p o in t, b ot h t he re d a nd g re en in d ica to r l ig h ts ar e i llu m in at ed .
B ot h lig h ts a re il lu m in ate d w h en eve r th e va lv e i s b etw e en t he n ear f u ll op en an d clo s ed
pos itio n.
A lso, the torq ue by pass lim it sw itch "E A ST " co ntacts are now open , allow ing "C T /L S " to
in terr upt po w er to the clos e c oil for th e r em ain der of th e clo s ing cy cle.
"O T / L S " h as r es et f or t he su bs eq ue nt op en m o vem ent op era tion .
F ig u r e 6 . 3 - 1 1
T y p ic a l C l o s i n g C y c l e V a l v e M o v i n g in t h e C l o s e d D ir e c t i o n
(C o n tr o l C ir cu it S h o w n w ith th e V a lv e at th e N e a r O p e n P os ition )
6-19
N O T E : R efer to F igur e 6 .3- 12 entitled "T ypica l C lo s ing C ycle V a lve M oving in the
C lo sed D irection (C ontr ol C ircuit Sho w n w ith th e V alve a t the N ear C los ed
P o sitio n)" .
F i gu re 6 .3- 1 2 sho w s th at th e va lv e h as cl os e d an d is at th e n ear se ate d co nd it io n.
T he lim it s w itc h "C A S 2 " h as o pen ed , b re aki ng the c ur re nt p ath t o th e red ind ic ato r lig h t.
F ig u re 6 .3 -1 2
T y p i c a l C lo s i n g C y c le V a l v e M o v i n g i n t h e C l o s e d D i r e c t i o n
(C o n tro l C irc u it S h o w n w ith th e V a lve a t t he N ea r C los ed P os ition )
N O T E : R efer to F igur e 6 .3- 13 en titled " Typ ical C los in g C ycle V alve F ully C lo sed
(C ontr ol C ircu it Sho w n w ith the V alve jus t after the N ear C lo sed P os ition -
C losing C oil D r ip s O ut, R ea dy fo r O pening C ycle.
6-20
F ig ur e 6 .3 -1 3 s ho w s th at the clo s in g coil h as d e-e ner gi zed an d the m o to r po w er s up ply

cir cuit con tacts "C " h ave op ened to d e-en erg ize the m oto r. T h e v alve is n ow ful ly clos ed an d
is rea dy f or a n op en in g cyc le w hen r eq ui red .
T o r qu e s w itch "C T /L S " o p en ed it s co n tact s as th e actu at or t or qu ed t o th e pr es et v alu e

r equ ir ed to se at the v alv e. A s " C T /L S " co nt acts op en , th e c ur ren t pa th to t he clo s in g co il i s
in te rr u p te d .
F i g u r e 6 .3 - 1 3
T y p ic a l C l o s i n g C y c l e V a l v e F u l ly C l o s e d
(C on tr o l C ir cu it S h ow n w ith th e V alv e ju st a fte r th e N e ar C los ed P os ition -C lo sin g C oil
D r i p s O u t , R e a d y f o r O p e n in g C y c l e )
6-21
7.0 GENERAL NAMEPLATE DATA
E a ch R o to rk A ctu at or is p r ov id ed w ith a sing le n am ep lat e th at pr o vi de s i nf o rm ati on

r el at ed t o t h e co n fi g ur a tio n of th e a ctu a to r . I n fo r m a ti on p ro v id ed o n t he na m e p lat e
in cl ud es th e actu at or si ze an d ty p e, sp eed (R P M ) m ot or h o rse po w er a nd w iri ng di ag ram
n u m b e r. P rio r to in itia l in sta lla tio n o f th e a ctu a to r, th e in sta ller sh o u ld en su re th at th e
ac tua to r m ee ts al l req u ire m en ts (i.e., R PM , ho rs e po w er , etc.) n ece ss a ry f o r pr op er
f un ction ing o f the va lve bein g op era ted.
7.1 Motor Nameplate Data
7.1.1 Actuator Size and Type
T h e si ze an d ty pe o f ac tua to r is d esi gn ate d us i ng a se rie s o f n um ber s and lett er s ( e.g ., 7A ,

7A X , 7 N A ) . T h e s i ze a n d t yp e a re al w ay s s h o w n t og e th er . O th er le tt er s an d nu m be r s ar e
us ed in th e ac tu at io n na m e p lat e i nf o r m a tio n to d esi gn a te n u cl ear sa fe ty re la te d
qu alif ica tio n an d acti ve/ pas s iv e s tatu s o f th e actu ato r (s e e S ec tio n 1.1) .
F or an act u ato r u s e d in co m m er ci al ( no n - nu cl ea r saf et y r el ate d ) ap p lic at io ns i nt er pr e tat io n

of th e na m ep late s ize /ty pe da ta is il lus t rate d be low (s ee F ig ur e 7.1- 1 ).
A ctuator Size - '7 throu gh 9 62

(see S ection 1 .1 an d T ables 10.3-2 - 10 .3-8 )
D rive B u sh ing T ype (S ee F igu re 1 .2- 1)

A - T ype A - S tand ard C o m m ercia l
A X - T yp e A w ith T hr us t C om pen sat or
A T - T y pe A w ith T o rqu e L im iter
A Z - F or u se w ith L ar ger S te m V alv es
A B - N o n T h ru s tin g (b ut terf ly V al ves )
A R - N on T hru s ting M odel
F i g u r e 7 .1 - 1
N a m p la te S iz e /T y p e
( C o m m e r c i a l A p p l i c a t io n s )
N O T E : A X a nd A T M od els a r e typ ica lly no t s u pp lie d on c om m er cia l ac tua to rs .
7-1
F o r an ac tu at or u s ed in nu cl ea r sa fe ty re la ted ap p li cat io n s in ter p r et ati on o f t he n a m e pl at e

si ze/typ e d ata is illu s trated b elow (s ee Fi gur e 7 .1 -2 ).
7 N A 1
A ct uato r S ize - '7 t hr ou gh 9 5'

(see S ection 1 .1 an d T ables 10.3-2 - 10 .3-8 )
In d icat es A ctu atio n

Q ualif ied fo r N u clear S afe ty R elated U s e
D rive B us hin g T ype (s ee F igur es 1.2 -1)

A - T y pe A - S tand ard C o m m ercial
A X - T y pe A w ith T hr us t C om p ens ato r
A T - T yp e A w ith T orq ue L i m iting B r ake
A Z - F or us e w ith L ar ger S tem V alves
S afety R elated D uty A p plication (s ee S ection 1.1 )

1 - A ctiv e d uty ( in sid e or o uts id e co nt ainm ent)
2 - P as s iv e d uty ( in sid e or o uts id e co nt ainm ent)
4 - P as s ive du ty (i ns ide o r ou ts ide con tain m en t)
5 - A ctive d uty (o uts ide contain m ent)
F i g u r e 7 .1 - 2
N a m ep la te S iz e /T y p e
( N u c l e a r S a f e t y R e l a t e d A p p li c a t i o n s )
U si ng t he ab ov e illu s tra tio n the f oll ow in g ex am p le in ter pr etat ion s a re pr o vid ed :
• 14N A X 1
S iz e 1 4 ac tu ato r, n u clea r s af ety r ela ted ( N ), A X d ri ve b us h in g (h as a thr u s t
co m p en sat or ) , can be u s ed a s a n ac tiv e du ty co m p on en t in a h ar s h en v ir on m e nt
(1).
• 16 N A T 2
S ize 16 , n ucle ar s af ety relat ed (N ), A ty pe dr ive bu sh ing ( A ) , equ ipp ed w it h a
to rq u e li m iti ng b rak e (T ) , acc ept abl e f or u s e as a pa ss i ve du ty co m p on en t i n a
h ar s h en vir o nm ent ( 2) .
7.1.2 Revolutions per Minute (RPM)
T h e R P M o n th e act uat or m o to r na m ep la te re fe rs to t he ce nt er co lu m n re vo lu tio n s p er

m in u te an d n o t th e m o to r s p eed .
7-2
7.1.3 Motor Horsepower

T h e m ot or h o rs ep o w er p ro v ide d on the n am epl ate can be u s ed to d et erm in e t he m o to r
r un n in g c u rr en t . R o to rk m o t or s ar e s p ec ial pu r p os e an d n o t "N E M A " r a ted . T h e
ho rs epo w er ratin g is us ed fo r com p aris o n p ur po se s on ly.
E ar lie r ve rs io n s o f th e R o to rk actu ato r s u ch as s ize s 6 a nd 1 2 m ay li st a m p s in l ieu o f

ho rs epo w er . M o re info rm atio n on m oto r h or sep ow er can be fou nd in Se ction 12 .0 of this
m a n u al .
7.1.4 Wiring Diagram Number
T he w iri n g d iag r am n um b er o n t he a ctu at or m o to r n am ep lat e re fe rs to th e R o t or k f ac to ry

w i ri n g d iag r am . T h e d ia gr am is re pr e s en tat iv e o f a s in g le s e ri es o f ac tu ato r s , w i th s im i lar
o p er at io n . T he di ag r am n u m b er m a y a ls o be fo u n d in th e t er m i na l h o us i n g co v er . T h e
w ir ing d iagr am is ne ces sar y fo r pr ope r c on nectio n of th e w ir ing , sw it ches a nd m o tor .
A ty pi cal ex am p le of a R o tor k w ir in g di ag ram n um be r is 2 2 21 -0 0 . T h is n um be r can b e

i nt erp r ete d us i ng F igu r e 7.1- 3 . T h e di ag ram n u m b er m ay b e s uf fi xe d by an " N O " w hi ch
d esi gn ate s i t as a n P r e- 19 7 8 ve rs i on of t he a ctu ato r w i th a m e ch an ica l l atc h f or
a nt ih am m er p ro te ctio n o r a "V N O " w hi ch in d ica tes an e xte rn al el ect ri cal an tih am m er
c ir cu it is re qu ir ed . A n ex am p le o f n u m b er in g w ith an e lec tr ica l a nt i ha m m e r ci rc ui t
r eq u ir ed w o u ld b e: 2 22 1 -V N O . E x ter n al co n tr ol c irc ui t w ir in g f or an el ect ri cal a nt iha m m er
c ir cu it v a ri es f ro m t ha t o f th e m ec ha ni ca l lat ch . I f th e ac tu ato r is u pg r ad ed b y th e u s er , th e
n am ep lat e s ho u ld b e r es ta m p ed i nd ic ati ng th e ne w c on f ig ur ati on . F o r e xa m p le, if a s w i tch
m ech an is m is i nst all ed w ith o ut a m ech an ic al la tch i n an act ua to r w h ich p rev io u s ly ha d a
l atc h, t he n am ep lat e c ou ld be r es ta m p ed :
• O ld : 2 22 1 -N O
• N ew : 2 221 -V N O
T h e R o tor k f acto ry dia gr am fo r nu cle ar g rad e actu ato rs w ill alw a ys be fo r th e sy n cro s et
act ua to r. T h e sy n cr ose t actu at or do es no t h av e a b u ilt in m ot or c on tr o l cen ter or lo cal
co ntr ol s w i tche s. T h e "s yn cro pak " typ e actua tor p ro vid es o pti on s fo r oth er co ntr ol fu nct ion s
s uch as local an d m od ula ting co ntr ol, b ut is n ot qu alif ied fo r nu clear s erv ice.
R o tor k a ctuato rs ar e av ailable fo r clo ckw is e a nd cou nter clock w i se to clos e cen ter colu m n
dir ectio ns . N o rm al val ue clos ur e d irectio n is clo ckw is e. C o unt erclo ckw is e ( C C W o r
anticlo ckw ise) to clo se actuato rs ar e den oted w ith an " A " suff ix (i.e., 2 22 1-N O A ). T he op en
an d clo se sw itch es are p hy s ically r ev ers ed on C C W act uat or s an d re qu ire slig ht ly dif fe ren t
s etup p ro ced ur es .
7-3
7.1.5 Development Chart for Basic Rotork Wiring Diagram Numbering
Fi gu re 7.1- 3 in dic ates h o w th e R ot or k w irin g d iag ram nu m b er s co de is c on st ru cted .
Base Syncroset Wiring Diagram Num ber 2 2 2 0 - 0 0 A
Syncroset - ----------------------------------------------- 2
M ar k II ( No Therm ostat ) ------ ------ ------- ------ 0

M ark II --------------------------------------------- 2
Sw itch Mechanism O nly---------------------------- 0

Sw itch M echanism and Heater------------------- 2
N o End Travel Sw itch es-------- -------- --------- ----- 0

N o Interm ediate Sw itches A- ----------- ----------- -- 0
N o P otentiom eter --------------------------------------- 0
6 In ter m ed iate S w itc hes a nd P ot ---- --- ---- ---- -- 1
Single Potentiom eter Only-------------------------- 2
12 Sw itch Add-on-Pak and Potentiom eter ----- 3
6 Interm ediate Switches------------------------------ 4
12 Switch A dd-on-Pak, N o Potentiom eter --- 9
Switch Designations
2 Cir cu it C hange O vert 00

(Standard Product - 4 Pole, Double Break)
2 Circuit Change Over ------------------------------------- NO

(Nuclear Product) Pre-1978 - 4 Pole, Double Break)
Sin gle Pole C hang e O ver ------- -------- --------- ---- VN O

(Nuclear Product) Post-1978 No Latch - SPDT Form C
Anti Clockwise, Close Operation A------------------ A
Clockwise, Close O peration ---------------------- BLANK
F i g u r e 7 .1 - 3
R o t o r k W i r in g D i a g r a m N u m b e r i n g
7-4
8.0 GENERAL PRECAUTIONS FOR USE AND REPAIR OF ROTORK

"NA" RANGE ACTUATORS
T he pr ec au ti on s th at s h o u ld b e ad d r es s ed w h en op er at in g o r p e rf o rm in g m ain t en an ce o n
R o to rk a ctu at or s w i ll be c ov er ed i n th is s ecti on . C o nd u ct of m ain te na nc e i s s ue s
( ho us ek eepi ng , p er so nn el saf ety , etc.) ar e b ri efly co ver ed , h ow ev er th e f ocu s is o n s pecif ic
e lect ric al and m ech an ica l c on cer n s an d p re cau tio ns .
8.1 General Precautions
A s s e m b li es th at d o no t e ff e ct th e a ct ua to r t or q u e o ut pu t ( i.e ., ha n dw he el a s s em bl ie s ) ar e
cl assif ied by R o to r k as cu sto m e r re pl ace ab le. F or rep ai r/ re pl ace m en t o f th ese asse m b lie s
n o s pe cia l t ra in ing or cer tif ic atio n i s n eed ed by m ain te na nc e p er s o nn el f or in st all atio n o r
re pl acem en t. H o w eve r, i f th e m od u le is n o t c lassif ied as c usto m e r re pla ceab le ( i.e ., m ot or
as s em b ly, ge ar cas e as s e m b ly , to r qu e s w itc h as s e m b ly ), m ain te na nc e pe rs o nn el m us t b e
q ual if ied t o s ite s p ecif ic m a in ten an ce pr o ced ur es to r ep air /r ep lace t he m o d ul e a nd rec er tif y
th e ac tu a to r 's o u tp u t to r q u e.
• E ns u r e ap pr o pr ia te p er s on al p r ot ect io n is u s ed w h en ex p os e d to lu br ic an t o r c lea ni ng
s o lv en t. R e fer to th e a pp lic abl e M a ter ial S afe ty D ata S h eets (M S D S ) f or sp eci fic
i ns t ru ct io ns o n v en tila tio n , r es p ir ato ry , s k in , a nd ey e pr o tec tio n.
• E nsu re ad eq ua te ve nti lati on i s p ro v ide d w he n w or k ing in co nf in ed sp aces.
• M a tch m ar ki ng o f co m p on en ts b ef or e d is as s em bly w ill re du ce the p ot ent ial fo r er ro r

d u ri ng re as s em bl y.
C A U TI O N : E ns u re m at chm a r ks d o no t d am a ge cr iti cal s eal ing o r m a chin e- fit

su r fa c es .
. L oo s e par ts s h o uld b e co ntr ol led to pr eve nt lo s s , dam ag e a nd co n fu s ion w i th o the r

s im ila r p arts .
. D o no t atte m p t t o d is as s em b le o r r em o ve an y a ctu ato r o r ge arb o x w hi le it is un de r lo ad .
C A U T IO N : Q ua r ter t urn va lves or va lves w ith no nlo cki ng stem - s tem nu ts m a y

ab ru ptly r epo sitio n th em s elves w h en the actua tor or g ear box is rem oved .
Su itab le stem gag s ar e recom m end ed to p reven t repo sitio nin g.
. D o no t ex p os e g ea rs , lu br ic an t, o r s ea ls w he n th e s u rr o un d in g en v ir on m e nt c on ta in s
e xce ss i ve m o is tur e or co n tam in ati on .
8-1
• E ns u re g ear cas e oil s o f di ff er ent ty p es o r br an ds ar e n o t m ix ed du r ing pr ev ent ive o r

co rr ect ive m ai nte nan ce activ iti es.
• B ef or e cha ng in g va lve p os it ion , en s ur e th at O per ati on s s u pe rv is or con cu rs w ith t his

a ctio n an d h as ev alu ate d th e c on s eq ue nc es .
8.2 Electrical Precautions
• E n su re all el ectr ical po w er co nn ectio n s to th e actu ato r hav e been d e- ene rg ized p rio r to
pe rf or m in g an y han ds - on m ain ten anc e. V ol tag e f ro m oth er A C o r D C s ou rc es m ay be
pr es e n t at th e li m it s w i tch co n tac ts ; th er ef o re , ap p ro p r iat e pr ec au tio n s s h o u ld b e ta ke n
(ex am p le: act uato rs w ith in ter loc k con tr ol po w er ).
• V eri fy th at all co ntr ol and p ow er cir cui ts hav e been d e-en erg ized b y electr ical
m e as u re m en t pr io r t o w o rk in g in s id e ac tua to rs .
• T ag a nd ta pe lead s p ro per ly w h en disco n nect ing t o ensu re pr op er r econ n ectio ns .
• T a ke pr ec aut ion s t o av oid con ta ct w ith el ectr ica lly en er gi zed p ar ts o f th e actu ato r w h en
p er fo rm in g o pe rat io na l t es ts or m ai nte na nc e.
• D o n ot cy cle th e m ot or r ep etit ive ly (s t art /s top ) . S uch actio n ca n cau se t he m o to r to

ov erheat if th e duty cycle is exceeded .
• E n sur e th e su r ro un d in g ar ea is f r ee fr om e xce ssive m ois t ur e, d ust , etc . pr io r to

rem ovin g t he lim i t s w itch co ver.
• A d ju s t th e to r qu e s w it ch s e t po i nt o n ly w i th t he a ctu a to r in th e m an u al p o s iti on w ith

th e sp r ing pac k re lax ed.
• T o pr ev en t d am ag e t o th e s w itch es an d w ir es , l ift t he li m it s w itc h co v er s tr aig h t a w ay

f ro m th e a ctu ato r w h en r em o v al is req u ire d.
• E n s u re p r eca ut ion s ar e tak en to q u ick ly d e- en er g ize t he a ctu ato r m ot or af ter elec tr ica l
r eco n ne cts o r li m it s w i tch ad ju s tm e nt s . T h is is to p r ev en t m o to r s ta ll s h ou ld m o to r
ro tati on r ever s al o r a sw it ch m alf un ctio n occ ur .
• D o n o t m ak e an y to r qu e s w itc h ad ju s tm e nt s u n les s di re cted by E n gi nee ri ng or

ap pr op r iate w or k o rd er.
• E n s u re t em po r ar y w ir e m ar ke rs o r ju m p e rs ar e r em o v ed .
• A u tom atic m ai nta ine d cir cui ts , w hic h m ay o pe n or c los e th e v alv e au tom atica lly , m ay
n eed to be d isa bled p ri or to v alve elec trica l o r m an ual op era tion .
• A lth o ug h lea vin g ac tua tor s w it h co ver s o f f is n o t r eco m m e nd ed , an y tim e an actu ato r
w ill be lef t u nat tend ed w ith th e co ve rs o ff an d th e M C C ener gi zed, " D a ng er H igh
V oltag e" tape sh ou ld b e u s ed.
8-2
• S cre w dr ive rs sh ou ld n ot be u s ed to pr y co ver s a par t f ro m the g ear case.
8.3 Mechanical Precautions
• D o no t u se ex cessi ve fo rce w hen d epr essin g the d eclut ch lever . If d eclutc h lever is
di ffi cult to en gag e, ro tate han d w hee l 9 0 deg ree s and t ry ag ain.
• D o no t f orc e th e d eclut ch lever to m o ve in the di rectio n op po sit e th at f or d eclutc hin g t he

ac tu at or . S u c h ac ti on co u ld d a m ag e o r d i s ab le t he i nt er n al t ri pp er m e ch an is m .
• D ur in g el ectr ica l op er atio n , do no t pl ace th e actu at or i n m an u al ex cep t i n an e m er ge nc y

s ituat ion to s top d riv e s lee ve m otio n.
• D o n o t u s e an y to r qu e am pl if yi ng d ev ic e to ai d in ha nd w h eel r ot atio n . L o ad pa th
co m p o ne nt s ar e d es ig n ed to car r y o nl y th e to rq u e th at can be m an ua lly e xe rt ed o n t he
ha nd w hee l r im w itho ut a to rq ue am p lif yin g de vic e.
• D o n ot lif t the act uat or b y ty in g to , or p ick in g up t he act uat or b y th e d ecl utc h lev er .
• D u rin g a ctu ato r r em o v al, tak e pr eca ut io ns to m in im i ze th e b en d in g lo ad a pp lie d to the

val ve stem .
• I f th e va lv e is seat ed m an ua lly it sh all b e u nse ate d m a nu al ly . I t is po ssib le t o ex er t

m o re for ce m anu ally th an the m o tor is a ble to ov erco m e to electr ically o pen th e v alv e.
8-3
.
9.0 ENVIRONMENTAL QUALIFICATION SUMMARY

9.1 Rotork Model NA1 Required Maintenance
R o tor k M od el N A G act uato r s ar e q ual ifie d fo r a 4 0 y ear lif e. It is reco m m e nd ed th at the
f ollo w ing m ain ten ance item s are per fo rm ed :
1. E v ery fiv e y ears, on e M od el N A 1 actuato r sh ou ld be select ed f ro m in sid e

c on t ain m en t f or in s p ec ti on . T h e ac tu at o r s h o u ld b e a t le as t t h e s am e ag e a s t h e
in specti on an d be equ ipp ed w ith seals o f the sam e age (i.e., 1 0 year in spect ion ,
1 0 y ear o ld ins t alle d ac tua to r, s e als an d pa rt s ). T he in s p ecti on sh o ul d in clu d e:
b en ch tes t ing (p rio r to d is as s em bl y) , di s as s em b ly an d in s pe ctio n. T he in s p ectio n
s h ou ld pa y p art icu la r att en tio n to s eal c on di tio n . A n y s ig ns o f s eal d eg r ad atio n
s h ou ld b e n o ted an d ex am i ned f o r gen er ic im p lica tio ns . S it e E ng in eer ing /R oto r k
s ho uld b e no tif ied if s eal d egr ada tio n is n oti ced du e to an en vi ro nm e ntal
q ual ific atio n con s id erat ion . A R ot or k rep re se nta tive s h ou ld, if p o ss ib le, w it nes s
an d as s is t in th e ins p ec tio n.
2 . A t lea s t on ce a y ea r, a s i te en g in eer in g r ep re s en tat iv e s ho u ld r ev ie w , w it h a
R ot or k re pr es en tat ive al l w o rk per f or m ed o n R ot or k act uat or s in the p re vio u s
y ear. T h is r eview s ho uld in clud e id en tifica tion o f any p rob lem s w h ich co uld b e
g en eri c. M ain tain in g a rec or d o f the s e r ev iew s w i ll gr eatl y aid in ide nti fic atio n
of po tential pr ob lem s pr ior to oc curr ence.
3. B o th C as tr ol N u cleo l a nd E xx on -S p ar tan E P 1 50 oil s ar e q u alif ied f or u s e in
R oto rk N A 1 and N A 2 /N A 4 ac tuato rs. W h en it b eco m es n ecessary to ad d oil to
th e gear case, C astr ol N uc leol an d E x xo n S par tan E P 1 50 oils can b e m ixe d.
N O T E : T h e Y e ar t ea r d ow n in s p ec tio n r eco m m e n da t io n i n I te m 1 is th e
in itia l R oto r k r eco m m e nd atio n fo r s eal deg r ad tio n tr end ing . O ther
m etho ds of tr end ing seal failures m ay be an acceptab le alterna tive to th is
recom m endation .
9.2 Equipment/Part Replacement Intervals

S ea l r ep lace m en t int erv als s ho u ld b e d ete rm i ned bas e d on t he in s pe ctio n co nd u cted p er
S tep 9.1.1.
9.3 Electrical Termination Method

1. F ield cab le e lect rica l t erm ina tio n is to a q ua lif ied te rm i nal b loc k ins i de th e
syn cr o s et as s e m b ly .
2. P r e- 1 97 8 A c tua to rs : P u s h o n l ug s u s ed fo r i nte rn al c on n ect io ns .
3. P o s t- 1 97 8 A ct ua to rs : R in g te rm in als u se d f or in ter na l co nn ec tio ns .
9-1
9.4 Cable Entrance Sealing
C ab les en t er in g th e a ctu at or s h ou ld b e w ate r tig h t s ea led .
9.5 Gearcase Breather Tubes
1. G ear c as e b r eat he r t ub e s s h al l b e in s ta ll ed o n th e u pp er m os t g r ea s e p lu g f it tin g

o n ac tu ato rs in s id e co nt ain m en t an d s h ou ld n o t be p ain te d or op en in gs
o b s t ru c te d i n a n y m an n e r. T he b re at h er tu b e f u n ct io n is t o p r ev e nt g ea rc as e
pr essu r iza tio n in th e ev ent o f i nc rea sed c on ta in m en t pr essu r e.
2 . T h e ac tu at or s ca n b e m o u n ted in an y o r ie nt at io n.
9.6 Shelf Life
T he assem bl y sh elf life is 3 2 year s. T he sh elf lif e is b ased on E P R I N P - 64 08 "G ui delin es f or

E s tab lis h in g, M a int ain ing , an d E x ten din g th e S hel f L if e C ap ab ility of L i m ite d L if e I tem s
(N C lG - 13 )" . T h e lim i tin g m at eri al fo r s he lf lif e is n itr ite ( s eals ) . If t he as s em bly is t o be
u se d af te r th e in di cat ed sh elf lif e ha s e xp ir ed , th e ap p ro p ri ate en g in eer in g
or gan izat ion /R o to rk s ha ll b e n ot ifie d in or der to ev alu ate the co nd itio n of th e
equ ipm e nt/co m po nen t.
9.7 Design Environments
1 . N o rm al C o nd itio n s
A ll N A a ctu ato rs are ca pab le of op er atin g fo r 1 5 m in ut es i n an y on e ho ur a t
aver age v alve lo ad u nder the fo llo w ing cond itions :
a. A m b ient pr ess u re o f 8 to 1 8 p s ig
b. R elative hum idity of 100 %
c. T em p eratu res up to 1 48 °F
d. A ccu m ulated rad iation dos e w ith no chan ge o f c om po nents o f 1.5 x 107 rad
e . P la n t in d u c e d v ib ra tio n o f 0 .7 5 g ' s fo r a ll fr e q u e n c ie s
2. A ccident C o ndition s
A ll P os t- 19 78 N A 1 a ctu ato rs a re cap ab le of 2 0 op er atio ns , m i nim um , un der t he
fo llow in g con diti ons:
a. A m bi ent pressure o f 70 psig
b . A m b ie nt m ax im u m tem pe ra tu re o f 3 7 0° F
c. A tm osp h ere o f satu rat ed ai r a nd ste am m ix tu re w i th a ch em ic al sp ray o f
H 3B O 3 , N 2 S 2 0 3 , and N aO H
d. S eis m ic acceler ation of 6 g's in an y d irectio n o ver a fr equ ency of 0.2 to 34 H Z
e. R adiatio n life accu m ulated d ose o f 2 x 1 0 8 rad
3 . N A 2 /N A 4 a ctu ato r s w il l ret ain st ru ctu r al in teg r ity u n der th e L O C A co n dit io ns
i de nti fie d f or T yp e N A 1 act uat or s . N A 4 ac tu ato rs ar e n o t desi gn ed t o op er ate
d u ri ng o r a ft er th es e co n di tio ns .
4. N A 5 act uat or s ar e c apa ble o f a m ini m um o f 20 op era tion s t o un de r the f oll ow in g
c o n d itio n s :
a. A m b ien t pr es s u re o f 1 0 ps i g
b . A m b ient tem p eratur e of 16 0 °F (7 0 °C )
9-2
Rotors Maintenance Manual
c. A t m o s p h er e o f s a tu r at ed air an d s te m m i x tu re w it h a c he m i ca l s p ra y
con sis ting of 0.28 m olar N A 2 S 2 O3 and N aO H ( pH 10.5 at 77°F ,
appro xim ately 5 9% )
d. S eis m ic acceleratio n in any dir ection of 6 g 's o ver a fr equen cy r ange of 0.2 to
34 H Z
7
e. L if etim e accu m u lated r adia tion d ose of 3 x 1 0 r ad
9.8 Specific Characteristics of NA1 Actuators
1 . G re y ca st iro n a n d /o r m alle ab le g e a rc a se m a te rials are u se d .

2 . Sw it ches and sw itch m e chan is m s cap ab le o f w ithstan di ng hi gh er se is m ic l evels
are u se d.
3 . L u b ric atin g o ils , s eal s , w rin g s an d s w itc he s ar e s uit abl e f o r the h ig he r rad ia tio n,
tem per at ur e, an d p ressu re le ve ls ,
4 . A ge arc as e br eath er is pr ov id ed to a llo w f or th er m al ex pa ns io n o f the o il and air
u nd er acci de nt a m b ie nt te m p er at ur e co n di tio n s .
5 . C l as s 'H ' r ad iat io n re s is ta nt in s u lat ion is us e d fo r m ot or w in din g s .
6 . S pec ial p ain t i s u s ed. C ar b oz inc I I un d erc oa t w i th P h eno lin e 30 5 to p co at pai nt is
us ed .
S pecific com p onen t m ater ials are pro vided in T able 9.8 -1 .
9-3
T a b le 9 .8 - 1
A c tu a to r C o n s tr u c tio n D et a ils
C o m p on e n t NA 1 N A2 NA4 NA5 'A ' R a nge

Gearcase G re y c a s e i r o n a n d / o r G re y a n d / o r m a ll e a b l e G re y c a st iron a nd /or G rey c as t iro n an d/o r G rey c as t iro n an d/or
m a ll e a b l e c as t iro n, no sn ap rin g m allea ble m allea ble m a llea b le . N o sn a p rin g
m a ch in ed m ac h
D y n a m ic o il s ea ls V i t o n b a c k u p r in g s M e dium nitrile V ito n b ac k rin gs M ed ium nitrite M e diu m nitrite
S t a t ic 'O ' r in g M e d i u m N i t ri l e M e dium nitrile M e diu m nitrite M ed ium nitrite M ed iu m n itrite
'O ' R in g s f o r b e a r in g V iton M e dium N itrile V iton M ed ium nitrile M e diu m nitrite
s t o p r in g
P ai nt sy ste m C arbozin c II un derco at Stan da rd 'A ' R an ge C a rbo zinc II u nd erc oa t S ta n da rd 'A ' R an ge C hrom atic prim e r A crylic
P he noline 3 05 topc oat P he no lin e 3 05 top coa t reinfo rc ed S yn the tic
( no t e 1 ) (note 1) a lkyd top co at
L u b r ica n t R ad iation re sis tan t oil S A E 80 E P O il R a dia tio n res is ta nt oil S A E 80 E P oil S A E 8 0 E P oil
M o t o r h o u s in g G r e y c a st i r o n A l u m i n u m w it h a l c h r o m e G rey c as t iron A lum in um w ith a lc h ro m e A lu m inu m w ith alc hrom e
co ating coa tin g c oa ting
S y n c ro s e t h o u s in g G re y c a st i r o n G rey ca st iro n G re y ca st iron A lu m in um w ith a lch ro m e A lum in um w ith a lc hrom e
coa tin g c oa ting
H a nd w heel H o t ro l l e d st e e l H o t R o l le d S t e e l H o t rolled s tee l H ot rolled s tee l H ot rolled s tee l
D riv e b u s h ( n o t e 2 ) A l u m in u m b r o n z e A lu m in um B ron ze A lu m inu m b ro nz e A lum in um b ro nz e A lum inu m bron ze
D r iv e b u s h r e t a in e r Z i n c p l a t e d -h i g h d u t y Z inc plated high w roug ht Z inc pla ted -h igh d uty Z inc p la ted -high d uty Z in c pla te d-h ig h du ty
(note 2) w rou gh t stee l ste el w rou gh t s te el w ro ug h t ste e l w ro ug ht s te e l
M o t o r in su la t io n C las s H Clas s B C la ss F C la ss F or H C las s F
O v e rlo a d p ro t e c tio n C u stom e rs relay T he rm o s ta t T he rm o s ta t C u s to m e r' s re lay T he rm o s ta t
S w it c h /M e c h s w it c h es B u rg e s s V - 1 2 B urges s T K -5 B u rg e ss T K - 5 B u r g e s s V -1 2 B u r g e ss T K - 5
A O P s w it ch e s H one yw ell nu clea r H o n e y w e l l (s td ) c a st i ro n H o n e y w e l l ( st d ) H on eyw ell nu clea r H o n e y w e l l ( st d )
3-pc cover fab ric ated s tee l / no
ind ic a tio n
C a b le in s u la t i o n T ers il H igh tem p erature PV C H ig h t e m p . P V C (n o t e 2 ) H i g h t e m p . P V C (n o te 2 ) H i g h t e m p . P V C (n o t e 2 )
(n o t e 2 ) or te rs il
P o t e n t io m e t e r O h m ite nu clea r C o l v e rn (s t d ) C o l v e r n ( s td ) O h m ite nu cle a r C o l v e r n ( st d )
L o c a l p o s it io n N o t a v a i la b l e N ot A v ailable N ot a vailab le N ot a va ila ble S ta nd a rd po in ter a nd d ia l
in d ic a t o r
H e at e r 1 2 w a tt 1 2 w a tt 1 2 w a tt 12 w a tt 1 2 w a tt
N o te 1 : S u r fa c e p r e p a ra t i o n f o r N A B a n d N A 4 i s t o s t e e l st r u c t u r e s p a i n t i n g c o u n c i l s p e c i fi c a t io n S S P C - S P 1 0 6 3 T , w i th g r i t b l a s t i n g to 9 5 % w h i t e m e t a l.
N o t e 2 : C r o ss l i n k P o ly m e r i c w i re i s a v a i l a b l e a s a n o p t i o n .
10.0 ACTUATOR CERTIFICATION PROGRAM

10.1 Introduction
A s p a rt o f t h e m a nu f act u ri ng p ro ce ss, e ach R ot or k act ua to r i s t est ed t o e nsu r e th at :
• E l ect ri cal p ar am ete rs a re w i th in s p ec if ica tio n s

• R ate d t or q u e is pr o d uc ed at th e m ax im um t o rq u e s w it ch s ett in g
• S tal l tor q ue is acc ep tab le
T hi s te st in g is a cco m pl is he d us i ng a to rq u e t es t b en ch w h ich i s cap ab le of app ly in g bo th a

fi x ed an d va r ia bl e t or q u e r es i s t an ce to th e a ctu a to r . S tem n ut to r q ue an d s pe ed , as w e ll as
m o to r v o lta ge a nd cu rr en t , ar e m o n ito r ed an d r eco r de d d u ri ng th e tes t in g .
T o m ai nt ai n ce rt if ic ati o n, R ot or k re qu ir e s t ha t th e 'N A ' s er i es act u ato r b e r et es t ed

w he ne ve r m a in ten an ce is p er fo r m ed th at co u ld a ff ec t i ts to rq u e ou tp u t cap ab il ity .
C e rt ifi cat io n te st in g is al w ay s r eq ui re d w h en th e sw it ch m ech an is m , m o to r, or ge ar case
are r eplaced ( see S ection 1.1) .
C e rt ifi cat io n te s tin g ca n b e pe rf o rm ed b y a q u alif ie d u s er w i th ac ces s to a to rq u e t es t s ta nd

or eq u iv ale nt a p pa ra tu s . T he f o llo w i ng pr o ce du r e id en ti fi es th e k ey a s p ect s a nd
con si der ation o f the cert ificat ion p roc ess.
10.2 Torque Test Bench Requirements
T he c ert ificat ion test b enc h sho u ld m ee t the fol lo w ing m in im u m req u irem en ts:
• C ap ab le o f ap p ly in g to rq u e re s is ta nc e and m ea s ur in g m ax im u m ex p ect ed s t all

t or q u e v al ue of th e a ct ua to r un d e r te s t
• C ap ab l e of m e as u r in g th e t or q u e va lu es w i th a n u n cer t ain ty w h ich is le s s th an
th e u nce rt ain ty a ssum ed in m o tor op er ate d va lv e (M O V ) se tu p cal cul ati on s
• C ap abl e o f ap p lyi ng r ed uc ed v olt age s to t he m o to r at v alu es l es s th an e xp ecte d
v olta ge in actu al M O V a pp licatio ns
• A p p lie s t he t or q u e re s is ta nc e s m o o th ly a nd re pe at ab ly
• P r ov id es s te m nu t an d m ou n tin g b as e ad ap te rs f or eac h s ize a nd m o de l to b e
tes te d
10.3 Rotork Certification Procedure

1. C h eck th e w or k o r de r to en sur e th e co r re ct ac tu ato r h as be en se lec ted fo r
certificat ion.
2. E n s u re th at a ll r el ev an t d o cu m en ta ti on is av a ila b le ( i.e ., w ir in g di ag r am s , s e tu p
in s t ru c tio n s , d at a s h ee ts ) .
3. R ec or d th e b as ic a ctu at or i nf o rm ati on on th e tes t d ata s h ee t (s ee F i gu r e 10 .3- 1 ).
4 . U sin g th e a p p ro p ria te a d a p te r h ard w a re, m o u n t th e u n it o n th e tes t sta n d .
E n s u re m o u nt in g b o lt s /s t u ds a re s ecu r e. R em o v e t he s yn c ro s e t an d s w itc h
m echanis m co ver f or access.
10-1
5 . U s i n g t h e ap p r op r ia te ad ap t er ha r dw ar e, ap p ly n o m o re th an 3 0 p s i a ir p re s s u r e
to th e up pe rm os t ge ar cas e oi l f ill er p lug . A ll ow to s ta nd f o r 16 m in ute s an d
ch eck for o il lea ks. R ep air a ny leak s bef ore pr oceed ing .
6 . A pp ly a hig h vo ltag e po ten tial tes t o f 2K v f or o ne s eco nd to a ll co n tro l an d h eater
te rm i nal s , an d a h ig h v olt age p ot ent ial tes t o f 1.7K v f o r on e s eco nd t o the th r ee
p o w er ter m in al s . R ec o rd th is i nf o r m a tio n un d er ap p r op r ia te h ea d in g s u n d er
b oth 'E le ctric al C he ck', an d 'M o to r C h eck' sectio ns o f th e te st da ta sh eet (s ee
F igure 1 0.3-1 ).
7 . P er fo rm a co ntin u ity ch eck o f all au xil iary sw it che s to th eir c or resp on di ng
ter m in al bl ock l ocat ion s ( ref er to a pp licab le w iri ng d iag ram o n actu ato r
n am ep lat e) . R ec or d th e re s ul ts o f th is c he ck o n th e tes t d a ta s h eet (s e e F ig u re
1 0.3-1).
8 . E n g ag e 'h an d ' o p er at io n a n d tu r n t h e ha n dw h e el f or th r ee r ev o lu ti o ns in ea ch
d ir e cti o n a g ain s t th e d r iv e d o g s . E n s u re th at th e u n it d o e s n o t d r o p o u t o f
'h an d'. In ad d iti on , v er if y t h e ha nd g ear ra tio ( i.e., to p h an d w h eel i s 1 :1 , s i de
han d w hee l can b e va rio u s r atio s a cco rd in g to si ze) , an d r eco rd o n th e test d ata
s heet (s ee F igu re 1 0.3-1 ).
9 . C o n ne ct th e m ot or an d co n tr ol c ir cu it le ad s t o th e ac tu ato r . R eco r d te st vo lt ag e
o n th e tes t da ta s hee t (s ee F ig u re 1 0.3- 1 ).
1 0 . E lec tr ic al ly op e ra te t he act u at or m th e c lo s e d d ir ec ti on . E n s u r e th at th e
d ir ecti on o f r ot atio n is co rr ect an d r eco rd resu lts o n th e t est da ta shee t ( s ee
F ig ur e 10 .3 -1 ). R ep eat th is p ro cess fo r the o pen dir ecti on , bu t no r eco rd o n th e
tes t da ta s he et i s ne ce s s ar y .
1 1. D isen g ag e t he sw i tch m ec han is m c lu tch assem bl y an d en su re t hat t he o p en an d
clo s e to rq ue s w i tches are s et to 'S ' ('M A X ') an d tha t th e to rq ue/ lim it sw it ch
s elector is set to 'L IM IT '.
1 2. E le ctr ic ally op er at e th e act ua to r in e ith er di re cti on an d co u nt n u m b er o f
r ev o lu ti on s o f th e c en ter co lu m n p er m in u te . R ec or d th e re s u lts o n t he tes t d a ta
s h ee t (s e e F ig u re 1 0 .3 - 1) an d e ns u r e th is v alu e ag r ees w i th t he n am ep la te
in for m ation .
N O T E : T he a ctu ato r m a y s ta g du r in g th e f oll ow in g ver i fica tio n ch eck . If

this s h ou ld occu r, d o no t m ain tain th e s ta ll co nd ition a ny lon ger tha n
a bs o lute ly n e ce ss a ry .
1 3. E lec tri call y o per at e t he ac tu ato r in e ith er d ir ect ion w hi le ap pl yin g a r am p loa d
u s in g th e tes t sta n d b ra k e u n til th e to rq u e sw itch trip s . E n s u re th at th e
ap p r op r ia te to r q ue l im it s w i tch de - en er gi ze s u n it . R ep ea t th is o pe ra ti on in t h e
o ther di rectio n.
1 4 . E le ctr i ca lly o p er at e th e a ct u at or in ei th e r d ir e cti o n w i th th e t es t s ta nd b r ak in g
m ech a ni s m r el ax ed . R ec o rd th e 'L ig h t R u n ' cu r re nt on th e te s t d at a s h eet (s e e
F ig u re 1 0 .3 - 1) . R ep ea t th is op er ati on in o th er di re cti on an d re co rd th e re s ul ts .
10-2
N O TE : D o not m a inta in s tall cond ition lon ger tha n is necessa ry for testing .
1 5. E lectr ica lly o pe rat e t he act uat or in eith er d ire ctio n w h ile ho ld in g the to r qu e
s w i tc h f ro n tp la te i n m id p o s it io n S l ow ly a pp l y th e t es t s t an d b r ak e u nt il th e
m oto r s talls (lo ck ed ro to r) . R ec or d st all tor qu e (lo ck ed ro to r tor qu e) an d s tall
c ur r ent ( lo ck ed ro to r cu r ren t) on th e tes t d ata s h eet ( s ee F ig u re 1 0 .3 - 1) . R ep eat
t hi s o p er atio n i n th e o th er d ir ec tio n an d r ec or d t he r es u lts .
N O T E : Sta ll tor q ue figu r es s ho uld b e w ithi n l im its s pec ified by T ab le

10.3-1 . I f s tall to rq ue is b elow thes e lim its, see Step 17, belo w .
1 6. E le ctri cally o pe rate th e a ctua tor in e ithe r dir ectio n w hi le s lo w ly ap ply in g the
t es t s ta n d b r ak e un t il t h e to r q u e s w i tc h t r ip s th e un i t. N o te th e t or q u e
d ev elop ed at s w itch t rip . R ep eat th is o pe rati on f or th e op po s ite dir ectio n w hi le
al s o no ting t he to rq ue dev elo pe d at s w itc h trip .
N O T E : A c tua to rs m an ufa ctu r ed in th e U .K ofte n ha ve sp ecia lly w o un d m ot or s

for s pecific voltag e con dition s. T he or igina l R oto r k cer tification s heet s ho uld
be us ed to deter m ine the " as built" ra ted torq ue for th ese s pecia l applications .
E ns u r e th e to rq u e v alu es o bt ain ed ar e w ith in th e r an ge s p ec if ied by th e

a pp li cab le ch ar t (s e e T ab le s 1 0.3 -2 th ro u gh 1 0 .3 - 7) . F o r ac tu ato r s w h er e th e
v oltag e d rop is n ot sp ecified , us e th e "1 0% " ch art (s ee T ab le 1 0.3-1 ). M oto r
c u rr en t v a lu es p r esen t ed in th e ch a rt s ar e f or r ef er en c e on l y. I f t he r a ted to r q u e
( i.e., t orq ue sw itch s ettin g of '5') i s ou t of s pec ificatio n, th en t he m oto r s p ring
p ack w i ll hav e to b e adj uste d. L o o s en th e sp r ing p ac k if th e val ues ex ceed t ho s e
s p ecif ied in the ch art s; ti gh ten th e sp ri ng p ack if t he va lue s f all bel ow tho s e
sp ec if ied . A f te r ea ch sp r in g p ack ad ju stm e nt , en su re t he t or q ue sw i tch fr o nt
p o in ter i s in th e c en ter p o s itio n b y a dju s ti ng t he t or qu e p lu ng er .
O p en a nd c lo s e t or qu e v alu es s h o ul d be w it hi n 5% . I f n ot, m ar k th e or ig in al
p os i tio n of t he to rq ue p late p oi nte r and bal anc e t he o pen a nd c los e to rq u e b y
m ov i ng th e po s it io n o f t he t or q u e s w itc h f ro n tp la te. If th e ad ju s tm en t re qu i re s
t he tip o f th e t or qu e sw i tch f ro ntp lat e p oi nte r to b e o ff s et fr om th e cen ter b y
m or e t ha n 1 /8 ", re tu r n th e p o in ter to t h e or ig in a l po s it io n a nd ad ju s t th e t or q ue
p lu n ge r le ng th en in g t he t or q ue p lu n ge r m ov es th e to r qu e p lat e c lo ck w is e . F o r
7 0/ 9O N A ac tua tor s , add itio na l ad ju st m en t is pr ov id ed by th e rat io lev er pla te.
10-3
T h e r at io lev er p lat e i s lo cat ed o n the b ack o f th e sw itch m ech an is m an d can no t

b e s ee n o nc e in s t all ed . T he pl ate in ter f ac es b etw e en th e to r q ue p lu n g er an d t he
s w it ch m ec ha n is m h el ix t h ro u gh an ad di ti on al h e lix ad ap te r p in . T he he lix
ad ap ter p in i s al so att ach ed t o th e bac k o f th e sw i tch m ech an is m o ve r th e h el ix
gear.
T h e s w itc h m e ch an is m do es n ot n ee d to b e r em o v ed to ad ju s t the r at io p lat e. A

ho le in the s w itch m e chan is m fr om pla te ( jus t to th e l eft of th e p o inter ) pr ov id es
ac cess to th e r ati o p lat e ad ju stm en ts in th e ba ck o f th e sw itc h m ech an is m . A
slo t i n th e sw i tch m ech an is m ba ck p lat e r ev eal s tw o sc re w s. T he t op sc rew is a
loc kin g scr ew an d the b otto m s cr ew is t he adju s ting s cr ew .
If th e tor qu e o utp ut is low o n a s etting o f '5 ', lo os en the lock ing s crew ( top ) and
tu rn th e a dj us t in g s cr ew s lig ht ly c loc kw i s e the n r eti gh ten lo ck ing s cr ew . T e s t
o ut pu t t or q u e an d r ep e at ad j us t m e nt i f n ec es s a ry .
R ep eat th is p ro cess u nt il ra ted op en a nd clo s e to rq u e ar e b al an ced an d w ith in

spe cification s .
R eco rd the a ve rag e to rq u e an d m o to r cu rr en t fr o m th ree o p era tio n s in each

d ir ect io n u nd er th e 'T o rq u e S ett in g 5 m ax ' h ea di n g o n th e te s t da ta s h eet ( s ee
Fig ure 1 0.3- 1).
17 . T h is s tep is r eco m m en d ed if th e s t all tor qu e va lues ob tai ned i n S tep 1 5 are

ou tsi de th e accep table lim it and if sp ecific un der voltag e co nd ition s are expe cted
to be below 90% of rated.
N O T E : T he ac tua to r m a y st all d urin g th e f oll ow in g verifi cat ion c hec k. If

this s h ould o ccur ) do no t m ain tain the s tall cond ition a ny lo ng er tha n
a b so lu tely n e ce ss a ry .
E le ctr ical ly o per ate th e actu at or at ( or b el ow ) th e de sign basi s u nd er vo ltag e

w h ile s l ow l y a pp ly in g t he t es t s t an d b ra ke u n ti l th e to rq u e s w it ch t ri ps . V er if y
th at r ated to r qu e is ach ieve d in bo th 'op en ' an d 'cl os e' d ir ectio ns .
I f th e ac tu at or sta lls o r if r ate d to r q ue i s n o t ac hi ev ed , t he act ua to r p er f or m an ce

is n o t a ccep tab le fo r an u nsp ecif ied app lic atio n. T he to rq ue sw itc h can b e se t t o
a le ss than ' M A X " setti ng in a sp ecific app licatio n as lo ng as th e to rq ue sw it ch
tr ip s p r io r to s tal l an d th e to rq u e s ele cto r i s n o t ra is ed ab ov e th is s ett in g in th e
fu tu r e.
If th e a ctu ato r d oe s p r ov id e rat ed t or qu e at r ed uce d v olt ag e con d iti on s, r etu rn

th e v olt age to 10 0 % and co nt inu ing t es ting .
10-4
18 . S et the o pen and clo se tor que sw itch es to '4 '.
E l ectr ical ly op er ate th e a ctu ato r in eit her dir ecti on w h ile slo w ly ap pl yin g th e
to r q ue s tan d br ak e u n ti l to rq u e s w i tch tr ip o ccu r s . R ec o rd th e av e ra ge t o rq u e
an d m oto r c ur re nt f ro m th r ee op er ati on s in ea ch d ir ect ion un d er th e 'T o rq u e
S et tin g 4 ' h ead in g o n th e t es t da ta s he et (s e e F i gu re 1 0 .3 -1 ) .
R ep eat th is s t ep f or a ll tor q ue s w itc h s etti ng s d o w n to '1 ', and rec or d th e ave ra ge

to r q ue an d m ot o r cu r r en t f ro m t hr ee op er a tio n un d er th e ap p r op r ia te h ea di n gs
o n th e t es t da ta s hee t ( s ee F ig ur e 10 .3- 1) .
P lo t th e r eco r de d to r qu e v alu es f or eac h to rq u e s w it ch s et tin g o n t he t es t d ata

shee t ( use A ' for cl os e a nd 'O ' fo r op en) . C o nn ect t he plo tted p oin ts .
19 . F ro m res u lts o bt aine d in S tep 1 7 abo ve, s et th e o p en and c los e tor qu e s w i tche s to
p rod uce the re qui red to rqu e f or th e s pe cific valv e a ppl ication , if req uir ed.
E le ctri cally o per ate th e ac tua tor in o ne d irec tion w h ile s low ly a pp lyi ng th e
to r q u e te s t s ta n d b r ak e u n ti l to r q ue s w it ch tr ip o cc ur s . If n ec es s a r y, r ead j us t
th e t o rq u e s w i tc h s e tti n g u n til th e r eq u ir ed to r qu e i s pr o d uc ed . R e p eat th is
p ro ce s s f o r th e op p o s ite d ir ect io n. R e co rd th es e re s ul ts on th e tes t d ata s h ee t
( se e F ig ur e 1 0.3- 1) u nd er th e " T o rq ue s et at ' he adin g .
I f n o f u r th er a d ju s tm en ts to th e to r q ue s e tt in gs a re t o b e m ad e, be nd u p ta b s o n
'loc k & b lock ' w as her s ar ou nd b oth to rq ue s w i tch adju s ting k no bs .
20 . E n gag e th e sw it ch m ech anis m clu tch .
21 . S et th e o pen an d clos e tor qu e/lim it s w itch s electo r to th e 'to rq ue' p os itio n.
2 2. S e t th e l im i t s w i tch s t ro k e l en gt h to a m in im u m nu m b er of t ur n s to acti va te (s e e
Section 2 0.0).
N O TE : D o not ru n the m oto r lo nger tha n necessa ry to check sw itch o pera tion
as d am a ge could occur to the clu tch .
23 . E lect ric ally o pe rate th e actu ato r in bo th th e 'op en' an d 'c lose' dir ect ion s an d
en su re t h at th e au x ili ar y sw i tch es o pe ra te at t he e n d o f tr av el , b ut d o n o t d e-
en er g ize t h e act ua to r.
24. S et the 'o pen ' and 'clos e' to rq ue/lim i t s w itch sel ector bac k to th e 'lim it' pos itio n.
25 . E lect ric ally o per ate th e a ctu ator i n bo th 'op en ' an d 'clo se ' d irec tio ns a nd en sur e
th at th e lim it s w i tc he s o p er at e at th e e nd of tr av el a n d d e- en er g ize t h e act ua to r .
2 6. O n all ac tuat or s w ith c ent er col um n sp eed s o f 86 R P M a nd h igh er th e sw i tch
m ech an is m stop pin s m ust b e d r ive n in f lu sh to th e sur fac e o f th e br ass fr am e.
27 . A p pl y red tam per p ain t to th e sc rew d riv er s lots on b oth s w itc h pack ec cent ric
cam s an d to th e hex ag on so ck et of t he to rq u e sw it ch fr o nt p late sets cr ew .
N O T E : A t th is stag e the p erfo rm ance tes ting of th e actua to r is co m p leted .
10-5
2 8 . E n sur e th at th e sw it ch m e ch an is m co v er o -r in g o n th e g ear case i s p re s en t a nd in

go od co ndi tion . L igh tly coat the o- rin g w ith C as tro l N uc leol G 1 10 G r ease , o r
eq ua l. C are fu lly in st all th e s w itch co ver , an d ti gh ten s ecu ri ng s c rew s ( se e
S ectio n 2 0.6 f or s crew to rqu e r equ irem en ts) .
29 . E n sur e m oto r and con tro l po w er ar e d e-e ner gi zed, t hen d isco nn ect m o tor a nd
co ntro l circu it leads.
30 . E n s ur e th at the S y ncr o s et cov er o -r in g on the g ear cas e is pr es en t a nd i n go o d
c on ditio n . L igh tly co at the o- rin g w ith C as tro l N u cleo l G 1 10 G r eas e, or e qu al.
I ns t all the co v er an d tig ht en th e 4 c ou nt ers u nk s c rew s us in g g oo d cr aft p rac tice.
3 1. R e m o v e th e ac tu ato r fr o m th e te s t s ta nd an d r em o ve t he t es t s t an d d r iv e
b u s hi ng ad ap ter fr o m th e act ua to r.
3 2 . In s ta ll th e n o rm al a c tu a to r d riv e b u s h in g a n d reta in e r. E n su re th a t th e retain e r
i s f itt ed s n ug ly b y en g ag in g m an u al m o de , ho ld in g th e ha nd w h eel an d ta pp in g a
s pa n n er w r en ch w i th a m al le t u n ti l th e h a n dw he el tu r n s w it h t h e r et ai n er ri n g .
E n s u re t h at t he re ta in er s et s cr e w (s ) a re e n ga g ed .
3 3 . P er fo rm v isu al ch eck of t he ac tu ato r to e nsu r e t ha t t he re ar e no oi l l eak s o r o th er
un us ual co nditio ns .
10-6
W O N o: D a te :
A c tu a to r S /N S iz e & M o d e l
M o t o r D e t a i ls M otor C h eck
W /S N o P o le s
M ak e W o r m g e a r r a t io
S p e c i f ic a tio n Flashed at
T h e r m o s ta t T r ip R PM
I n s u la tio n c la s s
E le ct r ic al C h ec k M e c h a n i ca l C h e c k
C o n tin u ity c h e c k e d to d ia g r a m L im it s w itc h r a tio
C o n tr o l c i r c u it f la s h e d a t L ea d sc re w
A O P 1 p o t. v a lu e o b ta in e d Turn set at
R a te d v o lt a g e A c tu a tio n d ir e c tio n
H a n d g e a r r a t io
F i g u r e 1 0 .3 - 1
T e s t D a ta S h e e t
10-7
Table 10.3-1
Post -1978 Stall Torque Ratings
Revolutions Per Minute

5OHz 18 24 36 48 72 96 144 192
60Hz 21 29 43 57 86 115 173 230
STALL
Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max
ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb
nm nm nm nm nm nm nm nm nm nm nm nm nm nm nm nm
7 35/ 551 35/ 55/ 32.21 50/ 28/ 44/ 28/ 44/ 22.41 35/ N/A N/A N/A N/A
NA 47 75 47 75 44 68 38 60 38 60 30 47
11 70/ 110/ 70/ 110/ 63/ 100/ 56/ 981 56/ 98/ 44.8/ 70/ N/A N/A N/A N/A
NA 95 149 95 149 85 135 76 133 76 133 61 95
13 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
A*
14 168/ 264/ 168/ 264/ s 140/ 220/ 112/ 176 / 112/ 176/ 84/ 132/ 63/ 99/ - N/A N/A
NA 228 358 228 358 190 298 152 239 152 239 114 179 85 134
16 315/ 495/ 315/ 495/ 266/ 418/ 210/ 330 / 210/ 330/ 154/ 242/ 112/ 176/ N/A N/A
NA 427 671 427 671 361 567 285 447 285 447 209 328 152 239
30 560/ 880/ 560/ 880/ 525/ 825/ 420/ 660/ 420/ 660/ 336/ 528/ 266/ 418/ N/A N/A
NA 759 1193 759 1193 712 1119 569 895 569 895 456 716 361 567
40 1050/ 1650/ 1050/ 1650/ 875/ 1375/ 700/ 1100/ 700/ 1100/ 560/ 880/ 420/ 660/ N/A N/A
NA 1424 2237 1424 2237 1186 1864 949 1491 949 1491 759 1193 569 895
70 1540/ 2420/ 1540/ 2420/ 1330/ 2090/ 1050/ 1650 / 1050/ 1650/ 770/ 1210/ 665/ 1045/ 560/ 880/
2088 3281 2088 3281 1803 2834 1424 2237 1424 2237 1044 1641 902 1417 759 1193
NA r
90 2100/ 3300/ 2100/ 3300/ 1750/ 2750/ 1400/ 2200 / 1400/ 2200/ 1050/ 1650/ 896/ 1408/ 756/ 1188/
NA 2847 4474 2847 4474 2373 3728 1898 2983 1898 2983 1424 2237 1215 1909 1025 1611
Acceptable Limits for Stall Torque (ft-lb / nm)

* Size 13 is not available as NA
Table 10.3-2
Post -1978 Ratings For U.S. Manufacturer

50Hz 18 24 36 48 72 96 44 192
60Hz 21 29 43 57 86 115 173 230
RATED TORQUE SWITCH SETTING (ft-lb / n•m)

NOM +10% NOM +10% NOM +10% NOM +10% NOM +10% NOM +10% NOM +10% NOM +10%
(MIN) (MAX) (MIN) (MAX) (MIN) (MAX) (MIN) (MAX) (MIN) (MAX) (MIN) (MAX) (MIN) (MAX) (MIN) (MAX)
ft-lb / ft-lb / ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/
n•m n•m n•m n•m n•m n•m n•m n•m n•m n•m n•m n•m n•m n•m n•m n•m
7 30/ 33/ 25/ 27.5/ 25/ 27.5/ 20/ 22/ 20/ 22/ 15/ 16.5/ N/A N/A N/A N/A
NA 41 45 34 37 34 37 27 30 27 30 20 22
11 60/ 66/ 55/ 60.5/ 50/ 55/ 40/ 44/ 40/ 44/ 32/ 35.2/ N/A N/A N/A N/A
NA 80 89 75 82 68 75 54 60 54 60 43 48
A*
14 130/ 143/ 120/ 132/ 110/ 121/ 95/ 104.5/ 80/ 88/ 65/ 71.5/ 50/ 55/ N/A N/A
NA 176 194 163 179 149 164 129 142 108 119 88 97 68 75
16 245/ 269.51 225/ 247.51 205/ 225.51 185/ 203.5/ 160 176/239 120/ 132/ 95 1 104.5/ N/A N/A
NA 332 365 305 336 278 306 251 276 /217 163 179 129 142
30 495/ 544.5/ 440/ 484/ 410/ 451/ 355/ 390.5/ 300/ 330/ 240/ 264/ 205/ 225.5/ N/A N/A
NA 671 738 597 656 556 611 481 529 407 447 325 358 278 306
40 825/ 907.5/ 750/ 825/ 660/ 726/ 605/ 665.5/ 525/ 577.5/ 440/ 484/ 385/ 423.5/ N/A N/A
NA 1119 1230 1017 1119 895 984 820 902 712 783 597 656 522 574
70 1210/ 1331/ 1100/ 1210/ 1045/ 1149.5/ 905/ 995.5/ 790/ 869/ 605/ 665.5/ 520/ 572/ 440/ 484/
NA 1641 1805 1491 1641 1417 1559 1227 1350 1071 1178 820 902 520 776 597 656
90 1650/ 1815/ 1540/ 1694/ 1375/ 1512.5/ 1210/ 1331/ 1045/ 1149.5/ 825/ 907.5/ 715/ 786.5/ 590/ 649/
NA 2237 2461 2088 2297 1864 2051 1641 1805 1417 1559 1119 1230 969 1066 800 880
Acceptable Limits for Rated Torque (ft-lb / norm) Setting (3-Phase Units) -10% Voltage drop
Table 10.3-3
Post-1978 Ratings For U.S. Manufacturer

50Hz 18 24 36 48 72 96 144 192
60Uz 21 29 43 57 86 173 230
115
ft-lb / ft-lb / S ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb /
7 30/ 33/ 25/ 27.5 25/ 27.5/ 20/ 22/ 20/ 22/ 15/20 16.5/ N/A N/A N/A N/A
NA 41 45 34 37 34 37 27 30 27 30 22
11 60/ 66/ 55/ 60.5 45/ 49.5/ 40/ 44/ 35/ 38.5/ 30/ 33/ N/A N/A N/A N/A
NA 81 89 75 82 61 67 54 60 47 52 41 45
A*
14 120/ 132/ 110/ 121/ 110/ 121/ 95/ 104.5/ 80/ 88/ 65/ 71.5 50/ 55/ N/A N/A
NA 163 179 149 164 149 164 129 142 108 119 88 /97 68 75
16 225/ 247.51 205/ 225.51 200/ 220/ 180/ 198/ 155/ 170.5/ 115/ 126.5/ 92/ 101.2/ N/A N/A
NA 305 336 278 306 271 298 294 268 210 231 156 172 125 138
30 480/ 528/ 440/ 484/ 410/ 451/ 355/ 390.5/ 300/ 330/ 230/ 253/ 200/ 220/ N/A N/A
NA 651 716 597 656 556 611 481 529 407 444 312 342 271 298
40 775/ 852.5/ 725/ 797.5/ 640/ 704/ 605/ 665.5/ 515/ 566.5/ 440/ 484/ 365/ 401.5/ N/A N/A
NA 1051 1156 983 1081 868 955 820 902 698 768 597 656 495 544
70 1190/ 1309/ 1100/ 1210/ 1040/ 1144/ 905/ 995.5/ 790/ 869/ 605/ 665.5 / 520/ 572 / 440/ 484/
NA 1613 1775 1491 1641 1410 1551 1227 1350 1071 1178 820 902 705 776 597 656
90 1600/ 1760/ 1500/ 1650/ 1325/ 1457.5 1200/ 1320/ 1035/ 1138.5 815/ 896.5/ 700/ 770/ 580/ 638/
NA 2169 2386 2033 2237 1796 1976 1627 1790 1403 1544 1105 1215 949 1044 786 865
Acceptable Limits for Rated Torque (ft-lb / norm) Setting (3-Phase Units) -15% Voltage drop
Table 10.3-4

50Hz 18 24 36 48 72 96 144 192
60Hz 21 29 43 57 86 115 173 230

ft-lb / ft-lb / ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/ ft-lb/
7 25/ 27.5 25/ 27.5 20/ 22/ 20/ 22/ 20/ 22/ 15/ 16.5 N/A N/A N/A N/A
NA 34 /37 34 /37 27 30 27 30 27 30 20 22
11 55/ 60.5/ 50/ 55/ 45/ 49.5/ 40/ 44/ 35/ 38.5/ 30/ 33/ N/A N/A N/A N/A
NA 75 82 68 75 61 67 54 60 47 52 41 45
A*
14 120/ 132/ 110/ 121/ 100/ 110/ 90/ 99/ 75/ 82.5/ 60 66/ 45/ 49.5/ N/A N/A
NA 163 170 149 164 136 149 122 134 102 112 81 89 61 67
16 225/ 247.5/ 205/ 225.5/ 190/ 209/ 170/ 187/ 145/ 159.5/ 110/ 121/ 90/ 99/ N/A N/A
NA 305 336 278 306 258 283 230 254 197 216 149 164 122 134
30 450/ 495/ 400/ 440/ 375/ 412.5/ 325/ 357.5/ 275/ 302.5/ 220/ 242/ 190/ 209/ N/A N/A
NA 610 671 542 597 508 559 441 485 373 410 298 328 258 283
40 750/ 825/ 650/ 715/ 600/ 660/ 550/ 605/ 480/ 528/ 400/ 440/ 350/ 385/ N/A N/A
NA 1017 1119 881 969 814 895 746 820 651 716 542 597 475 522
70 1100/ 1210/ 1000/ 1100/ 950/ 1045/ 825 907.5/ 720/ 792/ 550/ 605/ 475/ 522.5 400/ 440/
NA 1491 1641 1356 1491 1288 1417 1119 1230 976 1074 746 820 644 708 542 597
90 1500/ 1650/ 1400/ 1540/ 1250/ 1375/ 1100/ 1210/ 950/ 1045/ 750/ 825/ 650/ 715/ 540/ 594/
NA 2034 2237 1898 2088 1695 1864 1491 1641 1288 1417 1017 1119 881 969 732 805
Acceptable Limits for Rated Torque (ft-lb / n•m) Setting (3-Phase Units) -20% Voltage drop
Table l0.3-5

50Hz 8 24 36 48 72 44
96 92
60Hz 21 29 43 57 86 5 73 230
ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb /
7 25/ 27.5/ 25/ 27.5/ 20/ 22/ 18/ 19.8/ 18/ 198/ 13/ 14.3/ N/A N/A N/A N/A
NA 34 37 34 37 27 30 24 27 24 27 18 19
11 45/ 49.5/ 50/ 55/ 38/ 41.8/ 35/ 38.5/ 30/ 33/ 27/ 29.7/ N/A N/A N/A N/A
NA 61 67 68 75 52 57 47 52 41 45 37 40
A*
14 95/ 104.5 90/ 99/ 95/ 104.5/ 85/ 93.5/ 70/ 77/ 55/ 60.5/ 40/ 44/ N/A N/A
NA 129 142 122 134 129 142 115 127 95 104 75 82 54 60
16 180/ 198/ 165/ 181.5/ 160/ 176/ 150/ 165/ 135/ 148.5/ 105/ 115.5/ 75/ 82.5/ N/A N/A
NA 244 268 224 246 217 239 203 224 183 201 142 157 102 112
30 425/ 467.5/ 360/ 396/ 355/ 390.5/ 295/ 324.5/ 265/ 291.5/ 210/ 231/ 160/ 176/ N/A N/A
NA 576 634 488 537 481 529 400 440 359 395 285 233 217 239
40 630./ 693/ 575/ 632.5/ 525/ 577.5/ 520/ 572/ 460/ 506/ 365/ 401.5/ 300/ 330/ N/A N/A
NA 854 940 780 858 712 783 705 776 624 686 495 544 407 447
70 975/ 1072.5 950/ 1045/ 940/ 1034/ 900/ 990/ 810/ 891/ 540/ 594/ 465/ 511.5/ 385/ 423.5/
NA 1322 1454 1288 1417 1274 1402 1220 1342 1098 1208 732 805 630 694 522 574
90 1325/ 1457/ 1225/ 1347/ 1090/ 1199/ 1150/ 1265/ 925/ 1017/ 740/ 814/ 630/ 693/ 520/ 572/
1796 1976 1661 1827 1478 1628 1559 1715 1254 1380 1003 1104 854 940 705 776
NA
Table 10.3-6

50Hz 18 24 36 48 72 96 144 192
60Hz 21 29 43 57 86 115 173 230
(MIN) (MAX) (MIN) (MAX) (MIN) (MAX) (MIN) (MAX) (MIN) (MAX) (MIN) (MAX) (MIN) (MAX:) (MIN) (MAX)
ft-lb / ft-lb / ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb
7 20/ 22/ 20/ 22/ 15/ 16.5 15/ 16.5/ 15/ 16.5/ 10/ 11/ N/A N/A N/A N/A
NA 27 30 27 30 20 22 20 22 20 22 14 15
11 40/ 44/ 40/ 44/ 35/ 38.5/ 30/ 33/ 25/ 27.5/ 20/ 22/ N/A N/A N/A N/A
NA 54 60 54 60 47 52 41 45 34 37 27 30
A*
14 95/ 104.5/ 85/ 93.5/ 80/ 88/ 70/ 77/ 60/ 66/ 45/ 49.5/ 35/ 38.5/ N/A N/A
NA 129 142 115 127 108 119 95 104 87 89 61 67 47 52
16 180/ 198/ 160/ 176/ 150/ 165/ 135/ 148.5/ 115/ 126.5/ 85/ 93.5/ 70/ 77/ N/A N/A
NA 244 268 217 239 203 224 183 201 156 172 115 127 95 104
30 360/ 396/ 320/ 352/ 300/ 330/ 260/ 286/ 220/ 242/ 175/ 192.5/ 150/ 165/ N/A N/A
488 537 434 477 407 447 353 388 298 328 237 203 224
NA
40 600/ 660/ 520/ 572/ 480/ 528/ 440/ 484/ 380/ 418/ 320/ 352/ 280/ 308/ N/A N/A
NA 814 895 705 776 651 716 597 656 515 567 434 477 380 418
70 880/ 968/ 800/ 880/ 760/ 836/ 660/ 726/ 575/ 632.5/ 440/ 484/ 380/ 418/ 320/ 352/
NA 1193 1312 1085 1193 1030 1133 895 984 780 858 597 656 515 567 434 477
90 1200/ 1320/ 1120/ 1232/ 1000/ 1100/ 880/ 968/ 760/ 836/ 600/ 660/ 520/ 572/ 430/ 473/
NA 1627 1790 1519 1670 1356 1491 1193 1312 1030 1133 814 895 705 776 583 641
Table 10.3-7
Commercial, Pre-1978 NA and U.K Manufactured Post-1978 Ratings

50Hz 18 24 36 48 72 96 144 192
60Hz 29
21 43 57 86 115 173 230
RATED TORQUE SWITCH SETTING (ft-lb)
ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb / ft-lb /
7 25/ 27.5/ 25/ 27.5/ 23/ 25.3/ 20/ 22/ 20/ 22/ 10/ 11/ N/A N/A N/A N/A
NA 34 37 34 37 31 34 27 30 27 30
11 50/ 55/ 50/ 55/ 45/ 49.5/ 40/ 44/ 40/ 44/ 32/ 35.2/ N/A N/A N/A N/A
NA 68 75 68 75 61 67 54 60 54 60 43 48
13 N/A N/A 80 88 70 77 60 66 N/A N/A N/A N/A N/A N/A N/A N/A
A*
14 120/ 132/ 120/ 132/ 100/ 110/ 80/ 88/ 80/ 88/ 60/ 66/ N/A N/A N/A N/A
NA 163 179 163 179 136 149 108 119 108 119 81 89
16 225/ 247.5/ 225/ 247.5/ 190/ 209/ 150/ 165/ 150/ 165/ 110/ 121/ N/A N/A N/A N/A
NA 305 336 305 336 258 283 203 224 203 224 149 164
30 400/ 440/ 400/ 440/ 375/ 412.5/ 300/ 330/ 300/ 330/ 240/ 264/ N/A N/A N/A N/A
NA 542 597 542 597 508 559 407 447 407 447 325 358
40 750/ 825/ 750/ 825/ 625/ 687.5/ 500/ 550/ 500/ 550/ 400/ 440/ N/A N/A N/A N/A
NA 1017 1119 1017 1119 847 932 678 746 678 746 542 597
70 1100/ 1210/ 1100/ 1210/ 990/ 1089/ 750/ 825/ 750/ 825/ 550/ 605/ 420/ 462/ 330/ 363/
NA 1491 1641 1491 1641 1017 1119 1017 1119 746 820
90 1500/ 1650/ 1500/ 1650/ 1250/ 1375/ 1000/ 1100/ 1000/ 1100/ 750/ 825/ 600/ 660/ 460/ 506/
NA 2034 2237 2034 2237 1695 1864 1356 1491 1356 1491 1017 1119
11.0 ACTUATOR UPGRADE NOTES (PRE-1978 VS. POST-1978)

S i nc e 19 7 3, st an da rd 'A ' r an ge c om m er cia l act ua tor s ha ve h ad f ew ch an g es . H o w ev er , d ue
t o ch an ge s i n q ual if icat io n r equ ir em en ts f o r act ua to rs ut iliz ed i n nu cl ear a pp li cati on s ,
m od if ica tio ns an d u pg r ad es h av e be en im pl em e nte d o n th e 'N A ' act ua tor s m ain ly to
im pro ve seis m ic capabil ity.
T h e t er m s P r e - 19 7 8 an d P o s t- 1 9 7 8 a re m e n tio n e d t hr o u g h ou t th is d o cu m en t . I n th e
d is a s s em b ly s ect io ns o f th is m a nu al , th e di ag ra m s ut ili zed illu s tr at e th e di ff er en ces in th e
t w o cate go ri es . In 19 78 , m a jor c ha ng es p r im ar ily t o th e 'N A G ' actu ato r w er e i nco r po ra ted ,
p r inci pal ly af fect ing com po nen t and su b as se m b ly in terc han g eabi lity .
I n th e fo llo w in g, ea ch s ub as s em bly is d is cu s se d in tu rn and m ajo r d iff er enc es b etw ee n th e

P r e- an d P ost- 19 78 co m p on ent s ar e d escr ibed .
11.1 Gearcase Subassemblies

F o r the g earc ase su bassem b ly , the fo llo w ing d iff ere nces be tw een P re- a nd P ost- 19 78 m od els
w er e ide ntified .
1 . S eal b ac ku p w as h er s w e re a d de d to th e w or m s ha ft a nd to rq u e p lu ng er on P os t -
1 9 7 8 m o d els . T h e s eal s a re n o t in ter ch an g eab le b et w een P r e- an d P os t -1 9 78
m o d el s.
2 . T o r q u e p lu n g e rs o n P o s t- 1 9 7 8 7 , 1 1 , 4 0 , 7 0 , a n d 9 0 N A 1 m o d e ls w e r e c h an g e d t o
a n 8m m dia m ete r fr o m a 1 4 m m d iam eter o n P r e-1 9 78 m od els .
3. M o tor m ou ntin g s crew s izes w ere increas ed on P os t-19 78 7, 11 , 3 0, 70 , an d 9 0
N A 1 m o del actuat ors .
4 . L i m i t s w it ch s h af t ex t en s io n s w er e a d de d t o P o s t - 19 7 8 7 / 1 N A 1 ac tu a to r s .
11-1
T h e f ollo w ing t able de sc rib es v aria tion s in th e con s tru ctio n of R oto rk act uato rs , P re -1 97 8
N A Y , P os t-19 78 N A and N A 2 / N A 4 , as com par ed to th e initial 'A ' ran ge.
T a b le 1 1 .1 -1
G e a r c a s e C o m p a r is o n
N A 1 P o s t- 1 9 7 8 / N A 4 N A 1 P re-19 78 NA2
B as i c 'A ' r an g e ca s ti n g B a sic 'A ' ran ge cas tin g S am e as 'A ' R an ge.
m achin ed to N A 1 fi tted w it h vit on s ea ls
sp ecificatio ns . an d w r in g s . N o b a ck u p
w a s h er s .
V ito n s eals f itte d on M ot or h ar dw a re as ST D
w o r m s h af t t or q u e pl u ng er 'A '.
b as e , an d s eal b ac k up
w as he rs fi tte d o n
w o rm sh aft ax is .
8 m m to r qu e p lu ng er f it ted
t hr o u g ho u t r an g e.
M o to r fitting s o n 7/1 1/13: A ll s cr ew s an d n uts
1/4 " -2 0 U N C , 30 : 5/1 6 " -1 8 tigh tened to specif ic
U N C L E 7 0 /9 0 : 1 / 2 " U N C t orq ue s.
N y loc nu ts rep laced b y B re ath e r f itt ed .
m echan ically lo ckin g n uts .
A ll s crew s tig hten ed to L u br ica nt s as P os t -1 97 8
sp ecific to rques. N A 1.
G e ar c ase b r ea th e r f i tt ed i n P ain t as P os t- 19 78 N A 1.
pl ace of th e u pp er m os t
filler plug.
G ea rc ase assem b ly f in al
te s t at 9 0 p s i .
L u b r ica ti on - r ad ia ti on
res istan t.
P ai nt- 2 p ar t epo x y s ys t em :
g ritb las t, car bo zin c; p rim er:
P hen oline 305 ; fin ish :
w h it e
11.2 Switch Mechanism
T he fo llo w ing d iff eren ce i n t he Pr e- and P o st-1 97 8 S w itc h M ec han is m s w ere id entif ied
1. P us h on co nn ect ion o n s w itch es w er e chan g ed to r ing te rm i nals on P o s t-1 97 8

ac tu at or s. W h en ne w s w itc h m ech a ni s m s ar e f it ted , ri ng ta gs sh o ul d r ep l ace t h e
p us h o n t er m i na ls .
11-2
2. P os t -1 9 78 s w i tch m ech an is m s ar e no t fi tted w ith a nt iha m m e r lat ch es w h ic h

a llo w th e to r qu e l im i t s w itc h t o r es et o n hi gh er s pe ed act ua to rs . P r eca ut io ns
m u s t be t ak en to e ns u r e th at s u it ab le e lec tr ic al to r qu e s w i tch by p as s ci rc u its ar e
utilized.
3 . T h e P r e- 19 7 8 a ctu at or he at er w a s m o un te d o n t he s w itc h m e ch an is m ba ck pl ate .
I f new lo om s a re f itted (f or exam ple, fit ted w ith a sy ncr os et m od ule) it i s
a cce pta bl e to r em ov e th e he ater an d r eco nn ec t to th e o ld h eat er u s in g su ita bl e
c ri m p s s u ch as A M P P I D G , r ad ia tio n r es i s tan t, a nd re tu rn to t he c lip on th e
sw itc h m ech an is m b ack pla te.
T h e f ollo w ing t able de scr ib es v ariat ion s in th e co ns tr uct ion o f R o tor k actu ator P r e-1 97 8
N A Y , Po st- 197 8 an d N A 2 / N A 4 sw itch m echanis m s as com p ared to in itial 'A ' ran ge.
T a b l e 1 1 .2 -1
R o to r k A ctu a to r S w itc h M e c h a n is m V a r ia tio n s
N A 1 P ost-19 7 8 N A 1 P r e -1 9 7 8 N A2 / NA 4
A l um in um electr ical fro nt G las s filled, nylon S w it ch m e ch ani s m sam e
p la te . plastic co m po nents . as 'A ' rang e.
N o latch. TK 5 s w itches (D PD T ). C as t ir on cover or on e
pie ce f abr icate d ste el
cover, n o indicatio n.
P lastic com pon ents - F itt ed on e w ay latc h.
R yt on R 4 ; A d ju s tin g c am s
- ca st b r on ze; h elix - cast
br as s, n o b oo st.
L ock an d b lock w ash ers G lass filled nylon
f itted. s pa ce rs a nd ad ju s t in g
c am s.
S teel spac ers fitt ed. H eate r s am e a s 'A '
r an ge .
Sp ecial sw itch es - B ur gess O n e pie ce fab ricated
V 12 (SP D T ) cas e m o ld ed steel cover, n o
in D A P . indication.
R ing ter m ina l con nect ions .
S w itch pak s e cur ed w it h
nu ts to give rigi d lo cation .
S p ecial lim it sh aft/ clutch
a ssem b ly.
A ero tig h t st if fn ut s f itte d to
m ai n s tu d s .
N o ind ication.
F it ted f ab r ic ate d
cov er.
H eat er m o un te d o n to
ge arcase.
11-3
11.3 Syncroset
T he fo llow ing d iffe rence s betw een the P re- and P os t- 197 8 sy ncr os et w er e ide ntifi ed.
P r e-1 9 7 8 v er s io ns o f th e s yn cr o s et w er e f itt ed w i th p u s ho n t er m in al s i nt er na lly . I f a n ew

s yn cro se t m o du le is re qui red , it w ill be s up plie d w i th loo m s w hi ch w ill h ave ri ng ter m in als
on th e sw it ch m ech an is m and ad d- on - pak end . T his w ill n eed t o b e r ep lac ed w ith pu sho n
ter m i nal s ( A M P P I D G r ad iat ion res i s tan t typ e) u s in g a s ui tab le cr im p in g to o l.
T h e f ollo w ing ta ble des cr ibe s va riati on s in th e co ns tr ucti on o f R ot or k actua tor P re -1 97 8,

P os t- 197 8 N A B an d N A 2 / N A 4 sy ncro sets as co m pared to in itial 'A ' ran ge.
T a b le 1 1 . 3 - 1
R o to r k A c tu a to r S y n c ro se t V a r ia tio n s
N A 1 P o s t -1 9 7 8 N A 1 P r e -1 9 7 8 N A2 / NA 4
S olid term in al block. S o lid ter m in al S ta n d a rd E P te rm in al
b lo ck . b lo ck .
T e r m in a ls th r ead e d o n b o th In t er n al p u s h - o n
en ds. co nnections.
R ing tag co nnectio ns . T er sil 18 w ir es.
R i ng t ag t er m in a ls a n d b ut t
crim p connector s (A M P
P I D G ra d iat io n r es i s ta nt ).
T y -r ap s an d ca bl e m ar k er s
rem oved on "join-up"
T y-r aps rep laced b y S co tch
N o . 27 g las s b raid a dh es ive
tap e.
St eel co nd uit en tr y pl ug s
fitted .
T ers il w ire.
11.4 Add-on-pak 6 & 12 Switch

T he follo w in g diff erences in P re- and P ost-19 78 add -on -pak s w er e id entified .
1 . G ear s o n P r e-1 97 8 m o d els w e re s ep ara te br as s g ear s p in ned t og eth er to a chi eve

cl us ter s . P o s t- 1 97 8 g ear s ar e c as t . O n e t yp e w ill no t m es h w it h t h e ot h er .
2 . S w itch es o n P re- 1 97 8 assem b lies w er e fit ted w ith p ush on te rm i nals, P o st-1 97 8
ar e f itt ed w i th r in g ter m i na ls. W h en f it tin g a ne w a dd - o n- p ak t o a P r e- 1 97 8
a ctua tor , th e lo om s m u s t b e m od if ied fo r ri ng te rm in als .
11-4
T h e fol low in g tab le d es cri bes var iatio ns in the co ns tr ucti on o f R o tor k actu ator P r e-1 97 8,
P os t-1 978 N A 1 an d N A 2 / N A 4 ad d-o n-p aks (6 an d 1 2 s w itch) as com p ared to in itial 'A '
r an g e.
T a b le 1 1 . 4 -1
R o to r k A ctu a to r A d d -o n -p a k V a ria tio n s
N A 1 P o s t -1 9 7 8 N A 1 P r e -1 9 7 8 NA 2 / NA 4
B r as s in p u t g ea r s a n d S pecial high S w itch es Sam e as 'A '
dr iv e ad apt or . te m p era tu re r an g e.
s w itches .
S t eel sp ac er s a nd T er sil 18 w ires . 3 p iece cast iron co ver.
m ou nt ing pil lar s .
R yt on R 4 cam s and P us h- on conn ectio ns .
sp acer.
S p ecial cam shaf t. 3 piece cast iro n
co ver.
Sp ecial s w itches . G e ar s asse m b led
w it h p ins .
S t r ik er pl at es f itt ed w it h
a nti -v ib ra tio n s pr in gs .
S olid spacer fitte d in place
o f s pr ing o n s tr iker s h aft .
S w itch p aks h eld in p lace
b y r e ta in i n g p l at e an d
s pr in gs (n ot h eld w ith
n ut s).
S pe cially m achin ed
f ro n tpl ate.
S pecial po tent iom eter .
P o te n ti om et er g ea r
selected p rio r to asse m bly
(T hes e ar e i nd ivi du al, n ot
clus ter ).
P o ten tio m e ter , n o
indication.
F abr icated co ver .
F i tt ed w ith an ti -v i br at io n ,
s te ady f itted on 1 2 s w i tch
add -on- pak.
11.5 Torque Limiters

T w o ty p es of to r qu e li m it er s w e re s u p p lie d. T h e tw o t yp e s a re n o t in ter ch an g eab l e. T he s e
to rq u e li m its pr ov id e t he s am e fu nc tio n; ho w ev er, t her e are s ig nif ican t dif fe ren ces in th e
le ng th a nd con s tr uc tio n.
11-5
T he f ollo w ing t able de sc rib es v ari ation s in t he con s tru ctio n of R oto rk a ctua tor P re -1 97 8
N A T , P os t- 197 8 N A 1 and N A 2 torq ue lim iters as com p ared to initial 'A ' r ang e.
T ab le 1 1.5 -1
R o to r k A c t u a t o r T o r q u e L im ite r V a r ia t io n s
N A 1 P ost-19 78 N A 1 P re-19 78 NA2

Special m otor co ver C ou pling to m otor via slo t S am e a s P r e-1 9 78
r equ ir ed. and pin . N A 1.
Sp ecial w or m shaft .
11.6 Thrust Compensator
T he f ollo w ing t able de sc rib es v ari ation s in t he con s tru ctio n of R oto rk a ctua tor P re -1 97 8
N A T , P os t- 197 8 N A T and N A 2 t hru s t com pen sato rs as com p ared to initial 'A ' r ang e.
T a b le 1 1 .6 -1
R o t o r k A c t u a t o r T h r u s t C o m p e n s a t o r V a r ia t io n s
N A 1 P ost-19 7 8 N A 1 P r e -1 9 7 8 NA2
S am e as P re -1 97 8 C ast ir on b ody. Sa m e as P re- 1 97 8
N A T. NAT.
S teel int ern al com po nen ts .
B ronze d rive sleeve.
11.7 Motor
T h e f oll ow in g table d es crib es v ari ation s in th e con s tru ctio n of R oto rk ac tuato r P re- 19 78
N A T , Po st- 197 8 N A T and N A 2 m o tors as com p ared to initial 'A ' ran ge.
T a b le 1 1 .7 1
R o to r k A c t u a to r M o to r V a r ia t io n s
N A 1 P o s t -1 9 7 8 N A 1 P re-19 78 NA2
S ta to r r ew ou n d S am e as P os t-19 78 N A 1. S am e as 'A '
w ith c las s H r an ge.
in s ul atio n.
N o t he rm o s tat . m o u nt in g h ar d w ar e s am e
as 'A ' rang e.
L ead- ou ts: T ers il
18 .
M o tor co ver, cast
ir on .
L ow voltage
rew inds po ss ible.
11-6
11.8 Handwheel
T h e f ol low in g tab le des cr ib es v aria tion s i n the co ns tr uct ion o f th e R oto r k actu ator P r e- 19 78
N A Y , Po s t-19 78 N A 1 and N A 2 han dw heels as com pared to initial 'A ' rang e.
T a b le 1 1 . 8 - 1
R o to r k A c tu a to r H a n d w h e e l V a ria tio n s
N A 1 P o s t -1 9 7 8 N A 1 P r e -1 9 7 8 NA2
N A B handw heel Sam e as Pos t-19 78 N A Y Sa m e as P o s t-1 97 8
fa br ica ted steel NA 1
assem b ly.
N e e dl e t h r us t
w a s he r f it ted on th e
70/90 N A 1 s id e
h an dw h eel.
1/16 " diam eter ho le
d rilled in
h an d w he el b un g o r
cov er tub e for
p re s s u r e
eq ual izatio n.
11-7
12.0 ACTUATOR PERFORMANCE DATA

T h e i nf or m ati on in t his s ectio n w ill p ro vid e the r eade r w ith b as ic inf or m at ion o n ele ctri cal
an d m ec ha ni ca l de sig n c ha ra ct er isti cs u ni qu e t o R o to rk act u ato r s . D e tai led el ect ri ca l an d
m ec han ic al d at a i s p ro vi ded f o r P re- 1 97 8 an d P ost- 1 97 8 act uat or s .
12.1 General Motor Performance Requirements
A ty p ical risi ng stem m o to r op era ted v alve w h ich is clos i ng an d op en ing a gai ns t dif fe ren tial
pr ess ur e and flo w exh ibits the follo w ing load pro file:
• T or q ue at t he o pe n p os it io n is lo w s i nce t he re is lit tle d if fe ren ti al pr es s u r e. A t

t his lo catio n in t he str ok e, p ack ing and st em rej ectio n f or ce are ty p icall y the
la rg est co m po nen ts o f tor qu e.
• D u ri ng c los u re w h en th e val ve b eco m es the d om ina nt fl ow res i s tan ce in th e
sy stem , a dif fe re nti al pr essur e fo r ce is p r od uc ed acr o s s th e va lve d isk . T h e
ac tuato r m u st no w ap ply su ff icien t lo ad to ov erc om e th e co m bi ned d iff eren tial
p ressu re, p acki ng , and stem re jectio n fo rce .
• T he v al ve st if fn ess b eco m e s g r eat est at t he p o in t of seat c on ta ct. S tem l oa d
i nc re as es r ap id ly a s t he v al ve s e ats .
• D u r ing va lve o p eni ng , an d af te r stem co m p r essio n an d stem -d is k c lear an ces ar e
e lim in ate d, a hi gh m o m en ta ry fo r ce m a y b e ne ces s a ry to in it ial ly u n s eat t he
v alv e.
• A f ter u nw e dg in g an d un til th e v alv e is s u ff ici ent ly o pen s u ch th at it is no lo n ger
t he d o m i na nt syst em f lo w re sista n ce, th e act ua to r m ust s up p ly t he lo ad
n ece ss a ry to o v erc om e th e dif f eren tia l p re s su r e an d p ack ing fo rce m i nu s th e
stem rejectio n fo rce.
• A t fu ll op en , th e d if fer ent ial pr essur e fo rce acr oss the v alv e d isk r each es a
m in im u m an d th e act uat or nee d o nly sup p ly th e lo ad n ece ssary to o ve rc om e t he
d iff eren ce b etw een the pack ing an d stem re jection f or ce.
B eca us e o f th es e u n iqu e o pe ra tin g d em an ds , t he a ctu at or m o tor m u s t ha ve t he f ol lo w in g

p erf o rm a nc e c ha rac ter is tic s :
• A h ig h s ta ll to rq u e c ap ab ilit y av aila bl e at ne ar s y nch r on o us s pe ed f or se ati ng ,

u ns e ati ng , a nd o th er h ig h l oa d r eg io n s o f t he v al ve s t ro k e. D ur in g o p en in g, a
lost m otion r egion is ty pically pr ov ided to allow th e m o tor to reach fu ll no -lo ad
s peed pr ior to un w edg ing.
• A r el ativ ely hi gh s t art in g to rq u e t o en ab le th e val ve to be jo g ged du r ing hi gh
lo ad p or ti on s o f th e s tr ok e w he n th e b ac kla s h is tak en u p.
12-1
Fi gu re 1 2.1- 1 s ho w s t he R oto rk m ot or s p eed -to r qu e c har act eri st ics , d es ign ed t o m eet
ty pi cal v al v e pe rf o rm an ce r eq u ir em en ts . T h e m o to r p r ov id e s s t all t or q u e at h ig h s p ee d an d
a s ta r t to r q ue w h ich is a t le as t 8 0% o f t h e s ta ll v a lu e a t h ig h s pe ed . T h e s t em n u t t o rq u e
av ai la b le t o se at th e v al v e at th e m ax i m u m t o rq u e sw it ch set ti ng i s th e a ctu a to r ra te d
to rq u e. S tal l to r qu e g iv e s a s a f ety m a rg in o f u p t o 2 1 o ve r th e r at ed to rq u e to en s u re
un s e at in g , e v en w it h r e d uc ed v o lta g e. ( S ta ll a n d s t ar t t o rq u e v a ry a pp r o x im at el y a s th e
sq u are o f the p erc ent o f rate d vo ltag e s up pl ied to th e m o tor .)
0 Speed (% synchrono us) 100
F ig u r e 1 2 . 1 - 1
R o to r k M o t o r S p e e d T o r q u e C h a r a c t e r i st ic s
In o r de r to m i n im iz e th e po t en t ia l f o r v al v e d am ag e it i s im p o rt an t th at th e m o to r p ro d u ce
th e a b ov e s p ee d t o r qu e ch ar a ct er i s ti cs w ith m in i m u m k i n et ic en er g y , i.e., th e ro t o r s h o u ld
be lo n g an d th i n r a th e r t h an s h o r t a nd t h ic k.
12.2 Motor Performance Data

F o r a th re e p h a se m o to r th e re a re th re e d a ta p o in ts th a t c a n b e m e a s u re d : lo c k e d ro to r
cu rre n t, lo c k e d ro to r (p u ll-o u t) to rq u e a n d sta ll to rq u e . L o c k e d ro to r cu rre n t is im p o rta n t
fo r th e se le ctio n o f c o n tro l d e v ic e s , o v e rlo a d p ro te c tio n an d c a b le siz in g . S ta ll to rq u e is
im p o rtan t w h e n se le ctin g th e c o rre ct siz e a ctu a to r fo r a g iv e n v a lv e a p p lic a tio n . L o c k ed
ro to r a n d sta ll to rq u e a re a p p ro x im a te ly th e sa m e . R o to rk p ro v id e s c e rtifie d s ta ll to rq u e
on ly .
M o tor d uty cycle is b ased o n an a vera ge lo ad tor qu e w hich I S 33 % of the rated v alue.
12-2
12.3 Rotork Published Motor Currents

R oto rk p u blis h es t he fo llo w in g thr ee cu rr ent s fo r act uat or s at a sp eci fied vo ltag e:
• L o cke d R o to r C u rr en t ( s tar tin g)

M a x im u m in ru s h c u rre n t w h ic h ty p ic a lly la s ts fo r o n ly th r e e c y c le s d u rin g
n o rm al s ta r ti ng u n le s s th e m o to r is s t al le d . L o ck e d r o to r cu r r en t s ho u l d b e u s e d
f o r s i z in g ca b le s to e ns u re th a t t he v o lt ag e d r o p d o es n o t e x ce ed a p pr o x i m a te ly
15 % d ur in g s tar tin g.
• R ate d T o r q ue C u r re nt ( s ea tin g )
C u r re n t c o rr e s p o n d in g to t he ac tu a to r r at ed t or q u e , w hi c h m ay o c cu r f or a b r i ef
d u ra tio n n e a r th e v a lv e c lo se p o s itio n . It s h o u ld b e u s e d fo r se le c tio n o f fu s e s
an d th er m al t r ip s w h er e r eq u ir e d.
• A v er ag e L o ad C u r re n t
C or r es p on d s t o 3 3% o f th e m a xi m u m r ate d to r qu e, an d s h ou ld b e us e d f or s izi ng
m oto r con trol gear .
I n a dd it io n , a n o m i n al h o rs e p ow er i s als o li s te d ( in d ep en d en t o f v o lt ag e) . T h is v alu e i s th e
eq u iv a len t s i ze of a co n v en ti o na l m ot o r w h ic h w o u ld d r aw ap p r ox i m a tel y t h e s am e lo c ke d
r ot o r an d av er ag e l o ad c u rr en t s .
A ct ua to r m o to r s a re n o t de s ig n ed f o r co n tin u ou s ru n ni ng . T he 1 5 m in u te d ut y cy cl e at 3 3%
o f ra te d to rq u e is s u ffic ie n t to co v e r n o rm a l v a lv e tra v e l tim e s o f 1 -5 m in u te s a s w e ll a s
thr ot tle ( jog gin g) ap plic ation s .
12.4 Electrical Performance Data

T a b le s 12 .4 - 1 a n d 1 2 .4 -2 p r ov i d e R ot o r k e le ct ri ca l r at in g s f or P r e- 1 9 7 8 a n d P o s t - 19 7 8 f or
57 5 vo lt A C m oto rs . F or v oltag es o ther th an 5 75 V A C se e R oto rk P ub licat ion A E 2 /0.1.
12.5 Mechanical Performance Data

T a bl es 12 .5- la an d 1 2 .5 - lb p r ov id e R ot or k m ech an ic al s p eci fic ati on s , r at in gs an d m ou n tin g
fl ang e dim en si on s f or P r e-1 9 78 an d P o st -1 97 8 actu ato r s.
12-3
Table 12.4-1 (Page 1 of 3)
Performance Summary for Rotork Electric Actuators
Electrical Data
Commercial, Pre-1978 and U.K. Manufactured Post-1978 Actuators
575VAC 60 HZ
Rated Locked Rated Average Average Average Average Average

Actuator Output Torque Motor Rotor Torque Load Load Load Load Load
Size RPM ft-lb / n•m Poles Current Current Current Horsepower Power Power Efficiency
Amps Amps Amps hp kW Factor %
7NA, AZ, AB 21 25/34 4 1.7 .9 .4 .13 .10 .49 51
29 25/34 4 1.7 .9 .4 .13 .10 .49 51
43 23/31 4 1.7 .9 .4 .13 .10 .49 51
57 20/27 2 3.8 1.4 1.0 .25 .19 .40 50
86 20/27 2 3.8 1.4 1.0 .25 .19 .40 50
115 10/14 2 3.8 1.4 1.0 .25 .19 .40 50
11NA, AZ, AB 21 50/68 4 3.7 1.2 1.0 .24 .18 .39 47
29 50/68 4 3.7 1.2 1.0 .24 .18 .39 47
43 45/61 4 3.7 1.2 1.0 .24 .18 .39 47
57 40/ 54 2 5.1 1.75 1.4 .38 .28 .40 50
86 40/54 2 5.1 1.75 1.4 .38 .28 .40 50
115 32/43 2 5.1 1.75 1.4 .38 .28 .40 50
14NA ,AZ 21 120/163 4 6 2.5 1.5 .6 .45 .45 67
29 120/163 4 6 2.5 1.5 .6 .45 .45 67
43 100/135 2 9 3.2 2.1 1.1 .82 .55 71
57 80/108 2 9 3.2 2.1 1.1 .82 .55 71
86 80/108 2 9 3.2 2.1 1.1 .82 .55 71
115 60/81 2 9 3.2 2.1 1.1 .82 .55 71
Table 12-4-1 (Page 2 of 3)
Electrical Data
575VAC 60 Hz

Size RPM ft-lb / Poles Current Current Current Horsepower Power Power Efficiency
n• m Amps Amps Amps hp kW Factor %
16NA, AZ 21 225 /305 4 14 4.5 3.0 1.2 .9 .48 63
29 225 /305 4 14 4.5 3.0 1.2 .9 .48 63
43 190 /257 2 17 5.3 3.6 1.8 1.35 .54 70
57 150/203 2 17 5.3 3.6 1.8 1.35 .54 70
86 150 /203 2 17 5.3 3.6 1.8 1.35 .54 70
115 110/149 2 17 5.3 3.6 1.8 1.35 .54 70
30NA, AZ 21 400/542 4 24 5.5 3.8 2.0 1.5 .56 71
29 400/542 4 24 5.5 3.8 2.0 1.5 .56 71
43 375/508 4 24 5.5 3.8 2.0 1.5 .56 71
57 300 /407 2 40 8.5 5.5 3.6 2.7 .68 72
86 300/407 2 40 8.5 5.5 3.6 2.7 .68 72
115 240/325 2 40 8.5 5.5 3.6 2.7 .68 72
40NA, AZ AR 21 750/1020 4 40 9.0 6.0 3.3 2.5 .57 73
29 750/1020 4 40 9.0 6.0 3.3 2.5 .57 73
43 625 1 845 4 40 9.0 6.0 3.3 2.5 .57 73
57 500/680 2 59 13.5 7.5 5.4 4.0 .65 82
86 500/680 2 59 13.5 75. 5.4 4.0 .65 82
115 400 /542 2 59 13.5 7.5 5.4 4.0 .65 82
Table 12-4-1 (Page 3 of 3)
Electrical Data
575VAC 60 HZ

Size RPM ft-lb / n• m Poles Current Current Current Horsepower Power Power Efficiency
7NA,AZ, AB 21 1100/1490 4 58 14 8 4.5 3.3 .56 74
29 1100/ 1490 4 58 14 8 4.5 3.3 .56 74
43 990/1340 2 80 21 13 7.8 5.7 .6 75
57 750/ 1015 2 80 21 13 7.8 5.8 .6 75
86 750/ 1015 2 80 21 13 7.8 5.8 .6 75
115 550/ 745 2 80 21 13 7.8 5.8 .6 75
173 420/590 2 80 21 13 7.8 5.8 .6 75
230 330/445 2 80 21 13 7.8 5.8 .6 75
90NA, AZ, AR 21 1500/2035 4 70 16 12 7.2 5.4 .57 79
29 1500/2035 4 70 16 12 7.2 5.4 .57 79
43 1250/ 1695 4 70 16 12 7.2 5.4 .57 79
57 1000/ 1355 2 124 31 17.5 12 9.2 .65 81
86 1000/ 1355 2 124 31 17.5 12 9.2 .65 81
115 750/1015 2 124 31 17.5 12 9.2 .65 81
173 600/ 815 2 124 31 17.5 12 9.2 .65 81
230 460/ 625 2 124 31 17.5 12 9.2 .65 81
91AR 173 1000/ 1355 2 166 67 21.6 21 15.6 .79 87
230 1000/ 1355 2 166 67 21.6 21 15.6 .79 87
95A, AZ 29 2200/2985 4 70 22 13 7.8 5.8 .57 78
Electrical Data
US Manufactured Post-1978 575VAC 60 HZ

Size RPM ft-lb / Poles Current Current Current Horsepower Power Power Efficiency
n-m Amps Amps Amps hp kW Factor %
7NA,AZ, AB 21 30/40 4 1.7 .9 .4 .13 .10 .49 51
29 25/34 4 1.7 .9 .4 .13 .10 .49 51
43 25/34 4 1.7 .9 .4 .13 .10 .49 51
57 20 /27 2 3.8 1.4 1.0 .25 .19 .40 50
86 20/27 2 3.8 1.4 1.0 .25 .19 .40 50
115 15 /20 2 3.8 1.4 1.0 .25 .19 .40 50
11NA,AZ, AB 21 60/81 4 3.7 1.2 1.0 .24 .18 .39 47
29 55/74 4 3.7 1.2 1.0 .24 .18 .39 47
43 50/68 4 3.7 1.2 1.0 .24 .18 .39 47
57 40/ 54 2 5.1 1.75 1.4 .38 .29 .40 50
86 40/54 2 5.1 1.75 1.4 .38 .29 .40 50
115 32/43 2 5.1 1.75 1.4 .38 .29 .40 50
13NA,AZ, AL 29 80/108 4 5 2.6 1.45 .5 .37 .49 52
43 70/95 4 5 2.6 1.45 .5 .37 .49 52
57 60/81 4 5 2.6 1.45 .5 .37 .49 52
14NA, AZ 21 130/176 4 7 2.8 1.8 5.6 .43 .45 67
29 120/163 4 7 2.8 1.8 .6 .43 .45 67
43 110/ 149 2 10 3.0 2.1 1.1 .8 .555 71
57 95/129 2 10 3.0 2.1 1.1 .8 .55 71
86 80/108 2 10 3.0 2.1 1.1 .8 .55 71
115 65/88 2 10 3.0 2.1 1.1 .8 .55 71
173 50/68 2 10 3.0 2.1 1.1 .8 .55 71
Tattle 12.4-2 (Page 2 of 3)
Electrical Data
US Manufactured Post-1978 575VAC 60 HZ
Actuator Output Rated Motor Locked Rated Average Average Average Average Average
Size RPM Torque Poles Rotor Torque Load Load Load Load Load
ft-lb/n m Current Current Current Horsepower Power Power Efficiency
16NA, AZ 21 245 1 332 4 14 4.8 3.0 1.2 .9 .48 63
29 225 /305 4 14 4.8 3.0 1.2 .9 .48 63
43 205 /278 2 17 5.3 3.6 1.8 1.3 .54 70
57 185/251 2 17 5.3 3.6 1.8 1.3 .54 70
86 160/217 2 17 5.3 3.6 1.8 1.3 .54 70
115 120/ 163 2 17 5.3 3.6 1.8 1.3 .54 70
173 95/ 129 2 17 5.3 3.6 1.8 1.3 .54 70
30NA, AZ 21 495/671 4 24 6.0 3.8 2.0 1.5 .56 71
29 440/596 4 24 6.0 3.8 2.0 1.5 .56 71
43 410/556 4 24 6.0 3.8 2.0 1.5 .56 71
57 355/481 2 40 10.5 5.5 3.6 2.6 .68 72
86 300/407 2 40 10.5 5.5 3.6 2.6 .68 72
115 240/325 2 40 10.5 5.5 3.6 2.6 .68 72
173 205 /278 2 40 10.5 5.5 3.6 2.6 .68 72
40NA, AZ AR 21 825/1118 4 40 11.0 6.0 3.4 2.5 .57 73
29 750/1020 4 40 11.0 6.0 3.4 2.5 .57 73
43 660/895 4 40 11.0 6.0 3.4 2.5 .57 73
57 605 /820 2 59 18.0 7.5 5.9 4.4 .65 82
86 525/712 2 59 18.0 75. 5.9 4.4 .65 82
115 440/596 2 59 18.0 7.5 5.9 4.4 .65 82
173 385 1 522 2 59 18.0 7.5 5.9 4.4 .65 82
Electrical Data
US Manufactured Post 1978 575VAC 60 HZ
Actuator Output Rated Motor Locked Rated Average Average Average Average Average
Size RPM Torque Poles Rotor Torque Load Load Load Load
ft-lb/n-m Current Current Current Horsepower Power Power Efficiency
70NA,AZ, AR 21 1210/1640 4 58 17 8 4.4 3.3 .56 74
29 1100/1490 4 58 17 8 4.4 3.3 .56 74
43 1045/ 1417 2 80 21 13 7.8 5.8 .6 75
57 905/1227 2 80 21 13 7.8 5.8 .6 75
86 790/ 1071 2 80 21 13 7.8 5.8 .6 75
115 605/820 2 80 21 13 7.8 5.8 .6 75
173 520/705 2 80 21 13 7.8 5.8 .6 75
230 440/596 2 80 21 13 7.8 5.8 .6 75
90NA, AZ, AR 21 1650/2237 4 70 21 12 7.2 5.4 .57 79
29 1549/2100 4 70 21 12 7.2 5.4 .57 79
43 1375/1864 4 70 21 12 7.2 5.4 .57 79
57 1210/1417 2 124 31 17.5 12 9.0 .65 81
86 1045/1417 2 124 31 17.5 12 9.0 .65 81
115 825/1118 2 124 31 17.5 12 9.0 .65 81
173 715 /969 2 124 31 17.5 12 9.0 .65 81
230 590/800 2 124 31 17.5 12 9.0 .65 81
T a b le 1 2 .5 -la
P e r f o r m a n c e S u m m a r y f o r R o t o r k E le c t ri c A c tu a to rs
M e c h a n ic a l D a t a
N o te s:
* A c tu a to rs a re ty p ic a lly su p p lie d w ith th e lo w e r lim it sw itc h tu rn s ra n g e u n le ss th e tu rn s re q u ire d b y th e v a lv e
a re sp e c ifie d , in w h ic h c a se th e h ig h e r tu rn s ra n g e w ill b e p ro v id e d . T h e h ig h e r tu r n s ra n g e is p ro v id e d
w h en e v e r th e sp e c ified tu rn s e x c e e d s th e fo llo w in g va lu e s:
7 A / llA / 1 3 A 39 tu rn s
1 4A /1 6 A 49 tu rn s
3 0A /4 0A 59 ta rn s
70A / 90A 69 tu rn s
9 1 A JR / 9 5 A 69 tu rn s
12-10
T he r e is a s p ec ial m ed iu m r a ng e l im i t s w i tch ra ti o p r ov i de d b y R o to r k . T h e a ctu a to r t es t

c ert ifi cate s h o uld be u s ed to det er m in e w hic h lim it s w itc h ra ng e is us ed .
R efe r to R o tor k C o nt ro ls In c. f or spe cial app licati on s w he re valv e trav el tim e exc eeds 10
m in ut es or fo r t u rn s ex cee di ng m a xi m u m lis t ed . F o r d im en s io n s , s ee R o to rk pu b li cat io ns
A E 2/1 (S yncro pak) or A E 2/2 (S yncro set)
T a b l e 1 2 .5 - l b
R o to r k M o u n ting F la ng e D a ta
12.6 Sizing Guide for Rotork Electric Actuators
R efer to R oto rk pu blicatio n A E 2 /0.2 fo r R oto rk s pecific sizin g info rm atio n, the N M A C
A p pl icatio n G u ide fo r M o tor -O p er ated V alv es in N ucl ear P o w e r P lant s ( N P - 66 6 0) , and t he
E P R I M O V P erf or m an ce P re dic tio n P ro gr am re su lts fo r g ene ral v alv e s p ecif ic in fo rm atio n
t o en s u r e pr o p e r a ct u at o r s iz i ng . I t i s i m p o r ta n t t o u s e t h e l at es t in d u s t r y in f o r m a ti o n
w h en p er f or m in g siz in g cal cul ati on s f o r ne w v alv e ap pl icat io ns an d act ua tor re pla cem ent s .
O n c e th e v al ve o p er at io n al r eq u ir em en ts a re e s ta bl is h ed , s el ect t h e s iz e an d s p e ed a ct ua to r
capable of:
• A c ce pt in g t he s tem d i am e te r
• S tr u ct u ra ll y ac co m m o d at in g t he th r u s t a n d t o r qu e re q u ir em e nt s
• P r o v id in g t h e re q ui r ed t o rq u e at r e du ce d v o lt ag e an d ele v ate d t em pe ra tu r e,
w he re ap p lica ble
• P r o vi di ng th e re qu i re d o pe ra tin g s p ee d
12-11
13.0 ACTUATOR MOUNTING BOLT SPECIFICATION
T h e f ollo w in g inf orm ation pr ov ides g uid elines f or m o unt ing R o tor k e lectric m oto r o per ator s
a nd g ear re du c er m ou n ti ng f lan g es . It i s i nt en d ed t o p r ov i de b o lt in g m a te ri al o p tio n s a n d
b o lt t or q u e re q ui re m e nt s .
13.1 Bolting Material Requirements
R o to r k re com m en d s b ol tin g m a ter ials w ith s uf fi cien t m ec ha nic al pr o per ti es t o w ith s tan d al l
op er ati ng l oa ds . T he s ele ctio n o f b ol t g r ade a nd a pp lie d to rq ue i s b as ed o n 1 00 % a ctu ato r
th ru s t ra tin g , s eis m ic lo ad s , m o u nt in g b ol t s i ze an d n um be r o f b olt s p er actu at or .
A S T M and A S M E m ate ria ls s u ita ble f or actu ato r m o u nt ing are g iv en in t he T a bl e 1 3 .1 -1 .

T h e r eco m m en d at io ns s t ate d ar e n o t re tr o act iv e. E x is ti n g m o u n tin g b o lt s w hi ch d o no t
m ee t t hese r eco m m end ati on s n eed no t be r epl aced or r eto rq u ed to c om ply w ith th ese
gu id elin es sp eci fic site r equ ir em en ts and eng in eer ing j ud gm ent sh ou ld b e u s ed in d eci din g
to r epla ce or r eto rq ue bo lts .
T a b le 1 3 .1 - 1
A c ce p ta b le B o lting M a te r ia ls
A l l bo l tin g m ate ri al s h all b e o f s u ita bl e len g th t o e ns u r e fu ll a ctu at or m o un t th r ead

e ng a ge m en t, m o u nt in g f la ng e th ic k ne s s , an d fu ll n u t th re ad en ga ge m e nt ( f or s tu d s o r
t hr ea de d ro d ).
A l l b o ltin g s h all b e clea n an d f ree o f an y d ir t, g ri t, b ur rs , e tc. A l l w o r ki ng t hr ead s a nd loa d

b ea rin g su rf ace s sh all b e l ub r icat ed w ith ap pr ov ed l ub ri can t pr io r to a s se m b ly .
13-1
I f th e m a ter ial u s ed i n an ex is tin g a pp lic ati on is n o t id ent if ied i n th e tab le a bo v e, th e

m ater ial s ho ul d be re pla ced if /w h en th e a ctu ator is r em o ved fr om th e v alv e.
13.2 Torque Requirements
F ig u res 1 3.2-1 th rou gh 13 .2 -6 prov id e R o to rk A c tu ato r M ou n tin g F lan ge d eta ils. T abl e
1 2.5-lb prov id es m o un tin g fla ng e d ata in clud in g bo lt si ze, bo lt pat tern a nd b olt circle size.
4 "}( 1 0 2 m m )
BO L T P A TT E R N
3 /8 " (U NC )
BO L TS
4 1 5 /1 6 "} ( 1 2 5 m m )
O U TS I D E
F ig u r e 13 .2- 1
R o tor k A c tu ato r M o u ntin g F lan g e
S iz e s 7 ,1 1 , 1 3
5 1/2" }(1 40m m )

BOLT PATTERN
5 /8 " (U N C ) B O L T S
71 /8 " } (18 1m m )
O U T S ID E
F i g u r e 1 3 .2 - 2
R o t o r k A c t u a t o r M o u n t i n g F la n g e
S iz e s 1 4 , 1 6
13-2
6 1/2"} (165 m m )
BO LT
3 /4 " (U N C )
B O LT S
81/4 "} (2 10m m )

O U T S ID E
F i g u r e 1 3 .2 - 3
R o to r k A c t u a t o r M o u n t i n g F l a n g e
S iz e 3 0
10"}(254m m )
B OL T P A TT E R N
5/8 Id (U N C ) B O L T S
11 3/8 "} (289m m )

O U T S ID E
F i g u r e 1 3 .2 - 4
R o tor k A c tu ato r M ou n tin g F lan g e
S iz es 40 A R , 7 0A R , 9 0A R , 9 1 A R
13-3
1 0 "} (2 5 4 m m )
B OLT PATTER N
5/8 " (UNC ) BO LTS
11 3 / 8 II } (2 8 9m m )
O U T S ID E
F ig u r e 13 .2- 5
R o t o r k A c t u a t o r M o u n t in g F l a n g e
S iz e s 4 0 , 7 0
1 1 3 /4 "} ( 2 9 8m m )
BOLT PATTE RN
3/4 " (UN C) B OLTS
1 31/2 ''} (343 m m )

O U T S ID E
F ig u re 1 3 .2- 6
R o tor k A c tu ato r M o u ntin g F lan g e
S iz e 9 0
T h e tor q ue r eq uir em ent s p ro v id ed in T ab le 13 .2- 2 m a y be h ig he r th an r eco m m e nd at ion s

fo u n d o n v al v e m an u f act ur e rs ' d ra w in g s o r in s tr u cti on m a nu al s . T he va lu es g iv en a r e
ba s ed o n u tili zati on o f th e h igh s tre ng th m ate ria ls l is ted in T a bl e 1 3 .1 -1 , an d s h ou ld be
ap p lie d if th es e m a te ri als ar e u s ed . E n g in ee ri ng re vi ew s h ou ld be c on d u cte d to en s ur e th at
th e u s e o f hi g he r t o rq u es w i ll n o t r es ul t in d am ag e to o th er ac tu a to r c om p o ne n ts . If
exis tin g b oltin g m aterials (no t co nfo rm in g to T able 13.1- 1 s p ecificatio ns ) are us ed,
ap plic atio n of t he to rq ues in T ab le 13 .2- 2 cou ld d am ag e the s e f as ten ers an d sh o uld n o t b e
us ed w i tho ut en gi neer in g rev iew .
13-4
T a b l e 1 3 .2 -2
T o r q u e R e q u ir em en ts
13-5
/
14.0 PREVENTIVE MAINTENANCE INSPECTIONS
E m pl oy m en t o f go o d pr eve ntiv e m ain ten anc e p ra ctice s can in cr ease the lif e of an y syste m
o r co m po n ent. T he fo llo w in g inf or m at ion i s in ten ded t o su p po rt de velo p m en t o f a sa fe an d
c orr ect in sp ecti on m et ho d and ef fe ctiv e p rev en tive m ai nten an ce p rac tices fo r R o tor k val ve
a ctu at or s . P er io d ica lly c he ck in g o il lev el i n th e ge ar cas e i s r eq ui re d to m ain ta in t he 4 0
y e ar w ar r an ty o f th e a ct ua to r . O th er pr a cti ce s di s cu s s e d , s u ch as v al v e s te m lu b r ic ati o n
a nd O - ri ng in s pe cti on s an d l ub r ica tio n s a re r ec o m m e nd ed m a in ten an ce t ha t is n ot r eq u ir ed
b y R o t or k to m ee t w ar r an ty r eq u ir em en ts .
O th er i nspectio ns co ver ed inclu de:
• T o r qu e s w itch se ttin g s
• I nst alla tio n o f ge ar case b rea th er p lu g an d v alv e stem co v er tu be , p rese nc e o f a
m ech an ic al la tch
• A ch eck fo r rol l pi ns d rive n in o n the sw itch m e chan ism
• V N O / N O d es ig n atio n i n th e w ir in g di ag ra m nu m b er o n n am ep late
• V is u al ins p ectio n of t he lim i t s w itc h com par tm en t
• I ns p ec tio n f or q u alif ie d w ir e i n th e ter m in al b u ng c om pa rtm en t
14.1 Precautions
T h e f ollo w ing p rec auti on s sho uld b e o bser ved w h en co nd ucti ng an y actu ator in spec tion o r .
m a in t en a n ce :
• A lth ou gh le avi ng ac tua tor s w ith cov er s of f is no t r eco m m e nd ed, a ny ti m e an

actu ato r w ill be lef t un atte nd ed w ith th e cov er s o ff an d th e M C C en er giz ed,
"D ang er H ig h V o ltage" tape s hou ld be us ed.
• A ssem b lie s t hat d o n ot a ff ect t he ac tu ato r to rq u e ou tp ut a re cl assif ied b y R o tor k
as cu stom er r ep la ceab le . F o r re pa ir /re pl ace m en t of th ese assem bl ies no spe cia l
tra in ing or ce rti fic atio n is ne ede d by m ain ten an ce pe rs o nn el to i ns ta ll or r ep lace .
H o w ever , if th e m o dule is no t classified as cu stom er rep laceable (i.e., aff ects
to rq u e ou tp u t) , m a in ten an ce p er s on n el m u s t b e qu ali fi ed t o s it e rep ai r/ in s pe cti on
pr o ced u re t o r ep air /r ep la ce th e m o d ul e an d r ece rt if y th e ac tu ato r 's o u tp ut
to rq ue . R e fer to S ect io n l.0 fo r cu sto m er r ep lac eab le m o du les.
14.2 Procedure
1 . O bt ain a pp lic ab le to rq ue s e ttin g d oc um en ts f o r act ua tor be ing re pla ced .
2 . O b ta in ap p lic ab le va lv e d at a s h eet .
3 . R ec o rd al l n am ep la te d at a.
W A R N IN G : V olta ge m ay s till b e pr es en t on con tro l circu it w ir ing fr om

inter locks w ith oth er C alves an d /or in dication an d a larm cir cuitr y.
14-1
4 . M atc hm a rk a dd -o n -p ak co ve r to g ear case co ve r an d re m ov e ad d- on - pak c ov er .
C A U T IO N : D o no t m a ke s w itc h ad ju st m e nts w it ho ut S ite E ng in eer in g

co n cur ren ce.
5 . R ec o rd as f ou n d t or q u e s w it ch s e tt in gs .
6 . In sp ect sw itc h m ec han is m f or inst alla tio n of a m ech an ical l atch ..
N O T E : T h e w i ri ng d ia gr a m n um b er on th e na m ep lat e s h o uld c on ta in an
"N O " d es ign at ion if the s w itch m ech an is m co nta ins a m ec ha nica l la tch . A
"V N O " des ignation indicates n o m ech anical latch is pr esent.
7 . V er if y th e pr es e nc e o f t he la tch i f th e "N O " d es ig n ati on i s p r es en t O R v eri fy th at

th er e is no t a m echa nic al l atch if t he "V N O " des ig n atio n is p res e nt.
8 . V er if y t he s w i tch m ec ha ni s m ro ll p in s ha ve b ee n d ri ve n m .
9 . I n spe ct co m po n en ts in sw itc h m ech an is m co m p ar tm en t fo r :
• L oo s e set screw s
• L oo s e w ir in g h arn es s ter m i na tio n s to s w itch pa ks
• W o rn t eeth on a dd -o n -p ak
• O i l le aka ge in s ide co ve r
10 . Ins pect sw itch co ver O - ring for dam ag e (i.e., cu ts, cru sh ed, o r b rok en) and
r epl ace as n eed ed . L u br icate O - rin g an d seali ng su rf aces w ith E x xo n U n ire x N 2
g rea se p r ior t o rep la cem en t.
N O T E : If oil level is excessive o n larger size actua tors, o il na y run ou t vent

p lu g w h en the actu ator is electrically op erated.
1 1. C h eck oil level by r em ov ing u pper m os t filler p lug . L evel sh ou ld be w ith in

app rox im ately o ne i nch of b otto m of f iller ho le, u p to a m ax im um lev el ev en w ith
the bo ttom of th e f iller ho le. A dd or r em ov e S p artan E P 1 50 oil (o r cas tro l n ucleo l
52 8 ) as n ee de d to o b tain p ro p er o il lev e l.
1 2. I f th e actu ato r is loc ated i n an ar ea susce pt ibl e t o steam lin e br eak s o r L O C A s,
v erif y a br eather pl ug is installed in the gear case.
14-2
13 . V erif y s tem lu bricatio n per the f ollow ing s teps :
N O TE : P r o per s tem lub r icatio n is a ccom p lish ed by en s ur ing tha t th e

s ectio n o f the valve stem th rea ds th at en ga ge s tem nu t a re in s atis facto r y
c on ditio n an d ar e ad equ atel y lu br ica ted . C lea nin g an d ins p ectio n of ste m
th rea ds m ay b e necessa ry if the lu br icant co nditio n a ppea rs deg ra ded or
a ctu ato r's m eas u re d t hrust is low er th an exp ected. C lean ing in vol ves
r em ova l o f a ll for eig n m a teria l ( inclu ding o ld lu br ica nt) fro m the s tem
t hread s. I nspectio n ensures th at thread s ar e n ot da m a ged , severely w o rn ,
o r im p ro per ly m ach ined . A deq ua te lu br ica tion in volves pr op er ly a pp lying
a ppr oved lub rica nt to all en gag ing th rea d s ur faces do w n to th e thr ead ro ot.
F o r sh or t stroke va lves ( 4 inch es or less ) o r w hen stem to stem n ut
en gag em en t threads a re n ot visible, extr a attention m ay be necessary to
en su re th at the en gag ing section o f the stem has received adeq uate
l ub r ica ti on . V ie w i ng t he s te m n ut a nd s tem th ro u gh st em du s t cov er m a y
h elp to a ccom plis h th is tas k.
a. I F the valv e IS fou nd op en A N D h as a s h ort s trok e, go to S tep 1 4.2.13.g.

IF th e va lv e i s f ou n d op en A N D d oes N O T ha ve a s h or t s tro k e, p os it io n th e
v alv e clo sed . G o to S tep 14 .2 .1 3.b .
IF the v alve is f oun d clo sed , g o to S tep 1 4.2 .13 .b.
b. W ith t he val ve clo se d, in sp ect th e as fo un d con di tion o f the lu br ican t in t he
stem to s tem nu t c on t act ar ea. I de n tif y th e co n d iti on o f t he l u br i can t a s
e ithe r sa tis fact or y or u ns atis f acto ry p er the f ollo w ing d ef initi on s .
• S a ti s f act o ry : L u br i can t a p pe ar s f re s h w it h n o c o n tam in a nt s or f or e ig n
m at er ial s . G o t o S te p 1 4 .2 .13 .d.
• U ns a ti s fa ct or y : L u b r ica nt ap pe ar s d ry , c ak ed o r g um m y , or h as
c on ta m in an ts s u ch as d us t o r in s u lat io n f ibe rs . G o to S tep 1 4 .2 .13 .c.
c. C lean ste m t o rem ov e old l ub ri can t a nd f or eig n m at eri al.
d. I ns p ect po rt ion o f v alve s tem th at en gag es s t em nu t f or d am a ge, c or ro s ion ,
se ve re w e ar , o r r ou g h m a ch in ed su r fa ces. IF co n di tio n o f t he th r ead ed
p o rti on o f th e s te m is d eg rad ed , con tac t a pp ro pr iat e e ng in eer ing /tec hn ical
sup por t bef ore proceed ing.
e. E n s ur e ad eq u ate s tem l ub r ica tio n b y us i ng a br u s h to ap p ly a pp r ov ed
lu br ica nt o n e ng ag em en t s u rf ace s d o w n t o th re ad r o ot . D o N O T ap pl y
lub ri can t to th e s m oo th p or tio n o f th e s t em .
f. IF t he va lve w as fo un d op en A N D h as a s h or t st ro ke, p ro cee d to S tep
1 4 .2 .1 3.g. I F t he v alv e w as fo un d cl os ed A N D has a sh o rt s tr ok e, po s iti on
v alv e op en . I F t he v alv e d oes N O T h av e a s h o rt s tr ok e, pr oc eed to S te p
4.2.14.
g. R em o ve du st cap .
N O T E : I n sp ect ion of s tem lub r ica tio n th r ou gh the d us t ca p m ay

requ ire us e of a flas h lig ht a nd ins pection m ir r or .
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h. W ith th e val ve op en , ins p ect th e as fo un d co nd itio n o f the lu br ican t m th e

s t em t o s t em n u t co n ta ct a re a. Id e nt if y t he co n di tio n o f th e l ub r ic an t as
eith er sa tis fact ory o r un s atis fact ory f ro m t he fo llow in g def ini tion s :
• S at is f a ct or y : L u br i ca nt ap p ea rs f r es h w i th n o c o nt am in a nt s o r f o r ei gn
m ate ri als . G o to 1 4 .2 .13 .j.
• U n s a tis f ac to r y: L u br ic an t ap p ea rs d ry , cak ed o r g u m m y , or ha s
c on tam in an ts s u ch as d u s t or i ns u lat io n f ibe rs . G o to 1 4 .2 .1 3 .i .
i. C lea n th e st em to r em o v e o ld lub r ican t an d fo re ig n m at eri al.
N O T E : I ns p ec tio n o f th e s t em th r ou g h th e d u s t ca p m a y r ew ir e u s e o f
f las hlig ht an d ins pec tion m ir r or .
j. In s p ect s m oo th a nd thr ea de d po r tio n o f th e s tem f o r da m ag e, co rr os i on ,

sev er e w ear , o r ro u gh m ac hi ned sur f aces. IF th e co nd iti on of e ith er sm oo th
O R th re ade d po rt ion o f th e stem is d eg ra ded , co nt act en gin eer in g/ tech ni cal
s u pp or t fo r eval uat ion .
k . E n s u r e ad e q ua te s te m lu b r ic at io n b y u s in g a b r us h a nd / o r a pp r o p ri at e
ap pli cato r to ap p ly ap pr ov ed l ub ric ant o n en gag em ent su rf aces do w n to
th re ad r oo t. D o N O T a pp ly l ub r ican t to s m oo th p or ti on o f th e s tem .
l. I nstall/replace d ust cap.
m . I F v alv e w as f o un d op en A N D has a s ho rt s tr ok e, p os it ion val ve clo s ed . G o to
s tep 1 4 .2 .1 3 .b . I F th e va lve w as fo u nd c lo se d A N D h as a sh o rt s tr ok e,
p roceed to S tep 14.2.1 4.
1 4. V er ify a ll un us ed th r eade d op en ing s in s y nc ro se t h ou s in g hav e a m etal pi pe pl ug ,
tr eat ed w it h pi pe jo in t co m p ou n d, a nd are in s ta lled .
15 . R em o ve s yncr oset hous ing cover and in sp ect for :
• L o o se co nn e ction s
• M oistu re
• C o rros io n
• N icked or dam aged w ir es
1 6. V i sua lly i nsp ect al l ter m in at ion s w ith in te rm in al bu n g an d v eri fy no a dj acen t
t er m i na l lu g s a n d te rm in al s a r e co nt ac tin g e ac h o th er .
1 7. I n spec t t er m in al bu n g ju m p ers fo r E Q r eq uir em ent s :
• I n s pe ct al l in s tal led ju m p er w i ri ng to i de nt ify m a nu f actu r er a nd ty pe o f
w i r in g .
• A ny jum per w ire fo und to b e u naccep tabl e pe r ab ov e in spectio n sh all be
c han g ed ou t and r ep laced w i th qu ali fied j um per s.
18 . Ins p ect s yn cros et hou s ing cov er O - rin g f or dam a ge ( i.e., cu ts , cr us hed , o r
br o ke n ). R ep lac e as n ec essa ry . L u br i cat e O - ri n g an d seal in g s ur f ac es w it h
E xx on U n ire x N 2 g re as e p rio r to r epla cem en t.
1 9. R e place s yn cro s et h ou s ing co ve r a nd s ecu re w i th fo ur co ver s cr ew s. T i gh ten
s crew s us ing go od craft practices .
2 0. V eri fy ex tern al l im it sw it ches are secur ely m o un ted.
2 1. V er if y jam nu ts on v alv e s te m a re tig ht .
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N O T E : Th e fo llow ing steps ve rify correct w iring an d set up o f T orqu e

B ypa s s fu nctio n by m an ua lly a ctu atin g op en tor q ue s w itch co nt acts and
electrica lly o penin g va lve. I f w irin g a nd se tup ar e correct, th e va lve shou ld
open and s to p a t pos ition To rq ue B ypa ss w a s set to actua te.
2 2. W hi le p erfo rm i ng S teps 1 4.2.23 and 1 4.2.2 4, o bs erv e th e co nd ition s of th e ad d-

on - pa k g ear clu s te rs . R e pl ace a s n ec es s ar y .
23 . H ave valve electr ically o perated to f ull clos e p osition.
N O TE : F or clo ckw is e to clos e valves , r ota ting tor que sw itch fr ontp late
counterclockw ise w ill actuate op en torqu e sw itch contacts .
24 . R o ta te to r qu e s w i tch fr o nt p lat e un ti l op en to r qu e s w i tch co nt act s a ct ua te. H ol d

fr on tplat e m thi s po s ition as val ve is elect rical ly op ened .
25 . V er ify v alve op ens a nd s top s at t orq ue by pas s p os itio n sp ecif ied per ve ndo r
in fo rm atio n. I f inf o rm at ion i s no t s peci fied , v alve o pen s an d s to ps b etw ee n 25 %
to 75 % of total valv e trav el.
26 . I ns p ect f o r ch ipp ed or r em ov ed p ai nt o n act ua tor . R ep air a s n ece s s ary .
14.3 Restoration
1 . V e ri fy th at a ny to r qu e s w i tch ad ju s tm en ts m a d e ha ve re cei ve d S i te E ng in ee r in g
review .
C A U TIO N : Incor rect a lig nm en t of new typ e add- on-p ak covers can caus e
bind ing of add -on -p ak s w itch cau s ing err on eous indica tion and /o r contr ol
of interlocked valves.
2 . A li gn m at ch m ar k s o n sw i tch co ve r to ge arc ase an d i nst all sw i tch co ve r. C o at

thread s of cap scr ew s w ith U nirex : N 2 and torq ue c aps crew s as follo w s.
T a b le 1 4 .3 - 1
C a p sc r e w T o r q u e G u id e
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15.0 ACTUATOR INTERNAL WIRING DIAGRAMS
T h is secti on c on ta ins ty p ical d ia gram s fo r a ctu ato r in te rn al w irin g.
F ig u r e 1 5 .0 - 1
A c tu a tor In t er na l W irin g D iag r am
( 1 2 S w it c h A O P w it h P O T , N o T h e r m o )
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F i g u r e 1 5 .0 - 2
A ctu a to r I n ter n al W irin g D iag ra m
( 6 S w i t c h A O P w it h P O T w i t h T h e r m o )
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F ig u r e 15 .0- 3
A c tu a tor In t er na l W irin g D iag r am
( 6 S w it c h A O P , N o P O T , N o T h e r m o )
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F i g u r e 1 5 .0 - 4
A ctu a to r I nt ern a l W irin g D ia g ra m
( 1 2 S w it c h A O P , N o P O T , N o T h e r m o )
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16.0 SPECIAL TOOLS

S om e of th e spec ial to ol s r equ ir ed f or th e m ai nte nan ce o f the R ot or k act uat or s ar e sho w n in
th is s e ctio n. H ow ev er , th is s ec tio n do es no t co ver a ll th e t oo ls t hat m ay b e n ece ss a ry f or all
the m o dels d es crib ed in this d ocu m en t. A ls o , s o m e o f the too ls are des ig ned s peci fically f or
th e r ep air e q ui pm en t av ail ab le at t he R o to rk s ho p . T h es e t oo ls m a y h av e to b e m o d if ied
de pen di ng o n th e eq u ipm ent av ailab le at the en d u se r faci lity . (F o r e xam p le, T O -8 6 9 ha s a
2" dia m eter h ole a t the center to fit in a R oto rk bench pr es s. If the en d u ser h as a differ en t
.
s iz e p r es s , th is d r aw in g w i ll h av e to b e m o d ifi ed I t is a g o od pr ac tic e to m ar k t he t oo l
n um b er o n eac h to ol. R o tor k s h ou ld b e c on tact ed f or an y o the r to ols or a dd iti on al tech ni cal
d etail s th at m ay be n eces s ar y f or r ep air o r s pe cial as s em bly pr oce du re s .
16.1 Material
R eco m m en de d m ate ria ls f or t he s pe cial to ols an d th e ac tua tor m od el( s ) on w h ich the y are
us ed are giv en b elow :
T a b l e 1 6 .1 - 1
R e co m m e n d e d M a te r ia ls fo r S p e c ia l T o o ls
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T a b le 1 6 . 1 -1 (c o n t . )
R e c o m m e n d e d M a te ria ls fo r S p e cia l T o o ls
16.2 Dimensions & Surface Finish

If n ot s h ow n, the lim its o n m achin ing dim ens ion s w ill b e + 0 .0 05" (o r 1/64 " o n fra ction al
d im en s ion s ). I n s om e o f the d raw in g a reco m m e nd ed s ur fa ce f in is h has bee n s ho w n as
g iven belo w . If n o s ur fa ce fin is h is s h ow n , re m ov e all bu rr s an d s har p ed ges , a nd f ini sh a s
s m oo th a s pos s ible.
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17.0 ACTUATOR FAILURE MODES/TROUBLESHOOTING
17.1 Actuator Falls to Start
1. C h eck cir cui t b rea ker , m ain c on tacto r an d ov erlo ad s in th e m ot or co ntr ol cen ter
( M C C ). If en er gize d pri or to r em o vin g po w er, r ecor d con tact or p os itio n. T h is
act ion m ay pr es er ve th e p re vio us op er atin g co nd itio ns bef or e the f ailu re.
2. C he ck co ntr ol tran sf or m er fus e.
C A U TI O N : T erm in als on line side of b r eaker a r e H igh V o ltag e ev en w ith

b re a ke r o p en .
3. O p en b r eak er at M C C an d v eri fy m ot or w i nd in g re sistan ce be tw een ph ases us in g

an ohm m eter . P hase to phas e res istance s hould be app roxim ately b alan ced .
4. V er ify m o to r in s ul ati on r es i s tan ce b etw e en ea ch p h as e an d g ro un d a t M C C . U s e
th e n ex t hi gh er vo lta ge r an ge ab o ve t he m o to r r ate d v olt ag e on t he m eg ger .
R e sistan ce v alu es sho u ld b e gr eat er th an 1 .5 M .O hm s .
5. V is u ally in s pec t a ctua tor li m it s w itch es . R ec or d all s w i tch p os iti on s pr io r to
o pe ra tin g th e v alv e b y ha nd . T hi s p re s er ve s f ail ur e co n di tio ns .
6. O p erat e v alv e b y h and to chec k m ech an ical op era tio n and sw itc h op era tio n.
7. C heck contro l cir cuit w ir ing.
17.2 Actuator Fails to Completely Close Valve
N O T E : Th e pr o bab le cau s es for this pr oblem ar e:

• V alve s tem lu br icatio n, or s tem n ut degr a datio n
• A ctuator sw itch m echanis m s w itches a re not set pr operly affr ont torqu e
pla te s etting )
• M echan ical dam ag e to the a ctuator ha s o ccurr ed
• M ech anical d am age to th e valve has o ccu rr ed
• E xces sive differ ential pres su re
1 . L ub r ic at e v al v e s te m th r ea d s us i n g a n a p pr o v ed h eav y g ra d e, hi g h t em pe r atu r e
l ub r ica nt .
N O TE : D o n ot ad jus t tor q ue sw itch s etti ng s w it hou t pr op er en gin eer in g

d ocum en tation.
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2 . D et er m in e the r eq uir ed s e ttin gs fo r th e s w itch m ech an is m to rq u e/li m it s ele cto rs

an d in sp ect f or th e cor re ct se ttin g. U n les s sp eci fie d, n o va lve s ho u ld be to rq u ed
o p en. T he m o tor d ri ve sho ul d no t b e us ed t o bac kseat v alv es u nle ss spec ifi cally
d es igned to d o so .
3. V er ify pr ope r p has e ro tation .
N O T E : T he s w it ch m ec ha n is m tor q u e pl ate i s m a r ked 1 th r ou g h 6 a n d

som e actuator s have a bo ost p osition. N ever leave the s elector in "b oos t"
becau s e valve da m a ge m a y o ccur. E ach increm ent betw een 1 a nd 5 m a y b e
nonlin ear ; no s pecific valu e can be a ss um ed w ithou t testin g on a tor que tes t
bench or w ith dia gno stic eq uipm ent.
4. If p ossible , v isually o bserv e t he sw itch m e chan is m o per ation w hi le th e v alve is

electr ically cycle d an d if n ecessary reset sw itch m ech anis m .
5 . I f th e actu at or is s e t u p f o r lim it an d is to rq u in g in to t he s ea t, r ech ec k pr im ar y
s w itch s et u p.
6 . If l im it s w itch es app ea r to fu n ctio n p ro per ly , th e p ro b lem m ay be du e to cl os in g
t orq ue be ing s et t oo low , m ec han ical d am ag e, or o bs tru ctio n i ns ide of th e v alv e
o r a ctu ato r .
7 . If th e s w it ch m ech an is m is d am ag ed , rep air o r rep lace as nec es s ary .
17.3 Freeing a Jammed Valve Manually

1 . F r eein g a jam m ed c lo se d va lv e b y o pe rat ing the v alv e m an ua lly as de s cri be d
b elo w :
C A U TIO N : N ever us e excess ive for ce to m ove th e m anua l /auto lever in to

m a nu al a s thi s m ay da m ag e in ter n al com p on ents .
• E ng a g e m an u al op e r at io n b y m o vi n g th e m an u al /a u to le v er to t he m a n u al
pos ition .
• I f the m anu al/ aut o lev er w ill n ot go to th e m an ual p os it ion , lo os en the
ac tu at or m o un t in g b ol ts . It s h o ul d n o w b e p o s s ib le to en g ag e th e m a nu al
pos ition.
• O p er ate th e han d w hee l us in g av ai lab le ha m m e r bl ow to f re e j am m ed v alv e.
• R eti gh te n ac tu ato r m ou n tin g b o lts .
17.4 Actuator Motor Trips Continually on Overload

1. V e ri fy pr o pe r o v erl o ad h ea ter s ize . T h e h eat er m ay n ee d to b e am b ie nt
co m p ensate d or m a y be u nd ers iz ed fo r th e ap pl icati on .
2 . C h eck tor qu e/lim it se lector s fo r pro per p os itio n.
3. V er if y th e to rq u e s etti ng fo r th e re qu ir ed t or q ue .
4. V er ify th e m oto r is w ire d f or th e ap pl ied vo ltag e.
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5 . E n su re th e m oto r is d e- ener gi zed, m egg er th e m oto r fo r ins u latio n br eak do w n.

6 . E n s u re th e m ot or i s d e-e ne rg ized , ta ke p has e to p h as e m ot or w i nd in g re si s tan ce
r e ad i n gs t o de t ec t s h o r ts .
7 . U s in g a d am p en am h m e ter o r o t h er di ag n o s ti c e qu i pm en t , t ak e c u rr e nt re ad i ng s
to ve r if y n o rm al s t ar ti ng an d r u n ni ng cu r re nt .
17.5 Actuator Runs Without Driving Valve

1 . If th e actu ato r is s iz e 1 4 or l arg er an d th e h an d/ auto leve r is lo ck ed in a ny o ne
p o si tio n the y ok e as se m b ly m ay b e inc or rec tly ad ju st ed. L ock u p occ ur s w he n th e
h an d/ aut o lev er ca m t rav els to o far and l od ge s b ehi nd t he ro lle r on t he y ok e
a s s em b ly . T he y ok e s h ou ld be r ep air ed o r a dj us t ed as n ece ss a ry .
2 . I ns p ect the d riv e b us h ing a nd en s ur e it is c or rect ly po s itio ned an d lo cked i n
p lac e .
3. If the driv e b ushin g w as co rrectly lo cked in place, the pro blem is likely to be
w it h in t h e ge ar ca se. I n sp ect a ll d r iv e tr ai n c om po n en ts a nd re p lac e w h er e
necessary .
17.6 Actuator Will Not Engage or Stay in Manual Mode

1. R em o ve actuato r hand w heel.
2. V isually inspect clutch com po nen ts for m echan ical d am age.
3. In sp ect p in s ecur ing h and /auto clu tch cam for d am ag e o r p os s ible s hear ing o ff.
4. R epla ce d am a ged cl utch c om p on en ts . C h eck all co m po ne nt clear an ces an d
adju st clutch o r y ok e fo r pro per o perati on.
5. R ein s tall han d w h eel
6. E ng ag e ha nd op er ati on a nd c he ck o pe ra tio n o f actu at or i n m a nu al an d m o to r
m o de .
17.7 Actuator is Leaking Oil

1. D eter m ine s ource o f the oil leak.
2. I f th e s o u rce o f the le ak is an o il d r ain p lug or h an dw h eel re tain er s cr ew , tig h ten
to sto p l eak.
3. If t he leak is s to pp ed , ref ill a ctua tor w ith ap pr op ria te o il.
4. If th e lea k is fr o m an a ctu at or oi l s eal, re pl ace d am ag ed s e al. D eter m ine a nd
do cum en t c aus e o f the seal f ailu re.
17.8 Actuators Mounted on 90° Butterfly Valves Fail to Take Valve to Full Travel
1 . C he ck lim it s top n uts for p ro per ad ju st m ent.
2 . R eset pr im ar y sw itc h m ech anis m and if u s ed, ad d- on -p ak sw i tches.
3 . O n b u tter f ly v alv es , s et t he s w it ch m e ch ani s m at th e s w i tch t rip po in t on the
clo sed s ide a nd not at th e ro ll pin po s ition.
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17.9 Control Circuit Malfunctions

1. T rou bles ho ot w irin g and indiv idu al com pon ents .
2. V er ify bar rel nu t tigh tnes s an d l ead co nf igu ration s .
17.10 Remote Indication Not Correct
1 . C heck con tro l w irin g. (S ee C hap ter 6.0 f or typ ical co ntr ol circu it op eratio n.)
2 . If pr oblem is no t in con trol w iring , r em ov e the sw itch m ech anis m co ver, cycle the
valv e an d ob serv e sw i tch o per atio n.
3 . If th e s w itch m e cha nis m s w itch es are d am ag ed , rep lace as nec es s ary .
4 . If th e s w itch m e cha nis m is no t s et p ro pe rly , res e t as ne ces s ary .
5 . I f the add -o n- pak s w itch es ar e d am ag ed, re place s w itche s (ad d- on -p ak) as
n ecessary .
6 . If th e ad d- on -p ak is n ot set pr op erly , reset ad d- on -p ak as n ecessar y.
17.11 Computer Points are Erroneous
1. R echeck add -on -p ak o r sw itch m echani sm sw itch setup.

2. R ech eck p rim ar y sw itch setup .
3 C h eck d igital op tical is o lator s if u s ed for th at pu rp os e.
17.12 Actuator Hammering
C A U T I O N : A ctua tor ham m er ing u su all y r es ults in d am ag e to eit her th e va lve

or the actuator . If it is neces s ary to electrically cycle valve to tr oublesh oot, be
pr epa red to im m ed iately r em ove p ow er fro m actua tor if h am m erin g b egins .
H am m er ing occur s w hen the actua tor is repea tedly ener giz ed an d de- energ ized
at a r apid rate.
1. R ev iew th e ap p licat ion o f th e actu ato r to d eter m in e i f ant iha m m er f u ncti on s

w ere pro vided or need ed.
2. A nti ham m er e lectric al co ntac ts are req ui red on ly if:
a. T h e a ct u at o r i s a V N O w i r in g d ia g r am
b . Is a v al v e a c tu a to r w i th a s p ee d o f g r ea t er th a n 4 3 r p m
c. H as li m i t/ to rq u e s w i tch e s s et f o r to r q ue co nt r ol
d . R ecei ve s a m ain tai ne d co n tr ol s ig n al ( e.g., s af et y act ua tio n s i gn al)
I f th e actu ato r ha s an tih am m er fu n ctio ns ch eck th e fo llo w in g:
1 . F or m e cha nica l la tche s, c hec k to m ak e s u re th e la tch is no t b ro ke n or

b ind in g . T h e lat ch i s lo ca ted b eh in d a nd nea r th e to p o f th e s w itc h
m ech anis m fr on tp late.
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2. T he an ti ham m er fu n ctio n s li s ted o n ly f u nct io n at th e en d o f th e va lve s t ro ke .

I f ha m m er ing occu rs at m id tra vel, chec k dr ive b us h ing c on dit ion a nd
lu br ication . A lso ch eck valv e fo r m echan ical bind ing .
17-5
/
18.0 VALVE PROBLEMS AFFECTING ACTUATOR OPERABILITY
18.1 Valve Packing
I m p ro p er v al ve p ac ki ng re pl ace m en t o r ad ju s tm en t can af fec t va lv e op er at io n. P os t -

m a in te na nc e p er fo r m a nc e tes t in g s h o ul d b e d on e a ft er p ac ki n g r ep lac em en t or ad ju s tm en t
sin ce th ese act ivi ties ca n sig nif ica nt ly ch an ge th e to rq u e/th r ust r equ ir ed t o op en o r cl os e a
v alv e. In som e case s , th e v alv e p ack in g c an b e o ve rt ig ht en ed su ch th at th e ste m is lo ck ed
in p lac e an d can n o t b e m o v ed b y th e ac tu at or . Im p ro p er ali g nm en t ca n c au s e th e p ac k in g
g land f lan ge o r glan d f ollo w er to in ter fer e or b ind t he va lve s tem , c aus in g s im ila r pr ob lem s .
T h e u s e of "l ive" lo ad ing c an red u ce t he nee d fo r pac kin g gl and a dju stm en ts d ue to p ack ing
co ns o lid atio n. U s e of " eng in eer ed" p ack ing s e ts in co m b in atio n w ith g lan d bo lt tor qu e
m eas ur em en t s m ay p re cl u de t h e n eed f o r a r et est af te r p ac ki n g a dj u stm en t.
18.2 Valve Stem

T h e v a lv e s t em m u s t b e m ai nt ai n ed to p re v en t a dd i ti on a l d ra g o n th e a ct u at or . T y p ic al
val ve s tem pr ob lem s m ay in clu de :
• Im p ro p er o r i n ad eq u at e s t em l u br i can t
• C hem ical b ui ld up o n th e stem
• F o r ei gn m a te ri al a d he s io n to th e s te m l ub r ic an t
• C or ro ded , p itted , or bu rr ed va lve s tem s
• B en t o r w a rp ed v al ve s te m s
It em s th a t c o nt ri bu te t o v alv e s te m o pe ra tio n al d eg ra da tio n in clu d e:
• E x ce s s iv e t or q ue /th ru s t ap p lic atio n

• F r eq u e nt op e ra ti n g s t r ok e s
• H i g h a m b i e n t t em p e r at u r e
• H ig h s ys tem v ibr atio n lev els
• P ac ki ng lea ks
M an y o f th es e co n di tio n s a re n o t pr act ica l to co r re ct. O th er s m ay b e m it ig ate d b y en h an ced

pr ev e nt iv e m a in ten an ce t ec hn iq u es , s uc h as :
• P er io dic ally cl ean ing , in s pec tin g, an d lu br ica tin g the v alv e s t em
• C on tro llin g p ack ing ad ju s tm en t o n va lve s, a nd r epl acin g pac kin g be fo re
ex te ns i ve st em r esist an ce is cr ea ted
• V alv e y oke w rap pin g to exclu de fo reig n m ateri al f rom co m ing in to con tact w it h
t he v a lv e s te m
18.2.1 Improperly Sized Stem Nut for Valve Stem
V al ve s tem s ize an d s t em n u t th r ea d p it ch an d l ea d m us t b e c ar ef u ll y m atc h ed . V a lv e

s te m s c an h av e s i n gl e, d ou b l e, or tr i p le s t ar t t h re ad s . I t is c ri ti ca l th a t th e v a lv e s t em
th r ea d ty p e b e d e te r m i n ed to en s ur e th at th e s te m n u t t hr e ad i s pr o p er l y m a ch in e d s o t h at
18-1
EPRI Licensed Materia l
p r op e r th r ea d m es h oc cu r s . I n a dd it io n , t he re m u s t b e pr o p er c le ar an ce b e tw ee n t he s tem
a n d s t em n u t t h r ea d s I f th e s t em an d s te m n u t ar e m is m a tc h ed , v a lv e s t em s e iz u r e o r
g all in g can oc cur . T he re ar e di ff er en t typ es o f acm e thr ea d co nf ig u rat io ns . T he t w o m o st
co m m on ty pes f or v alv es ar e ge ner al p ur p os e an d stu b ac m e th re ads. T h e m ajo r d if fer en ce
i n th es e t w o t yp es i s t he h ei g ht o f t he s t em t hr ea d ( o r d ep th o f th e th re ad cu t) . C ar e s h ou ld
b e t ak e n t o e n s u re th at th e s t em an d s te m n u t ac m e th r ea d t yp e s ar e p r o pe r ly m a tc h ed .
1 8.2 .2 V alve S te m F ailu re
V alv e stem fai lur es c an occ ur d ue to ex cessiv e str ess o r co rr os io n. M an y stem f ailu res hav e
b ee n att ri bu te d to i nt er gr an u lar s t re s s c or ro s io n c ra ck in g ( IG S C C ) w h en th e
m anu fa ctu rer 's sp ecif ied su rf ace h ard n ess h as b een e xce ede d (n or m al ly fr o m i m pr o per h eat
t rea tm e nt o f T y p e 41 0 s ta in les s s tee l) . T h er e hav e al s o be en r ep o rte d I G S C C fa ilu re s o f
v alv e s tem s f ab r icat ed f ro m 1 7- 4 p h s ta in les s us e d in h ig h te m p er atu re a pp lic ati on s
( > 6 00 °F ) . I G S C C n o rm all y re qu ir es an aq u eo us en vi ro nm en t w hi ch ca n be p r esen t at
t em p er at ur es le s s t ha n 2 00 °F . T y p ica lly th e aq ue ou s en vi ro n m e nt w o u ld r es u lt f r om v al v e
le aka ge o r leak ag e fr om ad jac ent eq u ipm en t.
I G S C C of s te m m ater ial s o ccu rs in aq u eou s s o lu tio ns w ith p r im ar y co ol ant ch em is tr y

G e ne ra lly , th is w o u ld r esu lt f ro m h ig he r th an ex pe cte d ste m str esses. T h ese str esse s c ou ld
b e pr es e nt d u e t o im pr o pe r he at tr eat m en t o r f abr ic ati on (e.g ., po o rly m ac hi ne d th re ad
r o ot s). C o n tam in an ts s uch as sul fu r , ch lo r in e or flu o ri ne c an a cce ler at e I G S C C . T h ese
c on ta m in an t s m ay b e p re s en t in lu br ic an ts , i ns u la tio n or cle an in g f lu id s . C ar e s h ou ld be
t ak en to e ns ur e t h at t h e s te m r em ai n s d ry an d f re e o f t h es e co n ta m i na n ts . O n ly ap p r o ve d
lu b ric ant s , in su lat io n and clea nin g f lui ds sho ul d be u s ed. If ev id en ce of st em w ettin g is
p r esen t th e stem sh o ul d be c ar ef ul ly in sp ect ed . F ai lur e in ten s io n o f a v alv e stem
( ba cks e atin g) n o rm ally i nit iates fr o m c rac kin g at th e th rea d ro ot u nl es s co r ro s ion o r o th er
f ailu r e m ech an is m s are p rese nt ( e.g ., un ex pec ted b en di ng l oad , m a ter ial or fab ri cati on
d efe cts).
18.2.3 Valve Stem Fouling
V alv e st em fo ulin g o ccur s w h en th e stem lu br ican t b eco m es deg ra ded o r con tam inat ed, o r
w h en p ac kin g l eak ag e c au s es a c hem ica l b u ild u p. S t em fo u lin g in cr ease s th e v alv e st em
d r ag an d m a y c au s e pr e m a tu r e to r q u e s w i tc h t ri p . F o r ei g n m at er i al c an b e tr a ns p o r te d b y
t he v a lv e ste m in to th e st em n u t. P re s en ce o f co nt am in at io n o r d e gr ad e d lu b r ica n t m ay
a cce ler at e w ear of th e stem nu t th r ead s. I n e x tr em e c ases, va lv e stem fo u lin g m ay cau se
stem seiz ur e.
18.3 Valv e Therma l Binding

W ed ge t yp e g ate a nd pl ug va lv es ar e s us c ep tib le to th er m a l b in d in g . T h er m a l bi nd in g c an
o cc ur w he n to r qu e sea ted v alv es ar e cl os e d at e lev at ed sy ste m tem p er atu r es. A s co o lin g
o ccu rs , th e v alv e b o dy an d/ or p ipin g s ys te m m ay co ntr act m o re tha n the v alve d is c c aus in g
it to beco m e lo cked b etw een the seats.
18-2
T h e bo un d valv e can of ten b e f reed u s ing a lo cal hea ting d evi ce o r by h eati ng th e sy st em .
N o rm ally n o r esid ua l d am age o ccu rs to th e va lve o r act ua tor w h en t his p ro ced ur e is u s ed a s
lo ng as exce ss iv e to rq ue /thr us t is n ot app lied to f ree the di sc .
W hen t he rm a l b in di ng f or ce s ex ceed s actu ato r cap ab ili ty, t he o nly actu ato r p ro tect ion is th e
o ver lo ad he ater s ( if equ ip ped ) sin ce t he op en to rq ue sw itch i s n or m ally b y passed at th e
b eg inn in g o f th e v alv e s tr ok e. M an ua l app lic atio n o f ex ces s iv e tor q ue m ay als o d am a ge th e
v alv e or a ctu ato r.
R e fe re n c es : A nch or /D arlin g O n -L ine, "F eed w ater H eater Is o lation V alv es", F H I 2 .5 M ,
M ay, 1 98 7 IN P O S O E R 84 -7, D ecem ber, 198 4
U .S . N uclea r R egu lato ry C om m i ss io n, "S p ecial Stu dy - P ressu re L ock ing an d
T her m al B ind ing of G ate V alv es" A E O D /S 92- 07 , D ecem ber, 1 992
18.4 Valve Pressure Locking

V alv e p ressur e lo cki ng oc cur s w hen liq uid is trap ped in th e b on net cav ity of a clos ed g ate
v al ve , an d th e li qu id is he ate d. T h e pr es s u r e in cr eas e d u e to l iq ui d ex p an s io n m a y b e
s u f fi ci en t to pr ev e nt t he act ua to r f r o m op e ni ng th e v al ve . I n e xt re m e c as e s , th e v al v e can
r u p t u r e.
P r es s u re l oc ki ng can be p re ve nt ed b y a u s in g a li ne t ha t co nn ec ts t he b o nn et w i th t he
u p s tr eam p ip in g . R eli ef o r i s ol ati on v alv es m a y b e re qu ir ed in t hi s l in e w he re b id ir ec tio n al
f lo w is r equ ir ed . S om e m an uf ac tur er s h av e als o r eco m m end ed dr illi ng a s m all h ole in th e
u ps tr eam s id e o f th e g ate o r bo dy br idg e w all to pr o vid e a p re ss u re eq ua lizat ion p o rt.
R ef er en c e : IN P O S E R 49 -8 2, F eb ru ary , 19 82
IN P O S E R 07- 84, N ovem b er 4, 19 83
A nch or/D ar ling, O n- L ine, B O P , J uly, 1 985 , 150 0
U .S . N uclea r R egu lato ry C o m m issio n, "S pec ial S tu dy - P ressur e L o ckin g and
T her m al B ind ing of G ate V alv es " A E O D /S9 2- 07, D ecem b er, 19 92
18.5 System Pressure Induced Valve Position Change
S o m e m o tor op era ted v alv es c an o pen du e t o lin e pr essur e. T h is can o ccu r w he n th e v alv e
is c los ed m an ually an d t he stem is n ot se lflo ckin g.
W he n an a ctu at or i s i n m a nu al m o d e, t he v alv e s te m is r es t ra in ed o nl y b y th e fr ic tio n

b et w een th e stem a nd th e stem n u t, p ac ki ng fric tio n , d isk a nd stem w e ig ht ,
w ed g ing /s ea tin g fo rc e a nd th e dr iv e sl eev e b ea rin g an d seal f ric tio n. D r iv e sle ev e b ear in g
an d sea l fr icti on are n or m a lly m in im al . T h e va lve ca n self o pen w he n th e st em re ject io n
f or ce du e to u p st ream p res s u re exc eeds th e ab ov e m en tion ed r es tra inin g fo r ces A N D w h ere
t he s tem an d s tem nu t a r e no n s e lf lo ck i ng . P h ys i ca ll y r es t ra in i ng th e h an d w h ee l ca n
p re ve nt o pe ni ng . I f th e actu at or h as a lo cki ng ge ar r atio , cl os i ng t he v alv e ele ctr ica lly
r at h er th an m a nu a ll y w i ll p r ev e nt in ad v er te n t o pe n in g .
18-3
18.6 Valve Yoke Failure
S om e valv e y ok es m ay also ex per ience crack s or fa ilure s. Y ok es shou ld be perio dical ly

ch ecke d for cr ack s w hen o ther m ainte nan ce is per fo rm ed .
18.7 Valve Seat Friction
G ate v alv e d is k to s e at fr ictio n can var y co ns id er abl y. I f di sk to s eat fr icti on i s

u n de rp r ed ic ted w h en e s ta bl is h in g t he c o rr ec t act u ato r s w itc h s e tti ng s , s ub s eq u en t
o pe rat ion un d er fl ow an d d iff er en tial p re ssu r e m ay ca us e th e to rq ue sw it ch to
i na d ve r ten t ly tr ip . In s it u v a lv e t es t in g r e s ul ts c an be us ed to e s ta b li s h t he co r re ct
ac tu at or s ett in gs . W h er e in s it u te s tin g i s n o t p ra cti cal o r n o t d es ir ed , t he E P R I M O V
P er fo r m an ce P r edi ctio n P r og r am pr ov id es a val id ated m eth o do lo gy t o pr ed ict s te m thr u s t
requi rem en ts fo r t ypic al fl ex w ed ge and solid w edg e g ate v alves.
18-4
19.0 ROOT CAUSE AND CORRECTIVE ACTION GUIDELINES

I n m o st ca se s w h en an ac tua tor f ails , e sp eci ally if it i s saf ety r elate d or ca us es a f o rced
o u ta ge , i ts r et u rn to an o p er ab le s ta tu s b eco m es i m p er at iv e . A s a r e s u lt, a f ai le d a ct ua to r
m ay b e r et ur ne d to s e rv ice w it ho ut d ete rm in ing the u n der ly in g o r ro o t c au s e o f th e fa ilu re .
F o r ex am pl e, to r qu e sw it ch ad ju stm en ts a re m ad e to o ve rc om e in cre ased actu at or lo ad
in s te ad o f id en ti fy in g an d c or re cti ng the r o ot p ro b lem . T h e ap pl ica tio n o f g re ater act uat or
to r qu e a llo w s th e va lve to b e re tur n ed to s er v ice bu t can le ad to a m or e s e rio us fa ilu re .
N R C I nf orm ation N otice 85 -2 0 p ro vid es add itio nal d is cus s ion o f th e im por tance of
id entif ying th e ro ot caus e o f i nitial M O V f ailur es.
T h er e ar e a nu m b er o f f ac tor s an d co nd it io ns th at can lea d to t he i no pe ra bi lity of actu at or s .

I n or de r to s im p lif y the r oo t c aus e fa ilu re de term ina tio n, th e fo llo w i ng g ui deli nes ha ve be en
p ro v id ed to a s s is t in t ro u b les h o ot in g an d r et ur n in g th e ac tu ato r s t o s er v ice in a tim el y
m an ne r. T h es e g ui de lin es p ro v id e b as ic d ia gn o s tic i ns t ru ct io ns u s in g a s y s te m at ic
ap p ro ac h to de ter m i ne t he r o ot c au s e fa ilu r e. I n m os t ca s es , i de nt if yi ng an d co r re cti ng th e
r oo t cau se o f actu ato r fa ilu re do es no t e xp en d any m or e tim e th an co rr ecti ng t he ob v iou s
p ro bl em , an d m a y sa ve co ns id er ab le t im e, m on ey , and per s on ne l e xp os u re lat er.
R eal izin g th at n o gu id eli ne can be al l i ncl us iv e, p r op er tr ai nin g an d ex p eri en ce m u st b e

u s ed w h en an aly zi ng actu at or fa ilu re s. T h is g ui de lin e is th er ef or e pr o vi de d as a to ol t o
assist in g ui din g th ese eff or ts.
W h en a m a lfu nc tion occ ur s w h ile the p lan t i s in an o p era ting m od e, o r du ri ng p os t-

m a inten an ce te st ing , it is no rm a lly rep or ted as o ne o f the fo llow in g co nd ition s :
• A ctuator fails to f ully open or clos e valve
• A ctu ator fa ils to op erate the val ve e lectric ally (i.e., no m o vem e nt)
• V alve po sitio n indica tion is no t w or king pr op erly
• A c tu ato r f ail s to op er at e m an u all y
• A ctu ator fai ls to st rok e v alve w ithin lim it s sp ecif ied by techn ical sp ecifi cation s
• V al ve o ver tor q ues in to seat o r slam s b ack seat w he n op er ate d elec tri call y
• A ctua tor m ov es valv e in rev ers e d irectio n of s w itch s electio n
T h e f oll ow in g data can b e co llected t o h elp ex ped ite the de term i natio n of th e f ailu re m o de of
t h e a ct u at o r :
• O bs erv ations o f pers on nel in volv ed

• P r eo p era tio n al/ po s t- m a in ten an ce te s tin g f ail ur e an al ys is d is cu s s io n
• S af ety cl ass an d cat ego ry o f act uat or
• D a te ac tu at or lu br ic an t w as in s t all ed o r ig in al ly
• T yp e of lu br ic an t in th e ac tu ato r
• D a te lu b ri can t w as la st ch eck ed in t he g ea rc ase an d l im i t sw itc h g ear fr am e
• E nv ir on m e nt al co n dit io ns o f th e in s tal led a ctu at or ( e.g ., t em p er at ur e, v ib r ati on ,
h ou sek eep ing )
• A ver age op erating fr equen cy ( e.g., daily , w eekly )
• F a ilu r es th at h av e oc cu r red to th is m o de l act ua to r i n r ece nt p la nt h is t or y ( 3
y ear s)
19-1
• A d ju s t m en t s m ad e t o t h e ac tu at o r s i nc e la s t r eg u la r p r ev en t iv e m ain t en an ce
cycle
• C om po n en ts n o w i ns t al led in t he act ua to r t ha t ha ve be en s u p er s ed ed
• F irs t in dica tio n of m a lfu nct ion
• A cti on s tak en s u b s equ en t to m alf u nc tio n
• P r ev en ti ve m ai n ten a nc e co m m en ts n o te d r el ati v e to t h e ac tu ato r
• D es i gn b as i s t es t/ b as el in e te s t d ata an d o p er ati n g d at a re co r ds
T he d ata co llect ed abo ve and th e r eco m m en ded g uid eline s pr ov ided in S ec tion 1 9.1 c an be
u s ed i n i de nt if y in g t he r o ot cau s e o f a R o to r k ac tu at or f ail ur e. I n o rd er to pe rf o r m a
co m p le te ev a lu ati on of th e ac tu ato r f ai lu r e, d o cu m e nt t he r esu l ts of all st ep s l ist ed a s t he y
ar e b ei ng p er f or m ed . T hi s w ill en su re t h at d at a is n o t lo st as t he act u ato r is in sp ec ted o r
di sa sse m b led as nee ded .
19.1 Root Cause Failure Analysis Guidelines
1 . O b tai n m an u f ac tu r er s ' in f o r m a tio n r el ate d t o th e ac tu a to r i n q u e s ti on . If

n ece ss ar y , loc ate add iti on al app lic able to rq u e set tin g do cu m en ts r efe ren ced f or
t he ac tu ato r be in g re fe ren ce d.
2 . E v a lu ate t he a s fo u n d co n di tio n o f th e act ua to r an d r e co rd pe rt in en t in fo r m a tio n .
D a m ag ed p ar ts s h ou ld b e s ave d fo r an aly s is .
3 . O b t ai n tr a n s ie n t d a ta p er t in e n t t o o p e r at io n o f th e ac tu a to r . I n s o m e s i tu a ti o ns ,
t h is da ta m ay b e re co r de d b y p l an t s y s te m s . If th e d at a w as n o t re co r de d ,
i nte rv iew p er s on nel o n du ty at th e tim e of fail ur e. A ls o re vie w co nt ro l r oo m
logbo oks, if applicable.
4 . D ur in g int erv iew s w it h per s on ne l, de term ine th e f ol low in g in fo rm atio n and
d ocum ent:
a. A ctivities b eing p erfo rm ed at t im e of f ailure (co ntr ol r oom actio ns as w ell a s
M O V auto m at ic ac tuat ion 's)
b . S y st em co nd ition s at tim e o f failu re
c. C ontro l R oo m ind icato rs
d . O peratin g f requ en cy o f th e com p onen t inv olved
W A R N IN G : H ig h V oltag e M a y B e P r esent In B r eaker C om par tm ent.

U se appr op ria te s afety equ ipm ent w hen w or king in b reaker
com pa r tm en t. V o ltag e m ay s till be p res ent on con tro l cir cuit w ir ing .
5. D ete rm in e th e p res ent con ditio n of com p on ents by ins p ection o f th e f ollo w i ng:
a. R eco r d b r ea ke r A s F o u n d p o s iti o n
b . L ea v e b r e a k er c l o s ed
6. D eterm ine the as f ou nd co nd ition o f the fo llow in g com po nen ts in th e M o tor
C on tr ol C enter (M C C ):
a. O v e r lo a d r e la y p os it io n
b . O v e r lo a d he a te r co n d i ti o n
c . O pe n co n t ac t or p o s i ti o n
d . C lo s e d co n tr ac to r p o s it io n
19-2
7. D eterm ine the as foun d cond ition of th e follow in g com po nents in the
B re ak e r /s t ar t er c om p ar t m e n t:
a. E vid enc e o f m ois tu re, d irt or o ther f or eign m ateri als
b. W i rin g tha t is fr aye d, p inch ed , ov erh eate d, o r dam a ged
c. L o ose term inations
d. E vid ence of ov erh eated equ ipm en t
8. E ns ure br eak er is C los ed.
9. M easure seco ndar y con trol transfo rm er voltag e.
1 0. E n s ure br eaker is O p en an d no loa d s id e vo ltage is p res ent.
1 1. M easure m oto r w ind ing s and feed er cab le fr om break er co m par tm ent as follo w s:
a. M ea s ur e m ot or w i nd in gs . R eco r d ph ase to p ha s e r ead in g s.
b. M eg ger m o tor w ind in g s an d in su lati on r esist an ce. R eco r d ph ase to p h ase
an d ph as e to g ro u nd .
1 2. R ecord contact po sition s in relation to pres ent v alv e pos ition as fo llow s:
a . M C C to v alv e O P E N co nt ro l c ircu it co nti nu ity . V erif y co nt act st atu s u si ng
ap pr op ri ate con tact de vel op m en t.
b . M C C to v alv e C L O S E c on tro l ci rcu it con tinu ity . V erif y co ntact s tatu s u si ng
ap pr op ri ate con tact de vel op m en t.
c . A s s oci ated per m i ss i ve co nt acts . V e rif y in ter lo ck an d p er m is s iv e s tatu s u s in g
t he a pp r op r iat e E le ctr ic al E l em e nt ar y.
d . A uxiliar y r elay co ntacts .
e. R eco rd o ver loa d h eate r s iz e an d rel ay s ettin g.
1 3. Perfo rm actuator/v alv e visu al insp ectio n as follow s:
a. R e co rd n am ep lat e da ta
b. V er ify v alve s tem do es n ot ap pear b ent or d am ag ed
c. V eri fy v alve s tem is f ree f rom r us t, co rr os io n, f or eig n m ater ial, an d thr ead s
do n o t a pp ear to be d am ag ed
d. V erif y th e v alve st em is p ro perl y lu br icated
e. C h eck th e va lve a nd o pe ra tor f o r leak s , b rea ks or o th er a bn or m al itie s
f. E n s ur e th e gear bo x oi l lev el is acc epta ble
N O T E : N otify ap pr op ria te per s on nel in r ega rd to per for m ing a m anu al

stroke of the valve in the fo llow ing step .
1 4. Pe rfo rm actu ator co m p artm e nt ins pe ction as fo llow s :

a. R em ov e sw itch com par tm ent cov er and in sp ect f or m issing o r b ro ken
ha rdw ar e, m o is tur e, cor ro s ion , loo s e te rm in atio ns , etc.
b . B ef or e pl acin g v alv e in m anu al , ve rif y co n tact sta tus ag re es w i th th at
ob tain ed in s tep 1 9.1.6.
c . V e rif y lim i t, by pa ss , in di catio n, i nter lo ck, an d to rq ue s w itch ac tua tion p er
applicab le contr ol d iag ram s as follo w s :
• P lace va lve in m an ual an d cycl e v alve to in ter m edi ate p osit ion w h ile
o bs er vin g lim it sw itc hes an d tor qu e s w itch .
• I n m anu al, con tinu e cy clin g v alve to op po si te A s F ou nd p os ition w h ile
o bs er vin g lim it s w itches and to rq ue s w i tch.
19-3
• W it h the v alv e in m an ual, c ycl e v alv e t o int erm edia te po s itio n w hile
o bs erv ing li m it s w itch es an d tor qu e s w itch .
• In m an ual, con tinu e cy cling val ve to o ppo s ite A s F ou nd po sitio n w h ile
o bs erv in g l im it sw it ches and to rq ue s w i tch.
N O TE : If th e valu e w ill n ot fu lly open or clo se m an ually,

d is as s em bly w i ll b e r eq uir ed fo r fur th er in sp ectio n. I f d isa s se m b ly
is r equir ed, d is as sem ble in accor dance w ith the a ppr opr iate s ection
o f this m a nu a l.
N O T E : If no failur e cau se is evident, conta ct the a ppr opr iate

en gineer ing or ga niza tion/R o tor k befor e p erfo rm ing an y rep air s.
19.2 Failure Analysis Review
1. B as ed o n in fo rm a tio n ob tai ned f ro m in s pec tio ns and c or re ctiv e m ain ten an ce,
do cum ent the m os t pro ba ble caus e of fail ure .
2 . A l low th e a pp ro pr iat e en g ine erin g o rg an izati on /R oto rk t o rev iew th e p r op os ed
c aus e of f ailu r e, and do cum ent co nc lus io ns .
19.3 Followup Actions

R eco r d d ata i n an a pp li cab le t re nd in g s y s te m or ot he r m e ch an is m to pe rm it tr en d in g o f
failu res .
19-4
20.0 PROCEDURE FOR SETTING SWITCHES
B eca us e th e R oto r k ac tua to r u se s a c lut ch sy stem o n t he sw it ch m ech an is m an d ad d -o n -

p ak , it is im p o rta nt to s et th e lim i t s w itch es pr o pe rly to a vo id s l ipp ag e of th e c lu tch . B y
us i ng th is p ro ced ur e, th e p os s ib ility o f clu tch s lip pa ge is m inim ized . T h e ac cur acy o f the
po s itio n in dica tion i s im p ro ve d by all ow in g the v alv es to b e s et v ery n ear th e e nd o f the
o pe n s tr ok e in a c on s is te nt m an ne r w h ich e ns u r es t ha t th e v al ve is f ul ly o pe n.
A n i nc re as e in th e len g th o f t he l im i t s w itc h s et up s tro k e m a y ca us e a n in cr eas e i n th e

p re vio u s ly m e as u red s tr ok e tim es . T h e in cr eas e s ho u ld n ot e xc eed t he "a s o r der ed "
m ax im um s tr ok e t im e fo r a giv en v alv e.
T he f ollo w in g is a gen eric pro cedu re f or R o tork S w itch S etu p w hic h can be us ed to d evelo p
site sp ecific setup pr ocedu res.
• 20.1 P r er eq u is it es
• 20.2 P re ca ut io n s
• 2 0 .3 Sw it ch M ech anis m S etu p
• 20.4 A d d-o n-p ak S etup
• 2 0 .5 E le ct r ic al S t ar t up
• 20.6 R e s to r ati o n
20.1 Prerequisites
1 . Pr io r t o rem o vi ng an y actu ator f ro m se rv ice, en su re th e co ns eq ue nces of th e
actu ator b ein g ou t o f serv ice (e .g ., w h ich alar m s , in dica tion s , and c om p ut er
po int (s ) w ill be af fect ed) a re fu lly u nd ers to od b y all p erti nen t par ties su ch as
O p er ati on s a nd M ain te na nc e p er s o nn el .
2 . B ef or e o per atin g val ve in m an ual or e lectr ic m od e, no tify a pp ro pr iate per s on nel
(e.g., C ontrol R oom , etc.).
3 . R eview app licabl e site T echn ical Sp ecifi cation s fo r req uir em ents asso ciated w ith
ino p era bil ity o f th e actu ato r.
4. N o tify Q A , if ap plicable, bef ore replacem en t or re- ass em bly of Q A parts as
n ecessary .
5 . D o n o t m ak e a ny tor q ue s w it ch ad ju s tm e nt s u nl es s d ir ect ed b y E n g ine er ing or
ap p ro pr iat e w or k o rd er .
6 . O b ta in ap p ro p ri ate v alv e d ata s h ee t a nd in fo r m at io n fo r t or q ue s w it ch s e tti ng s .
N O T E : V a lue stroke tim e m ea su rem ents a r e m ade to fu rth er verify pr op er

se t u p. T hes e m ea s ur em ent s ar e not in tend ed to sa tis fy res p on se tim e t est
requ ir em en ts .
20-1
7 . O btai n ap pr opr iate c onn ectio n d iagr am s fo r field cab le co nnect ions .
8 . E n s ur e pr op er s y s tem is o latio n , if r equ ir ed .
9 . In spec t sw itc h con tact d eve lop m en t lege nd o n ap pr op ria te e lectr ical ele m en tar ies
to d eter m in e if co nta cts se rv e a s p erm issive s to o pe rat e o th er v alv es, pu m p s, etc.
1 0. R evi ew ap pr op ri ate electr ical elem ent ary f or g uid an ce o n r equ ire d per cen tage o f
to r q u e b y p a s s .
20.2 Precautions
1. C i rcu its , w h ich m ay op en or c los e va lve au tom atica lly , m ay n eed to b e r en der ed
i no per ab le pr ior t o per fo r m in g elect rica l sta rtu p.
2 . " D a n g e r , H i g h V o lt a g e " tap e s ho ul d be u s ed a ny t im e th e actu ato r w il l b e lef t
u natten ded w ith c over s of f an d M C C energ ized.
20.3 Switch Mechanism Setup
1 . V e rif y f ee de r br ea ke r is op en .
W A R N I N G : V oltag e m ay be p resent on con tro l w iring .
N O T E : C o ver s w ill be r epla ced w h ile p er for m ing R E S T O R A T IO N per

Sec tion 2 0. 6 .
2 . M at ch m a rk s w itch m ec ha nis m c ov er t o g ear cas e an d r em ov e s w itc h m ec ha ni s m

c o ve r.
N O T E : T he term C L O S E sw itc hes d oes N O T refer to clo se con tact s. It

iden tifies s w itches w h ich actua te as s alve r eaches its clos ed po sition . T he
te rm O P E N sw itch es do es N O T r ef er to o p en co nt acts. I t id ent ifi es
s w itch es w h ich act uat e as val ve rea ches its o p en po s itio n.
N O T E : T o m in im i ze ti m e A N D m a nu al o pe r ati on of va lve , ad d- o n- pa k
S etup , Sect ion 2 0.3, m ay be pe rf or m ed alo ng w ith S w itch M ech an is m
Setu p.
3 . E n s ur e al l ro ll p in o v er ru n s t op s ar e dr iv en in f lu s h w i th s w i tch m ec ha ni s m ba s e
p late . R efe r to F i gu r e 2 0 .3 - 1 fo r r ol l pi n ov er r un s t op loc ati on s .
20-2
F i g u r e 2 0 .3 - 1
C lu tc h N u t D es ign S w itc h M ec h a n ism
4. D et erm i ne ty pe of s w it ch per r ev iew o f F ig ur e 2 0.3 -1 an d F igu re 2 0.3- 2. I F

s w itch m echan is m is o ld typ e ( clu tch nu t d es ig n, re fer to F ig ur e 2 0.3- 1) , then g o
t o S tep 20 .3.5. IF s w itc h m e ch ani s m is new ty p e (li m it s w i tch s h af t lo ck nu t
d esi gn, re fer to Fig ur e 2 0.3 -2 ), then go to S tep 20 .3.7.
F i g u r e 2 0 .3 - 2
N e w T y p e S w itc h M e ch a n is m
20-3
N O T E : T he fo llow ing steps a re for clo ckw is e to clo s e valu es on ly. IF

value tr avels open, then go to s tep 20 .3.6.
5. IF s w it ch m echan is m i s old ty pe (clu tch nu t d es ign ), an d t he v alv e is c lock w i se to

clo se, ref er to F igu re 2 0.3 -1 and per for m the follo w in g:
a. E n g age h an d/ aut o lev er t o H an d op er ati on .
b. L oo s en loc knu ts ( 17 ) and ( 18) . S crew bo th lock nu ts to o utb ou nd en d of
screw ed shaf t (15 ).
c. L o os e n clu tch nu t (2 2) a t leas t th re e f u ll tu rn s .
d. T u rn h and w heel clo ckw is e u nti l v alve is clo s ed.
e. R ota te sc rew e d s haf t (1 5) c ou nte rcl ock w is e un til tr av elin g nu t (1 6) com es
h ar d a gai ns t it s b ack s to p ( 19 ) .
f. U s in g ov er tra vel gu ide (2 0) f or lev er age, co nti nu e tu rn ing s cr ew ed s haf t ( 15 )
co unter clockw ise until o ver tr avel g uide ( 20) com es ov er clos ed roll p in
o v er ru n s to p ( 21 ) . D ur in g th is fi na l m ov em en t, en s u re C L O S E s w itc he s
a ct u at e.
g. W h ile ho lding ov er tr avel g uide (20 ) o ver its roll pin over run s top (21 ),
t igh ten clu tch n ut (2 2) fi rm ly .
h. R elea s e o ve r tra vel g uid e (2 0) . E n s ur e s w it che s do no t r es et.
i. M an ua lly o per ate va lve to w ard o pen dir ectio n u ntil s w itch es r es et.
j. C los e v alve an d en su re C L O S E s w itc hes actu ate.
k. M anu ally o per ate v alv e to b ack sea t p os itio n or o pen s to p
l. I f v alv e t rav el is 10 h an dw h eel tu rn s o r les s , th en u s e " ov er ro ll pi n ov er ru n
s top " in stead o f u pper s top .
m . P u ll o ve r t rav el gu ide (2 0) cl ock w is e u ntil it com es h ard ag ain s t u pp er
o ve rr u n s to p ( n o t s ho w n ). D ur in g t hi s f in al m o ve m en t, en s ur e O P E N
sw it ch es act ua te.
n. W h ile h old in g ove r trav el g uid e (20 ) aga ins t up per o ver ru n s to p, s cr ew
loc kn ut (1 7 ) do w n s cr ew ed s ha ft (1 5 ) un til it co m es har d ag ain s t t rav eli ng
nut (16 ).
o. M o ve sp acer ( 24) an d lo ckn ut ( 18 ) d ow n to lo ckn ut ( 17) . T ighte n lo ckn ut ( 18)
fir m ly .
p R ele ase o ve r tra vel g ui de (2 0 ). E n sur e sw i tch es d o n ot re se t.
q. M an ually o pe rate va lve tow ar d clo se d irect ion u nti l s w itch es r es et.
r. O pen v alv e and e nsu re O P E N sw itc hes actu ate.
s. G o to S tep 2 0 .3 .9 .
6. IF sw itch m ec han ism is o ld t ype (clu tch nu t d esi gn) an d valv e is clo ckw is e t o
o pen, th en refe r to F ig ure 20 .3- 1 and pe rfo rm fo llow ing :
a. T ur n han dw h eel cloc kw is e u n til v alv e is at b ack s eat p os it ion o r op en s top .
b. R ot ate s crew ed s haf t ( 15 ) co un terclo ckw is e unt il tr avelin g nut (1 6) com es
har d a gai ns t it s b ac ks to p ( 19 ) .
c. U s in g ov er trav el g ui de (2 0) fo r leve rag e, con tin ue tur nin g sc rew ed s haf t ( 15 )
co un ter cloc kw is e un til ov er tr avel g uid e ( 20 ) co m es u p ag ains t up pe r ov err un
s to p ( no t s h ow n ). D ur in g th is fi na l m o vem en t, e ns u re O P E N s w it ch es
a ct u at e.
20-4
d. W h il e h ol di ng o ve r tr a ve l gu i de ( 2 0) ag ai ns t or at it s s to p ( 2 1) , t ig h ten clu t ch
n u t ( 22 ) fi rm ly .
e . R el eas e o ve r tr av el g u id e ( 2 0) . E ns u r e s w itc he s d o n o t res e t.
f . M an u ally op er ate v alv e ha nd w he el co un ter clo ck w is e tow a rd t he cl os e d
d ire ctio n u n til s w itch es re se t.
g . O pe n v alv e an d en su re O P E N sw i tch es ac tu ate .
h . M anu ally oper ate v alve t o clo sed p os ition .
i . P u ll ov er tr ave l g ui de (2 0 ) clo ckw is e u nti l it co m es ov er it s r oll p in ov er ru n
s to p ( 21 ) . D u r i ng t h is f i n al m o v em e n t, en s u r e C L O S E s w it ch e s ac tu a te .
j. W h ile h o ld in g o v er trav e l g u ide (2 0 ) a g ain st its u p p er o ve rru n sto p , sc rew
l o ck n ut ( 1 7 ) d o w n s cr ew e d s h a ft (1 5 ) u n ti l it c o m e s h a rd ag a in s t tr a ve li ng
n u t (1 6 ).
k . M o ve spacer ( 24 ) and lo ckn ut (1 8) do w n to lock nu t ( 17 ). T ig hten lo ckn ut (1 8)
f irm ly .
l . R ele as e o ver tr av el gu id e ( 20 ) . E n s ur e s w itc he s d id no t re s et.
m . M an u al ly op e r ate v alv e t o w ar d o pe n d i re ct io n u nt il s w it ch es r e s et .
n . C l os e v alv e an d en sur e C L O S E sw itch es act ua te.
o . G o to S te p 2 0 .3 .9 .
7 . IF s w itc h m e ch ani s m is n ew ty pe ( lim it s w itc h s h aft l oc k nu t d es ig n) a nd th e
v a lv e is c lo ck w is e to c lo se, re fer to Fig u re 2 0. 3-2 a n d, th en p er for m the fo llow in g:
a. L oos en lo ckn ut ( 9) an d open s w itch s top n ut ( 7) . S cr ew b oth aw ay fr om inne r
trav eler (4) .
N O TE : F ollow in g steps ar e fo r clockw ise to clos e valves only. IF va lve

tra vels tow ar d o pen, go to Step 2 0.3.8 .
b . E n gage han dw heel and tur n h and w heel clock w is e u ntil valv e is fu lly clos ed.
c . M an u ally op er ate v alv e to w ar d o pen di rec tio n u nt il lim it s w itc h s ha ft ( 6)
m a kes 1 to 1/ 2 tu rn s .
d. L o os en b oth lim i t s w itch s haf t lo ck nu ts (1 ). S cre w bo th loc kn uts ( 1) to en d of
sh aft (6) .
e . P u ll o ut er sc rew ed s pi nd le ( 2) f or w a rd (t ow ard l im it sw it ch sh af t lo ckn ut s) as
need ed to dis eng age sc rew ed sp ind le f rom lim it sw itch s ha ft r oll pin (3 ).
f . R ot ate o ute r s cr ew ed s pin dle (2 ) cou nt erclo ckw is e un til inn er trav eler ( 4)
sto ps ag ain s t its b ack sto p.
C A U TI O N : F ailur e to cor r ectly en gag e s crew ed sp indle and lim it

s w itch s h aft r ol l pin m ay res ul t in actu ator o r valve da m a ge.
g. R o tate, as ne ces s ary , ou ter s cr ew ed s p ind le (2 ) to alig n an d eng ag e l im it

s w i tch s h aft r oll pin w ith clos es t s lot on ou ter scr ew ed sp ind le (2 ).
h . T i gh ten b o th lim it s w i tch s h af t lo ck nu ts (1 ).
i. T u rn act ua to r h an d w h eel u n til v alv e is f ul ly c lo s ed . (a dd - on - pa k an d s w i tch
m echanis m w ill s lip ).
20-5
j. E n sur e cl os e sw i tch es ac tu ate a nd ov er tr av el g ui de ( 1 0) is ha rd ag ain s t clo s e

up p er o ve rr u n.
k. U s in g a s c rew d r ive r fo r lev er ag e, ro tat e ( s lip ) o ver tr av el gu id e b ar d o w n to a
p os ition ov er r oll pin ov erru n sto p ( 21 ) ( sam e po sit ion as F igur e 2 0.3 -1) .
N O T E : F or valves s et to lim it clo se, s et over tra vel gu ide to actua te

s w i tch m ech an is m s w itch es jus t pr ior to n eeded va lve m o tor cu toff
l. M a nu all y o per at e v al ve to fu ll o pen po siti on (b ack seat ed ). E nsu re a dd -o n -

pak ro ll pin o r f lag does n ot hit A O P I o pen s top .
N O TE : I f va lve tra vel is 10 h an dw heel turn s or le ss us e o ver roll

p in s top ins tead of aga ins t up per over r un sto p.
m . Pu ll ove r tr avel gu ide (1 0) clo ckw is e u ntil it com es hard ag ain st up per
over ru n s top (n ot sh ow n) and ho ld.
n . T ig h ten o pen sw it ch sto p nu t (7 ) fir m l y aga ins t in ne r trav ele r (4 ) T H E N
release ov er tr avel g uid e.
o . M ov e w as he r (8 ) an d loc kn ut ( 9) ag ain s t o p en s w itch s to p n ut ( 7) . T ig hte n
lo c k nu t (9 ) f irm ly .
p . C los e valv e appr oxim ately 5 % o f trav el.
q . O p en v al ve. E n su r e O P E N sw i tch es actu at e p r ior to o ve rtr av el g ui de ( 10 )
reach ing up per ov erru n sto p (no t sho w n).
r . G o to Ste p 2 0.3.9 .
8. I F s w it ch m ech an is m is n ew t yp e ( lim it sw i tch s ha ft lo ck nu t des i gn ) and valv e is
clo ckw ise to o pen , th en r efer to F igu re 2 0.3 -2 and perf orm follo w ing:
a. T urn h an dw he el c lock w is e u nti l v alve is a t b ack sea t p os itio n or o pe n s to p.
b . M an ual ly o per ate va lve to w ar d clo s e d ir ectio n u ntil li m it s w itch s h aft m a kes
1 to 1 /2 tur ns .
c. L oo sen b ot h lim it s w itch s haf t l ock nu ts ( 1) . Sc rew bo th lock nu ts ( 1) to e nd o f
sh af t.
d . P u ll o uter s crew ed s pin dle (2) f orw ar d (tow ar d lim it s w itch s haf t lo ckn uts ) (1)
as need ed to d is eng age s cr ew ed s pin dle (2) f rom lim it s w itch s haft ro ll pi n ( 3).
e. R otat e o uter s cr ew ed s pin dle (2 ) cou nte rclo ckw is e un til i nn er trav eler (4 )
s t op s a ga ins t i ts b ac ks to p .
C A U TI O N : F ailur e to co rr ectly enga ge scr ew e d s pin dle and lim it s w itch

s ha ft r oll pin m ay r es ult in a ctuato r or va lve d am age .
f. R ota te, a s n e ce ss ary , o ute r s cre w ed s p ind le (2 ), to alig n a n d en g ag e lim it

s w itch s haft ro ll pin (3 ) w ith clos es t s lot on ou ter s crew ed s pind le (2 ).
20-6
g . T ig h ten bo th lim it s w itc h s h af t lo ckn u ts .

h . O p en va lv e. E n su re O P E N sw it ch es ac tu at e an d o v er t ra v el g ui d e is ov e r r ol l
pin o ve rr un s to p (21 ) (s am e as in F igu re 20 .3 -1 ).
i. M an ually op erate v alve to clo sed po sitio n.
j. P ul l o ve r tra vel gu id e ( 1 0) clo ck w is e u n til it c om e s o ver r ol l p in o ver ru n s to p
( n ot s h ow n ) a nd h o ld .
N O T E : O pen s w itch s top nu t ( 7) s erves as clo se s w itch s top nu t o n

c lo c k w ise to o p e n a ctu a to rs .
k . T ig h ten o pen sw it ch stop nu t ( 7) f ir m ly ag ain s t inn er tr av eler ( 4) , T H E N

r elease ov er tr avel g uid e (1 0).
l . M o ve w as h er (8 ) an d lo ck nu t ( 9 ) aga ins t o pen s w it ch s to p nu t (7 ). T igh ten
locknu t ( 9) firm ly.
m . O pen valv e app rox im ately 5 % o f trav el.
n . F u lly c lo se v alv e. E ns u re C L O S E s w itch es actu at e a nd o v er tr av el gu id e i s
o ver roll pin over run s top (no t s how n) .
o . G o to Step 20 .3.9.
9 . E n s u r e t ha t n o t o rq u e s w i tc h a dj u s tm en ts w e r e m a d e un l es s d ir e cte d b y
E ng in ee rin g o r a pp ro r iat e w or k o rd er .
20.4 Add-on-pak Setup
N O T E : A d d- on -p ak s w it ches m as t be s et u p an d ver ifi ed an ytim e cha ng es a r e

m a de to pr im ar y s w itch s etup or ad d-o n- pak.
1. IF n um b er of d riv e g ear clus ter s ar e N O T K N O W N to b e co rr ect, th en go to S tep

20.4.3.
2. IF nu m ber o f dr ive g ear clus te rs ar e K N O W N to be co rre ct, the n go to S tep
20.4.7.
3. S elect co rrect num b er o f g ear clu s ters /sp acers as fo llow s:
a . E ns ur e v alve is in full clos e o r full op en pos itio n.
b. W H IL E o pe rat ing v alv e fr om o ne en d of tr av el to ot her e nd o f tr ave l, cou n t
tu rn s o f lim it s w it ch s ha ft.
c. R ev iew F ig ur e 20 .4 .1 , th en us e T ab le 20 .4 -1 t o det erm i ne nu m b er o f gear
cl us te rs an d sp acer s req u ir ed.
20-7
T a b le 2 0 .4 -la
P o s t-1 9 78 N A T A D D -O N -P A K I G e ar S e le ction C h a rt
( F o rg e d M e ta l G e ar s)
A C TU A TO R LIM IT M IN / M AX LIM IT SW ITC H SH AFT TU R N S

M O D EL S W IT C H C EN T E R D U R IN G FU LL VAL VE STR O KE
R A TIO C O LU M N
TURNS
7N A 1 25 : 8 1 .1 5 / 80 0 .36 8 0 . 75 2 1.5 3 6 3 .1 2 6.24 1 2 .8

11 NA 1 to to to to to to
14 NA 1 0.752 1 .52 3 .0 7 2 6.24 1 2 .6 4 2 5 .6
16 NA 1
30 N A 1 5 :1 1.8 75 / 127 0 .3 7 5 0 .76 1 .5 4 3.1 6 .3 1 2.8

40 N A 1 to to to to to to
70 N A 1 0.7 5 1.5 2 3 .1 6 .2 12.6 25 .4
90 N A 1
N o te 2 1 1 1 1 1 1
N u m b e r o f G e a rs N o te 3 0 2 4 6 8 10
an d S p a ce rs N o te 4 5 4 3 2 1 0
NOTE: 1 F la t S la s h e r N 4 0 0 4 9 is u s e d w i th fo r g e d m et a l g e a r s O N L Y . P la c e w as he r o n o ut e r m o s t g e a r to p r e v e n t s lip p a g e
a lo n g s h a ft.
2 S N 2 1 3 3 9 -48 /3 7 te et h s p u r g e a r c l a s te r .
3 S N 2 1 33 7 - 37 / 2 6 t e e th s p u r g e a r c lu s t e r .
4 S N 2 1 3 3 8 d r iv e s p a c er .
5 L im it S w i tc h R a tio is r a tio o f n u m b e r o f c e n te r c o lu m n tu r n s to n u m b e r o f lim i t s w itc h s h a ft tu r n s .
6 S p e c ia l le a ds c r e w fo r s w it c h m e c h an is m a v a ila b le f o r a p p lic a tio n s w he r e m a w c e n te r c ol u m n tu r n s e x c e e d s ta n d a r d v a lu e s .
20-8
T a b le 2 0 .4 - lb
P re -1 9 7 8 N A T , N A 2 a n d c o m m e rc ia l A D D -O N -P A K I G e a r S e le c tio n C h a rt
(P la s tic a n d M a c h i n e d B r a s s G e a rs )
AC TU AT O R LIM IT M IN / M AX LIM IT SW ITC H SH AFT TU R N S

M O D EL S W IT C H C E N T ER D U R IN G FU LL VALV E STR O K E
R A TIO C O LU M N
TURNS
1 .5 /8 0.5 0 .6 5 1 .2 8
L o w 2 5 :8 to to to
0 .65 1 .2 8 2 .5 6
7 /1 1 A 8/26 7 0.9 6 1.32 2 .6 4 5 .5 2 1 1.0 4 2 2 .0 8
M id 2 5 : 3 to to to to to to
1 .3 2 2 . 64 5 .52 1 1 .04 2 2 .0 8 32.04
1 3 8 /4 0 0 1 1.0 4 2 2 .0 8
H ig h 2 5 : 2 to to
2 2 .0 8 32
6 .2 5 / 1 0 0 0 .5 0 .6 5 1 .2 8 2 .56
Lo w 2 5:2 to to to to
0.6 5 1 .2 8 2 .6 5 8 .0
1 4 /1 6A 1 5 /4 8 0 0.9 9 1.33 2 .66 5 .4 9 1 0 .9 9 2 1 .9 9
M id 1 5 :1 to to to to to to
1 .3 3 2 .6 6 5 .4 6 10 .99 21.99 31 . 9 9
27 5/800 1 0 .9 6 22
H ig h 2 5 : 1 to to
22 32
2 /2 0 0 .4 0 .7 1 .3 2 .7
L o w 5 :1 to to to to
0 .7 1 .3 2 .7 4
3 0 /4 0 A 2 0 /64 0 1 1 .3 2 2.6 5 5.5 11 22
1 .3 2 2 .6 5 5 .5 11 22 32
55 0/80 0 22
H igh 25:1 to
32
2 /2 5 0 .4 0.7 1 .4 2.8
Lo w 5 :1 to to to to
0 .7 1.4 2.8 5
7 0 /9 O A R 2 5/8 00 1 1 .4 4 2 .88 5 .8 4 1 1 .6 2 3 .4
1 .4 4 2 .8 8 5 .8 4 1 1 .6 1 5.4 32
2 5 /1 0 0 0 0 .7 5 1 .4 3 2 .8 4 5 .8 4 1 1 .6 2 3 .3 9
H ig h 3 3 : 1 to to to to to to
1 .4 3 2 .8 4 5 .8 4 1 1 .6 23.39 3 0 .3
No te 2 1 1 1 1 1 1 1
N u m b e r o f G e a rs N o te 3 0 2 4 6 8 10 12
a n d S p a ce rs N o te 4 6 5 4 3 2 1 0
NOT E: 1. F la t W a s h e r N 4 0 0 4 9 i s u s e d w i th fo r g e d m e ta l g e a r s O N L Y .
2. S 0 9 8 5 4 - 4 8 / 3 7 t e e th s p u r g e s c lu s t er .
3. 5 0 9 8 5 5 - 3 7 /2 6 t e e th s p u r g e a r c l u s te r .
4. S0 98 57 - N u m b er of d ri ve sp ace r.
5. P o te n ti o m e te r g e a r s e le c ti o n is b a s e d o n A O P la b e l s e c to r . R e fe r t o p u b . "A E 5 /3 .
6. (M i d ) L im i t s w itc h r a ti o is u s e d in a lm o s t a ll a p p l ic a ti o n s .
7. L im i t S w i tc h R a tio i s r a t io o f n u m b e r o f c e n t e r c o lu m n tu r n s to n u m b e r o f l im i t s w i tc h s h a ft tu r n s .
8. S p e c ia l le a d s c r e w fo r s w itc h m e c h a n is m a v a ila b le fo r a p p lic a ti o n s w h e r e m a x c e n te r c o lu m n tu r n s e x c e e d s ta n d a r d v a lu e s .
20-9
d . F o llow in g com p letio n of th is s tep go to S tep 2 0.4 .7 . IF n um ber of g ear

clu s ter s is N O T co r rec t, go t o S tep 2 0.4.4 an d 2 0.4.5 as a pp lica ble . IF
nu m b er of g ear c lus ter s i s co rr ect, th en g o to S tep 2 0.4 .6 an d 20 .4.7, as
applicable.
4 . R eview Fi gur es 2 1-7 th ro ug h 2 1- 12 , an d per for m t he f ollo w ing as n eces s ary fo r
add -on -pak rem oval:
a. R em ove type "A " o r "N A " (old vers io n) add-on-p ak as follow s (refer to F ig ure
21 -8 ):
• L o o s en t hr e e A l le n s c r ew s ( 3 2 0 )
• S l id e ad d -o n - pa k o f f m o u n tin g pi lla rs ( 3 21 )
b. R em ove ty pe "N A " ( new versio n) add -on-p ak as follow s (refer to Figu re 21- 9:
• R em ov e cap s c rew s (3 1 2) f r om s w itc h ho ld in g p lates ( 31 3)
• R e m o v e s w itch ho ld in g p la tes ( 31 3 ), s pr in g s ( 3 10 ) , an d w as h er s (3 0 9)
• M ov e sw itch ba nk s t o sid e fo r acc ess t o soc ke t cap scr ew s
• R e m ov e s oc ke t c ap s cr ew s (3 15 ) f ro m m o un tin g p ill ars ( 33 0)
• S lid e ad d -o n -p ak of f m o u nt in g p ill ar s
5. In stal l co rrec t nu m be r o f gear clu ster s /sp acer s as fo llow s :
a. L o o s en s et s cr ew in l oc kin g p lat e. S ee F ig u re 2 0.4 -1 b el ow .
F i g u r e 2 0 .4 - 1
A d d -on -p a k T y pica l A O P I G e ar Sp a ce r A rra n gm e n t
20-10
b. R e m ov e lo cki ng pla te, dr ive adap ter and sp acers.

c. R em ov e g ear cl us ters if nec ess ary .
d. O bt ain cor rect n um b er of g ear clus te rs /s pace rs n eed ed.
e. A ssem bl e g ear clu s ter s, sp acer s, dr ive ad apt er and l ock ing p lat e o n add -o n-
pak as sem bly.
f. S ecu r e com po n en ts t og et he r by tig ht en in g set scr ew in l ock in g p lat e.
6. R ev iew F ig ur es 21 -7 th ro ug h 21 -1 2, and p erf or m f oll ow ing as nece ss ar y fo r a dd-
on - pa k in s tall ati on :
a. Ins tall type "A " or "N A " (old vers ion, P re-19 78") ad d-on -pak as follow s (refer
to Figu re 21- 8):
• A lign ad d- on -p ak w it h m oun tin g p illar s (3 21 )
• I F ne ces s a ry , r o tate d r iv e ad ap ter to en g ag e w ith lim it s w it ch s h af t ro ll
p in
• S l id e a dd - on -p ak on to p il lar s ( 32 1 )
• T igh ten A llen s crew s ( 32 0) to s ecur e ad d- on -p ak in place
b . Ins tall type "N A " (n ew v ersio n, "P os t-19 78") add- on-p ak as follo w s (r ef er to
F igure 21-9) :
• A lig n add -o n -p ak w ith m o un tin g pill ars (3 30 )
• I F n ec es s a ry , ro ta te d r iv e ad ap te r to en g ag e w it h l im i t s w it ch s ha ft ro ll
p in
• S lide add-on-pak onto m ounting pillars and s ecure by ins talling w ashers
(31 6) and so ck et cap scr ew s (31 5)
• E ns ure alig nm en t o f sw itch b an ks is co rrect (s w itch pak s hafts ins erted
into holes o f add -on -pak back plate) (no t sh ow n)
• Install, s pring s (310) and s w itch ho lding plates (313) on s w itch pak s haf ts
an d s ecu r e w ith w a s her s (3 0 9) a nd c ap s cr ew s ( 31 2)
C A U TI O N : F ailu r e to pr op er ly a djus t add -o n-p ak po sitio n flag s

m a y r e su lt in va lve/a ctu at or d am a ge .
7. A djus t pos ition flag s as follow s :

a. P os ition v alve appr oxim ately 5% off of its clo se seat.
b. G rasp a nd h ol d clu tch g ear f ir m ly to pr eve nt str ess o n ge ar clu s ter s .
c . R ota te an d po s ition b ack b ras s f lag jus t s ho rt of co ntact w ith its clos e s top ,
t hen r elea se clu tch g ear . S ee Fi gu re 20 .4- 2.
N O T E : F or n ew s tyle a dd -o n-p ak (P o s t-1 978 ), u se r oll pin in ste ad of

b ack b ras s flag.
20-11
F i g u r e 2 0 .4 - 2
S w itc h M ec h a n ism P o s itio n F la g s
d. O perate valve to its fu lly clos ed pos ition .

e. E nsur e b ack br ass fla g i s < 1/1 6" fr om its clo s e sto p as val ve reach es f ully
clo sed .
f . R epe at St eps (a) thr ou gh (e) f or f in e tu n ing , in cre as ing o r d ecre as ing
distanc es in S teps ( a) or (c) as n ecessary.
g. L oo s en alien scre w w hich secu res back an d fr ont fl ang es to geth er.
h. O p erate v alve to its f ully op en p os ition .
i. M ove fron t flag to < 1 /16" from open s top, tighten alien s crew .
8. R evi ew F igu re 20 .4 -3 , a nd per fo rm fo llow in g to adju s t ad d- on -p ak sw itc hes :
20-12
F i g u r e 2 0 .4 - 3
F r o n t V i e w o f S w i t c h M e c h a n i s m S w i t c h e s a n d A d d - o n - p a k W i r in g
N O T E : A d d- on -p ak s w i tch s etti ng is ent ir ely ind ep end en t o f sw itc h

m ech anis m a nd m a y be set to a ctuate at a ny p os ition of valve tr avel.
N O T E : To r que B ypa s s con tacts p r ovid e a lim it a ctua ted sw itch in pa ra llel
w ith T o rq ue Sw itch to " byp as s " To r qu e S w itch a nd en s ur e a ctua tor w ill
not torq ue o ut w hile tr ying to u ns eat valve.
20-13
a . R ev iew m an u fa ctu re r's in fo rm ati on and ap pr op r iat e e lec tri cal el em e nt ary to
id en tify d es ire d fu nctio n of a ll ad d- on -p ak s w itch es an d to de term ine if an
ad d -o n- pa k s w itch co n tact is u s ed f or i ncr eas ed t or qu e by pa ss fu n ctio n.
b. If ad d- o n- pak sw it ch co nt acts are to a ctua te as v alv e r eac hes op en an d /or
clos e end of tr avel, then perfo rm fo llo w ing :
• M e a s u r e to t al v a lv e t ra v e l. R e c o r d m e as u r em e n t
• C al cu la te 5% an d 1 5% o f t o ta l v alv e tr av el fr o m p r ev i ou s m eas ur e m e nt
c. C h ang e v alve po s itio n ( tow ar d op en and to w ard clo s e), as n ecessary , to
o b s er ve a nd un d er s tan d c or re lat io n o f ca m s to s t ri ke r p late s i n ei th er
d irection of travel.
N O T E :A d d- on -p ak s w itc hes t ha t a re in tend ed to ac tua te a s va lue

r each es clo se en d o f tra vel, SH A L L be a djus ted to actua te w ithin 10%
( ± 5% of to ta l salve tr avel) A F T E R clos e p rim ar y sw itch m echan ism
clos e lim it s w itches res et. V alve is traveling from clos e to op en.
N O T E : A d jus tm en t of clo s e a dd -o n- pa ck s w itc hes m us t be m ad e s u ch

tha t as va lve tra vels fro m open to clos e, ad d-o n-p ack a djustm ent ca m
tr avels fro m a p os ition on U P P E R s ide o f sw itch p ack to s w itch
actua tion point.
d . A dju st clo se dir ectio n sw itch es as fol low s :

• O pen valv e f rom fu lly clos ed po s ition . S et trip po s ition of clo se dir ection
add -o n- pak sw itch es at 10 % ± 5% af ter clos e lim it sw it ches reset
• L o os en clu tch n u t
• M o ni tor co n tacts w ith a V O M an d ro tat e ap p ro pr iate cam (s ) u ntil sw itc h
co n ta ct s a ct ua te
• T i gh te n cl u tch nu t to 10 to 12 in ch l bs . D o N O T ov er tig h ten
N O T E : A d d- on -p ak sw itch es t ha t a r e in ten ded to a ctu ate as valv e

r eaches op en end of tr avel, S H A L L be ad justed to actu ate at 1 0% ( ±
5 % ) after res et of p rim ar y s w itch m echan ism op en lim it sw itches.
E X A M P L E : I f to ta l v al ve t ra ve l is t en ( 1 0) ha nd w h eel tu r ns th en op en
di rec tio n add - on -p ak s w itc hes s ho uld be s et to act uat e b etw ee n ½ an d 1½
h an dw h ee l tu r ns af te r o pe n d ir ect io n p r im a ry lim it s w i tch es r es et w h en
valv e is travelin g fr om o pen to clo se d irection .
20-14
N O T E : A dj us t m en t of o pe n a dd - on - pa t s w itc he s m u s t be m a d e
s uch tha t as valve tr avels fr om clos e to open, add -on- pak
ad jus tm ent cam tr avels fr o m a po sitio n on U P P E R si de o f s w itch
pa ck to s w itch actu atio n p oin t.
5. A d just o pen d ir ection sw itches as fo llo w s :

a. IF a dd -on -p ak co ntact is u s ed fo r I ncr eased T o rq ue B y pass f un ctio n,
then perfo rm follow ing:
C A U T IO N : F a ilur e to p ro per ly a djus t and ver ify p ro per

op er atio n of th e add -on -pak co ntacts us ed for tor qu e bypa ss m ay
result in severe va lve/actu ato r da m a ge. U s e extrem e ca re w h ile
per for m ing the follow ing s teps .
• O p en v alv e to a pp r ox im a tel y m id - tr av el po s iti on

• L oo s en add -o n- pa k clut ch nu t
N O TE : B ecaus e tw o s ets of con tacts ar e w ir ed in pa ra llel,

T o rq ue S w itch conta cts m as t be O P E N to allow p os itive
con clu sion o f Tor que B ypas s con ta ct a ctua tion .
N O T E : S om e va lve ap pl ica tion s m a y us e a com p lem en ta r y

con ta ct (clos ed w hen O pen T orqu e Bypa ss co ntacts ar e o pen
and vice vers a) off s am e r otor to p rovide a C los ed Tor que
B ypa s s fu n ctio n. I f t his is t he ca se , ad jus t m e nt of O p en
To rq ue B ypa ss a ctua tion po int als o sets a ctua tion po int of
C losed To rqu e B yp ass con ta ct. H o w ever, co rr ect sw itch
co ntact s tatus M U ST s till be verified for each.
• Id en tify T orq ue Sw itc h (O T /L S ) w hich co ntrols v alv e O P E N circu it

an d act ua te (co n tact s o pe n) t his sw itch
• M oni tor iden tified O pen T o rq ue B yp as s con tacts w ith a V O M
c on n ecte d ac ro ss c on tac t t er m in als in t er m in al b un g
• W ith O p en T o rq ue S w itch con tact s o pen , slo w l y ro tate ap pr op r iate
cam u nti l id en tifi ed O pe n T or qu e B y pass con tact s actu ate ( op ens )
• T ig hten clu tch n ut to 1 0 to 1 2 in ch lb s. D O N O T ov er tig ht en
b. I F add -o n-p ak con tact is N O T u sed f or In crea sed T o rq ue B y pass
fu nctio n O R h as oth er o pen dir ection s w itches , then pe rfo rm follo w ing:
20-15
• C los e valv e to a des ired tr ip po sit ion of o pen di rectio n sw itch es at

10% ± 5% af ter op en li m it s w itche s res et
• L oo s en clu tch nu t
• M o n ito r co n tact s w i th a V O M an d r ota te ap pr o pr ia te cam u n til
s w it ch c on ta cts act ua te
• T ig hten cl utch n ut to 10 to 12 in ch lbs . D O N O T o ver tig ht en
6. V erif y pr oper actuation of all add- on-p ak s w itch es as follow s :
a. C o nn ec t a V O M to ap p ro pr iat e t erm in als in te rm i na l b u ng f or any
open d irection ad d-o n- pak con tact be ing us ed.
b . F ro m a s uit abl e v alv e tr ave l p o s itio n, m an ua lly o pe rat e v alv e op en .
V erify ad d-o n-p ak contact dev elopm en t f or open end o f tr avel
co rr es pon ds w ith elem e ntar y sw it ch lege nd A N D actu atio n occu rs
b etw ee n 5 an d 1 5% to tal v alv e tra ve l t o pr im ary s w itch m ech an is m
op en lim it sw itches .
c. IF ad d- on -p ak con tact ser ves f or to rqu e b yp ass in clos e circu it p erf or m
foll ow ing :
• T hen T orq ue S w itch (C T /L S) w hich co ntro ls v alve C L O S E cir cuit
an d a ctu at e ( co n tac ts op en ) th is sw it ch
• M o nito r id entif ied C lo se T or que B y pas s con tacts w ith a V O M
co n ne cted acr oss co n tact t erm in als in t erm in al b un g
• W it h C lo s e T or qu e S w itch co n tacts op en , m an ual ly op er ate va lve
to w ar d clos e
• V erif y iden tified C los e T or que B y pas s co nta cts actu ate ( op ens ) at
appr oxim ately m id- travel po sition
d. I F add -o n-p ak con tact ser ves for T o rq ue B y pass in o pen cir cuit,
pe rfo r m fo llo w ing :
• Id en tify T orq ue S w itch ( O T /L S ) w h ich con trols v alve O P E N circuit
and actu ate ( con tac ts o p en) thi s s w itc h
• M o nit or iden tif ied O p en T o rqu e B yp ass co ntacts w i th a V O M
co n ne cte d acr o ss co n tac t ter m in al s m t erm in al b un g
• W it h O pe n T o r qu e S w it ch co n ta ct s op e n a nd v al v e tr a ve l in a
s u ita bl e po s it io n, m an u all y o pe ra te v alv e to w ar d o pe n. V er if y
id en tif ie d O p en T or q ue B y p ass co nt act s a ctu at e (o p en s ) at
ap pr o xim atel y m id -tr av el po sitio n .
C A U TI O N : F ailur e to verify cor rect conta ct actu ation m ay

re su lt in val ve/a ctua to r da m ag e.
20-16
N O T E : A ct ua t ors w ith V N O de sig n sw it ch m e ch an i s m s a n d

w hich re ceive an " auto m atic m a intai ned" s ign al ( e.g ., SSP S,
E S F , A S P T r a ns fer Sig na l), u s e a dd -o n- pa k con tac ts w ir ed
in s er ies w ith a uto m a tic m ain tain ed s ign al to pr eve nt
ha m m ering as valve reaches clo se end of tr avel. F a ilu re to
identify A N D ver ify co rr ect a ctu ation of thes e contacts as
va lve r eaches clos e end of tr avel M A Y r esu lt in
va lve /a ct ua t or d a m ag e. U S E C A R E w h e n p er f or m i n g n ext
step .
e. C o nn ect a V O M to a pp ro p ri ate te rm i na ls i n te rm i na l bu ng fo r an y
clos e d irection add -on -pak con tact bein g u sed .
f. M anu ally o perate v alve f ully clos ed.
g. V erif y add- on -pa k co ntact dev elop m ent for clo se end of tr avel
cor res p on ds w it h elem en tar y s w itc h legen d A N D actu atio n occ urs
betw ee n 5% an d 15 % of to tal va lve tra vel P R I O R to pr im ar y s w itch
m echanis m clos e lim it s w itches .
20.5 Electrical Startup
C A U T I O N : E l ectrica lly ba cksea ting t he val ve m a y c au se d am a ge. O p en

sw itches sho uld be set to pr event the va lve fr om con tacting ba cksea t du rin g
co astdow n.
1 . I F c on tr ol ci rc uit w a s al ter ed an d h as N O T bee n re s to red , th en res t or e

alte ratio n s a t th is tim e .
2 . S et O P E N and C L O S E T or qu e/L im i t S ele ctor s p er s tatio n sp ecif ied s etti ng s.
R efer to F igu re 2 0.4 -4 for s elector identif ication.
3 . E ns u re o il level is w ithin 1" of bott om o f u pp erm os t f ill p lug. A dd oil, typ e
S p ar tan E P 1 50 or C astr ol N u cleo l 52 8, a s n ecessar y.
4 . M anu ally o pe rate v alve to ap pr ox im at ely m id tr av el p osit ion .
C A U T I O N : F a ilur e to fo llo w s te p 20 .5 .5 an d 2 0.5.8 can r es ul t in s e ver e

eq u ip m en t d am ag e.
5 . S elect one of th e fo llow in g m ethod s to pr otect actuato r/v alve in c ase m oto r
r ot ati on i s r ev ers e d.
M e t h o d 1 : R e qu es t op er at or to s tan d b y , p r ep ar ed to o p en M C C b re ak er , o r
allo w t ech nic ian to o pe n M C C b re ake r in cas e act uato r m o to r ro tati on is
rev ers ed .
20-17
F ig u re 2 0 .4 -4
P rim a r y S w itc h M ec h a n ism S e lec to r
M e th o d 2 : Id en tif y to rq u e s w i tch w h ich c on tr ol s v alv e C L O S E c irc uit an d b e

p re p ar ed t o ac tu ate t h is s w itc h in ca s e act ua to r m ot or ro ta tio n is re ve rs e d.
M e t h o d 3 : B e p re p ar ed to e n ga ge an d h o ld h a nd w h ee l o pe ra ti on le ve r u n til
pow er can be rem ov ed fr om m otor.
6. R em ove lo ck fr om feeder breaker.
7. N o tif y app r op ria te O p er atio ns O rg an izati on an d clo s e fee der b re ake r fo r tes tin g .
8. M on ito r v alv e tr av el an d h av e O per at ion s star t actu at or in C L O S E d ire cti on .
IF valve star ts O P EN , T H E N im m ediately im plem ent M ethod 1 , 2 or 3 as
selected in Step 20.5 .5. IF valve s tarts C L O S E , allow valv e to com plete its
tra ve l.
9. IF v alv e m ov em ent w as incor rect, p erfor m fo llow in g:
a. E nsur e 3 p hase po w er is pr op erl y i so lated ( feed er br eak er in op en po si tion ).
b . R ever se tw o ou tsi de m oto r l eads ( T 1 and T 3 ) o n load s id e of m o tor s tar ter.
T ig ht en lea d s a n d d o cu m e nt t o rq u e v al ue p e r ap p r op r ia te m an u fa ctu r er 's
info rm ati on.
20-18
C A U T IO N : R epeated cycling of the actuator can caus e excessive hea t

and r esu lt in m oto r dam ag e. A llow m otor to co ol w hen it b ecom es ho t.
N O T E : To m in im ize cyclin g of sa lve, r eview all act ivities to b e

perfo rm ed in Step 20 .5.1 0 a nd cons olida te for each end of tr avel.
10. H av e O p eratio ns cycle valve an d perf orm f ollow in g:

a. W he n v alv e r eaches clos e end o f t rav el, ensur e cl os e d irec tion au xilia ry lim it
s w itch es ac tuate .
b. W hen v alv e r each es o pen e nd o f trav el, en sur e o pe n dir ectio n au xili ary li m it
s w itch es actu ate.
c. W he n v alv e r eache s op en end o f trav el, ensu re valv e is N O T bac kseated .
d. W h en valv e r eaches ope n an d clos ed en d of trav el, ensu re e ach add -on -p ak
sw i tch us e d co n fo r m s w ith pr o pe r ele m en ta ry co nt act d ev el op m e nt . IF an
a dd -o n- pak s w itch c on tact is b eing u s ed fo r to rq ue by pas s , th en s peci al
a tten tio n s ho u ld b e g iv en to e ns u re co rr ect s etu p .
e. IF va lve h as a tim e r es p on s e re qu ir em e nt an d w i ll N O T be M O V tes te d, t he n
m o ni to r va lve s tr o ke ti m e an d en s ur e fu ll tr ave l is w i thi n re qu ir ed ti m e lim it.
D ocu m en t s tr ok e tim e.
N O T E : C lutc h sl ipp ag e o ccu r s if ad d- on -p ak ca m s h aft s top s tu r nin g

PR I O R to valve reachin g end of tr avel.
1 1. W hen valv e reaches each end of travel, inspect ad d-o n-p ak clu tch fo r slipp age.
12 . IF clu tch s lipp age is N O T p res ent, th en go to S tep 20 .5.11 .

I F clutch s lippag e is pr esen t, it is due to o ne o f th e fo llow ing :
a . Po s itio n fla gs i m pr op er ly adj us ted . R e fer to S te p 20 .4 .6 .
b . A dd -o n- pak im p ro per ly g ear ed, cau sin g po sit ion fla gs to m o ve ou t o f
p r op o rt io n w it h v alv e tr av el. R e fe r to S t ep 2 0 .4 .2.
c . A d d- on -p ak s w i tches im p rop er ly adju s ted. R efe r to St ep 20 .4 .7 .
N O T E : T h is s tep verif ies cor r ect w ir ing an d set up of T or qu e B yp as s

fun ction b y m a nu ally actu ati ng op en tor q ue s w itch co nta ct an d
electrically o penin g va lve. IF w iring and set up ar e correct, then valve
sh ould op en a nd s top at req uir ed m id- tra vel po sitio n.
20-19
N O T E : T his sec tion s ha ll b e p er for m ed for all actu ato r s w it h o pen

T or que B ypas s w ir ing m od ifica tion.
1 3. O perate v alve electrically to f ull clos e pos ition.
N O T E : F o r clockw is e to clos e valves r otatin g to rq ue s w itch fro nt p late

counter clockw ise w ill actuate open to rque s w itch contacts.
1 4 . R ot ate t or q ue sw i tch f r on t p lat e un ti l op en to rq u e sw itch co nt act s a ctu at e. H o ld

f ro nt p late in th is pos itio n as valv e is electr ically ope ned.
1 5. V erif y v alve op ens an d s to ps at torq ue by pas s po si tion s pecifi ed p er
th e ap p r op r iat e m a nu f act u re 's i nst ru c tio n s . I F N O T sp eci fi ed , v al ve o p en s an d
s tops b etw een 2 5% to 75% o f to tal valv e tr avel.
20.6 Restoration
1 . I F R e m o te P u s h bu t to n w as u s ed , t h en re m o v e o r en s u re it h as b e en re m o v ed .
2 . A l ig n m a tch m ar k s o n s w it ch c om pa rt m en t co v er ( if a pp lic ab le) , a nd ins t all
s w i tc h c o m p ar t m en t co v er .
3 . C oa t thr ead s of c ap scr ew s w ith U n ir ex N 2 a nd t or qu e cap sc re w s as fo ll ow s.
C a p S c r ew T h re a d T o r q u e ( f t .l b . )
1 0 -2 4 S A E G R 8 4 .5 to 5.5
1 /4 - 2 0 S A E G R 8 1 0 to 1 2
20-20
21.0 7/11/13 NA1 ACTUATOR
N u m be re d re fe re nc es in p ar en th es e s , ( ), co rr es p o nd to F i gu r es 21 - la th ro u g h 2 1- 1 9.
N O T E : T his p r oced ur e h as b een w r itten util izin g a m o du lar a pp ro ach to

m ain tena nce activ ities . D u e to th is ap pr oa ch, cer tai n s tep s w il l be r epea ted
w i th sp ecific m o du le m a inten an ce in m in d.
21.1 Actuator Removal From Valve
1 . E n s ur e act ua to r fe ed er b re ak er is in o p en p o si tio n .
W A R N IN G : A dditio nal circu its m a y need to b e is olated by r em oving fus es ,

lifting lead s, op ening s liding links , etc.
W A R N I N G : If the s yste m is p res s ur iz ed , th e v alve st em m ay sli p r es u lting

in s er ious inju ry to per so nnel p erfor m ing m a in tenan ce on th e actua tor .
2. G ag valv e stem as r equ ired b y secur ing v alve stem t o y ok e.

3. T o r em ov e syncro set cover (15 1), rem ove fo ur s crew s ( 188).
4. D is con nect and rem o ve field w iring f rom s yncr os et b ody ( 150 ). M ark w iring f or
re c o n n e c tio n , a s n e c e ss a ry .
5. R eplace s yncros et cover (1 51).
6. R eplace fo ur screw s (188 ).
7. T o rem ov e the lim it sw itch co ver (25 0, 251 , 25 2), rem o ve th ree caps crew s (25 7),
an d s pr ing w a sh er s ( 25 8) .
8. D is en ga ge th e p rim ary l im it s w itch a nd lo os en add -o n- p ak clu tch n ut, i f
app licab le (r efer to S ectio n 2 0 f or d etails).
9. R eplace lim it sw itch cover (2 50, 25 1, 252 ) w ith caps crew s (25 7) and sp rin g
w a sh er s (2 58 ).
C A U T IO N : W hen r igging the actua tor fo r r em o val /rep la cem ent, ca re

sho uld b e taken to avoid co nnecting to either th e han d au to lever ( 9),
ha n d w h e el h o o p (7 7), o r h a n d w h ee l sp o ke s (76 ).
1 0. In s ta ll ri gg in g a s n ece s s ar y to s up p or t th e w eig h t of th e a ctu at or an d pr ev en t

s t em d am ag e du r i n g r e m o v al .
11 . M at ch m ar k ac tu ato r as s em bl y an d v alv e y ok e to e s tab lis h o r ig in al in s tall ati on
p os it io n .
12. R em ov e t he m ou ntin g b olts or s tud n uts f ro m b elow th e v alve yo ke or g earb ox
fl a ng e .
21-1
13. R em ove actuato r fro m valve as follow s :

a . G l o be V a lv e s
- E n s ur e v al v e s te m ke y s a r e re m o v ed an d p r o pe rl y m ai nt ai ne d u n ti l th e
a ctu at or is re pl ace d/ re in s tal led .
b . G a te V a lv es
- F o r th r ead e d s h af t v al ve s te m ap p lic at io n s , r o tat e o p er ato r ha n dw he el
t ow a rd c lo s ed d ir ect ion un ti l t he a ctu ato r u ns c re w s f ro m th e v alv e s tem .
c . Q u a rte r T u rn V a lv e s
- F o r k e ye d s h af t ap pl ic ati on s , e ns u r e th e ac tu ato r i s p u ll ed s t ra ig ht o f f o f
t he va lve stem o r gear b ox sp lin e sh aft to av o id va lve stem d am ag e.
14 . T r an s po r t act ua to r to pr o pe r ar ea f o r s to r ag e an d/ or re pa ir .
21.2 Actuator Disassembly
21.2.1 Motor Assembly Removal and Inspection
W A R N IN G : If the a c tu ator ha s n ot b e e n r e m ov e d fro m the v a lv e p rior to

m o to r as s e m b ly r em ov al , en s u r e a ct ua to r fe ed er br e a ker is in o pe n p o s iti on .
A d dition al c irc u its m a y a ls o ne e d to b e iso la te d b y re m o v ing fu se s , lifting
lead s , o pen ing slid ing lin ks, etc.
1 . C heck m oto r w in dings (6 7) fo r dam age as fo llo w s :

a . U s i ng a d ig i tal m u lt i- m e te r, m e asu r e w i nd i ng r esi stan c e b etw een ea ch
p ha s e. N o w in d in g re s is t an ce s h ou l d r ea d o p en an d t h e r es i s ta nc e v al ue s
s ho uld b e a pp ro xim a tely b alanc ed.
b . U s in g a m e gg ar ( 1 00 0 v ol t scale ), m easu r e t he r esist an ce be tw ee n on e m o to r
w in d in g to th e m o to r h o us i ng . T he r es i s tan ce v al ue s h o ul d b e ≥ 1 .5
m egohm s .
c. I f r es is t an ce v alu es v ar y f ro m r es u lt s i nd ic ate d ab o v e, c on ta ct th e
ap p r op r ia te en g in e er in g r ep r es e nt at iv e o r a R o to r k r ep r es e nt at iv e.
2. D rain o il from gearcase ( 1) b y rem o ving lo w er plug (8).
3 . P lac e the a ctu ato r in th e h an d o pe ra tio n m o d e b y d ep re s s in g ha nd aut o le ver (9 )
t o th e m a nu al m od e.
4 . I f the m o to r is h an gin g v ert ical fr o m t he actu ato r r efer t o S ectio n 2 1.2.2, S w i tch
M ech ani s m R em o va l to ensu re sw itch m e cha nis m (2 5 9, 2 61 ) and t or qu e sw it ch
s haf t (2 3, 9 0) ar e rem o v ed pr ior t o m ot or r em o val . P r oc eed to S tep 2 1 .2 .1 , St ep
5 , if th e m ot or is h or iz o nt al t o th e a ctu a to r.
C A U TIO N : Im p rop er rem oval o f the m o to r cover (58 ) from the g ea rcase (1)
cou ld r esu lt in da m a ge to oils ea ls (21 , 59 ) an d b ear in gs (1 9).
5 . R em ov e th re e c ap s cre w s ( 68 ) an d s p ri ng w as he rs (7 1 ) th at re tai n th e m ot or
cover ( 58) to the gearcase (1 ).
21-2
6 . R em o ve th e m o tor cover (5 8) slo w ly fr om the g earcase (1 ).

7 . L o ca te bu tt co n ne cto r s u nd er fib er g las s s lee vi ng a nd cu t m o to r lea ds on bo th
s id es o f b utt con nec tors .
8 . R em o v e t he m o to r cov er O - ri ng ( 69 ) an d in spe ct fo r da m ag e. R epl ace as
n ecessar y.
N O TE : If the o il s eal (21 ) is d eterm ined to need r eplacem ent, the cir clip
(52 ) a nd backu p w as her ( 59) m us t be rem o ved fir s t on P os t-19 78 m odels
on ly.
9. R ep lace oil seal ( 21 ) and n eed le b eari ng ( 19) a s req ui red b y i nd icatio ns of oi l
lea ka ge o r dam ag e.
N O TE : Sectio n 2 1.2 .1, Step 10 per tain s to P r e-1 978 actu ator s on ly.
10 . In s pec t w o rm sh af t b u sh ( 2 0) f or d am ag e an d rep lace as nec es s ary .
21.2.2 Switch Mechanism Removal and Inspection
N O T E : I f th e v alu e i s lim it op ena c los ed , then g oi ng p as t the lim its w ill

res et th e s w itch es an d th e s tr oke. Th is do es not occu r on tor qu e clos e
va lv es.
1 . P o s t - 1 9 7 8 A c tu a to r s
a. E n su re e le ctr ic al p o w er i s i s o lat ed or di sco n ne cte d.
b . V isu al ly i nsp ec t fo r p r op er m o ve m en t o f th e sw it ch m ech an is m ( 2 61 ) a s t he
v al v e is m a n ua ll y o p er at ed . If th e s w i tc h m ec ha n is m ( 2 6 1 ) s h o ul d n e ed
a dj u s tm en t re f er to S ec ti o n 2 0 .0 of th i s m a n ua l. I f d a m a g e is i n di ca te d ,
re p lac e th e s w itc h m ec h an is m (2 6 1 ) a s n e ces s ar y .
N O T E : Sec tion 2 1.2.2.1, S tep c) is no t r eq uir ed i f r ep lac ing s w itch

ba nks only.
c. D rai n o il f rom gear case (1 ) b y rem o ving lo w er p lug (8 ).

d . R em ov e th e t hr ee cap s cr e w s ( 2 6 7) an d s p r in g w a s h er s ( 2 5 8) th at r et ain th e
lim it sw itch cov er ( 26 0, 251 , 262 ) an d pull cov er s traig ht off .
e. I f th e act ua to r is to rq ue d o ut in eith er the o p en o r cl os ed po s iti on , t he to r qu e
a dj us t in g f r o nt p l ate 's po in t er w ill n o t b e v er ti cal . I n t hi s in s ta nc e, m o v e th e
21-3
h an d a ut o le ve r ( 9 ) in to th e ha n d p os i tio n t o c en ter th e to rq u e ad ju s ti ng fr o n t
p la te as ne ces sar y.
f . D isco nn ect th e sw i tch m ech an ism lead s f ro m th e sw i tch b an ks (2 62 ) o n th e
sw itch m ech an is m assem b ly ( 26 1) . M ar k w ir in g fo r r eco nn ecti on , as
nece ss ar y.
g. T o rem o ve sw itch b ank s (26 2) , scr ew loc king h ex nut (2 69) to w ards sw itch
bank (2 62).
h. M o ve s w i tch ba nk (2 62 ) to w a rd th e f ro nt pla te ( 27 0) f ar eno ug h to re leas e
the s w itc h ban k (2 6 2) f ro m s w it ch m ec han is m rea r pla te ( 27 2 ).
i. R em ov e tw o capscre w s ( 26 4) on the sw i tch m echan ism basep late ( 263 ).
C A U T IO N : U s e ca re w h en r em ovin g sw itch m echan is m (2 61) to avo id

dam age to the O -ring ( 271).
j. C are fu lly r em o ve th e s w it ch m ec han is m (2 61 ) f ro m t he ge arc as e ( 1) .

k. R em ov e th e l im it s w itch d riv e g ear as se m bly ( 26 , 2 7, 1 7) fr om the s w itch
m ech an is m s h af t ( 26 1 ) b y d ri vi ng ou t th e s p rin g p in (2 7 ) lo ca ted ne ar t he
lim i t sw it ch r ear p late (2 7 2) .
1 . R em ove the tor qu e s w itch s haf t (2 3) .
N O T E : If r epla cem en t o f oil sea l is r equ ired , cir clip (49 ) a nd ba ckup
w a sh er (50 ) m us t b e r em o ved p rio r to r epla cem en t in 21.2.2 .1 S tep m ).
m . V isuall y inspe ct o il sea l ( 21 .) fo r leak age or d am ag e. R e place as n ecessar y.

n. V is u ally in s pec t to rq ue s ha ft s hr ou d (3 6) an d ne edle b eari ng ( 18 ) fo r w e ar or
d am a ge . R ep la ce p ar ts as ne cessa ry .
2 . P re -19 78 A ctuato rs
a . E nsu re el ectr ica l p o w er is is o lated or d isco n nec ted .
b . V is ua lly in s pe ct fo r pr o per m ov em ent o f th e s w i tch m e cha ni sm ( 25 9 ) as t he
v a lv e is m a nu al ly op e ra ted . I f th e s w it ch m ec ha ni s m ( 25 9 ) s h o u ld n e ed
a d ju s tm en t r ef e r t o S e cti o n 2 0 of th is m an u al . I f d a m a ge is in d ic at ed ,
r ep la ce th e s w itc h m ec ha ni s m (2 5 9) a s n ec es s ar y.
N O T E : Sectio n 21.2.2 .2 , S tep c) is not r equir ed if r ep lacin g s w i tch

ban ks o nly.
c. D rain oil fr om gear cas e (1 ) b y rem o ving low er plug (8 ).

d . R em ov e th e th ree c ap sc re w s ( 25 7 ) an d s p ri ng w a s he rs (2 5 8) t ha t r et ain t he
lim it s w itch cover (2 50, 25 1, 25 2) and pull cov er s traig ht o ff.
e. If t he ac tu ato r is to rq u ed o ut in eith er the o p en o r clo s ed po s iti on , th e to rq u e
ad ju s t in g f r on t p la te's p o in ter w il l no t b e v er ti cal . I n t hi s in s ta nc e, m o ve t h e
21-4
h an d a ut o le v er ( 9 ) in to th e h an d p o s it io n to ce nt er t he to rq u e ad ju s ti n g f ro n t
p lat e as ne cessa ry .
f . D is co n nec t t he s w itc h m ec ha nis m le ad s f ro m the s w it ch b an ks (2 60 ) o n th e
sw itc h m ec han is m assem bl y (2 5 9) . M ar k w ir ing fo r r eco nn ect ion , as
ne cessa ry .
g. T o rem ove s w it ch b ank s (2 60 ), com p res s w as her (2 66 ) a nd s prin g (26 5) b y
m o vi ng s w it ch ba nk ( 26 0 ) tow a rd s th e fr on t pla te (2 70 ) p ull ing s w i tch b ank s
(2 60 ) ou t o f the sw i tch m ech anis m re ar plate (2 72 ).
h. R em ove tw o ca ps crew s (2 64 ) o n the s w itch m echa nis m b asep late ( 26 3).
C A U T I O N : U s e car e w hen r em ovin g s w itch m ec han is m (2 59) to a void

dam age to th e O -r ing (27 1).
i. C aref ul ly rem ov e t he sw itch m e cha nis m (2 59 ) f ro m th e gea rcase (1 ) an d slip

th e g ea rcase h eate r ou t of cl ip lo cat ed on the b ack o f th e sw i tch m e cha nis m .
j. R e m ov e t he lim it s w itch d riv e g ear as s em b ly (2 6, 2 7) f ro m the s w itch
m e ch an is m s h af t ( 25 9 ) b y d ri vi ng o ut t he s p r in g p in ( 2 7 ) lo ca ted ne ar t he
lim it s w itch r ear p lat e ( 2 72 ).
k. R em ove the tor que s w it ch s h aft ( 90 ).
l. V i su ally in spec t o il sea l ( 89 ) fo r leak age or d am ag e. R eplac e as nec ess ar y.
m . V isu all y in sp ec t n eed le b ear in g (1 8 ) fo r w ear or d am age . R e pla ce pa rts as
n ecessar y.
21.2.3 Add-on-pak Removal and Inspection
1 . P o s t- 19 7 8 A ct uat or s
a. E n su re elec trica l p ow er is i so lated o r disco nn ected .
b . R em ov e th e th ree c ap s cr ew s ( 2 57 ) a nd s p r in g w as h er s ( 2 58 ) th at r et ain t he
lim it s w itch cover (2 50 , 2 51, 2 52) and pu ll co ver str aigh t of f.
c. D isco nn ect t he add -o n- pa k l eads, w ith in th e sw itch m echa nis m loo m (1 72 ),
f ro m t he ad d- o n- pa k s w itch es (3 03 ). M a rk w i rin g f or r eco nn ect io n, as
n ecessary .
N O T E : I f r ep lac ing a dd -o n-p ak s w i tch ba nks (3 03 ), per fo r m S teps d)

an d e) o nly of the r em ain ing S teps in Sect ion 21 .2.3.1.
N O T E : If rem o ving the ad d-o n- pak as s em bly ( 30 0, 30 1, 30 2) for

r ep air /i ns p ectio n of th e act ua tor , el im ina te St ep d) a n d e) an d p er for m
the rem a ining s teps in Sectio n 2 1.2 .3.1.
d. R e m ov e th e s w itch ho ldin g p lates ( 31 3), co m pr es sio n sp rin gs ( 31 0) and

w ashers ( 30 9).
21-5
e. P ull a dd -o n -p ak s w it ch p ak s h aft ( 3 11 ) to w ar ds th e f r on t pla te (3 1 4) a nd

r em ov e s w it ch b anks (30 3).
f . R em o ve tw o cap scr ew s ( 31 2), w ash ers ( 309 ) an d com pr es sio n s p ring s (31 0)
t ha t r eta in sw it ch h ol din g p lat es ( 3 13 ) to t he f ro nt p lat e ( 3 14 ) .
g. R em ove s w itch ho lding plates ( 313 ).
h . M o ve s w itch ban ks (3 03 ) to the s ide to allo w en tran ce of alle n k ey in to the
soc ket cap scr ew s ( 31 5) th at re tain s th e add -o n- p ak (3 00 , 3 01 , 30 2) t o the
m o unt ing pi llars ( 33 0) .
i. R em ove the th ree so cket capscrew s (3 15 ).
j. R em o ve ad d-o n-p ak ( 30 0, 301 , 3 02) fr om the s w itch d rive sh aft ( 273 ).
k. L oo sen s et s crew ( 32 8) in lo ckin g p late ( 329 ), then rem o ve lockin g plate
(3 29) , sp acers (3 26 ) an d g ear clus ters ( 325 ).
1. P e rf or m vi sual in sp ectio n o f g ear cl us te rs (3 25 ) , spac ers ( 32 6) , d riv e ad apt er
(3 2 7) , lo ck ing p lat e ( 3 29 ), m ou n tin g pil lar s ( 33 0) and se t s c rew (3 2 8) f or
d a m a g e a n d a b n o rm a l w e a r.
m . If m o un tin g p illar s (3 30 ) are dam a ged , u ns cr ew f rom s w itch m ech anis m
as sem bly (26 1).
n . R ep lace p art s as n ece ss ar y.
2 . P r e- 19 7 8 A c tu ato r s
a. E n sur e e le ctr ic al p o w er is is ol at ed o r di sco n n ect ed .
b . R em ov e th e thr ee c ap sc re w s ( 2 57 ) an d s p ri ng w as h ers ( 25 8 ) th at r etai n th e
lim it s w itch cov er (25 0, 251 , 2 52 ) an d p ull co ver s traigh t of f.
c . D i sc on ne ct th e a dd -o n- p ak lea ds , w it hin the s w itc h m ec han is m lo om ( 17 2 ),
f ro m the ad d- o n- pak sw i tch es ( 31 9 ). M ar k w ir in g fo r re con n ecti on , as
n ecessary .
N O T E : If r epl acin g ad d- on -p ak s w it ch ba nks (3 19 ), o f th e r em a ini ng

step s in S ection 21 .2.3.2 , p erfo r m Steps d ) th ro ug h f) on ly.
N O T E : If r em o ving th e ad d- on- pa k as s em bly (30 0, 30 1, 30 2) for

r epair s ins pection of the a ctu ator , elim in ate Step s d) th ro ugh A ) and
p erfo r m the r em a ini ng s teps in S ection 2 1.2 .3 .2 .
d . L oo se n tw o f ro nt m o un tin g n ut s (3 24 ) nea res t to sw it ch ban ks (3 19 ).

e. Scr ew lock ing he x n ut (32 1) tow ard s s w i tch b ank s (3 19) .
f . M ov e s w itc h ban k s (3 19 ) to w ard s f ro nt p late (3 14 ) fa r eno ug h to r eleas e
s w itch b ank s (3 19 ) fr om ad d- on -pa k m ain fr am e.
g . L o o s en th r ee a lie n s c re w s (3 2 0 ) th a t re tai n t he ad d- o n -p a k m a in fr am e to th e
m ou ntin g pilla rs ( 321 ).
h . R em o ve ad d- on -p ak ( 30 0, 3 01 , 30 2) f ro m the s w itch m ech anis m d riv e sh af t
(27 3).
i. L oos en s et s crew (32 8) in lock ing plate (32 9) , th en rem o ve lo ckin g plate
(3 29 ), sp acers ( 326 ) an d gear clus ters ( 325 ).
21-6
j. P er fo rm vi su al insp ectio n of g ear clu st ers ( 32 5) , space rs ( 32 6) , dr ive ad apte r

( 327 ), lockin g p late (3 29 ), m oun ting pillars ( 32 1) and set scr ew (32 8) for
d am a g e an d a bn o r m al w ear .
k . If m o un ting pi llars ( 32 1) are dam aged , u ns cr ew fr om s w itc h m echan is m
ass em bly (2 59).
1. R ep lace p ar ts a s n ecessa ry .
21.2.4 Syncroset Disassembly and Inspection
1. E n sur e elec trica l p ow er is is o lated o r d iscon ne cted.

2. R em ov e fou r s crew s (1 88) fro m the sy ncro set b ody (1 50) and rem o ve cov er ( 151 ).
3. R em ov e O -r ing ( 16 4) and v is ually in sp ect for d am ag e.
4. D i s con n ect an d r em ov e all e xte rn al w ir in g . M ar k w ir in g f or r ec on n ecti on , as
n ecessary .
N O T E : To r eplace d am aged term ina l block (15 2) o nly, co m p lete Section

2 1.2.4 .6; throug h 7. To rem o ve th e entire syn croset assem b ly p roceed to
S ection 21.2 .4.8 .
5 . R em o ve g ro un din g lu g con nectio ns ( 15 8, 15 9, 1 60, 1 65 , 1 66 ) a nd retai nin g r ing

(17 4) f rom insid e the s ynch ros et bo dy ( 150 ).
C A U TI O N : W hen r em o ving the term ina l blo ck (1 52 ) d o n ot p ull o n th e

b r as s te rm in al s tud s .
6. P u ll th e t erm in al blo ck (1 52 ) st raig ht ou t o f the s yn cro s et b od y (1 50 ) us ing t w o

p air s o f pli ers by g rip pi ng an d pu lli ng o n ter m ina l b lo ck s epa rato rs .
7. R em o ve int ern al w i rin g fr om the b ack of te rm in al blo ck (1 52 ). M ar k w irin g fo r
r e co n n ec ti o n, a s ne ce s s a r y.
8. R em ov e fou r cap scr ew s ( 167 ) b etw een the syn croset b ody (1 50) and gear case ( 1).
9. R e m ov e s yn cro se t an d v is ually in sp ect O - rin g (17 0) .
10 . O n ce th e syn cro set assem bly is rem oved f rom the gear case (1 ), th e w ire loo m s
( 17 2, 1 84 , 18 5) m a y be dr aw n ou t th ro ug h the g earc ase ( 1) op en ing .
N O T E : S ection 21 .2.4.1 1 th ro ugh 13 ar e to b e per for m ed o nly if rep air ing

da m ag ed ter m in al block (152 ) after the s ynchr os et ha s b een r em o ved .
1 1. R em ove gr ou ndi ng lug co nnec tion s (15 8, 1 59, 1 60, 1 65, 1 66 ) an d retain ing rin g
( 174 ) fr om ins ide th e sy nchr oset body (1 50).
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C A U T IO N : W h en rem ovin g th e ter m inal block (15 2) do no t pu ll or a pply

for ce to the b ra ss ter m in al s tud s.
1 2. P u ll th e term i nal blo ck (1 52 ) s trai gh t o ut of th e s y ncr os et bo dy ( 15 0) u si ng tw o

p air s o f pli ers by g rip pi ng an d p ulli ng o n ter m in al b lo ck s epa rato rs .
A dd it ion all y, th e ter m in al bl ock (1 52 ) m a y be tap p ed f ro m t he r ear to a id in
r em oval.
13 . R e m ov e inte rn al w ir in g fro m the b ack of te rm i nal bl ock ( 15 2) . M ark w ir ing f or
re con ne ctio n, as ne ces s ary .
21.2.5 Handwheel Removal and Inspection
N O T E : P rio r to rem ov ing han dw heel m od ule, no te th e po sitio n o f th e actu ato r

to d eterm in e if dr ainag e of oil fr om gear case (1) is necessa ry. I f the han d w heel
is in a tw elve o 'clock pos itio n) S tep 21.2 .5.1 is n ot r eq uired.
1. D rain o il by rem ov ing low er plug (8) from g ear cas e (1) .
2. R em o ve han dw h eel r etain er sea ling p lug (5 1) f rom th e g earcas e (1 ).
N O T E : T he han d w hee l m ust tu rn in a clockw is e d irecti on w h ile rem ovin g

the n ylo n ha ndw heel retain er ( 48).
3. R em ov e th e h and w hee l r etain er (48 ).

4. In sp ect n ylo n han dw he el r etainer ( 48 ) f or d efects .
5. L i ft the h and w he el m od ule s tr aig ht of f us in g car e no t t o dam age th e O - rin g ( 45 )
or th e oil s eals (44 ).
6. R em ove an d ins pect O -ring (45).
7. V i sual ly in spe ct oi ls eal s ( 44 ) f or l eak age o r d am ag e. R ep lac e par ts as n ec essary
21.2.6 Gearcase Module Removal and Inspection
1 . G e ar c as e R e m o v a l a n d I n s p ec t io n
a. R em o ve actu ato r fr om val ve per S ec tion 2 1.1.
b. D ra in a ll o il fr om actu ator gea rcas e ( 1) by lo os en ing low er m o s t pl ug (8 ).
c. R em ov e t he fo llow in g actu ator co m po ne nts p er ap plicab le se ction s :
• M oto r: S ection 21 .2 .1
• Sw itch M echanis m : S ectio n 2 1.2.2
• Sy ncroset: Section 21 .2.4
• H an dw heel: S ection 2 1.2 .5
d. R em ov e r em a ini ng g ear case inte rn al com po nen ts p er th e fo llo w ing sec tion s :
• C lutch and W orm g ear : S ectio n 2 1.2 .6.2
• D riv e B us hing : Section 21.2 .6.3
• H an d A uto L ever : S ection 21.2.6 .4
21-8
• O il S eal: S ectio n 21 .2.6 .5

• W or m s h aft B us h in g: S ect ion 2 1 .2 .6 .5 , S tep c
2. C l utch an d W orm gear R em ov al

a. R em ov e actu ato r fr om v alve p er S ecti on 2 1.1
b. R em o v e h an dw h ee l a ss e m b ly f ro m the a ctu ato r pe r S ecti on 2 1 .2 .5
c. D r ain all oil fr om actu ator g earca se (1 ) by lo os en ing lo w er m os t plu g (8 )
W A R N I N G : Th e clu tch sp rin g (30 ) in th e fo llow ing s tep is still un der

lo ad and cou ld ca us e s erio us in jur y if ca re is not taken w hen r em o ving
the clutch r etain in g cir clip ( 32) . A lw a ys utilize the pr op er siz e cir clip
pliers to slow ly r eleas e pres sur e on the clutch sp ring (3 0).
d . R em ov e th e clu tch r etainin g circlip (3 2) , sp ecial w asher (3 1) , an d clutch

sp ring (3 0) fr om top of center colum n (3 ).
e . S lid e th e clu tch rin g ( 28 ) o ff th e cen ter colu m n (3 ) ta king car e n ot to dr op
clu tch keys ( 29) into th e gear case (1) .
f . V erify d riv e b ushing r etainer (37, 41 ) is installed. If not, install per Section
2 1.3 .1.4 , S tep d ).
g . R em o ve r etain in g pin (7 ) at bas e of a ctu ato r gea rcas e b y jack in g it ou t u s in g
a 3/8" x 1½ " s ets crew .
C A U TIO N : U s e a piece of w ood or a rub ber m allet to ta p the center

colum n (3) fr ee in the fo llo w ing step to prevent d am age to th e center
c o lu m n (3 ) .
h . T ap cent er colu m n (3 ) fr om top t o d ri ve it an d bea rin g (5 ), be arin g st op ri ng

(6 ) and t he lim it s w it ch w or m (2 ) ou t fr om th e actu ato r gea rca se b as e.
i. V isu ally in s pect o il s eal (4 ), bearin g ( 5), bear ing sto p r ing (6) fo r w ear or oil
le ak ag e. R e p lac e as ne ce ssar y.
j . T h e w or m w heel (56 ) is left fr ee in th e gea rcase ( 1) and can b e re m ov ed f ro m
th e top o f t he g earcase (1) .
3 . D r iv e B u s hin g R em o va l a nd I n sp ec tio ns
N O T E : T he a ctuato r m ust be rem o ved fr o m the va lve p rio r to d r ive

bu shin g r em oval refer to Section 21 .1.1 .
N O T E : So m e a ctu ato r s h ave a h ole w hich i s no t plu gg ed . In th is ca s e o m it

S tep 21 .2.6.3 , S tep a ).
21-9
a. U ns crew an d rem o ve p lug (3 3) on s ide of actuat or bas e.

b . U s ing h an d aut o lev er (9 ), p os it ion a ctua tor t o han d op er atio n.
c . R ot ate t he h an d w he el as s em b ly u nt il th e b us h in g r eta in er s e ts cr ew (3 8 ) is
v is ib le t hr ou gh th e ho le m th e gea rcas e ( 1) b as e.
d. R em ove s etscrew (38).
e . U n sc re w d ri ve b u sh in g r eta in er ( 37 , 4 1) by u s in g a s p ann er w ren ch in se rt ed
into t he tw o ho les p ro vid ed o n the dr ive b us hin g re tain er (3 7, 41 ).
N O TE : F or type A dr ive bus hing (39) ) r eco rd the pos ition o f the dr ive
bu s hin g ( 39 ) pr ior t o r em o val: P o siti on 1 D riv e B a sh ing ( 39) is
in s er ted in to th e ce nte r co lum n ( 3) . P o s itio n 2 D ri ve B us h ing ( 39 )
pr o tr ud es f ro m th e cen ter co lu m n i f). W hil e p er fo rm in g 2 1.2.6.c, Ste p
f) R em ove the dr ive b lu sh ing (39 , 42 ) b y pullin g it s tr aigh t out of the
c en te r c o lu m n ( 3) .
f. V is ua lly in sp ect thr ead s of t he dr ive bu s hin g (3 9, 4 2) f or d am ag e.

g. V isu ally in sp ect m ach in ed sh ou ld ers of th e d riv e b u sh ing ( 39 , 42 ) at the
con tact p oin t w ith th e cen ter colu m n (3) d ogs for cr acks o r sh ears.
h. R ep lace da m ag ed pa rts as n ecessar y.
4. H an d A u to L eve r R e m o va l a nd I n sp ec tio ns
N O T E : T o g ain a ccess to th e ha nd a uto lever com po nents ) the actuato r

ha ndw heel a ss em bly m a st firs t b e r em o ved p er Section 21 .2.5 a nd acces s
w ill als o be im pr oved b y rem oving th e cen ter colum n (3) p er 2 1.2.6 .2.
a. N ew er V er sio n
• B ack o ut s top s cre w (1 3) en oug h to allo w han d aut o l ever (9 ) to be ro tated
pas t s top in coun ter clo ckw ise directio n.
• W h ile r ot atin g t he h an d au to le ver (9 ) co un te r clo ck w is e, r o tate th e h and
au to jac k (1 2) f ro m th e h an d aut o lev er s ha ft.
• H ol d leve r retu rn sp rin g (1 1) a nd sp acer ( 83 ) to pr eve nt dr op pi ng in to
g ear case ( 1) an d p ul l h and au to leve r ( 9) f ro m th e g ear case ( 1).
• V isual ly insp ect O - ri ng ( 10 ) f or l eaka ge or d am ag e. R ep lace as n ecessar y.
• V isu ally i nsp ect pa rts fo r da m ag e o r w ear a nd r ep lace as nece ssa ry .
b. O ld V ersion
• B ack ou t s top s cr ew (1 3) en ou gh to allo w han d auto lev er (9 ) to b e r otat ed
p ast sto p in co unter clock w is e d irection .
• R em ov e the p in ( 88 ) o n th e i ns id e of the g ear cas e (1 ) th at r etai ns han d
au to jack (12 ) to h and auto lev er ( 9) .
• P u ll h an d au to le ve r (9 ) s tr ai gh t ou t of g ea rca s e (1 ) w h ile at th e s am e
t im e c atch in g t he h an d au to jack (1 2 ), s p ac er ( 8 3) , an d t he le ve r re tu rn
spr ing (1 1) as they slid e o ff sh aft.
• V isu ally in spec t O -r in g (1 0) fo r leak ag e o r dam age. R epl ace as n ecessary .
21-10
• V i su al ly in spe ct par ts fo r d am ag e or w e ar an d r epl ace as nec essar y.
5. O il S eal R em oval
a. O n P os t- 19 78 r em o ve back up w as h ers ( 52 , 49 ) on th e m oto r w o rm sh aft b ore
a nd t or q ue s h af t b o re .
b. R em o ve o ld o il seals.
c. O n P r e-19 78 insp ect, r em ov e & rep lace w or m shaf t bu sh ( 20 ) as r equ ired .
21.3 Actuator Assembly
21.3.1 Gearcase Module Assembly
1 . B earing A s sem b ly
a . Fi t n eed le bear in g (1 8) o nt o the w or m sh aft be arin g to ol, l ocat e i n gear case
(1 ), and pres s ho m e.
b . F it ne edl e b ear in g ( 19 ) o nto the w o rm shaf t be ari ng t oo l, l oca te in g ear case
(1 ), an d pr es s ho m e.
c . C o at th e o u ts id e of t he w o rm s haf t's oi l s e al (2 1 ) w ith H y lo m ar and pr es s int o
g ea rc as e ( 1) w it h th e w o rm s ha ft s e al to o l.
d . P ost- 19 78 on ly: F it seal back up w ashe r ( 59 ) and cir clip (5 2) int o g ear case (1 ).
e . P re -1 97 8 on ly: F it w or m s ha ft bu s h (2 0) in to g earc as e ( 1) .
f . P os t -1 9 78 o n ly : L oc ate th e to r qu e s ha ft's o il s eal ( 21 ) o n to th e to rq u e s haf t
s ea l to o l a n d p r es s h o m e .
g . Pr e- 19 7 8 on ly : L oca te the to rq u e s h af t's o il s eal (8 9) on to th e tor qu e pl un ge r
s hr o ud and oi l se al to ol a nd pr es s ho m e.
h . F it t he to rq u e s h a ft 's s ea l b ack u p w as h er ( 50 ) an d cir c lip ( 49 ) in to g ea rc as e
(1 ) .
2 . H and A uto L ever A ss em b ly
a. N ew er V ers ion
• Fit O -ring (1 0) on to hand auto lever (9).
• S m e ar th e ha nd a ut o lev er s h af t w i th E x x on U n ir ex N 2 and ins e rt th e
h and au to lev er (9 ) into th e gear case ( 1) .
• F i t h an d a ut o lev er r et ur n s p ri ng (1 1) an d up to t hr ee s p ecia l s pa cer s ( 8 3)
(d u e t o cas t ing va ria tio ns ) a nd t he h an d au to ja ck ( 12 ) o nt o th e l eve r
s h aft (9 ) alig n m ent g ro ov e, m ak in g su re th e s p rin g (1 1 ) i s lo cated o nt o the
ledge o f the g earcase (1).
• F it st op s cr ew ( 1 3) an d s pr in g w as her ( 15 ) o n ou ts id e p late o f han d au to
lev er (9 ) and t igh ten .
b . O ld V er si on
• F it O -rin g ( 10) on to han d au to lev er (9 ).
• S m ea r t he h an d au to l ev er s ha ft w ith E x x on U n ir ex N 2 an d in s er t th e
han d au to leve r (9) i nto th e g ear case ( 1) .
• F i t h an d a ut o lev er r et ur n s p ri ng (1 1) an d up to t hr ee s p ecia l s pa cer s ( 8 3)
( d ue to c as tin g v ar iati on s ) an d th e ha nd aut o jac k (1 2 ) o nto the l eve r
s ha ft (9) a lign m en t g roo ve , m akin g s ur e th e s p rin g ( 11 ) is lo cated o nto th e
ledg e of th e gearcase (1).
• S ec ur e h an d au to lev er s h aft b y ins er tin g r oll p in (8 8 ) int o lev er s haf t.
21-11
• F it s top s cr ew (1 3) an d s pr in g w as her ( 15 ) o n ou ts id e p late o f han d au to

l ever ( 9) an d tig hte n.
3 . C en ter C olu m n an d C lu tch an d W o rm g ear A ssem bl y
a . A pp ly P etit e to cent er co lum n kn ur l a nd p re ss th e li m it s w itch w o rm (2 ) o nto
the cen ter colu m n ( 1) if old w orm is b eing replaced.
b. F it the th ru st ba se 's oil s eal ( 4) o nto th e cente r c olu m n (3 ).
c . P ress th e t hr ust be ari ng ( 5) on to th e cen ter co lu m n ( 3) .
d. U s ing car e to av oid dam age to oil sea l (4 ), assem bl e cen ter colu m n assem bly
i nt o low e r ge arc as e.
e. F it be ari ng s to p rin g (6 ) in to g earc as e ( 1) , en su ri ng th e ho le in the s id e o f th e
b ear ing st op r in g is lin ed u p w ith t he h ole in the g ear cas e.
f. F i t th e re tain in g p in (7 ) th rou g h h ole s i n th e g earcase (1) an d b earin g sto p
r ing ( 6).
g. Sli de w o rm w h eel ( 56) o nto cen ter colu m n (3 ) in side the gear case (1 ) ensur ing
dr ive pi ns ( par t o f w o rm w h eel) ar e u pp erm o s t an d also that w orm w he el is
sho ul der ed ag ain s t ce nte r colu m n ( 3) a nd m a chin ed sh elf sur fa ce o f th e
gearcase (1).
N O T E : C lu tch key 's (2 9) or ienta tion is cr itical. W id e s ide of keys

an d clutch r ing (2 8) m us t be up per m os t, n ot aga ins t w or m w h eel
h . I ns tal l clu tch k eys (29 ) in to clutc h rin g (2 8) an d place as s em b ly on th e c enter

colum n (3).
i. P ress clu tch sp ring ( 30) , sp ecial w asher (3 1) , an d circlip (3 2) do w n o nto cen ter
co lum n ( 3) en sur ing th e cir clip (32 ) lock s in to center co lu m n's ( 3) g roov e.
4. D rive B us hin g A s s em bly
a. V erif y th read s ar e i n g o od co nd itio n and ar e geo m etr icall y cor rect f or va lve
stem ap pli catio n.
b . V er if y re qu ire d m o un tin g po s iti on o f th e d r ive b us h ing (3 9, 4 2) a nd i ns er t
in to the gear case b ase in side of th e cen ter co lum n ( 3) .
c. E ns u re th e s l ots of t he dr iv e b u s hin g (3 9 , 42 ) ar e f ul ly en gag ed w it h th e
act uat or 's cen ter co lu m n shaf t dr ive d og s .
d . I ns t all an d tig h ten d r iv e b u s hin g r eta in er ( 37 , 4 1) .
e. U s in g a fee ler ga ug e, v erif y g ap bet w een d riv e bu sh in g re tain er (3 7, 4 1 ) and
bu sh in g (3 9, 42) does not ex ceed 0.03 inch .
f . I ns t all a nd tig h te n d ri ve b u s hi ng re tai ne r s cr ew ( 3 8) .
g. Pr e- 197 8 on ly: reins ert r edcap plu g (3 3) in to gear cas e (1 ).
21.3.2 Syncroset Assembly
1 . W iri ng L oo m In ter na l C o nn ecti on s to T er m in al B u n g

a. C o nn ect hea ter w ire s to ter m in als 4 an d 5 on b ack o f term ina l b lock ( 15 2 )
fro m th erm os tat lo om (18 5).
b. C o nne ct m o tor w ires to ter m ina ls 1, 2, an d 3 o n back of ter m inal blo ck (1 52)
fr o m m o to r lo o m (1 8 4 ).
21-12
c. C onn ect nu m ber ed sw i tch m ech anis m and ad d- on -pa k l oom ( 172 ) to
co rr es pon din g nu m be red ter m inal s on b ack of ter m ina l b lock (1 52 ).
d . P erfo rm con tinuity ch eck w ith m eter fr om f ield sid e of ter m inal block (1 52 ) to
ea ch sw itch co nta ct t o ensu re co rr ect sw i tch is w ir ed to c or rect ter m in al.
2. A ss em bly of T er m inal B lo ck into S yncro set
a. S m e ar O -r ing ( 16 4 ) and te rm in al bl ock o ut er bo re w ith g rea se an d pla ce O -
rin g ( 164 ) into low er r ad ial gro ove of s yn cros et.
b . C ar efu lly p os itio n ter m in al b un g in si de s yn cro s et b od y (1 50 ) tak ing ca re no t
to p inch o r d am ag e an y w i res o r the O - rin g (1 64) .
c. S ec ur e te rm in al blo ck ( 15 2) b y pl acin g reta inin g ri ng ( 17 4) in to o uter r ad ial
gr oove of the s yncros et body ( 150).
d . I ns tall gro un din g lug as s em bly ( 166 , 15 9, 16 5, 16 0, 1 58) in to sid e o f
s yncroset body (150).
3. A ss em bly o f S yncro set M od ule to G earcase
a. E nsu re he ater assem bly ( 18 7) ( P os t -1 97 8) is secu red t o gea rcase w ith t w o
s cr ew s i n tw o pr e- tap pe d ho les dir ectl y be nea th s yn cr os et en try op eni ng i n
th e g ear case .
b. In spe ct ge arc ase an d syn cr ose t se alin g su rf ace s f or a ny dam ag e t ha t w o u ld
hi nd er p ro per se alin g.
c. E n s ur e O - rin g (1 70) i s fit ted pr op erly ar ou nd b od y (1 50 ) and f it i nto g earca se
(1) op en in g.
d. Se cure w ith fou r caps crew s ( 16 7) and s pr ing w as her s (1 71) . T orq ue caps cr ew s
to 1 0-12 f oot pou nds.
21.3.3 Switch Mechanism Assembly
1. P re- an d P os t-1 97 8 A ctuato rs

a. I f lim it s w itch w heel or dr ive ass em b ly ( 26 ) is d efectiv e o r h as been rem oved
in o rd er to rep la ce tor q ue sw itc h m ec han is m it m u st be r epl aced on l im it
sw it ch m e cha nis m sh af t.
b. E ns u re lim i t s w it ch w hee l a nd d riv e as s em b ly (2 6 ) is f ull y ins er ted h ar d
ag ain s t th e sw it ch m ec han is m ( 26 1) b r ass lo cat ion b u s hin g .
c. U si ng th e ho le in th e lim i t d ri ve as s em b ly ( 26 ) as a t em p late, dr ill a 1 /8 i nch
h o le th ro ug h th e s w itc h m ec ha nis m a s se m b ly ( 26 1 ) s ha ft's br as s bu s h ing .
d . S ecu re lim it s w it ch driv e a ss em b ly (2 6) on s w itch m ech ani sm as s em bly b y
ins er ting s p rin g pin ( 27 ) t hro ug h 1/8 in ch ho le dr illed in S tep c.
e. C lip h eater t o back o f rep lace m en t sw itch m echa nis m assem b ly if P re- 19 78
h ea ter (o b s ol ete ) is st ill i nst all ed . ( P re -1 9 78 sw it ch m ech an i s m s ha d h eat er
clip s po p- rivete d to th e bac k o f t he m e chani sm )
f . G rease O -rin g (27 1) on sw itch m ech anis m .
N O T E : T he fo llow in g steps ca nn ot b e perfor m ed u nless m otor m od ule

h as been in sta lled .
g. In s tall to rq u e s w it ch s ha ft (2 3 , 90 ) in to o pe nin g in g ear cas e in s ur in g

sh akep ro of w ash er end is f acin g sw i tch m ech anis m .
21-13
h . C aref ul ly pu s h sw i tch m ech an is m ( 26 1 ) i nto g ear cas e (1 ) un til gear s m a te.

i . R eplace on e capscr ew (2 64) in to sw itch m echan is m b ackplat e (2 63 ) an d
t ig ht en i n o rd er to v er if y to r qu e ad ju s ti ng fr o nt pl ate ( 2 70 ) t ur n s t ow a rd th e
v ert ical p os iti on (p oin ter alig ns w it h arr ow ).
j. If n ot in ver tical p os itio n, r em ov e c aps cre w (2 64 ) a nd w ithd raw sw itc h
m echan ism (26 1) aw ay f rom gearcase ( 1).
N O TE : In cr eas ing the sh afts (23 , 9 0) over all leng th w ill cau se the
fro ntpla te (2 70) to ro tate clo ckw is e w hen view ing the sw itch m ech anism
( 261) from the fr ont.
k . R em o ve tor qu e s w itch s haf t (2 3, 9 0) and ad jus t caps cr ew (2 5, 9 1) in or der to

c ent er po in ter o n to rq ue ad ju s tin g fr on tp late ( 27 0) .
1. T i gh ten a er oti gh t s tif fn u t ( 2 4) a ft er ad ju s tin g to rq u e s w i tch s h af t (2 3 , 90 ) ,
t aki ng ca re no t to ov er tig hten a nd d am a ge cap s crew (2 5, 91 ).
m . R ep eat S tep s h ) an d i) . I f ali gn m en t is ach iev ed g o to S t ep n ). I f n ot r epe at
S tep s j) th ro ug h m ).
n . R eplace tw o cap s crew s (2 64 ) an d tor que to 4.5 - 5 .5 ft.lbs .
o . C o n n ect a ll i n ter n al w ir in g t o t he ap p ro p r iat e te rm in al s an d s e cu r e w ir i ng
l oom to s w itch m e chani sm w ith Sco tch T her m os ettin g T ape (27 ).
N O T E : T he c over o rien tatio n is im p or tan t o n th e 1 2 s w itch add -o n-p ak

as s em bly. A n a dd- on -p ak s u pp or t is w elded to th e in sid e o f th e co ver
(252).
p. G rease O - rin g (2 54 ) and in stall o n gea rcase (1 ). In stall l im it sw itc h c ov er

(25 0, 25 1, 25 2) and s ecur e w ith thr ee cap s crew s (2 57 ) & w ash ers ( 28 8).
G reas e an d to rqu e caps cr ew s ( 257 ) to 1 0 - 12 ft.lbs . ( 4.5 - 5.5 f t.lbs . on pr e-
19 78 ).
q. R efer to S ectio n 20.0 fo r s w itch m ech ani sm adj us tm en t p roc edu re.
2. M o dula r R eplacem en t o f S w itch B an ks o n M ech anis m
a. P r e- 19 7 8 A ctu ato r s w i th N O de sign S w itc h M ech an ism s I nst alle d
• C om p re ss w as her ( 26 6 ) and s p rin g (2 6 5) b y m ov in g s w i tch to w ard s th e
fro ntplate (27 0).
• P u ll s w itc h ban ks (2 60 ) ou t of th e s w it ch m ech an is m r ear pla te ( 27 2) .
• In s tall r ep lace m en t s w itch ban k s ( 26 0 ) de pr es s in g w as h er ( 26 6 ) an d
sp rin g (26 5) an d sn app ing sw itch ban k (2 60) in p lace.
b . P os t -1 9 78 A ctu at or s
• S crew lo ck ing hex nut (2 69) to w ards s w itch b an k (2 62).
• M o ve s w itch bank (2 62 ) to w ar ds f ron t plate (2 70) , f ar en ou gh to r eleas e
sw itc h ban k (26 2) f ro m s w itch m echan is m 's re arp late (27 2) .
• In stall re pla cem e nt sw itch b an ks (2 62 ) in to f ram e an d h ol d in pl ace.
• E n su r e s m all b ar re l n u t is p o s itio n ed in r o un d ed ar ea o f s lo t on f r on t
plate (270 ).
21-14
• S crew lock ing h ex nu t ( 26 9) fir m ly ag ains t i nside sur face of fr on t p late

(2 70 ).
21.3.4 Add-on-pak Assembly
1. Po st-197 8 A dd-on- pak

a. I nspect add- on -pack fo r d am age.
b . E ns u re all p ow er h as b een r em o ved f ro m actu ato r.
c. V e rif y th at the re pla cem e nt ad d- on -p ak g ear cl us ter s ( 32 5 ) and sp acer s ( 32 6 )
m at ch th e da m ag ed add - on - pa ks .
d. If ad d- on -p ak is b eing in s talled f or th e f irs t tim e, re fer ence E n clos u re 20 .3 in
S ectio n 2 0 f or cor rect nu m ber s of gear clu ster s (3 25 ) an d sp acers ( 32 6) for
specific v alv e tr avel.
N O T E : N eve r m ix a nd m a tch g ea r in g th at is pi nn ed w ith g ea r in g tha t

is inves tm ent ca st.
e. R em o ve tw o caps cr ew s (3 12 ) tha t r etain s w itch h old ing p lates (3 13 ) t o the

ad d- on -p ak fr on tp late.
f. R em o ve sw itch h old ing plate s (31 3) , s p rin gs (3 10 ), and w as her s (3 09) h eld
b eh in d t he s e pl ate s .
g . I ns tal l t he th ree m o u nti ng p illa rs (3 30 ) to th e s w itch m ech ani sm ( 26 1 ). S cr ew
u p tig h tly to th e n ut s r et ai ni ng th e s w it ch m ec h an is m s f r on tp l ate ( 2 70 ) an d
torq ue to 5 - 5 .5 ft.lb s.
h . I f po tentio m eter (3 08 ) i s fitted , sl ide it o n th e p illar .
i. In st all th e a dd -o n-p ak on to th e p illar s (3 30 ).
j. M ov e s w itches (3 03 ) to the si de to allow ins tallation of the caps crew s ( 315 )
and w ash ers ( 316 ) to p illars (3 30 ). T orq ue t o 5 - 5.5 ft.lbs .
k . R eplace sw itch es (30 3) in add- on-pak f ram e.
l. R ep lace spr ings ( 310 ), w ash ers (3 09) , h old ing plates (3 13 ) an d tw o capscrew s
( 31 2) that w e re r em ov ed in Step f ).
m . C onnect w irin g to the loo m (1 72) to the sw itches (30 3).
n . S ecur e th e loo m to th e pilla rs u s ing S co tch T h erm o s ettin g T ape 27 .
o . R efer to Sec tion 20 .0 fo r ad jus tm en t pr oced ure.
2 . Pre- 1978 A d d-o n-pak
a. I nsp ect a dd -o n- pack f or d am ag e
b. E n s ur e all p ow er h as bee n re m ov ed f ro m actu at or .
c. V er ify t ha t t he re pl acem ent ad d -o n- pa k ge ar clu s ter s ( 3 25 ) an d spa cer s ( 32 6)
m atc h th e da m ag ed a dd - on -p ak s .
d. If ad d- on -p ak is bein g ins ta lled fo r th e f irs t tim e, r efe ren ce E nclo s ur e 2 0.3 in
S ectio n 20 fo r co rr ect nu m be rs of g ear cl us ters ( 325 ) and spacer s (32 6) fo r
specific valve trav el.
21-15
N O T E : N ever m i x a nd m a tch g ear i ng th at is nyl on w ith g ear in g th at is

in vestm ent ca st.
e. L oo se n t w o f ro nt plate m o un ting n uts ( 32 4) .

f . S crew lock in g h ex n ut ( 321 ) tow ard s sw itch bank (31 9).
g . M o ve s w i tch ban ks ( 31 9) to w ard s fr on tplat e ( 31 4) far en ou gh to r eleas e
sw itch b anks (31 9) fr om add- on -pak f ram e.
h. I n s tall t he t hr ee m o u nt in g p illa rs ( 32 1 ) to t he s w it ch m ech an is m ( 25 9 ). S cr ew
u p ti gh t ly t o t he n u ts r et ain in g th e s w it ch m ec h an is m s f r o nt pl at e (2 7 0 ) an d
to rqu e to 5 - 5 .5 ft.lb s.
i. I f po tentio m eter ( 30 8) is f itted , sli de it o n the pilla r.
j. In s tall t he a dd- on -p ak on to t he pillar s (3 21 ).
k . In s tall alie n sc rew (3 20 ) in to up per h o le o f ad d- on -p ak fr am e an d tig hte n into
th e end o f the up per s u pp or t p illar ( 32 1) . T igh ten to 5 - 5.5 ft.lb s.
1 . L ocat ing t he bo tto m tw o pil lar s (3 22 ) in to th e a dd -o n- pa k fr am e and dr ive
ad ap ter ( 32 7 ) on to th e s w itc h m ec han is m ( 25 9) , ti gh ten t he tw o bo tto m alle n
screw s (3 20) to 5 - 5.5 ft.lbs .
m . I nstall sw it ches ( 31 9) in to a dd -on -p ak fr am e an d ho ld in place.
n. T igh ten tw o f ro nt plat e m o u ntin g n uts (3 24 ).
o. E ns u re s m all he x nu t ( 32 3 ) is p os itio n ed in ro u nd ed ar ea o f s lo t o n fr on tp late
(3 14 ).
p. S cr ew lo cki ng h ex nu t ( 32 1) f irm ly agai ns t t he insid e su rf ace of th e f ro ntp late
( 31 4 ) ens u rin g tw o h ex nu ts a re jam m ed to get her ( 32 2 , 32 3) .
q. C o nnect w iring fro m the lo om (1 72) to th e sw itches (31 9).
r. S ecu re th e l oo m to th e pil lar s u s ing S c otc h T h erm os et tin g tap e 27 .
s. R efer to S ecti on 20 f or ad justm en t p ro cedu re.
21.3.5 Motor Assembly
1 . P o s t - 1 9 7 8 A c tu a t o r
N O T E : A ll N A 1 m ot or s a re s up plied in a m o du lar fo r m . S ta tor s a re

a lrea dy fitted into the m o tor cover a nd th e r otor o nto the w or m sh aft pr ior
to leas ing the factor y.
a. In sp ect m ach ined su rfac es of m oto r a nd m o tor w or m shaf t ( 54 ) fo r d am ag e.

b. I ns p ect fo r dam a ge and g re as e O - rin g (6 9) an d en su re co rr ect po si tion o n
m otor cov er ho us ing.
c. V er ify tor qu e s w itch s h aft ( 23 ) is ins talled in gear case (1 ).
d . E n sur e m ot or l ead s a re co nn ect ed to a pp r op ri ate ter m in als o n ba cksi de o f
term inal block ( 152) as fo llow s :
• I n s ta ll f ib r eg la s s s le ev in g ov e r 3 S yn c ro s e t m o t or le ad s .
• S t r ip in s u la ti o n f r o m en d s o f S yn c ro s e t a nd m ot o r l ea ds .
• P u s h w i r es in t o a pp r o v ed bu t t co n n ec to r a n d c ri m p w i th ap p ro v ed to o l.
21-16
• P us h f ib re gl as s s l eev in g ov er m o tor lead s and bu tt co n ne cto rs an d tap e in

place w ith S cotch T h erm osettin g T ape 27 .
N O T E : A cor r ectly p osition ed m otor w ill ha ve a s tator locking scr ew on

the s ide next to the s yn cr os et hous ing.
e. A lign m o tor as follow s :

• W h ile k eepin g m otor lead s clean of o il an d g rease, feed spli ced m oto r
lea ds int o pa ss a gew ay on th e rig h t sid e of t he ge arc ase ( 1) and c are fu lly
slip m o tor w o rm shaf t (5 4) par t w ay in to gearcase ( 1) . T he f ibreg lass
s le ev ing s ho u ld k eep th e m ot or lead s s tra ig ht a nd a w ay f ro m th e m o to r
s ha ft.
• U nle ss r esista nc e i s en co un te red be tw een t he w o rm sha ft ( 54 ) an d
w o rm h eel (5 6) , co ntin u e f eed ing th e m ot or lea ds into p as s ag ew ay an d
caref ully pu sh m oto r f lus h w ith gear case (1 ).
• If t eeth of g ear s do n o t m es h to g eth er ea s ily , re m o ve m o to r an d tu r n
w o rm sh af t (5 4) sl igh tly and rep eat th e ab ov e as n ece ssa ry .
f. L u b ri cat e a nd in s tall t hr ee ca ps c re w s ( 68 ) a nd s pr in g w as h er s ( 7 1) to r eta in
m otor to gearcase (1 ).
g . T o rq u e b ol ting t o 12 f t.l bs . i 5% -
2. P re- 19 78 A ctu ator
N O T E : A l l N A 1 m o to rs ar e s u pp lied in a m od u lar fo r m . Sta to r s a re

a lrea dy fitted into the m oto r co ver and the ro tor on to th e w o rm s haft p rio r
to lea sing th e fa ctor y.
a. In spect m ach ined sur fac es of m o tor an d m oto r's w or m shaf t ( 54 ) for d am ag e.
b . In sp ect fo r dam a ge and g rease O -r ing ( 69 ) and en sur e co rr ect po si tion o n
m otor cover hous ing.
c. V erify to rqu e s w itch s haft (9 0) is ins talled in gea rcas e ( 1).
d. E ns u r e m o to r l ead s ar e c o nn ec ted to a pp r op r iat e ter m i na ls on ba ck s id e of
term in al block (1 52).
N O TE : A cor rectly po sitioned m o tor w ill have a s ta tor locking s crew on

the side next to the syncr oset ho using (150).
e. A lig n m otor as follow s:

• W hile k eeping m o tor lead s clean of oil an d g rease, f eed spliced m oto r
le ad s in to p as s age w ay o n th e r ig ht s id e o f th e gea rca s e a nd ca ref u lly s lip
m o to r w o rm sh aft (54 ) par t w ay in to gear case ( 1) .
21-17
• U n less re sistan ce is en co un ter ed bet w een t he w o rm sha ft ( 54 ) an d

w o rm h eel (5 6) , co nti nu e f eed ing t he m o tor le ads into passag ew ay an d
car efu lly pu sh m o tor flu s h w ith g earcase (1 ).
• I f tee th o f g ear s d o n ot m e s h to get he r eas il y, r em ov e m o to r an d tu rn
w o rm sh af t (5 4) sl igh tly a nd r ep eat th e abo v e a s n ecessar y.
N O TE : P r e- 19 78 act uat or s uti lize d a s m alle r m oto r m oun ting b olt

tha n the P os t-197 8 gear cas es. I F repla cin g a n ew P os t-1978 m o tor
on a P r e-1978 gearca se, ens ur e prop er bu shing s a nd w a sher s a re
ins talled.
f. I ns t all bu s h ing an d fl at w as he r w he n in s talli ng a P o s t- 19 78 m o tor on a P r e-

197 8 g earcase.
g. L u br ica te an d in stal l t hr ee ca pscr ew s (6 8 ) an d spr in g w ash er s ( 7 1) t o re tai n
m otor to gearcase ( 1).
h . T o rque 1/2 - 20 U N C x 1" b olting to 10 - 12 ft.lbs . an d 10 - 2 4 U N C x 1 1/4" to
5 - 5.5 ft.lbs .
21.3.6 Handwheel Assembly
1. A pply a th in coat of E x xon U nirex N 2 gr ease to O -rin g (4 5), and oil s eals (44 ).
2. P os itio n h and w heel as sem bly to pr even t cap s crew s (4 7) f rom be ing dir ectly ov er
o r align ed w ith clutch k eys (2 9) on clu tch r ing (28 ).
3 . C o at ny lo n han dw h eel re tain er (4 8) w it h gea rcas e oi l an d f eed in to ge arca se
w hile rotatin g hand w h eel ho op (7 7) coun terclock w is e.
4 . In s tall h and w he el reta ine r se alin g pl ug ( 51 ) an d tor qu e to fo llo w in g
specifications:
• I f ol d s ty le p lu g w it h p hi lli ps s cr ew , t or q ue t o 15 ft .l bs .
• I f ne w s ty le ex tr ac to r p lu g , t o rq u e to 2 0 - 21 . ft .lb s .
5. T ig ht en ph illi ps sc rew if in st alled .
6. V er if y ha nd w he el op era tio n in m anu al m o d e.
21.3.7 Post-maintenance Testing - Gearcase Pressure Check
1 . U s in g ap p ro pr ia te fit tin gs , i ns ta ll pr es s u re g au ge an d co n nec t a ir s u pp ly t o

gear case ho us ing (1 ) af ter re-as s em bly of all m od ules is co m plete.
2 . S low ly ap ply p res s u re to gear cas e un til g au ge read s b etw een 28 - 3 0 ps ig .
3 . I s ola te pr essur e so u rce an d r eco rd a ir pr essu re.
4 . A ft er 15 m inu tes rec or d fi nal air p re s su re an d r ecor d p res s u re dr op if any .
5 . I f pr es s ur e dr op pe d m o re th an 2 p s ig, det erm ine s o ur ce of le ak an d re pai r pe r
t h e ap p r op r ia te s u bs e ct io n .
6 . If gea rcas e did n ot dr op pr es s ure o ver 2 ps ig , con tinu e t o n ex t s tep .
7 . R elieve pressure from g earcase.
8 . F ill gear case w ith oil thro ugh oil fill p lug hole up to o ne in ch o f h ole b ottom
t h r ea d s .
9 . I ncr ease air p ressure to gear case slow ly to 18 - 2 0 p s ig.
21-18
10 . Is o late p ressur e so u rce an d rec or d pr essur e.

11 . A fter f if teen m in ut es r ecor d fi nal air p ressur e and r eco rd p ressur e dr op if an y.
12 . If g ear cas e pr es su re d ro pp ed m o re th an 2 ps ig , de term ine s ou rc e o f leak a nd
rep a ir p e r th e a p p ro p ria te su b se c tio n .
13 . If gea rcas e d id no t d ro p pre ss u re ove r 2 p s ig, co ntin ue to nex t s tep .
14 . R em ov e f ittin gs , p res s u re su p ply an d rel ieve g earca se p res s ur e.
21.3.8 Post-maintenance Testing - Requirement Matrix
C o m p o n en t T o rq u e F u n c t io n a l T im e * D ia g n o s tic
R e p a ir e d T est V e r if ic a tio n R esp o n se T e s tin g
B ench
Sw itch M ech. X X X X
M otor M odule X X X X
W o rm ge ar X X X X
G earcase M odu le X X X X
D ri ve B u s hin g X X X
H and w heel M odu le X
S yncro set M o dule X
A d d-on P ack M odule X
* R efer to S ection 26 for tes ting guidelin es.
21.3.9 Actuator Replacement

1. E n s ur e actu ato r fe ede r br eak er is o p en.
2. I f requ ired re m ove old d rive bu sh ing fr om old actu ator (4 2, 39 ) p er Sect ion
2 1 .2 .6 .3 and rei ns ta ll on r ep lace m en t a ctu ato r p er S ecti on 2 1 .3 .1 .4 .
3. E n s ur e v alv e s te m i s pr o per ly s ecu red t o avo id p ers o nn el inju r y or eq ui pm en t
da m age.
4. L u br ica te v alv e st em as n ecessar y.
5. I n st all r igg in g as ne ces s ar y to s u pp o rt th e w eig ht o f th e a ctu ato r.
6. In s tall a ctuat or as f ollo w s :
a. F o r pr essu re seal t yp e v alves, lo os en y ok e cla m p bo lts , ro tate y ok e a nd
a ctuato r as necessary to p ro vide access to y oke bo lts .
b. F o r key ed s h aft s tem ap pl icatio n s, p o si tio n actu ato r s o key w ay s lin e up an d
pu s h act ua to r s t r aig h t o nt o g ea rb o x s h a ft .
c. F o r thr ea ded sh af t val ve s tem a pp lica tio ns , p o s itio n act ua tor s o dr iv e
bu s hin g a nd v alv e s tem m a te. O p er ate h and w h eel ho o p (7 7 ) to w ard op en
d ir ecti on u nt il a ctu ato r is f lu sh aga ins t va lve y ok e.
d. F or glo be va lve app licatio ns after p erf orm ing S tep c) en su re ke ys ar e
ins t all ed i nt o y ok e an d s te m an d k ey r et ain er s a re r ep lac ed p er va lv e
dr aw ing s.
e. A li gn act ua to r to m at ch m ar k s a s a pp li cab le .
7 . S ecu re a ctu at or t o y ok e o r ge ar bo x u s in g ap p ro p ri ate b ol tin g h ar d w are .
8 . E n s u r e p ro p er to rq u in g re qu i re m e nt s a r e m e t pe r v al v e dr a w in g s .
9 . R em o ve te m po r ary r ig gin g .
10. R em ove syn cros et cover (151).
21-19
11 . C onn ect field cablin g to term in al blo ck ( 152 ) as r equir ed.

12 . I ns tall sy ncro set hou sing cov er ( 151 ).
13 . R em o ve valv e gag device fr om s tem as applicable.
14 . Per fo rm s w itch s etup per S ection 2 0.0 .
21-20
T his pag e int ent ion ally l eft b lank .
F ig u r e 2 1 -la
7/1 1 /1 3 G e a rc a se A ss em b ly
(S ee Fig ur e 2 1-l b for Pa rts De sc ription )
21-22
F ig u re 2 1 -lb
7 /1 1/1 3 G e a r ca s e A s se m b ly
21-23
F ig u r e 2 1 -2
7 /1 1 /13 D riv e B u sh A ss em b ly
21-24
F igu r e 21 -3
7 /11 /1 3 M o to r A ss em b ly
21-25
F igu re 2 1 -4
7 /1 1 / 1 3 H a n d w h ee l S u b a s s em b ly
21-26
F ig u re 2 1 -5
S p rin g P a k S h e et 7 /1 1 N A 1
21-27
F ig u re 2 1 - 6 a
(S ee F ig ur e 21 -6 b fo r Pa rts De sc rip tio n)
21-28
- Rotork Maintenance Manual
F ig u re 2 1- 6b
S yn cr o se t A s se m b l y
21-29
F ig u r e 2 1 -7
P o s t - 1 9 7 8 A d d - o n - p a k A s s e m b l ie s
21-30
F ig u r e 21 -8
T y p e " A " a n d T y p e " N A " O ld V e r s io n A d d -o n -p a k
P r e -1 9 7 8
21-31
F igu r e 2 1- 9
T y p e " N A " N e w V e r s io n A d d - o n - p a k
Po s t-1 9 7 8
21-32
F ig u r e 21 - 10
A d d -o n -p ak M od u la r R ep la cem e n t o f S w itch B a nk s
P o s t-1 9 7 8
21-33
F ig u re 2 1 -1 1
A d d-o n -p ak M o du la r R ep lac em e nt of S w itch B a n k s
P r e -1 97 8
21-34
F ig u r e 2 1 -1 2
A d d -o n - p a k T y p i c a l A O P I G e a r A r r a n g e m e n t
21-35
F ig u re 2 1 -1 3
N A 1 a n d N A 2 S w itch M ec h a n ism A ss em b ly
P r e -1 9 7 8
21-36
F ig u r e 2 1 -1 4
N A T S w itch M e ch a n ism A sse m b ly
P o s t -1 9 7 8
21-37
F ig u re 2 1 -15
S w itch M e ch an ism M o du le (N A T )
(F r on t V iew C r oss Se ction )
21-38
F ig u r e 2 1 -1 6
R e p la c e m e n t S w itc h M e c h a n ism S w i tc h P a k s
21-39
F ig u r e 21 -1 7
F a b ric ate d C ov er A sse m b ly f or S w itc h M e ch a n ism
21-40
F ig u r e 21 - 18
F a b rica ted C ov er A s sem b ly fo r 6 S w itch A d d -o n -pa k 1
21-41
F igu re 2 1 -1 9
F a b r ic a t e d C o v e r A s s e m b ly f o r 1 2 S w i t c h A d d - o n - p a k 1
21-42
22.0 14/16 NA1 ACTUATOR
N u m b er ed r ef ere nce s in par en th es es , ( ) , co rr es po n d to F ig u res 2 2- 1a th r ou gh 22 -2 1 .
N O T E : T his p ro cedu r e ha s been w r itten utiliz ing a m od ula r ap pr oa ch t o

m ain tena nce activit ies. D u e to this ap pr oa ch, cer tain s tep s w ill be r epea ted
w ith sp ecific m od ule m aintena nce in m ind .
1 . E n su re actu ato r fee der b reak er is in op en po s itio n.
W A R N I N G : A dd itiona l cir cuits m a y need to be iso lated by rem o ving fus es ,

liftin g lea ds , o pening s liding links , etc.
W A R N IN G : I f th e s ys tem is p res s ur iz ed , th e va lve s tem m a y s lip r es ultin g

in s eriou s in jur y to p er s onn el per fo rm ing m a intenan ce on the actu ator .
2 . G ag va lve ste m as re qu ired by se curin g va lve ste m t o yo ke.

3 . T o rem ove syn cros et cover (151 ), r em o ve fo ur s crew s ( 188) .
4 . D is con ne ct an d rem o ve fiel d w ir ing f ro m s y ncr os et b od y (1 50 ). M ark w ir ing fo r
re con ne ctio n, a s n ecessar y.
5 . R eplace syn croset cov er ( 151 ).
6 . R eplace fou r screw s (18 8).
7 . T o rem o ve t he lim it s w it ch co ver (2 50 , 2 51, 2 52) , r em ov e th ree cap s crew s (2 57) ,
an d s pr in g w as h er s ( 25 8 ) .
8 . D is en g age t he p ri m ar y li m it s w itc h an d lo o s en ad d -o n- p ak cl ut ch n ut , if
ap plicab le (r efer to S ectio n 2 0 f or details ).
9 . R eplace lim it sw itch co ver (2 50 , 2 51 , 2 52 ) w ith cap screw s (2 57 ) and sprin g
w ash er s ( 25 8 ) .
C A U T IO N : W hen rigging the actuator for rem oval /r eplacem en t, care

s ho uld be ta ken to a void con nectin g to eith er the hand auto lever (1 1),
h andw heel ho op (77, 78), o r hand w heel spokes (7 3, 75).
1 0 . I ns t all r ig gi ng as ne ces s ar y t o s u pp o rt t he w ei gh t o f th e act ua to r an d p r ev ent

s tem d am ag e d u ri ng r em ov al.
1 1 . M at chm ar k act ua to r as s em bly an d va lv e yo ke t o es ta bl is h o rig in al in s ta llat io n
pos ition.
1 2. R em ov e th e m o un ting b olts o r stu d nu ts fr om belo w the val ve y ok e o r gear box
flange.
22-1
13. R em ove actuato r fro m valve as follow s :

a. G lobe V alves
- E n s ur e v a lv e s te m k ey s ar e r em o ve d a nd p ro p er l y m ain t ain e d u n til th e
a ctu at or is re pl ace d/ re in s tal led .
b . G at e V a lv es
- F o r th r ea de d s h a ft v a lv e s te m a pp l ica ti on s , r ot at e op e ra to r ha n dw h e el
t ow a rd c lo s ed d ir ect io n u nti l th e actu at or u n s cr ew s fr om t he v al ve ste m .
c. Q u ar t er T u r n V a lv e s
- F o r ke yed s haf t ap pli cati on s , en s ur e the a ctu ato r is pu lled s tra igh t of f o f
t he valv e s tem or gear bo x sp line s haf t to av oid val ve stem da m age.
14 . T r an s po r t act ua to r to pr o pe r ar ea f o r s to r ag e an d/ or re pa ir .
W A R N IN G : If the actua tor h as n ot b een rem o ved f ro m the valve pr ior to

m o tor as sem bly rem ova l, ens ur e a ctuato r feed er br eaker is in o pen pos ition.
A dd itio na l ci rcu its m a y als o ne ed to be is ol ated b y r em o ving f us es , liftin g
leads , op ening s lidin g links , e tc.
1. C heck m o tor w inding s (90) for dam age as follow s:

a. U s in g a d ig it al m u lti - m et er , m e asu r e w in d in g re sis tan c e b etw een ea ch
p h a s e. N o w in d in g r es i s ta n ce s ho u ld r ea d o p e n a n d t he re s i s ta nc e v a lu es
s h ou ld b e ap pr ox im at ely ba lanc ed.
b . U s in g a m e gg ar (1 00 0 v o lt scal e) , m ea s ur e th e re sistan ce b etw e en o n e m o tor
w in d in g t o th e m o to r h o us i n g. T h e r es i s ta nc e v alu e s h o u ld b e 2 1 .6
m e g o h m s.
c. If r es i s ta n ce v al u es v ar y fr o m r es ul ts i nd i cat ed ab o v e, co n ta ct t h e
a p p ro p r ia te en g in e er in g r ep r es en ta ti v e o r a R o to r k r e p re s en t at iv e .
2. D r ain oil f rom g ear case ( 1) b y rem o ving lo w er plug (86 ).
3. P la ce th e ac tu ato r i n th e h an d o pe ra tio n m od e b y d ep r es s in g h an d a ut o le ve r
(1 1) to th e m a nu al m o de.
4. I f th e m oto r is han gi ng v er tical f ro m the ac tua tor r ef er to S ec tio n 22 .2 .2 , S w itch
M ech an is m R em ov al to en sur e sw i tch m e chan is m (2 5 9, 2 61 ) an d to rq ue sw itch
sh af t ( 10 4 ) ar e re m o ve d p rio r t o m o to r r em o v al. P ro cee d to S tep 2 2 .2 .1.5 , if t he
m o to r i s h o riz on ta l to t he ac tu ato r .
C A U T IO N : I m pr oper rem oval o f th e m o to r cover (4) from the g ea rcase (1)

co uld res ult in dam ag e to o ilseal (66 ) an d b ear in g ( 43).
5. R em o ve t hr ee c ap s cr ew s ( 1 24 ) a nd s p ri ng w as h er s (8 1 ) th a t re tai n th e m ot or
co ver (4 ) to th e g earcase ( 1) .
22-2
6. R em o ve the m o tor cov er (4 ) slo w ly fro m the gearcase (1) .

7 . L o cate b utt co n nec tor s u nd er f ib erg lass sleev in g an d cu t m oto r le ads on b o th
s id es o f b utt con nec tors .
8 . R em ov e t he m oto r cov er (4) O - rin g ( 46 ) and in sp ect fo r d am ag e. R ep lace as
ne cessary .
N O T E: If the oil s eal (SE ; ) is deter m in ed to need replacem ent, the circlip
(1 30 ) a nd backu p w as her ( 131 ) m u st be r em oved fir st on P os t-19 78 m odels
o nly .
9. R e place oil seal (6 6) and ne edle bearin g (4 3) as req uir ed b y ind ication s of oi l
l ea ka g e or d am ag e.
N O T E : S ection 22.2 .1.10 per tains to P re-1 978 actu ator s only.
10 . In spect w or m shaft sh ro ud (29 ) f or dam ag e an d r eplace as n ecessar y.
1. P o s t-1 9 78 A ctu ato r s

a. E n su re ele ctr ica l p o w er is is o late d or d isc on ne cted .
b . V i su al ly in spec t fo r pr o per m ov em ent o f th e sw i tch m e ch ani s m ( 2 61 ) as the
v al ve is m a nu al ly o pe ra te d. If th e s w i tc h m ech a ni s m ( 26 1 ) s h o u ld ne ed
adjus tm ent ref er to S ection 2 0 of this m anual. I f dam age is ind icated,
rep la ce th e sw it ch m ech an is m ( 2 61 ) a s n ece ssar y.
N O T E : 2 2.2.2 .1 , St ep c) is n ot r equ ir ed if rep la cing s w itch b an ks o nly.
c. D rain o il fro m gearcas e (1 ) by rem ov ing lo w er plug (86 ).

d . R em ov e th e th ree c ap s cre w s ( 2 57 ) an d s p r ing w as h er s ( 26 8 ) th at r etai n th e
lim it s w itch cov er (2 50 , 25 1, 252 ) an d p ull co ver str aight off .
e. If the a ctu ato r is to rq u ed o u t i n eit he r th e op en o r cl os e d po s it ion , t he to r qu e
a dj us t in g f r o nt p l ate 's po in t er w ill n o t b e v er ti cal . I n t hi s in s ta nc e, m o v e th e
h an d a ut o le v er ( 1 1) in to t h e ha nd po s i tio n t o ce n ter th e to rq u e ad ju s ti ng
fr o nt p la te as n ec es s ar y .
f . D isco nn ect th e sw i tch m ech ani s m l ead s f ro m th e sw it ch b ank s ( 2 62 ) o n the
sw i tch m ech an is m assem b ly ( 26 1 ). M a rk w ir in g f or r eco n nec tio n, a s
nec es sa ry .
g . T o rem ove s w i tch b ank s (2 62 ), sc rew lo ckin g h ex nu t (2 69 ) t ow ard s s w itc h
b a nk (2 62 ).
h . M o ve s w itch b ank ( 26 2) to w ard t he fr on t p late (2 70 ) far e no ug h to rele as e
the s w itc h ba n k (2 6 2) fro m sw itch m e c ha n ism re ar p late (2 7 2).
22-3
1. R e m ov e tw o caps crew s ( 264 ) on the s w itch m ec hanis m bas epla te (2 63 ).
C A U T I O N : U s e ca re w h en rem o ving sw itch m echa nis m (2 61 ) to a void

dam age to the O -ring (271) .
J. C aref ull y rem o v e th e sw itc h m ech ani sm ( 26 1) f ro m th e gear case (1 ).

k . R em o ve the lim it s w it ch dri ve gear as s em b ly ( 97 , 98 , 1 03 ) fr om the s w it ch
m e ch ani s m s h af t (2 61 ) b y dr iv in g ou t th e s p ri ng p in ( 9 9) l oca ted n ear t he
lim it s w itch rear p lat e ( 27 2) .
1. R em o ve the torq ue s w it ch s h aft (10 4) .
N O TE : If rep lacem en t of oil s eal ( 67) is req uir ed, circlip (12 5) and sea l
backu p w asher (1 26) m ust b e rem o ved p rio r to repla cem en t as
neces sa ry in 22.2.2 .1, Step m ).
m . V isu ally in sp ect oi l seal (6 7) f or lea kag e o r dam age. R ep lace as ne cessary .
n. V is u ally in s pe ct t or qu e s h af t s h ro ud ( 84 ), s n ou t bear in g (4 2) , an d nee dle
b ear ing (4 3) f or w ea r or d am a ge. R ep lace p art s as nece s sa ry .
2 . P re -1 9 78 A c tu ato rs
a. E ns u re electr ical po w e r i s is ola ted or d is con necte d.
b. V isual ly insp ect for p ro per m ov em en t o f the sw itch m ech ani sm ( 26 9) as t he
va lv e i s m anu al ly o pe ra ted . I f th e sw i tch m ech an is m ( 25 9 ) sho u ld n eed
ad ju s tm e nt r ef er to S ec tio n 2 0 o f t hi s m an ua l. I f d am ag e is in di cat ed ,
r eplace the sw itch m ech anis m (26 9) as n ecessar y.
N O TE : 2 2.2 .2 .2, Ste p c) is n ot r eq uir ed if r epla cing s w itch ba nks o nly.
c. D rain oil fro m gearcas e (1) by rem ov ing lo w er plug (86) .

d . R em ov e th e thr ee c aps c re w s ( 26 7 ) an d s p rin g w a s her s (2 68 ) t hat r eta in t he
lim it sw itch cov er ( 260 , 2 61 , 2 62) and pu ll co ver str aight off .
e . I f th e a ctu ato r is to r qu ed o u t i n eit he r th e o p en o r cl os ed po s iti on , th e to rq u e
a dj u s tin g fr o nt pl ate 's po in t er w ill n o t b e v er tic al . I n th i s i ns tan ce , m ov e t he
h an d a ut o le v er ( 1 1) in to t he h an d p o s it io n to cen te r th e to r qu e a dj us t in g
f r on t pl ate a s n ec es s ar y.
f . D is c on ne ct the s w itc h m ec han is m lea ds fr om th e s w itch b an ks (2 60 ) o n th e
s w it ch m e cha nis m as s em bl y (2 69 ) . M ar k w iri ng f o r rec on ne ctio n , as
n ecessary .
g . T o rem ove s w itch b ank s (26 0) , co m pr es s w as h er ( 26 6) and s prin g (26 6) by
m o vin g s w itch b ank ( 26 0) t ow ar ds the fr on t plat e ( 27 0) p ul ling s w it ch ban ks
( 26 0) o ut of the sw itch m ech ani sm re ar plate (2 72 ).
h . R em ov e tw o c aps crew s (2 64) o n th e s w itch m echan ism bas eplate (2 63) .
22-4
C A U TI O N : U s e care w hen rem ovin g sw itch m ech an ism (26 9) to avo id

da m age to the O -r in g (271 ).
i. C are fu lly re m ov e t he sw itch m ec han is m (2 59 ) fr om th e g ear case ( 1) a nd slip

g ear case h eat er ou t o f cli p loc ated o n the b ack o f the sw itch m ech anis m .
j. R em o ve the lim it s w itch d riv e g ear as s em bl y (9 7, 98 , 10 3) f ro m th e sw itc h
m e ch ani s m s h af t (2 59 ) b y dr iv in g ou t th e s p ri ng p in ( 9 9) l oca ted n ear t he
li m it s w itch r ear p late ( 27 2) .
k. R em o ve the to rq ue s w itch s haft (1 04) .
1. V isu ally in sp ect oi l seal (5 7) f or le akag e or d am ag e. R ep lace as n ecessar y.
m . V isu ally i nsp ect n eed le be ari ng ( 43 ) f or w e ar o r da m ag e. R ep lace p ar ts as
n ecessary .
1. P os t-1 97 8 A c tuato rs
a. E ns ur e ele ctrical po w er is is olated o r dis con nec ted.
b. R e m o ve th e th re e cap s cr ew s ( 2 67 ) an d s p ri ng w a s he rs (2 6 8) t hat r eta in th e
lim it sw itch cov er ( 260 , 2 61 , 2 62) an d p ull co ver s traigh t of f.
c. D is con nec t th e a dd -o n- pak lea ds , w ithi n the s w itch m ech an is m lo om ( 17 2) ,
fro m th e a d d- on -p a k s w itc h es (3 0 3 ). M a rk w irin g fo r re co n n ec tio n , as
n ec e s s a r y .
N O T E : I f r ep la cin g a dd -o n- p ak s w i tch b an ks (3 03 ), p er fo r m S tep s d )

a nd e) o nly o f the rem ain ing s teps in Section 22 .2.3.1 .
N O T E : If r em o ving th e ad d- on- pa k as s em bly (30 0, 30 1, 30 2) for r ep air

/ in s pe cti on o f th e act ua to r , eli m in ate S tep s d an d e) an d p er fo r m t he
r em ainin g step s in S ection 22 .2.3.1 .
d. R em ove the s w i tch h old ing p lates (3 13 ), co m pr ess io n s p rin gs ( 310 ) and
w asher s (3 09 ).
e. P u ll ad d- o n- pa k s w itc h pa k s ha ft ( 31 1) tow a rd s t he f ro nt p lat e ( 3 14 ) an d
rem o ve s w itch bank s (3 03) .
f. R em o ve tw o caps crew s ( 312 ), w a sh ers (3 09 ) an d co m pr ess ion s pr ings ( 31 0)
th at r etai n s w itc h ho ld in g p late s ( 31 3 ) to th e fr o nt p late ( 31 4 ).
g. R em o ve s w itch hold in g p lates (3 13) .
h. M ov e sw itc h b an ks ( 30 3) to th e s id e to al low entr ance of al ien key in to th e
s o cket cap s cre w s (3 15 ) th at r etai n add -o n- pa k (3 00 , 30 1, 3 02 ) to m o un tin g
pillars ( 330 ).
i. R em ov e the thre e socket capscrew s ( 316 ).
j. R em ove add- on- pak (3 00, 30 1, 302 ) f rom the s w itch driv e s haft (27 3).
22-5
k. L oos en set s crew (328 ) in lock in g plate (3 29), th en rem ov e locking p late ( 329) ,
sp acers ( 32 6) and g ear c lus ters ( 32 5).
l. P er fo rm v isual in spe ctio n of g ear cl uster s ( 32 5 ), sp acer s ( 32 6) , dr iv e ad ap ter
( 32 7) , lo cki ng p late ( 32 9) , m o un tin g p illar s ( 3 30 ) an d se t s c rew (3 28 ) f or
d a m a g e a n d ab n o rm a l w e a r.
m . If m o un ting pi llars ( 330 ) are dam ag ed, un s crew f rom s w itch m echan is m
as sem bly (2 61).
n . R eplace pa rts a s nece ss ar y.
2 . P re -1 9 7 8 A c tu ato rs
a. E nsur e electr ical p ow er is is olated or disco nnect ed.
b . R em ov e th e thr ee ca ps c rew s ( 25 7) an d spr in g w ash er s ( 2 58 ) th at r etai n th e
lim it s w itch cov er ( 250 , 2 51, 25 2) and pull cover s traight off .
c. D iscon nect th e ad d-o n- pak lead s w ith in the sw itch m echan is m lo om (1 72 ),
fr om th e ad d- on -p ak s w it che s ( 31 9) . M ar k w ir ing fo r rec on ne ctio n, as
ne ces sar y.
N O T E : If r epla cing a dd -on -p ak s w itch b an ks (3 19 ), pe rfo r m 22 .2 .3 .2,

Steps d) thr oug h f) only.
N O T E : I f r em oving the ad d-o n-p ak as sem bly (3 00, 30 1, 30 2) for

re pair /in sp ectio n o f th e a ctua tor elim in ate Sectio n S teps d) thr ou gh f)
and p erfo rm th e r em ainin g s teps in Sectio n 22.2.3 .2.
d . L oo se n t w o f ro nt m ou nti ng nu ts ( 32 4) ne ares t t o sw itch b ank s ( 31 9).

e. Sc rew lock ing hex nu t (3 22 ) to w a rds s w itch bank s (31 9) .
f . M ov e s w itc h ban ks (3 19 ) tow ar ds fr on t p late ( 31 4) f ar eno u gh to r eleas e
s w itc h ba nk s ( 31 9) fr om ad d- on - pak m ain f ra m e.
g . L oo s en t hr ee al ien s cr ew s (3 2 0) tha t ret ain t he ad d -o n -p ak m ain f r am e to the
m o un ting p illars ( 32 1) .
h . R em o ve a dd- on -p ak (30 0, 30 1, 3 02) f ro m th e s w itch m echa nis m d riv e s ha ft
(2 73 ).
i. L oos en set screw ( 328 ) in lockin g p late (32 9), then rem ov e lockin g p late (32 9),
spa cers ( 326 ) and ge ar cl us ters ( 32 5) .
j. P erf or m v isual in sp ectio n of g ear clu s ters (3 25 ), spac ers ( 32 6) , dr ive ad apte r
(32 7), lock ing plate ( 32 9), m ou nting pillar s (32 1) and set scr ew (32 8) for
da m ag e an d ab no r m al w ea r.
k . If m o u ntin g pi llars (3 21 ) are d am ag ed, u ns cr ew f ro m sw i tch m ech an is m
assem bly ( 259).
1 . R e pla ce pa rts as nec es s ar y.
1 . E n s u re e le c tric a l p o w e r is is o la te d o r d is c o n n e c t.
2 . R em ov e f our s crew s (1 88 ) f rom the sy ncr os et b ody ( 150 ) an d rem o ve co ver (1 51 ).
22-6
3 . R em o ve O -r ing (16 4) and vis ually ins pect for dam ag e.

4 . D is c on ne ct and rem ov e all ex ter n al w iri ng . M ar k w ir ing fo r re co nn ecti on , as
n ecessary .
N O TE : T o rep lace d am ag ed ter m ina l blo ck (1 52) on ly, com plete S ection
2 2.2.4 S teps 5) thr o ugh 7 ). T o rem o ve th e en tir e s yncr o se t as s em bly
p roceed to Sectio n 22.2.4 S tep 8).
5 . R em ov e gr ou nd ing lug con nectio ns ( 15 8, 15 9, 16 0, 165 , 166 ) and retain ing rin g
(1 74) fro m ins ide the syn cros et bo dy ( 150) .
C A U T IO N : W h en rem ovi ng the term in al b lock (15 2) do n ot p ull on the

b r as s ter m ina l st ud s .
6 . Pu ll the ter m ina l b lock ( 16 2) s tr aigh t out o f t he s yn cro se t b od y (1 50 ) u s ing tw o

pa irs o f pli er s b y gr ip pi ng a nd p u llin g o n ter m in al b lo ck s ep ar ato rs .
7 . R e m ov e inte rn al w i rin g fr om th e back o f ter m in al blo ck ( 15 2) . M ark w ir in g fo r
r econ nectio n, as nece ss ary .
8 . R em o ve f our capscrew s (1 67) betw een the syn croset b od y (1 50 ) an d g earcase (1) .
9 . R em o ve s yn cro set an d v is ual ly ins pec t O -r ing ( 17 0) .
1 0. O nce th e syn cro set assem b ly is rem ov ed fro m t he gear case ( 1), th e w ir e lo om s
(1 72 , 18 4, 1 85 ) m ay be d raw n ou t thr ou gh th e g ear cas e ( 1) o pen in g.
N O T E : Sectio n 22 .2.4 Step s 11 th r ou gh 13 a re to be per fo r m ed o nly if

r ep air ing da m a ged ter m in al block (16 2) after th e s yncr os et h as b een
r e m o ve d .
1 1. R em o ve gro un ding lu g co nn ections (15 8, 15 9, 160 , 165 , 1 66 ) an d retainin g ring

(1 74) fr om ins ide the sy ncr os et b ody ( 150 ).
C A U T IO N : W h en rem o ving the ter m in al bloc k (1 52 ) d o n ot pu ll or app ly

f or ce to th e b ra ss ter m in al st uds .
1 2. P u ll th e t erm in al blo ck (1 52 ) st raig ht ou t o f the s yn cro s et b od y (1 50 ) us ing tw o

p air s o f p lier s b y gr ip pin g an d p ull ing o n te rm i nal b lo ck s ep arat or s .
A d di tio na lly, the te rm i nal b loc k (1 52 ) m a y be ta pp ed f ro m the r ear to a id in
r e m o v a l.
1 3. R e m ov e int erna l w irin g fro m th e b ack of term inal bloc k ( 15 2). M ar k w ir ing fo r
rec on ne ctio n, a s ne ces s ar y.
22-7
N O T E : P rio r to r em ovin g h and w h eel m odu le, n ote the p os ition of th e a ctuato r
to determ ine if dr aina ge of oil fr om gea rca se ( 1) is n ecessary. I f the h and w heel
is in a tw elve o'clo ck pos itio n, S tep 22 .2.5 .1 S tep a) is n ot r equir ed.
1 . T o p M o u n te d H an d w h e el
a. D r ain oil by rem oving low er plug (86) fro m gearcase ( 1).
b . R em ov e h and w heel retain er se aling p lug (1 21 ) f ro m th e g earcase (1 ).
N O T E : T he ha ndw he el m u st tu rn in a clo ckw is e d irection w hil e

rem oving the nylo n ha ndw h eel retainer (1 22).
c. R em o ve the ha nd w h eel ret aine r ( 12 2) .

d. In s pect n ylo n hand w heel retain er ( 12 2) fo r d efects .
e. L if t t he h and w h eel m o du le s tr aig ht o ff u s in g car e n o t t o da m ag e the O - rin g
(49) or the o il s eals (50 ).
f. R em ove and ins pect O -r in g (49) .
g . V isu ally in sp ect oil seals (5 0) fo r leak age or d am ag e. R e place p arts as
n ecessary .
2 . S id e M o u n t ed H an d w h ee l
a. D r ain oil by rem oving low er plug (86) fro m gearcase ( 1).
b . R e m ov e ha nd w he el r eta ine r eatin g p lug (12 1) f rom the g earcas e (1 ).
N O T E : U s e sn ipe nos ed p lier s to gr ip th e end o f the r eta iner w hile

r em oving th e nylon hand w heel r etainer (12 2).
c. R em ov e t he han dw h eel retai ner (1 22 ).

d. In s pect n ylo n hand w heel retain er ( 12 2) fo r d efects .
N O T E : S ide m o un ted h an dw heel ca s ings ar e do w elle d a t th e top o f the

ge ar cas e (1 ), an d m ay req uir e g entle t app ing up w ar ds w ith a r ub ber
m a llet to r em ove.
e. L if t t he h and w h eel m o du le s tr aig ht o ff u s in g car e n o t t o da m ag e the O - rin g

(49 ) or the oil s eals (50).
f. R em o ve and insp ect O - ring ( 49) .
22-8
g. Visually inspect oilseals (50) for leakage or damage. Replace parts as

necessary.
1 . G ea r ca se R em o va l a nd I n sp ect io n
a. R em ov e actuato r f rom valv e per S ection 22.1.
b . D rain all oil f rom actuator gear case (1) by loo sen ing low er m o st plug (8 6).
c. R em o ve th e fo llow ing actuato r com po nen ts per applicab le section s:
• M o t or : S ec tio n 22 .2.1
• S w i tch M e ch an is m : S e ctio n 2 2 .2 .2
• S yn cr o s et : S ec ti on 2 2.2 .4
• H an d w h ee l: S e ct io n 2 2 .2 .5
d . R em ov e r em ain ing gea rcas e in tern al co m po nen ts p er th e f ollo w ing s ection s :
• C lu tc h an d W or m g ea r: S e cti on 22 .2.6 .2 .
• D r iv e B u s h ing : S ec tio n 2 2.2 .6 .3 .
• H an d A u to L ev er : S ecti on 22 .2.6.3 4.
• O il S e al: S ec tio n 2 2 .2 .6 .5.
• W o rm s ha f t B u s h i ng : S e c ti o n 2 2 .2 .6 .5, S te p c) .
2 . C l ut ch an d W or m g ear R e m o va l
a. R em ov e actuato r f rom valv e per S ection 22.1.
b . R em o ve han dw h eel a ss em b ly fr om the actu ator p er S ection 2 2.2.5.
c. D r ain all oil f rom actuato r g earcase (1 ) b y lo os ening lo w er m ost p lug (8 6).
d . R e tu rn actu at or to a ut o p os i tio n b y u s in g a s c re w dr iv er t o th e g en tly nu d ge
the fin ger ( 12 ) on th e y ok e as s em b ly (1 0) un til it an d the clu tch rin g (2 6) dr op
back do w n onto the w orm w heel (21).
W A R N IN G : T he clutch sp r ing (25 ) i n th e follo w in g s tep is s till un der

load a nd could cau se ser iou s injur y if car e is no t taken w h en r em oving
the clu tch retaining O -r in g (52) .
e. R em o v e th e clut ch re tain ing O - rin g (5 2 ), s pe cial w as he r ( 3 1) , and cl utc h

spr in g (25) from top of center colum n (8) .
f . Slid e the clutch ring (2 6) and yok e assem b ly ( 10) of f th e center colu m n ( 8)
tak ing car e n ot to dr op clu tch key s (2 7) int o th e g earc ase (1 ).
g . R em o ve th e ca ps cre w s (6 7, 3 6) an d s p rin g w as her s (6 1, 3 3) r etain ing th e
th ru s t p ad ( 15 ) .
h . L ift ou t thru st p ad (1 5) and w or m w heel (21 ) f rom g earcase (1).
i. R em ov e cap scr ew s (71 ) retain ing thr ust b ase (2 ) to g earcase ( 1). S tand
g ear case (1 ) so that th e han d au to lev er (1 1) i s u pp erm os t.
C A U T IO N : U se a p iece of w oo d or a ru bber m allet to tap the cen ter

colu m n (8 ) and ba s e as s em bly fr ee in th e fol low in g step to pr es ent
dam age to the cen ter colu m n ( 8).
22-9
j. T ap center colum n (8 ) as s em bly fro m top to driv e it o ut o f th e gear cas e 1 ).

k. T o w i thdr aw ba se as sem bly fr om the c enter colu m n (8 ), s upp or t th e
b as e/ cen ter c ol um n as s em bl y s o th at t he m o u nt in g ho le s ar e u pp er m o s t.
1 . U s ing a stan da rd ben ch pr ess or jack in g str ap pr ess ou t th e cen ter col um n ( 8)
and lim it s w itch w orm (19 ).
m . S up po rt t he li m it s w itch w orm (1 9) and p res s th rou gh th e cen ter c olum n ( 1) .
n . T o w ith dr aw th e th ru s t b earin g (4 1) f rom th e th ru s t b as e ( 2) rem ov e eig ht
scr ew s caps cr ew s (7 1), lif t o ff thr us t r ing (3 ) and lif t be arin g ( 41 ) o ut.
o . U s in g the d riv e b us h ing r etain er ( 5, 2 2) as a p res s t oo l, loc ate a gain s t t he
bear ing s top r ing (9 ), po s ition as s em bly u nde r b ench p res s and p res s o ut.
p . R em o ve all O -rin gs; inspect and replace as necessar y.
3 . D r iv e B u sh in g R em o va l an d I ns p ecti on s
N O T E : T he a ctuato r m u s t be rem oved fr om th e valve pr ior to dr ive

bu shing rem o va l (refer to Section 22 .1).
N O T E : S om e a ctu ato r s h av e a ho le w h ich i s n ot p lug g ed. I n th is c as e

o m it 2 2 .2 . 6. 3 , S te p a ).
a. U ns crew an d r em ov e p lug (59 ) on sid e o f actu ator bas e.

b . U s in g h an d au to l eve r ( 11 ), po s iti on actu at or t o h and op er ati on .
c . R o tate t he h an dw hee l as s em bl y un ti l th e bu s hi ng re tain er s ets c rew ( 65 ) i s
v isibl e th ro ug h th e h ole in th e gear case (1 ) base.
d . R em o ve s ets cr ew (65).
e . U n sc rew d riv e bu sh ing r etain er (5 , 22 ) b y us in g a sp ann er w r en ch inser ted
int o the tw o ho les p ro vid ed on t he dr ive bu s hin g reta iner ( 5, 2 2) .
N O T E : F or type A d rive bu shin g (7 ), r ecord the po sition of the d rive

b us hin g (7) p rio r to r em ova l. P os ition 1 : D r ive B us hin g (7) is i ns er ted
in to th e cen ter colu m n ( 8). P o sitio n 2 : D r ive B us hin g ( 7) pr otr ud es
fr om the center colu m n (8). W hile per form ing 2 2.2.6.3, Step 79 rem ove
th e dr ive b us hin g ( 7, 22 ) b y pu lling it s tr aigh t o ut o f the center co lum n
(8 ).
f . V is ually in sp ect th reads o f the d riv e bu sh ing (7 , 2 2) fo r d am age.

g . V isu ally in s pect m ach ine d sh ou lde rs o f the dr ive bu s hin g (7 , 22) , at the
co ntac t po int w ith the center co lum n ( 8) do gs , fo r cr acks or shear s.
h . R epl ace dam age d par ts as n ecessar y.
22-10
4 . H an d A uto L ev er R em o v al and In s pec tio ns
N O TE : T o ga in a ccess to the h and au to lever co m p onen ts, the a ctuato r

h and w heel as sem bly m us t fir st be rem oved p er S ection 22.2.5; A cces s w ill
a ls o b e im pr oved by r em oving the cen ter colum n (8) per 22.2.6.2.
a. F r om in side th e g ear case (1 ) h and w hee l e ntr y, l ocat e u pp er m o st seal lo ck p in

( 62 ). P os ition d rif t p unch ; tap o ut and rem ov e fr om gear cas e ( 1).
b . P u ll o ut han d auto lev er (1 1) .
c. U n ho ok s p lit pi n (6 3) f ro m cam ret ur n s pr ing ( 89 ) an d re m ov e han d au toc am
(17)
d . C a ref ul ly m an ip ul ate cam re tur n s p rin g ( 89 ) an d rem ov e it f r om lo cati ng p in
(1 6).
5 . O i l S eal R em o val
a. O n P os t- 19 78 r em o ve back up w as h ers (1 31 , 12 6) o n the m o tor w o rm s h aft
b or e a nd t or qu e sh af t bo re .
b. R em ove old oil s eals.
c. O n P re- 19 78 in sp ect, r em o ve & r epla ce w o rm s h aft s hro ud ( 29 ) as r equ ired .
6 . T o rq u e S h af t S h r o u d a n d W o r m s h af t B ea ri n g R em o v al
a. P o s itio n ge arca s e ( 1) s o th at s w itch m ech ani sm en tr y is u pp er m o st .
b . L oca te d r ift pu nc h into tor qu e s h af t s h ro ud ( 84 ) and s n ou t bear in g; (4 2) d ri ve
d ow n w ard s u nt il t hey are p ush ed in to th e g ear case (1 ) , and t hen r em o v e.
c. P osit ion g ear case ( 1) so th at the m o tor b or e is up pe rm o s t.
d . L oc ate dr ift p un ch in to m o to r bo re to r es t aga ins t th e e nd o f the n eed le
b ear ing ( 43 ) an d dr ive ou t i nto ge arcase (1 ) and re m ov e.
1 . B e a ri n g A s s em b l y
a. F it nee dle be arin g (4 3) o nt o the be arin g pr ess to ol , loca te in g ear case (1 ) at
m o tor w or m b or e, a nd pr es s ho m e.
b . P re- 19 7 8 on ly: F it w or m sh aft sh ro ud ( 29 ) o nto t he w or m sh aft n eed le b eat ing
tool , lo cate in g ear case (1 ) at m o tor w or m b or e an d p ress h om e.
c. C oat th e o uts id e o f th e o ne w or m shaf t o il seal ( 55 ) w ith H yl om ar a nd p ress
into g earc ase (1 ) (b oth d yn am ic s ides to the in sid e) w ith w or m s haf t o il se al
too l; repeat for the secon d seal (5 5) (dy nam ic side outside).
d. P os t-1 97 8 o nly ; F it s eal back up w ash er (1 30) an d ci rclip (1 31 ) in to gear case
(1) at m oto r w orm bor e.
e. F it sno u t b ear ing ( 4 2) o nto t he be ari ng to ol , loc ate in ge arca se ( 1) at to rq u e
sw it ch s ha ft bo re , and p re ss ho m e.
f . F it tor qu e s h aft s hr ou d (8 4) on to fl am ep ro of s hr ou d too l ( to rqu e sh aft en d) ;
lo cate m ge arc ase ( 1) a t t or qu e sw it ch sha ft bo re , and pr ess h om e .
g . L ocat e th e t orq u e sha ft oil seal (5 7) o n tor qu e sh aft seal too l an d pr ess h om e .
22-11
-
E P RI L ic e n s e d M a te ria l
N uclea r Ma intena nce A pplications C en ter
2 . H a n d A u to L ev e r A s s e m b l y
a. F it oi l s e al ( 5 6 ) u s i n g h a nd au t o s eal to o l o n to h an d au to le v er (1 1 ) s h af t.
b . F i t lo cat in g p in (1 6 ) a nd O - ri ng (5 3 ) i nt o g ear ca s e ( 1) , f it c am r et ur n s pr in g
(89 ) to end of locating p in (16) .
c. S m ea r E x xo n U n i re x N 2 g r e as e on h a nd a ut o le ve r (1 1 ) an d in s e r t th r o u g h
o il s ea l ( 5 6) s o th at th e h an dl e o f t he l ev er h an gs d ow n to w ard s th e ba s e
en try o f the gea rcase (1 ).
d. I n s er t t h e s p li t p in ( 6 3) in t o t h e ca m ( 1 7 ), an d lo c at e th e c am on t he ha n d
au to l ev er sh af t.
e. H o ok th e en d of th e spr in g ( 89 ) in to th e ey e o f t he sp lit p in ( 6 3) .
f. L i f tin g th e h a nd l e o f t he ha n d a u to lev e r ( 1 1 ) t o t he lef t , l in e u p th e h o le i n
th e ca m (1 7 ) w i th t h e ho le in t he ha nd au to lev e r s h af t an d d r iv e h om e th e
s prin g pin (62 ).
3. C en t er C ol u m n an d C lu t ch an d W o r m g e ar A s s e m b l y
a. S m ear O -r in g gr o ov e an d b o re o f t hr u s t b as e ( 2) us i ng E x xo n U ni re x N 2 .
b . S m ea r t w o O -r i ng s ( 51 ) w it h g r ea s e an d lo ca te i n t hr u s t b as e (2 ) .
c. W o rk in g f r o m th e to p o f th e ba s e, lo cat e b ear in g s to p r in g ( 9 ) a nd pr es s i nt o
pla ce so th at th e to p fa ce of the b ear in g sto p r in g (9 ) is lev el w it h th e be ari ng
s helf.
d . F it th ru st b e a rin g (4 1 ) in to th ru s t b a se (2 ).
e. A s s em b le t h ru s t ri n g ( 3 ) t o t hr u s t b a s e ( 2 ) u s in g ei gh t c ap s c r ew s ( 6 9) an d
torq ue to 3 8 - 4 3 f t. lbs .
f. A pp ly lo ck ti te to th e k nu r l o n th e ce nt er co lu m n (8 ) ; lo cat e lim it s w i tc h w o rm
(1 9) on to th e cen te r co lum n ( 8) a nd p r es s o n u s in g be nc h pr es s an d len gt h o f
tu b ing .
N O T E : E n s ur e co rr e ct r a tio l im it s w it ch w o r m i s fit ted a nd N O g a p

exists b etw een w o rm an d c enter c olu m n sho uld er w hen a ssem b led.
g . G r eas e l o w er se cti on of cen te r co lu m n an d O - ri ng gr o o ve

h . G r ease an d f it O - r ing (4 7 ) to cen ter co lu m n ( 8 ).
i . L o ca te ce nt er c o lu m n ( 8 ) th r o u gh t hr u s t b ea ri n g ( 4 1 ) an d in t o b e ar i ng s t o p
ri ng (9 ) u n de r a b en ch pr es s . P re s s h o m e u n til s h o ul de r o n t he c en ter co lu m n
co m e s to re st a gai ns t th e to p su rf ace o f th e be ar in g.
N O T E : D ur in g as s em b ly o f t he cent er co lum n in to th e th r us t ba se th e
be ar ing s top rin g w ill m o ve aw ay fro m the bea rin g.
j. In v e r t as s em b ly a nd u s e a s u i ta bl e s iz ed tu b e a n d m a ll et to g en t ly ta p th e
be ar in g s to p r in g b a ck in to p la ce. I n s er t d r iv e b u s h in g a n d t ig h te n r et ai n er
se cur ing w i th s crew .
k . F it tw o sp ira l p in s (3 4 ) to th ru st b a se .
1 . G r e as e t op s p ig o t o n t hr u s t b as e a s s em b ly an d f it O -r i ng ( 46 ) .
22 -1 2
m . G re ase ba se e nt ry b o re o n ge ar case an d assem bl e base a sse m b ly in to

gea rcas e , loc ate s pir al pin s ( 3 4) in to h ole s an d s ecu re b as e t o gea rca se u s ing
fo ur cap s cr ew ( 71 ).T i gh te n to 1 0 - 1 2 f t. l bs .
n. S lide w orm w h eel (21) on to center colum n (8) and allo w w h eel to s it on sh elf
acr oss cen ter o f g ear case en sur in g d riv e pi ns are u pp er m o s t.
o. P o s iti on th r us t pa d (1 5 ) s o th at the b lin d ho le in t he u pp er m os t le vel o f th e
pa d i s n e ar es t t h e s y nc ro s e t en tr y on th e g ea r cas e . S e cu r e u s in g f o u r
cap screw s (70 ); torq ue to 10 - 12 ft. lb s.
p. M an ip ul at e yo k e as s e m b ly (1 0 ) in t o p lac e en s u ri ng th at t he ha nd au to fi ng e r
as s em bl y lie s f lat o nt o th e w or m w h eel an d th e ad ju s tin g s et s cr ew loc ates
int o th e bl ind ho le in the t hr us t p ad ( s ee F ig u re 2 2.3 -1 ).
F i g u r e 2 2 .3 - 1
Y o k e A ss em b ly In s ta lla tio n a n d A d ju stm e n t
N O TE : C lutch key (27 ) or ienta tion is cr itica l. W id e s ide of keys an d

clu tch r ing (2 6) m us t be upp er m o st, no t ag ain st w or m w heel
q . In stall clutch key s (2 7) into clutch rin g ( 26 ) an d p lace assem bly on the center
c o lu m n (8 ).
r. P res s c lutch s p rin g (25 ), w as h er (3 1), an d O -r ing ( 52 ) d ow n o nto cen ter
colum n ( 8) ens urin g th e O -rin g ( 52) lock s into center colum n 's ( 8) gro ov e
us ing clutch s prin g co m pres s or tool to co m pr ess .
22-13
s . A d ju s t yo ke a dju s tin g s et s cr ew s o th at th er e i s ap p ro x im at ely 0 .0 1 5 in ch

cl eara nce be tw een th e y o ke lif ting t abs (1 0) an d th e cl utc h rin g sho uld er ( 26 )
w h en th e clu tch rin g an d k ey s ar e fu ll y en gag ed ( d ow n ) ag ain s t th e
w o rm w heel (2 1) (s ee Figu re 22.3 -1).
t. T ig ht en yo ke ad ju st ing s et s cr ew lo ck n ut s nu gl y on ce se t s cr ew i s pr o per ly
ad ju sted .
4 . D ri v e B u s h in g A s s em b ly
a. V erif y th read s ar e i n go od co nd itio n and a re geo m etr icall y cor rec t f or v alve
s tem ap plic atio n.
b . V e rif y req uir ed m o un ting p os itio n of th e d ri ve bu sh in g ( 7, 2 2) an d ins er t i nto
the gear case b ase in side of the cen ter colu m n (8 ).
c. E n s ur e the s lo ts o f th e dr ive b us h in g (7 , 22 ) ar e f u lly en ga ged w i th th e
ac tuat or 's cen ter co lum n shaf t d ri ve do gs .
d . I n s tal l an d t ig h ten d ri ve b u s h in g r et ain e r ( 5, 2 2) .
e . U s i ng a f eel er g au ge, ve rif y g ap b etw e en d ri ve b us h in g r etai ne r (5 , 2 2) an d
b ush ing ( 7, 2 2) d oes not ex ceed 0.0 22 in ch.
f. I ns t all a nd tig h ten dr iv e b us h in g r et ain er s cr ew (6 5 ).
g . P re -19 78 o nly : rein s ert red cap plu g (5 9) in to gea rcas e (1 ).
1 . W ir ing L oo m In ter n al C o nn ect ion s t o T er m in al B un g
a. C o n nec t h eat er w ir es t o ter m in als 4 an d 5 o n b ack o f ter m in al b loc k (1 5 2)
f r om th er m os t at loo m (1 85 ) .
b . C on ne ct m oto r w ires to ter m ina ls 1 , 2, an d 3 on b ack of t erm i nal blo ck ( 15 2)
f ro m m o to r lo o m (1 8 4 ).
c. C o nn ect n um b er ed sw itch m ech an is m a nd ad d -o n- pak loo m (1 72 ) to
co rr espo n din g n um b er ed ter m in als on back of te rm i nal b loc k (1 52 ) .
d. Pe rfo rm con tin uity ch eck w ith m eter fr om fi eld sid e o f term inal blo ck (1 52 ) t o
e ach sw itch co nt act to en su re co rr ect sw i tch is w i red o ut to co rr ect ter m in al.
2. A s s em bl y o f T erm in al B lock in to Sy ncr os et
a . S m ear O -r ing ( 16 4) a nd ter m in al blo ck ou ter b or e w it h gr ease a nd p lace O -
r ing ( 164 ) into low er rad ial groo ve of s yncro set.
b . C ar ef ully p os itio n ter m in al b un g ins id e s y ncr os et bo dy ( 15 0) ta kin g care no t
t o p inch o r d am ag e an y w ir es or th e O -r ing (1 64 ).
c . S ecu re te rm ina l b lo ck ( 15 2 ) by p lac in g ret ain in g rin g ( 17 4 ) int o ou te r rad ial
g roove of the s yncroset bod y (150).
d. In s tall g ro und ing lu g ass em b ly (1 66, 1 59 , 1 65 , 159 , 16 0, 15 8) into s id e of
s yncros et bo dy (150) .
3 . A ss em b ly of Sy ncr os et M o dule to G ear cas e
a. E n sur e h eate r assem b ly (1 87 ) (P o s t-1 97 8) i s secu red t o gear case w ith tw o
s cr ew s i n pr e- tap p ed h ole s d ir ectl y be nea th th e s yn cr os et e ntr y o pe nin g in
th e ge ar case.
b . I n sp ec t g ear ca se a nd sy nc ro set seal ing sur fa ces fo r an y da m ag e th at w ou ld
h in de r pr op er s ea lin g.
c . E n s ur e O - rin g ( 17 0) is fitted p ro per ly aro un d bo dy (1 50 ) and f it i nto ge arcas e
(1 ) op e n in g .
d . S ecur e w ith f our cap scr ew s ( 167 9 and sp ring w as hers ( 171 ). T orq ue caps crew s
to 10 - 12 foot po unds .
22-14
1 . P r e - a n d P o s t- 1 9 7 8 A ct u at o r s
a. If lim it s w itch w h eel o r d riv e as s em bly (9 7) is def ective or has b een rem ov ed
in or d er to re pl ace to r qu e sw it ch m e ch an is m it m ust b e re pl ace d on lim it
sw itch m ech an is m shaf t.
b . E n su re lim it sw i tch w he el and d ri ve as s em b ly (9 7 ) is f ull y ins er ted h ar d
a gai ns t th e s w it ch m ec han is m (2 61 ) b ras s loc atio n bu s hi ng .
c. U s in g th e ho le in th e l im it d riv e as s em b ly (2 6 ) as a tem pla te, d rill a 1 /8 in ch
ho le th ro u gh t he s w itc h m ec ha nis m a s se m b ly ( 26 1 ) s haf t's br as s bu s hi ng .
d . S ecu re lim it sw itch d riv e as s em bl y ( 97 ) on s w i tch m echa nis m as s em b ly by
ins ertin g sp rin gp in (9 9) thr ou gh 1/8 in ch ho le d rilled in S tep c).
e. C lip he ater to b ack of r epl acem en t sw it ch m ech anis m assem b ly if P re- 19 78
h eate r (o b s ole te) i s stil l inst alle d, ( P re -1 9 78 sw it ch m e ch ani s m s had hea ter
clips p op -riv eted to th e back of th e m echan is m ).
f . g rease O -r ing ( 27 1) o n sw itch m e chan is m .
N O TE : The fo llo w ing steps cann ot be per for m ed unless m otor m od a le

has been ins talled.
g . In s tal l t or qu e s w itch s h af t ( 1 04 ) in to o pen in g in g ear cas e in s ur in g s ha kep ro o f

w asher en d is f acin g sw itc h m echa nis m .
h . C ar efu lly p us h s w itch m echa nis m (2 61 ) in to gea rcas e (1 ) un til ge ars m ate.
i. R ep lace o ne cap scr ew (2 64) in to sw itch m echan ism back plate ( 263 ) and
tig h ten in o rd e r to v er if y t or q ue a dj us t in g f ro n tp lat e (2 7 0) tu rn s to w ar d th e
v ertica l p os itio n (p oin ter align s w ith ar ro w ).
j. If no t in v ertical po s ition , rem o ve caps cr ew ( 264 ) and w ith dr aw s w i tch
m echanis m ( 261 ) aw ay fro m gear case (1) .
N O TE : In crea sing the sh afts (10 4) over all leng th w ill caus e th e
fro ntpla te (2 70) to ro tate clo ckw is e w hen view ing the sw itch m echa nis m
(261) fr om the fron t.
k . R em ov e to rq ue sw itch s h aft (10 4) an d a dju st caps cr ew (2 5, 91 ) in or der to

cen ter p oin ter o n to rq ue ad ju s ting fr on tpl ate (2 70 ) .
1. T i gh te n ae ro ti gh t s ti ff nu t ( 10 2 , 1 28 ) a ft er ad ju s ti ng to rq u e s w itc h s h af t
( 10 4), t akin g care n ot to ov er tigh ten an d dam age cap sc rew ( 12 7, 1 00 ).
m . R epea t S te ps (h ) and ( i) . If al ign m en t is ac hiev ed g o to S tep ( n ). I f no t, re pea t
Step s ( j) th rou gh ( m ).
n. R eplace tw o cap scr ew s (2 64) and torq ue to 4.5 - 5 .5 ft. lb s.
o . C o nn ec t all i nt er na l w i ri ng to t he a pp r op r iat e t er m in al s a nd secu r e w ir in g
lo om t o s w itch m echa nis m w ith S cotch T h erm o settin g T ape (27 ).
22-15
N O T E : T he co ver or ien tation is im p or tant on the 12 s w itch ad d- on- pa k

as s em bly. A n ad d-o n- pak s upp or t is w eld ed to th e ins id e o f the cover
(2 52).
p . G r eas e O - rin g (25 4) an d ins tall on g earca se (1 ). I ns tall lim it sw itc h c ove r
(2 50 , 251 , 25 2) an d sec ure w ith thr ee c aps cre w s (2 57) an d w ash ers (2 88 ).
G rease and torqu e caps crew s (25 7) to 1 0 - 12 ft. lb s (4.5 - 5.5 ft. lbs on P re-
19 78 ).
q. R e fer to S ection 2 0.0 f or sw i tch m echan is m ad justm en t p roc edu re.
2. M o du lar R epl acem e nt of S w itch B an ks o n M ech ani sm

a. P r e-1 9 78 A c tu ato rs w ith N O d es ig n S w it ch M ec ha nis m s I ns t alle d
• C o m p res s w as h er ( 26 6 ) an d s pr in g ( 26 5) by m ov in g s w itc h to w ar ds th e
fro ntplate ( 27 0).
• P ul l s w itch b an ks (2 60 ) ou t o f the s w itch m echa nis m re arp late (2 72 ).
• In stall r epl acem ent sw it ch b ank s ( 2 60 ) de pr essin g w ash er (2 6 6) a nd
spr ing (2 65 ) and snap pin g sw itch ba nk (2 60 ) in p lace.
b. P o s t- 1 97 8 A c tu ato r s
• S crew lo cking hex nu t (2 69) tow ard s sw itch bank (2 62) .
• M ov e s w it ch ban k ( 26 2) to w ard s f ro nt p late (2 70 ), f ar en ou gh t o rele as e
sw i tch b ank ( 26 2) f ro m sw itch m e cha nis m 's rear p late (2 72 ).
22-16
• I nsta ll rep lace m en t sw it ch ba nk s ( 26 2) i nto f ra m e and h o ld in p lace.

• E ns u re s m all b arr el n ut is p os it io ned in r ou n de d ar ea of sl ot o n f ro nt
plate (27 0).
• S cr ew loc king h ex nu t ( 269 ) fir m ly again s t in sid e s u rfa ce o f f ro nt plate
(27 0).
1 . P ost-19 78 A dd-on- pak

a. In spect add -o n- pak fo r dam age
b . E n su re all p ow er h as b een r em o ved f ro m actu ato r.
c . V e rif y th at the re pla cem en t add -o n -p ak ge ar clu s ters (3 25 ) an d spac ers (3 26 )
m atc h th e d am ag ed ad d- o n -p ak s .
d . If add -o n- pak is bein g instal led fo r t he fir st tim e , r efe ren ce E n clo su re 20 .3 in
S ectio n 2 0 f or cor rect num b ers o f g ear clus ters ( 32 5) and spacers (32 6) fo r
sp ecific va lv e tra v el.
N O T E : N ever m ix an d m at ch ge ar in g th at is pin n ed w i th ge ar in g th at
is inves tm ent cas t.
e. R em o ve tw o cap scr ew s ( 31 2) th at r etain s w itch h old ing p lates (31 3) to t he

ad d -o n - pa k f ro n tp la te.
f. R em o ve s w itch ho ldin g plates ( 31 3), s pr ing s (3 10) , and w ash ers ( 30 9) held
b eh in d th es e p la tes .
g. I ns tal l t he th ree m o un tin g p illar s ( 33 0) to th e s w itc h m ech an is m (2 61 ). S cr ew
u p t ig h tly to th e n u ts r et ai ni n g t he s w it ch m ec h an is m s fr o n tp la te ( 2 7 0 ) an d
tor que to 5 - 5.5 f t. lb s.
h. If po tentio m eter (3 08 ) is fitted , slid e it on th e p illar.
i. In s tall t he add -o n- pak o nto th e p illar s (3 30 ).
j. M ov e s w itch es (3 03) to the s ide to allo w ins tallation of the caps crew s (3 15)
an d w ash ers ( 31 6) to pillar s (3 30 ). T or que to 5 - 5 .5 ft. lb s
k. R ep lace sw itches (3 03) in ad d-on -pak fram e.
l. R eplace spr ings ( 310 ), w asher s (30 9), ho ldin g p lates (31 3) and tw o capscrew s
(3 12 ) th at w ere rem o ved in S tep f ).
m . C on nect w ir ing fro m th e loo m ( 172 ) to the s w itch es (30 3) .
n. Se cure th e lo om to the pillar s us in g Sco tch T h erm o se tting T ap e ( 27 ).
o. R efer to Se ction 20 .0 for ad jus tm ent pro cedu re.
2 . P re- 197 8 A dd- O n-P ak
a. In sp ect ad d- on -pack f or dam ag e
b . E n s ur e al l p ow er h as b een r em o ved f ro m actu ato r.
c . V erif y th at the re pla cem en t add -o n- pa k gea r clus t ers (3 25 ) and sp acer s ( 32 6)
m atch the d am age d ad d- o n- pa k's .
d . If ad d-o n- pak is bein g ins tall ed fo r th e firs t tim e, r efer ence E n clos u re 20 .3 in
S ecti on 20 f or co rre ct n um b ers of gea r cl us ters (3 25) an d spacer s (3 26 ) fo r
specific valve travel.
22-17
N O T E : N ever m i x a nd m a tch g ea ri ng th a t is nyl on w ith g ea ri ng th at is

in vestm ent cast.
e. L o os en tw o fr on t p late m ou ntin g nut s (3 24 ).

f. S crew lock in g h ex n ut (3 22) tow ards s w itch ban k (3 19) .
g. M ov e s w itch ban ks (3 19) to w ard s fr on tplat e ( 314 ) far en ou gh to re leas e
s w itch bank s (3 19) fr om add- on- pak fr am e.
h. I ns ta ll the th re e m ou nt ing p ill ars (3 21 ) to t he s w itch m ech an is m ( 2 59 ). S cr ew
u p ti gh t ly to t h e n ut s re ta in in g th e s w i tch m ech a ni s m s f r o nt p lat e ( 27 0 ) an d
to rqu e to 5 - 5.5 f t. lb s.
i. If p oten tiom eter (3 08 ) i s fitte d, s lide it o n the pil lar.
j. I ns tall th e ad d-o n- pak on to th e p illars ( 321 ).
k. In s tall alie n sc rew (3 20 ) int o up per h ole o f add -o n- pak fra m e and ti gh ten in to
t he end o f t he upp er s up po rt pilla r ( 32 1) . T igh ten to 5 - 5.5 ft. lb s.
l. L o cati ng th e bo tto m t w o pill ars (3 21 ) in to th e a dd -o n- pa k fr am e an d dr ive
a dap te r (3 27 ) o nt o the s w it ch m e cha nis m ( 25 9) , ti gh ten t he tw o b o tto m a lien
sc rew s (3 2 0) to 5 - 5. 5 ft. lbs .
m . In stall sw itche s (3 19) in to add -o n-p ak fr am e an d ho ld i n p lace.
n. T i gh te n tw o fr on tp la te m o u nt in g n ut s ( 32 4 ).
o. E n s ur e s m all hex n ut ( 32 2) is po s itio ned i n ro un de d area o f sl ot on f ro n tpla te
(31 4).
p. S cr ew loc kin g h ex nu t ( 32 2) fi rm ly ag ains t the ins id e s ur face of th e f ro ntp late
(3 1 4) en s ur ing tw o h ex n uts are jam m ed to get her ( 32 2, 3 23 ).
q. C onnect w irin g to th e loom (172 ) to the s w itches (3 19) .
r. S ec ur e th e l oo m t o the pil lars us in g S cotc h T her m o s ettin g T ape 2 7.
s. R efe r t o S ect ion 20 .0 f or adj ustm en t p roc edu re.
22-18
1 . P o s t- 1 97 8 A ctu ato r
N O T E :A ll N A 1 m oto r s a r e su p pli ed in a m o du la r f or m . S tat or s ar e

alr ead y fitted into th e m oto r co ver and the ro tor on to th e w o rm s haft pr ior
to leaving the factory.
a. In spec t m ach ine d su r face s o f m o tor a nd m o to r w or m sh aft ( 24 ) fo r da m ag e.

b . I n s pe ct fo r d am a ge a nd gr eas e O - ri ng (4 6 ). E ns u r e c or r ect p os i tio n o n m o to r
cover h ous in g.
c. V e rif y tor qu e sw it ch shaf t ( 37 ) is i nstall ed in ge arca se ( 1) .
d . E n sur e m o to r l ead s ar e co nn ec ted to a pp r op r iat e ter m in als o n b ack sid e o f
term inal blo ck (152 ) as follow s:
• I ns ta ll f ib reg lass sleev in g ov er 3 S y ncr oset m oto r lead s.
• S trip in su la tio n fro m en d s o f S y n c ro se t a n d m o to r le ad s .
• Pu sh w ires into ap proved butt connector and crim p w ith app roved too l.
• P us h fi br eg la s s s l eev in g o v er m ot or lea ds an d b u tt co n ne cto r s a nd tap e in
p lace w ith S co tc h T h erm o setting T ap e 2 7 .
N O T E : A corr ectly pos itioned m o to r w ill have a sta tor locking s crew on
th e side next to the s yncro set hou sing.
e. A lign m otor as follow s :

• W hile keep ing m otor leads clean o f o il and grease, f eed spliced m otor
lea ds into passag ew ay o n th e r ig ht sid e o f th e g ear case (1 ) an d car ef ully
slip m o tor w or m shaf t ( 24 ) par t w ay in to gear case ( 1) . T he fib reg lass
slee vi ng sho u ld k eep t he m ot or l ead s st ra ig ht an d a w ay f ro m th e m o to r
sh aft .
• U n less re si stan ce is en co un ter ed bet w een t he w o rm sha ft ( 24 ) an d
w or m w he el ( 21 ), c on tinu e feed in g the m o tor lea ds i nto p as s agew a y and
car efull y p ush m ot or flu sh w ith ge arcase ( 1) .
• I f teet h o f ge ars d o no t m e sh to get he r eas i ly, rem ov e m o to r an d tu rn
w o rm sh af t (2 4 ) slig ht ly an d r ep eat th e ab ov e step s as n ecessar y .
f . L u b ri cate a nd in s tal l t hr ee c ap s cre w s ( 1 24 ) a nd s pr in g w as h er s (8 1 ) to r et ain
m oto r to gear cas e ( 1).
g. T or qu e bo lting to 10 - 12 ft. lbs .
2 . P re - 19 7 8 A ct ua to r
N O T E :A ll N A G m o to rs a re s u pp lie d in a m o du la r f or m . S ta tor s ar e
alr ead y fitted into th e m oto r co ver and the ro tor on to th e w o rm s haft pr ior
22-19
a. In sp ect m achi ned sur faces of m o tor an d m oto r's w or m shaf t ( 24 ) for d am ag e.
b. I n sp ect f or d am ag e and gr ease O -r ing ( 46 ) . E nsu re co rr ect po sitio n o n m o tor
co v e r h o us in g.
c. V er ify tor que s w it ch s h aft ( 37 ) is ins talled in gear case (1 ).
d. E n su r e m ot or le ad s ar e con n ecte d to ap p ro pr iat e t erm in als on b ack sid e o f
term in al block (15 2).
N O T E : A co rr ectly p osition ed m otor w ill ha ve a s tator locking s crew on

the side next to the syncr oset hou sing ( 150).
e. A lign m otor as follo w s :

• W hile keep ing m o tor lead s clean o f o il an d gr ease , f eed spliced m o tor
lead s i nto passag ew ay on th e ri gh t si de o f the g ear case an d car efu lly slip
m ot or w or m s haf t ( 24 ) p art w ay into g earc ase (1) .
• U nl ess r esista nc e i s en co un te red bet w een t he w o rm sh af t (2 4) and
w o rm w h eel (2 1) , con tin ue fee din g the m o to r leads int o pas s ag ew ay an d
caref ully p us h m oto r f lus h w ith gearc ase (1 ).
• I f te eth o f g ear s d o n ot m e s h to ge the r eas i ly, rem ov e m o to r an d tu rn
w or m sh af t ( 2 4) sli gh tly and rep eat th e ab ov e step s as n ecessar y .
f . L ub r icat e an d in stal l t hr ee c aps c re w s ( 12 4 ) an d sp ri ng w ash er s ( 81 ) t o re tai n
g. T or que b olting to 10 - 1 2 ft. lbs .

1. T op M ounted
a. A pply a th in co at of E xx on U n irex N 2 gr eas e to O -rin g ( 49) , an d o il seals ( 50) .
b. P os itio n han dw heel as se m bly to p reve nt c aps crew s ( 11 7) fr om bein g dir ectly
o ver or alig ned w ith clutch k eys (27 ) o n clutch rin g (2 6).
c. C oat n ylo n h and w he el reta ine r (1 22 ) w ith g ear case oil an d fe ed in to ge arca se
w hile r otating han dw heel h oo p ( 166 ) co unter clockw is e.
d. I ns ta ll h an dw h eel ret aine r s ealin g plu g ( 12 1) an d to rq ue to f ollo w in g
s pecifications:
• If old s tyle plug w ith phillips s crew to rque to 15 ft. lbs .
• I f n ew s tyl e e xt rac to r pl ug t or q ue to 2 0 - 2 2 f t. l bs .
e. T ig hten ph illips s cr ew if ins talled .
f. V erif y hand w heel o per ation in m anu al m o de.
2 . S id e M o u n ted
a. A pp ly a th in coat of E x xo n U nir ex N 2 g rea se to O -r ing ( 11 1) and f it o nt o
h an dw he el as s em b ly s pig ot .
b. G r ease han dw h eel oil seals (5 0) an d pr ess in to pl ace us in g si de han d w h eel
s eal tool.
c . P os itio n h and w heel ass em b ly caref ully an d lo cate dow el pin s (1 19) in to hole s
i n up per f ace o f gea rcase; tap into p lac e u s ing a r ub ber m allet .
d . C o at n ylo n h an dw h eel r eta ine r (1 4 7) w it h g ear case oi l a nd f ee d in to g ear case
w hile r otating han dw heel h oop (1 77, 78 ) co unter clockw is e.
22-20
e. I ns ta ll han dw h eel r etain er s ea lin g plu g ( 15 2) a nd t or qu e t o fo llo w in g

s pecifications:
• I f old s tyle pl ug w ith ph illips scr ew to rq ue to 15 ft.lbs .
• I f n ew s ty le ext racto r pl ug to rq ue to 20 - 2 2 ft.lb s.
f. T ig hte n ph illips s crew if ins talle d.
g . V eri fy h an dw h ee l o p era tio n in m anu al m o d e.
1 . U sin g ap p ro p ri ate fit ti ng s, i nst all p ressu re g au g e an d co n ne ct ai r su p pl y to

g earcase ho using (1) after re-assem bly of all m o dules is co m plete.
2. S lo w ly app ly pressure to g earcase u nti l g aug e read s bet w e en 28 - 3 0 p sig.
3 . Iso lat e p re ssu re so urce an d re cord air pressure.
4. A fter 1 5 m in ut es reco rd fin al a ir pressure and reco rd p re ssu re d ro p if an y.
5 . If p ressure d rop ped m ore tha n 2 psi g, d eterm in e sou rc e o f lea k and rep air p er
the app ro priate sub se ctio n.
6. If gearcase d id no t d ro p p ressure o ver 2 p sig, co ntin ue to nex t step .
7. R eliev e p ressu re fro m gearcase.
8. Fill gearcase w ith oil th rou gh oil fill plu g h ole u p to o ne in ch o f h ole b ase
th reads.
9. Increa se air pressu re to g earc ase slow ly to 18 - 20 psig .
10 . Iso late pressure so urce and reco rd p ressure.
11 . A fte r fifteen m i nu tes reco rd final air p re ssu re an d reco rd p ressu re drop if a ny .
12 . If gea rcase p ressu re drop pe d m ore than 2 psig , de term ine sou rc e o f lea k and
repa ir pe r th e a pp ro priate su bsec tio n.
13 . If g earcase did n ot dro p pressu re ov er 2 psig, co ntin ue to nex t step .
14 . R em ov e fit tin gs, p ressu re sup ply a nd relie ve gea rca se p ressu re.
22.3.8 Post-maintenance Testing - Requirements Matrix
C o m p o n en t T orque F u n c t io n a l T im e * D ia g n o s tic
R e p a ire d T e st V e ri fic a tio n R esp o n se T es tin g
B en ch
W orm g ea r X X X X
G earcase M o dul e X X X X
D riv e B u shi ng X X X
H and w hee l M o dul e X
S yn croset M od ule X
A d d-on-pak M odule X X
• R efer to Se ctio n 2 6 for te stin g g uidelines.
22-21
1 . E n su re act ua to r f ee de r b r eak er is o pe n.
2 . I f r equ ired rem ove old d riv e bu s hin g f ro m o ld actuato r (42 , 39) p er Sect ion
2 2.2.6 .3 a nd r ein s tal l o n r ep lacem en t a ctu ato r pe r S ect ion 2 2 .3 .1 .4.
3 . E n s ur e va lve s t em is pr o pe rly s ecu re d to avo id pe rs o nn el in ju r y o r eq ui pm en t
d am ag e.
4 . L u b r ica te v al ve s tem a s ne ces s ar y.
5 . I ns t all r ig g in g a s n ec es s a ry to s u p p or t th e w e ig ht o f t h e act ua to r.
6. I n stal l act ua to r as f ol lo w s:
a. F o r p re ss u re s eal typ e v alv es , loo s en yo ke clam p bo lts , ro tate yo ke an d
actu ator as necessary to p rov ide access to y ok e bo lts .
b . F or k ey ed s h aft s tem a pp lica tio ns , p os it ion a ctu ato r s o ke yw ay s li ne u p an d
p u s h act ua to r s tr ai gh t o nto ge ar bo x s h af t.
c. F o r th re ad ed s h aft v alv e s tem ap p lica tio ns , po s itio n a ctu ato r s o d riv e
bu s h ing and va lve s t em m at e. O p er ate h and w h eel h oo p ( 77 ) to w ar d o pe n
dir ect ion un til act uat or i s f lus h a gai ns t va lve y ok e.
d . F o r glo be valv e app licatio ns , af ter per fo rm in g S tep c) ensu re key s ar e
i ns t all ed i nt o y ok e an d s t em an d k ey re tai ne rs ar e r ep lac ed p er va lv e
d r aw i n g s .
e . A li gn ac tu ato r to m at ch m a rk s as ap p li cab l e.
7 . S ecu re ac tua tor t o yo ke o r ge arb o x us in g ap pr o pr iate b olt ing har dw a re.
8 . E ns u r e pr o pe r to rq u in g r eq ui re m en ts ar e m et p er va lv e d r aw in g s .
9 . R em ov e tem po rary rig ging .
10. R em ove s yncroset cover (151 ).
1 1. C on nect f ield cab ling to ter m inal b lock (15 2) as requ ired.
12. Ins tall s yn cr os et ho us in g co ver (151 ).
13. R em ove valve gag device fr om s tem as ap plicable.
1 4. Pe rfo rm s w itch s etup per S ection 20 .0.
22-22
T h is p ag e i nten tio na lly lef t bla nk .
F ig u r e 2 2 - la
1 4 /16 G ea r ca s e A s se m b ly
(S e e F ig u r e 2 2 -lb fo r P a r ts D e sc r ip tio n )
22-24
Part ID Part Description Notes Part ID Part Description Notes

1. Gearcase 76. Hammer Drive Screw
2. Thrust 79. Locknu
3. Thrust 84. Torque Shaft
8. Center Column 86. Taper
9. Bearing Stop Ring 89. Cam Return
10. Yoke 97. Limit Switch
11. Hand Auto 98. Limit Switch
12. Hand Auto Finger 99. Spring
14. Finger Return 100. Capscre Pre-1978 Only
15. Thrust 101. Nyloc Pre-1978 Only
16. Locating 102. Shakeproof Washer Pre-1978 Only
17. Hand Auto - 103. Spacer
18. Nameplate Label 104. Torque Switch
19. Limit Switch Warm 123. Shakeproof Post-1978 Only
21. Warmwheel 125. Circlip Post-1978 Only
25. Clutch Spring 126. Seal Back-up Washer Post-1978 Only
26. Clutch Ring 127. Capscre Post-1978 Only
27. Clutch Key 128. Aerotight Stiffnut Post-1978 Only
28. Drive 129. Shakeproof Post 1978 Only
29. Warmshaft Pre-1978 Only 130. Circli Post-1978 Only
30. Finger 131. Seal Back-Up Washer Post-1978 Only
31. Washe
32. Rolle
33. Washe. Pre-1978 Only
34. Spiral
36. Cap Screw Pre-1978 Only
37. Countersunk Head
41. Thrust
42. Snout
43. Needle Bearing
46. “O” Ring
47. “O” Ring
51. “O” Ring
52. “O” Ring
53. “O” Ring
54. Space
55. Oilseal
56. Oilseal Post-1978 Only
57. Oilseal
59. Redca Pre-1978 Only
61. Spring Washer Post-1978 Only
62. Sel-lok
63. Slit Pin
64. Sel-lok
66. Set Screw
67. Capscre Post-1978 Only
68. Sel-Lok
69. Capscrew
70. Capsre
71. Capscre
74. Hand Auto
Figure 22-1b
14/16 Gearcase Assembly
22-25
F igu r e 2 2 -2
1 4/1 6 D r iv e B u sh A sse m b ly
22-26
EPRl Licensed Material
F ig u r e 22 -3
1 4 /1 6 M o t o r A s s e m b l y
22-27
F ig u r e 2 2 -4
1 4 / 1 6 T o p H a n d w h e e l A s s e m b ly
22-28
T h is pag e int ent ion all y lef t b lan k.
F ig u r e 2 2 -5 a
1 4 /1 6 S id e H a n d w h ee l A s se m b ly
( Se e Figu re 2 2-5b for Pa rts De sc r ip tio n)
22-30
P A R T ID P A R T D E S C RIP TIO N N O TE S
1 3. S p e cia l sh o u ld e rC a p scre w
3 9. H a n d w he e l S p o ke 1 4 On ly
45. M ills S t ud C o u n te r-C lo c kw ise O n ly
50. O il S e al
5 8. C o ve r T u b e A s se m b ly
60. S cre w e d B u n g S u b -A s se m b ly
70. C a p screw
75. H a n d w h ee l S p o ke 1 6 O n ly
77. H a n d w h e el H o o p 1 6 O n ly
78. H a n d w h e el H o o p 1 4 O n ly
85. A rro w C o u n te r-C lo ckw is e O n ly
87. H an d le
1 0 5. W o rm sh a f t
10 6. W o rm w he el
10 7. W o rm C a sin g
10 8. E n d H o u sin g
10 9 . H a n d w h e e l H ub
11 0 . "O " R in g
11 1. " O " R in g
11 2 . " O " R in g
11 3. " O " R in g
11 4 . S e xin g W a s h e r
11 5 . W o rm w he e l R e t a in e r
11 6. D ra in P lu g
11 8 . S et scre w
11 9 . S p ira l P in
12 0 . Key
12 1 . H a n d w h e e l R e ta in e r S e a lin g P lu g
122 . H a n d w h e e l R e ain e r
F ig u re 2 2 -5b
14 /1 6 S id e H a n d w h ee l A s se m b ly
22-31
F ig u r e 22 -6
S p r in g P a k S h e et 1 4 N A 1
22-32
F ig u r e 2 2 - 7
S p rin g P a k S h e e t 1 6 N A 1
22-33
F ig u re 2 2 -8 a
(S e e F ig ur e 22 -8 b fo r Pa rts De sc ription )
22-34
P A R T ID P A RT DE SC RIP TIO N NO TES

1 50 . B ody
1 51 . C o ve r
15 2 . Term inal B lock
153. Co ntrol Te rm inal P art o f 1 8 3
15 4 . P o w e r T e r m in a l P art o f 1 8 3
1 5 5. Pow er Term inal S cre en
156. S hakeproo f W asher
157. Term ina l Nu t
158. Term inal N ut
15 9 . B ra s s W a sh e r
160. S p ri n g W a s h e r
161. Nut
162. S pring W asher
163. B rass W a sher
1 65. E arth Lab el
166. B ra ss S crew
167. C a p sc re w
170. "O" R ing
171. Sp ring W ashe r
172. S w itch M ech anism L oom
173. In se r t
174. Retaining Ring
17 5 . Sh akeproof W asher
1 76 . Tapite S cre w
1 77 . Te rm ina l Link
178. L ab e l
17 9 . 1 1 /2 " C o n d u it P lu g
18 0 . 1 1 /4 " C o n d u it P lu g
18 1 . S crew -H am m e r D rive
182. Code Cord
183. Termin al Blo ck S ub assem bly
l8 4 . M otor Lo om
1 8 5. The rm o stat Lo om P o s t - 1 9 7 8 O n ly
186. N yl o n W a sh e r
187. Lo o m -He a te r * P re - 1 9 7 8 is O b s o le te
188. S cr e w
190. Lo ckn ut S teel
F ig u r e 22 -8 b
S y n cr o se t A ss em b ly
22-35
F ig u re 2 2 -9
A d d -o n - p a k A s s e m b l ie s
22-36
F igu re 2 2 -1 0
T y p e " A " a n d T y p e " N A " O l d V e r s io n A d d -o n -p a k
Pre- 1978
22-37
F ig u r e 2 2 -1 1
T y p e " N A " N e w V e r s i o n A d d -o n - p a k
P o st -1 9 7 8
22-38
F ig u r e 2 2- 1 2
A d d - o n - p a k M o d u l a r R e p la c e m e n t o f S w it c h B a n k s
P o st -1 9 7 8
22-39
F ig u re 2 2 -1 3
A d d - o n - p a k M o d u la r R e p l a c e m e n t o f S w i t c h B a n k s
P r e-1 9 7 8
22-40
F ig u r e 2 2 -1 4
A d d -on -p a k T yp ica l A O P I G ea r A r ra n gem e nt
22-41
F ig u r e 2 2 -1 5
N A 1 a n d N A 2 S w itc h M e ch an ism A s se m b ly
P r e- 1 9 7 8
22-42
F ig u r e 2 2 -1 6
N A 1 S w itch M ec h a n ism A sse m b ly
22-43
F ig u r e 22 -1 7
S w itch M ech a n ism M od u le (N A 1)
( F r o n t V i e w C r o s s S e c t io n )
22-44
F ig u re 2 2 -1 8
R e p la ce m e n t S w itch M ec h a n ism S w itc h P a k s
22-45
F ig u re 2 2 -1 9
F a b r ic a t e d C o v e r A s s e m b l y f o r S w i t c h
22-46
F ig u re 22 - 2 0
F a b r i c a t e d C o v e r A s s e m b l y f o r 6 S w it c h A d d - o n - p a k 1
22-47
22-48
23.0 30 NA1 ACTUATOR

N um b er ed re fe r en ce s i n p ar en t he s es , ( ) , c o rr es p o n d t o F i gu r es 2 3 -l a th r ou g h 2 3 - 20 .
N O T E : T his p r oced ur e h as b een w r itten util izin g a m o du lar a pp ro ach to

m ainten ance activities . D ue to th is app ro ach , cer tain s teps w ill be r epea ted
w ith s pecific m od u le m aintenan ce in m ind .

1 . E ns u r e a ctu a to r f ee d er b r ea k er is in op e n p o s it io n .
W A R N IN G : A dd ition al circu its m ay need to b e is ola ted by rem o ving fus es ,

lifting leads , open ing slid in g lin ks, etc.
W A R N I N G : If the sys tem is pr es s ur iz ed, th e va lve s tem m a y s lip r es ultin g

in s er iou s in jur y to per s onn el per fo rm ing m a intenan ce on the actu ator .
2. G ag valv e s tem as r equ ired b y se cur ing v alve s tem t o y ok e.

3. T o rem ove s yncroset cover (151), rem o ve four s crew s (188 ).
4. D is con nect and re m ov e fie ld w ir ing fr om s yn cros et bo dy (1 50 ). M ark w irin g for
r ec o n ne ct io n , as n e ce s s ar y .
5. R ep lace syn cro set cover (151).
6. R ep lace four s crew s ( 188).
7. T o rem o ve th e lim it s w itch cov er (2 50, 25 1, 252 ), r em ove three cap scr ew s ( 257 ),
an d spr ing w ash ers (2 58 ).
8. D is en gag e the p rim ary li m it s w itch an d lo os en ad d- o n- pak cl utc h nu t, if
ap plicable (refer to S ection 20 .0 f or details) .
9. R ep lace lim it sw itch co ver (25 0, 251 , 2 52) w ith cap scr ew s ( 257 ) an d spr ing
w as he rs (2 58 ).
C A U T IO N : W hen r igging the actuator for r em oval /r eplacem en t, car e

sh ou ld b e ta ken to avoid co nn ecting to eithe r the han d aut o lev er (T V
han dw heel hoo p (80 , 87), or hand w heel spo kes (78 ,85).
1 0 . I ns t all r ig g in g as ne ces s a ry to s u p po r t the w e ig ht o f t he a ctu ato r a nd pr ev en t

s te m d am ag e d u ri ng r em ov al.
1 1 . M at ch m ar k ac tu ato r as s e m b ly an d v al ve y ok e to e s tab li sh or ig in al in s ta llat io n
po sition .
1 2. R em ov e th e m oun tin g b olts or s tud nu ts f rom be low th e v alve yo ke or ge arbo x
flan ge.
23-1
13. R em ov e actuator f rom valve as f ollo w s :

a. G lo b e V a lv es
• E n s u r e va lv e s te m k ey s a re re m o v ed a nd p ro p er ly m ai nt ain e d u nt il t he
a ct u ato r is r e pl ac ed / re in s t al le d .
b . G ate V alv es
• F o r th r ead e d s h af t v a lv e s te m ap p li ca tio n s , ro ta te o p er a to r h an d w h ee l
t ow a rd clo s ed d ir ec tio n u n til th e ac tu ato r u n s cre w s f r om t he v al ve s te m .
c . Q u arte r T u rn V a lv e s
• F o r k ey e d s h af t a p pl ic ati o ns , en s u r e th e a ct u ato r is p ul le d s t r aig h t o f f o f
t he v a lv e s te m or g ear b ox s p lin e s h af t t o av o id va lv e s te m d am a g e.
1 4 . T r an s po rt a ctu ato r to pr o per ar ea fo r s to r age a nd /o r r ep air .
W A R N IN G : If the a ctuato r has n ot b een r em oved fro m the va lve pr ior to m otor
a ss em bly r em oval, ens ur e actuator feeder br eaker is in open p osition.
A dditio na l cir cuits m a y a lso ne ed to b e is ola ted b y r em ovin g f us es, liftin g
lea ds , op ening slid ing lin ks, etc.
1. C h eck m o tor w in ding s ( 90) fo r d am age as fo llow s;

a. U s ing a di git al m u lti -m eter , m easu re w i nd in g r esista nc e bet w een each
p h as e . N o w in di n g r es is t an ce s h o u ld r ea d o p en a nd th e r es is tan ce v al u es
s ho uld b e ap pr ox im ate ly bala nced .
b. U s ing a m egg ar ( 100 0 vo lt scale) , m easur e th e r esistance betw een o ne m oto r
w in di ng t o th e m o to r ho u si ng . T h e re s is tan ce v alu e s ho u ld b e 2 1.5
m egoh m s.
c. If re s is tan ce v al ue s v ar y f ro m r es u lts in d icat ed a bo v e, c on tac t th e
a pp r o pr ia te en g in eer in g re pr es e nt ati ve o r a R o to r k r ep re s en tat iv e.
2 . D r ain o il fr om g earcas e (1 ) b y r em ovin g lo w er p lug (86 ).
3 . P la ce t he a ct ua to r i n th e h an d op er a tio n m o d e by d ep re s s in g ha nd au to le ve r
( 11 ) to th e m a nu al m od e.
4 . I f th e m ot or i s h an gin g v er tical f ro m th e a ctu ato r r efe r to S ec tio n 23 .2 .2, S w i tch
M ech an is m R em o va l to e ns u re s w itch m ec han is m (2 59 , 26 1) a nd to rq ue s w itch
s h aft ( 11 7 ) ar e rem ov ed pr io r to m ot or r em ov al. P ro cee d to S te p 2 3.2.1 .5 , if t he
m o to r is ho r izo nt al to t he ac tua to r.
C A U T IO N : Im p roper r em oval of the m otor cover (4) from the gearcase (1 )

could resu lt in dam age to oilseal (5 5) an d bear ing ( 43).
5 . R em o v e t hr ee cap scre w s ( 71 ) an d spr in g w ashe rs (2 0) t hat r etai n th e m oto r

c ov e r (4 ) to th e ge ar ca se (1 ).
6. R em ov e th e m otor cov er (4) slow ly fr om the gearcase (1).
23-2
7 . L o cate bu tt co nn ecto rs un der f ib erg las s s le evin g an d cut m o to r lead s o n bo th

s id es of bu tt con necto rs .
8 . R em ov e th e m o tor co ver (4 ) O -r ing ( 91) an d in spect for d am age. R eplace as
ne cessary .
N O T E : I f the oil s eal (5 5) is deter m ined to need repla cem ent, th e circlip
(95) an d b ackup w as her (9 7) m u st be r em o ved fir st on P os t- 197 8 m od els
on ly.
9 . R eplace o il seal (5 5) and need le bear ing (43 ) a s requ ired by indicatio ns o f o il
le aka ge o r d am ag e.
NOTE :23.2.1.10 pertains to Pre-1978 actuators only
1 0. I nsp ect w o rm shaf t sh ro ud ( 29 ) f or d am ag e and r epla ce a s ne cessa ry .
1 . P os t-19 78 A ctu ato rs

a. E n sur e ele ctri cal p ow e r i s is ola ted or d isco nn ected .
b. V i su ally in s pec t f or p ro per m o v em en t o f the s w itch m ec han is m ( 26 1) a s th e
va lve i s m an ua lly o p er ated . I f t he s w it ch m ech an is m ( 26 1 ) s h ou ld n ee d
ad j us t m e nt r ef e r to S ec tio n 20 .0 o f t hi s m an u al . I f d am ag e is i nd ic at ed ,
rep lace the sw itch m e chan is m (26 1 ) a s ne cessary .
NOTE : 23.2.2.1, c) is not required if replacing switch banks only
c. D rain oil fro m gearcase ( 1) by rem ovin g low er plug (86) .

d . R em o v e the t hr ee ca ps cr ew s ( 25 7) an d spr in g w ash er s ( 2 58 ) th at r eta in th e
lim it sw itch cov er ( 25 0, 251 , 252 ) an d pull cov er s traig ht off .
e. If th e actu at or is tor q ue d o ut i n eit he r th e op en or clo s ed p o s iti on , th e to r qu e
a dj u s ti n g f r o n t p la te 's p oi n te r w i ll n ot b e v er ti ca l. I n t h is i ns ta nc e, m ov e th e
h a n d a u to le v e r (1 1 ) in to th e h a n d p o s itio n to c e n te r th e to rq u e a d ju stin g
f ro n t p lat e as n ec es s ar y .
f . D isc on n e ct th e s w itc h m ec h an ism lea d s fr om the s w itc h b an k s (2 6 2) o n th e
sw itch m ech anis m assem b ly ( 26 1) . M ark w i rin g fo r re con nec tio n, as
n ecessar y.
g T o re m o v e sw itc h b a nk s (26 2 ), sc rew lo ck in g h e x nu t (2 69 ) to w ard s s w itch
ban k (2 62).
h . M o ve s w itch b ank ( 26 2) to w ar d t he fr on t p late (2 70 ) fa r e no ug h to rel eas e th e
sw itch b ank ( 26 2 ) f ro m sw i tch m ech an is m r ear p late (2 72 ).
i. R em ove tw o cap s crew s (2 64) o n th e s w itch m echanis m bas eplate (26 3) .
23-3
C A U TI O N : U se care w he n rem ovin g sw itch m echa nis m (2 61 ) to a void

dam age to the O -r ing (27 1).
j. C ar efu lly rem o ve the sw itch m e chan ism (2 61 ) fro m th e g earca se (1 ).

k. R em ov e th e li m it s w itch d riv e gear as s em b ly (1 02 , 121 , 12 2) f ro m th e s w itch
m e cha ni s m s h af t (2 6 1) b y d ri vi ng o u t the s p ir ol p in ( 12 4 ) lo cat ed n ear t he
lim i t sw itch r ear p late (2 72 ).
1 . R em ove the tor qu e s w itch sh aft (1 17 ).
N O TE : If rep la cem ent of oil s eal (57 ) is requir ed, circlip ( 98) a nd s eal
b ackup w ash er ( 96) m ust be rem oved prio r to replacem ent as necessary
in 23 .2.2.1 , S tep m ) .
m . V isu ally insp ect o il sea l (5 7) f or leak age or d am ag e. R ep lace a s nece ss ar y.

n . V is u ally in s pec t to rq ue s haf t s h ro ud ( 84 ), s n ou t b ear ing ( 42 ), an d nee dle
b ear in g (4 3) fo r w ear o r dam age . R ep lac e p ar ts as ne ces s ar y.
2 . P r e- 1 97 8 A ctu a to rs
a. E nsure electrica l po w er is is o lated o r discon nected .
b . V is ua lly in s pect f or p ro per m ov em en t o f th e s w itc h m ech ani sm ( 25 9) as the
v alv e is m a nu al ly o p er ate d. If th e s w itc h m e ch an is m ( 25 9 ) s h ou ld ne ed
a dj u s tm e nt r ef er t o S ec tio n 2 0 of t h is m an u al. If d am ag e is in d ica ted ,
rep lace the sw itch m ec han is m ( 25 9) a s ne cessa ry .
N O TE : 23 .2 .2.2, Step c) is n ot r equ ired if r epla cing sw itch b an ks only.
c. D rain oil from gearcase (1) by rem oving low er plug ( 86).
d. R em ov e th e thr ee ca ps cr ew s (2 57 ) an d sp ri ng w a sher s (2 58 ) th at r etai n th e
lim it s w itch cove r ( 250 , 251 , 252 ) a nd pu ll cov er str aigh t of f.
e. If the act uat or is to rq ued ou t i n eith er th e op en o r clo s ed po s itio n , the to rq u e
ad j us t in g fr o nt pl at e's p oi nt er w il l no t b e v er ti ca l. In th is in s t an ce , m ov e t he
h an d a ut o l ev er (1 1 ) in t o th e h an d p o s it io n t o ce n ter th e to r qu e a dj us tin g
f ro n t p lat e as ne ce ssar y.
f. D iscon ne ct t he sw i tch m ec han ism lead s f ro m t he sw itch b ank s ( 26 0) o n th e
s w itc h m ec ha ni s m as s em bl y ( 25 9 ). M ark w ir in g f or r ec on n ect io n, a s
nece ss ar y.
g. T o r em ove sw itch ban ks ( 260 ), com p res s w ash er ( 266 ) and sp rin g ( 265 ) b y
m o v ing s w i tch b ank (2 60 ) to w ard s t he f ro nt p late ( 27 0) p ul lin g s w itch b an ks
(26 0) o ut of the sw i tch m echan is m r ear plate (2 72 ).
h. R em ove tw o caps cr ew s (2 64 ) on the s w itch m ech anis m bas ep late ( 26 3) .
23-4
C A U T IO N : U s e care w hen rem ovin g sw itch m ech anism (2 59) to a void

dam age to the O -r ing (27 1).
i. C aref ul ly rem o ve the s w itch m ech ani sm (2 59 ) fr om the ge arcas e (1 ) a nd s lip

gea rcase heat er ou t o f clip lo cated o n the back o f the sw itch m ec han is m .
j. R em o ve the lim it s w itch dr ive gear as s em b ly (1 20 , 12 1, 12 2) f ro m th e s w itch
m ech an is m s h af t (2 5 9) b y d r iv in g o ut th e s p rin g p in (1 2 4) l oc ate d n ear t he
k . R em ov e the tor qu e s w i tch s h aft ( 11 7).
l. V isu ally insp ect o il seal (5 7) f or leak age or d am age . R epl ace as necessary .
m . V is u ally i ns p ect ne edl e b ear in g (4 3) f o r w ear o r dam age . R e pla ce p ar ts a s
n ecessary .
1 . P os t-19 78 A ctu ators

a. E nsu re e lectric al p ow er is is o lated or d iscon nected .
b. R em o ve t he th re e cap s cr ew s ( 2 57 ) an d s p ri ng w as he rs (2 5 8) t ha t r et ain t he
lim it s w itch cover (2 50, 25 1, 2 52) and pull cover str aight off.
c. D isco nn ect th e a dd- on -p ak leads, w ithin th e sw itch m ech ani sm loo m (17 2) ,
fr om th e ad d- on -p ak sw itch es ( 30 3) . M a rk w ir ing f or r econ nec tion , as
n ecessary .
N O T E : I f r ep lacin g add -o n-p ak s w itch b ank s (3 03) , of the r em a inin g

s teps in Section 2 3.2 .3.1 , per for m Steps d) and e) o nly.
N O T E : I f r e m ov ing th e ad d- on- pak as s e m b ly (3 00 , 3 01, 30 2) for

r e p air /ins p e c tion o f th e ac t uato r e lim in ate S te ps d) an d e ) a nd pe r fo rm
th e r e m a ining ste p s in S e c tion 23.2.3.1.
d . R em ove the sw itch ho lding p lates (31 3) , co m pre ss ion s prin gs ( 310 ) and
w as hers (309 ).
e. P u ll add - on -p ak s w itc h pak sh af t ( 3 11 ) to w a rd s th e fr on t pla te (3 14 ) an d
r em ov e s w itch ban ks (3 03 ).
f . R em ov e tw o cap screw s (3 12) , w as hers ( 309 ) an d co m pres s ion sp ring s (31 0)
t hat r etai n sw itch h o ldi ng p lat es ( 31 3 ) to th e fr on t pl ate (3 14 ) .
g . R em ove s w itch holding plates (313 ).
h . M o ve sw itc h b ank s (3 03 ) t o th e s id e to allo w en tran ce o f al len key int o th e
s o ck et cap s cr ew s ( 31 5 ) tha t r eta in ad d- o n- pa k (3 00 , 3 01 ,30 2) t o m o un tin g
pillars (33 0).
i. R em ov e the three so cket cap scr ew s ( 315 ).
j . R em o ve ad d-o n- pak (30 0, 301 , 3 02) fr om th e s w itch dr ive s haf t (2 73) .
23-5
k . L oo sen set scr ew (328 ) in lock in g p late (3 29), then rem o ve lock ing plate (3 29) ,
spacers (3 26) and gear clus ter s (32 5).
l. P e rf or m v isu al insp ecti on o f ge ar clu ster s ( 32 5) , spac ers (3 26 ), dr ive ad ap ter
(3 2 7) , lo cki ng p late ( 32 9) , m o u nti ng p illa rs (3 30 ) an d s et s cre w ( 32 8) f or
d a m a g e a n d a b n o rm a l w e a r.
m . I f m ou nt ing p illar s ( 33 0) ar e d am ag ed , un sc rew fr om s w itch m ec han is m
as sem bly (26 1).
n . R epla ce p ar ts as n ece ss ar y.
2 . P re -1 9 7 8 A c tu at o rs
a . E nsu re elec trical p ow er is is olated or di sco nn ected.
b . R em ov e th e t re e cap s cr ew s ( 2 57 ) a nd s pr in g w as h er s ( 2 5 8) th at r eta in t he
l im it sw it ch cov er (2 50 , 25 1, 2 52 ) a nd p ull cov er s trai gh t o ff
c . D is co nn ect th e a dd -o n- pa k lead s , w i thi n the s w itch m ech anis m lo om ( 17 2) ,
fr om th e a dd -o n- pak s w itch es ( 31 9 ). M ark w i rin g fo r reco nn ecti on , as
ne cessary .
N O T E : If r ep lacin g ad d-o n- pak s w itch b an ks (3 19 ), of the rem a inin g

step s in S ection 23.2.3 .2, per for m o nly S teps 23 .2.3.2 , d ) th ro ugh f)
on ly .
N O T E : If r em ovin g th e a dd- on- pa k as s em b ly ( 300 , 3 01, 3 02) for

r ep air / ins p ecti on o f the a ctu ato r el im in ate S tep s d ) thr o ug h f) a nd
per for m the rem ain ing s teps in Sectio n 2 3.2 .3.2.
1. E nsur e electrical p ow er is iso lated o r d isco nnected .

2. R em o ve fou r s crew s (18 8) f rom the s yn cr oset b ody (150 ) and rem ove cov er (15 1).
3. R em ov e O -ring (1 64) and vis ually ins pect fo r d am age.
4. D is con ne ct and r em o ve all ex ter nal w ir ing . M ar k w iri ng f or r eco nn ectio n , as
n e ce ssa r y .
N O TE : T o r eplace d am aged term inal block ( 152 ) on ly, com plete S ectio n
2 3.2 .4 Steps 5 thr o ugh 7. T o r em ove the en tire syn cro s et as s em b ly pr oce ed
to 2 3. 2 .4 .8 .
5 . R em ov e g rou nd ing lu g co nn ection s (1 58 , 159 , 16 0, 16 5, 16 6) and r etainin g rin g

(1 74) f rom ins ide the s ynchr oset b ody (150) .
23-6
C A U T IO N : W hen rem ovin g the ter m inal block (15 2) , d o n ot p ull o n th e

br as s te rm in al s tud s.
6 . P u ll th e term in al blo ck (1 52 ) str aig ht ou t o f t he sy ncr os et bo dy ( 15 0) us in g tw o

pai rs o f p lier s b y gr ipp in g and p u llin g on te rm i nal b lock se par ato rs .
7. R em ov e inter na l w ir ing f ro m th e back o f term inal b lock ( 15 2) . M ark w ir ing f or
r econ ne ction , as n ecessary .
8. R em ove fou r caps crew s (1 67) betw een th e s yncr os et bo dy ( 150 ) an d g earcas e (1) .
9 . R em ov e s yncr os et and vis ually insp ect O -rin g ( 170 ).
10. O nc e the s ync ros et ass em b ly is rem o ved fr om the gear case (1 ), the w ire lo om s
( 17 2, 1 84 , 18 5) m ay b e d ra w n o ut th ro ug h the ge arcas e (1 ) op eni ng .
N O T E : Sectio n 2 3.2 .4 Steps 1 l th r oug h 1 3 a re to b e per fo rm ed if r epair ing

dam aged term inal block (1 52) after th e syn chro set h as been r em oved.
1 1. R em o ve gr oun din g l ug con nectio ns ( 158 , 15 9, 16 0, 16 5, 16 6) and ret ainin g r ing

(17 4) f rom in sid e the s ynch ros et bod y ( 150) .
C A U T IO N : W hen rem ovin g th e ter m in al b lock ( 152 ) d o n ot p ull o r app ly

for ce to the b ras s ter m in al s tud s.
1 2. P u ll the ter m in al blo ck ( 15 2) s tr aig ht ou t of th e s y nc ro se t b od y (1 5 0) u si ng tw o

p air s o f pl ier s b y gr ipp in g an d pu lli ng o n ter m in al bl ock s e par ato rs .
A dd itio n ally , th e t erm ina l b lo ck ( 15 2) m ay b e ta pp ed f ro m the r ear to a id in
r em oval.
1 3. R em ov e in ter nal w irin g fr om the back o f term inal blo ck (1 52 ). M ar k w ir ing f or
r econ nec tion , as ne cessar y.
N O T E : P r ior to rem oving han dw h eel m o d ule, note th e pos ition of the a ctuator
to deter m ine if d rain age of o il fr om gear cas e (1) is n eces sa ry. I f the han d w h eel
is in a tw elve o'clo ck pos ition, Step 2 3.2.5.1, Step a) is no t r eq uir ed .
1 . T o p M o u n te d H an d w h e el
a. D r ain oil by r em ov ing lo w er plu g (86 ) fr om gear cas e ( 1) .
b . R em ov e ha nd w h eel r etai ne r seal in g p lug (1 0 0) f r om t he g ear case ( 1 ).
23-7
N O T E : T he ha ndw he el m u st tu rn in a clo ckw is e d irection w hil e

r em oving th e nylon ha ndw h eel reta in er (103 ).
c. R em ov e the hand w h eel retainer (1 03) .

d. In sp ect nylon han dw heel retainer (10 3) f or defects.
e. L if t t he han d w h eel m o du le st raig ht o ff us in g car e n ot to d am ag e the O -r ing
(1 0 8) o r th e o il se als (5 0 ).
f. R em ove and inspect O -ring ( 108).
g. V isu ally in spec t o il sea ls ( 50 ) f or l eaka ge or d am ag e. R e plac e p arts as
necessary .
2 . S id e M o u n te d H a n d w h e e l
a. D rain oil by rem oving lo w er plug (86) fro m gearcas e (1).
b . R em ov e han dw heel retainer sealing plug (1 00) fr om th e g earcase (1 ).
N O TE : U s e s nipe n osed pliers to gr ip the en d of th e reta in er w hile

rem oving the nylon han dw h eel retainer (1 03) .
c. R em o ve th e h and w he el r etain er (1 03 ).
d. I ns pe ct ny lon h and w h eel r etainer ( 103 ) for d efects .
N O T E : Sid e m o unte d h an dw h eel ca s ing s ar e d ow elled at th e to p of th e

gear ca se (1) , a nd m ay r eq uir e gen tle ta ppin g upw ar ds w ith a r ub ber
m a llet to r em ove.
e. L ift the h an dw h eel m o du le straig ht o ff usin g ca re n ot to d am a ge th e O -rin g

(10 8) or th e oil seals (50).
f. R em ove and inspect O -rin g (108 ).
g. V isu ally i nsp ect o il seals (5 0 ) fo r le aka ge o r da m ag e. R epl ace pa rts as
nece ssary.
1. G e ar ca s e R e m o v al an d I n s p ec ti o n
a. R em o ve actu ator f ro m valv e p er S ectio n 23 .1 .
b. D r ain all o il f ro m ac tuato r gear case ( 1) by lo os en ing lo w er m ost p lug ( 86 ).
c. R em o ve the fo llow in g actua tor co m po nen ts pe r ap pl icable sectio ns :
• M otor : Section 23.2.1
•. S w itc h M ech an is m : S ecti on 2.2 .2
•. S y nc ro s e t: S e ct io n 2 3 .2.4
.• H an d w h ee l: S e ct io n 2 3 .2 .5
23-8
d . R em ov e r em ai ni ng g ea rc as e in ter na l c om po n ent s p er t he f ol lo w ing s ecti on s :

• C l utc h an d W o rm gea r: S ect ion 23 .2 .6 S tep 2 .
• D riv e B u s hin g : S ec tio n 23 .2 .6 S t ep 3.
• H a nd A u t o L ev e r : S e ct io n 23 .2 .6 S te p 4 .
• O i l S ea l: S e ctio n 23 .2 .6 S te p 5.
• W o r m s h aft B u s hi ng : S ect ion 23 .2.6.5 , S tep c) .
2 . C l u tc h a n d W o r m g e ar R em o v al
a. R em o ve act uat or f ro m v alv e p er S ect ion 2 3.1 .
b. R em o ve han dw hee l as s em bly f rom the actu ator per S ectio n 23.2.5.
c. D rai n a ll o il f ro m ac tuato r gear case ( 1) b y loo sen in g l ow er m o st plu g (8 6) .
d. R e tu r n a ct u at or to au t o p o s it io n b y u s in g a s c re w d r iv er to th e g e n tly n u dg e
th e ha nd au to f in g er ( 12 ) o n t he y o ke a s s em b ly (1 0 ) u nt il it an d t he c lu tch
rin g ( 26 ) d ro p b ack do w n o nto th e w or m w heel (21 ).
W A R N IN G : T he clutch s pr ing (26; ) in th e follow in g s tep is still u nder

load an d co uld cau se ser iou s injur y if ca re is not taken w h en r em oving
the clutch r etaining O -r ing (5 2).
e. R em ov e th e cl utch r etaini ng O -r ing (5 2) , sp ecial w ash er (3 1) , a nd clu tch

s pring (25) f rom top o f center colum n (8) .
f. Slid e th e clutch rin g ( 26) and yo ke assem bly (1 0) of f th e center colu m n ( 8)
tak in g c are no t to d rop cl utch k eys ( 27 ) into th e g earca se (1 ).
g. R em ov e the ca ps cr ew s (7 0) t hat r etai n th e th r us t pa d (1 5 ).
h. L ift ou t th ru st pa d ( 15 ) a nd w or m w heel (21 ) fr om gear cas e (1 ).
i. R e m o ve c ap s cre w s ( 7 1, 61 ) r eta in in g th r us t b as e ( 2) to g ear ca s e. S ta nd
g ear ca s e (1 ) s o th at t he h an d au to l ev er ( 11 ) i s u pp er m o s t.
C A U T IO N : U se a piece of w ood or a ru bber m allet to tap the center

co lum n (8) an d bas e a ssem bly free in the fo llow ing step to pr even t
da m age to the center colum n (8).
j. T ap cen ter co lum n (8 ) ass em b ly f ro m to p to dr ive it o ut o f th e g earcas e(1 ).

k . T o w ith dr aw b as e a ss em bly f ro m t he cen ter co lum n ( 8) , s up po rt th e
ba s e/c ent er c olu m n as s em bly s o th at th e m o un ti ng ho les ar e up p er m o s t.
l. U s in g a s tan d ar d be nc h p res s o r jac ki ng s t ra p pr es s o ut th e cen te r co lu m n ( 8 )
and lim it sw itch w or m ( 19) .
m . S up po rt th e lim it s w itc h w or m (1 9) an d p res s thr ou g h the ce nte r col um n ( 1 ).
n . T o w it hd r aw th e t hr u s t b ear in g (4 1 ) f r om t h e th ru s t b as e (2 ) r em o ve e ig h t
s c re w s c ap s cr ew s ( 69 ) l if t of f t hr u s t ri ng (3 ) a nd lif t b ear in g ( 4 1) ou t .
o . U s in g th e dr iv e bu s hi ng ret ain er ( 5, 23 ) as a pr es s to ol lo cat e aga in s t t he
b ear in g s to p r in g ( 9) . P o s it io n as s em b ly u nd er be nc h p res s an d p r es s ou t.
p . R em ov e all O -r ing s and inspect an d replace as necessar y.
3 . D ri ve B u s h in g R e m o v al a nd In s p ec ti on s
23-9
N O T E : T he a ctua tor m us t be rem o ved fr om th e va lve pr ior to d rive

bus hing rem oval per S ectio n 23.1 .
N O T E : S om e a ctu at or s ha ve a h ole w hi ch is no t pl ug ge d. I n th is c as e
o m i t Step 2 3.2 .6 .3, Ste p a ).
a. U n s crew and r em o ve pl ug ( 59 ) on s id e o f actu ator b as e.

b. U s i ng h an d a ut o lev er ( 1 1) , p o si tio n a ctu ato r to ha nd op er ati on .
c. R o ta te t he ha n dw h e el a s s em bl y u n ti l th e b u s hi n g r et ain e r s et s cr ew ( 6 5 ) is
v is ib le t hr ou gh th e ho le i n the g earc as e ( 1) b as e.
d. R em ov e s etsc rew (6 5).
e . U n s cr ew d ri ve b u s h in g r eta in er (5 , 2 3 ) b y u s in g a s pa n ne r w r en ch in s er te d
in to the tw o ho les pr ov ided o n th e d riv e b u sh in g retai ner ( 5, 2 3) .
N O T E : Fo r typ e A dr ive bus hing (7) , r eco rd the po sition of the d rive
bushing (7) pr ior to r em oval.
P os itio n 1 - D r ive B us hing (7 ) is ins er ted into the cen ter colum n (8).
P ositio n 2 - D r ive B us hing (7 ) pr otr ud es from th e center colu m n (8 ).
W hile p erfo rm ing 23.2.6 .3, Step f), r em ove the dr ive bus hin g ( 7, 2 2) by
pulling it s tr aigh t ou t of th e center co lum n ( 8).
f. V isu ally in sp ect thr ead s of th e d ri ve bu sh in g (7 , 2 2) f or d am ag e.

g. V is u ally in s pe ct m ach ine d s ho uld er s o f the d riv e bu s hin g ( 7, 2 2) at th e
co n tac t p oin t w ith th e ce n ter c o lum n (8 ) d o g s fo r c rac k s o r s he ars .
h. Replace damaged parts as necessary.
4. Hand Auto Lever Removal and Inspections
N O T E : T o gain access to the han d a uto lever com p onents, the actu ator
ha ndw heel a ssem b ly m ust first b e rem o ved per S ectio n 2 3.2 .5; A ccess w ill
als o be im proved b y rem ovin g the center colum n (8 ) per 23.2.6.2.
a . F ro m in sid e th e gear case (1 ), h an dw h eel entr y u pp erm os t loca te se l-lo k pi n

(6 2 ). P o si tion d r ift pu nc h, ta p ou t a nd r em o ve fr om g ear cas e(1 ).
b . P ull ou t h and au to lever ( 11 ).
c . U n ho o k s pl it pi n (6 3 ) fr o m c am re tu rn s p r ing (8 9) and re m ov e h and au toc am
(17).
d . C are fu lly m a nip ul ate cam re tur n s pr in g (8 9) an d r em o ve it fr om lo cati ng p in
(16).
23- 10
5. O il S eal R em o val
a . O n P os t- 19 78 : r em ov e b ack up w as her s (9 7, 9 6) on th e m oto r w o rm sh aft bo re
a nd to rq u e s h af t b or e.
b. R em ove old oil seals .
c. O n Pr e-1 97 8: insp ect, rem ove & rep lace w o rm sh aft shro ud ( 29 ) as req uir ed .
6 . T o r q u e S ha f t S h ro u d a n d W o r m s h af t B e a ri n g R em o v al
a. P o s itio n ge arc as e ( 1) s o t hat s w itc h m ech an is m e ntr y is up pe rm o s t.
b . L o cat e d r ift p un ch in to t or qu e sh af t sh r ou d (8 4 ) and sn o ut b eari ng ( 4 2) an d
d riv e d ow n w ar ds u nti l the y ar e pu she d in to t he g ear case ( 1) an d th en
r em ov ed .
c. P osit ion g ear case ( 1) so th at t he m o tor b or e is up per m o s t.
d . L o cat e d ri ft pu nc h int o m o tor b o re to r es t a gai ns t the en d o f the n eed le
bea ring (4 3) ; dr ive ou t into g earcas e(l) an d r em ov e.
1 . B e ari ng A s s e m b ly
a. Fit nee dle bear ing (4 3) on to the w or m sh aft need le b eari ng/ flam ep ro of s hro ud
to ol, locate in g earcase ( 1) at m o tor w orm bor e, and press h om e.
b . Pr e-1 97 8 on ly: F it w o rm s haf t s h ro ud (2 9) o nto th e s no ut bea rin g t oo l lo cate
in g earc as e ( 1) at m ot or w or m b or e and p res s h om e.
c. C o at t he ou ts ide of t he on e w o rm sh aft oi l seal (5 5) w it h H y lo m ar an d pre ss
in to gear cas e ( 1) (d yn am ic si de to ins ide ) w ith w o rm s ha ft o il sea l to ol; rep eat
fo r the secon d seal (55 ) (d ynam ic side o uts ide).
d. P ost-19 78 on ly: Fit seal back up w ash er ( 97) an d cir clip (95 ) in to gearcase ( 1)
at m o tor w or m b ore.
e. F it sn ou t b ear in g (4 2) o nt o the sn ou t b ear in g too l; lo cate in g ear case (1 ) at
to rq ue s w itc h s haf t bo re, a nd p re ss ho m e .
f. F it to rq u e s h af t s hr o ud ( 8 4) on to s n o ut b ear in g to o l; lo cate i n g ear cas e( l) at
tor qu e s w itch s h af t b or e, a nd p re ss ho m e .
g. L o cate th e to rq ue sha ft's o il seal ( 5 7) o n tor qu e sh aft seal to ol and p re ss
ho m e.
2 . H an d A u t o L ev e r A s s em b ly
a. F it o il s eal (5 6 ) us in g h an d au to s eal to o l o n to h and aut o lev er ( 11 ) s h aft .
b . F it loc ating p in (1 6) an d O -ri ng (5 3) in to gea rcas e (1 ), fit cam ret ur n s p rin g
(89 ) to en d of locating pin (16).
c. S m e ar w i th E x x on U ni re x N 2 g r eas e an d i ns e rt h an d au to lev er (1 1 ) th ro u gh
o il s eal ( 56 ) s o t hat t he h and le o f th e lev er h an gs d ow n t ow a rd s t he b as e
en try o f th e g earc ase ( 1) .
d . In s er t the s p lit p in (6 3 ) in to th e cam (1 7 ) an d lo cate th e cam o n th e h an d
aut o lev er sh af t.
e. H oo k th e end o f th e s prin g (89 ) in to th e ey e of the sp lit p in ( 63) .
f . L if tin g the h and le of t he ha nd au to le ver ( 1 1) to t he lef t, lin e up th e ho le in
th e ca m (1 7) w ith t he h o le in t he h an d au to l ev er sh af t an d dr iv e ho m e t he
s el- lo k pin (6 2) .
23-11
3 . C ent er C o lu m n an d C lu tc h an d W o r m g ear A ss e m b ly
a. S m ear O -r ing gr oov e an d b or e of th rus t bas e ( 2) us ing E x xon U nir ex N 2 .
b. S m ear tw o O - rin g s (5 1 ) w ith g rease an d lo cate in th ru st base (2 ).
c. W o rk ing f rom th e t op of th e base, lo cate bear in g sto p rin g (9 ) and p ress into
pl ace so that th e t op f ace of th e b ear in g st op r ing ( 9) i s lev el w i th th e b ear ing
sh elf.
d . F i t t hr u st b ear in g ( 41 ) in to t hr u st b as e ( 2) .
e . A s se m bl e t hr us t rin g ( 3) to t hr us t ba se ( 2) u s ing eig ht cap s cre w s (6 9) and
torqu e to 38 - 43 ft. lb s.
f A pp ly lo ck tite to t he kn u rl on t he cen ter co lu m n ( 8) . L o cate lim it s w it ch
w or m (1 9) on to th e c enter c olu m n (8 ) an d pr es s on u s ing b enc h pr es s an d
len gth o f t ubi ng.
N O T E : E n su re cor rect ra tio lim it s w itch w or m is bitted and no ga p

exists b etw een w orm and center colu m n shou lder w h en assem b led.
g. G rease lo w er s ectio n of center colum n and O -r ing groo ve.

h. G rease and fit O -r ing (47 ) to center co lum n (8) .
l. L o cate cen ter co lu m n ( 8) th ro u gh th r us t bea rin g (4 1 ) and i nto b ear in g s top
rin g ( 9) u nd er a b enc h pr es s . P r es s h om e u n til s ho ul der on th e cen ter c olu m n
com es to rest ag ain st th e top su r fac e o f th e b ear in g.
N O T E : D ur ing as s em bly of th e cen ter colu m n in to the th r us t b as e th e

bea ring s top r ing w ill m ove a w ay fr om the bear ing.
j. In v er t as s em bl y a nd u s e a s u it ab le s i ze d tu b e an d m a lle t to g en tl y ta p t he
b ea ri ng s to p r in g b a ck i nt o p la ce. In s e rt d r iv e b us h in g an d t ig ht en r e tai ne r
secu rin g w i th s cr ew .
k. F it t w o s p iro l p ins (34 ) to thr us t bas e.
l. G r eas e top sp ig ot o n th ru s t bas e as s em bly a nd f it O -r in g (4 6 ).
m. G re ase base en tr y b or e on g ea rca se a nd a ssem b le ba se a ssem b ly in to
gear case; lo cate sp iro l p ins ( 34 ) i nto ho les an d sec ure base to gear case u sin g
fou r caps crew s (71) . T igh ten to 20 - 22 ft. lbs .
n. Slid e w o rm w heel (21 ) on to center colu m n (8 ), allow ing w h eel to sit o n s helf
acr oss cen ter o f ge arc ase, en sur in g dr iv e p in s a re up p erm os t.
o. P o s iti on t hr us t p ad ( 15 ) s o th at th e bl ind ho le in th e up p erm os t le vel o f th e
pa d i s n e ar es t t h e s yn c ro s e t en tr y o n th e g ea rc as e . S e cu re us i n g f o ur
caps crew s (70) . T o rque to 10 - 1 2 f t. lbs .
p. M an ip u lat e yo k e as s e m b ly ( 10 ) i nt o p la ce e ns u r in g t ha t th e h an d a ut o
f in ge r assem bl y lie s f lat o n to th e w o rm w hee l an d th e ad just in g gr u b
s cr ew l oc ate s i nto th e bl in d ho le i n th e th ru s t p ad .
23-12
N O T E : C lutc h ke y's ( 27 ) o r ienta tion is cr itica l. W id e s ide of keys an d

clutch r ing (26 ) m us t b e u pper m os t, n ot a ga ins t w o rm w h eel.
q. I nstal l c lut ch ke ys (2 7) i nto c lut ch ri ng ( 26 ) an d p lace assem b ly o n th e c ent er

co lu m n (8 ) .
r. P re ss clutc h s p rin g (2 5), w as h er (31 ), an d O -r ing (5 2) d ow n o nto cen ter
colum n (8 ), en su ring the O -r ing ( 52) locks in to center colum n 's ( 8) g roo ve
u s ing clutch sprin g com p resso r to co m pre ss .
4 . D riv e B u sh ing A ss em bly
a . V er ify thr ead s are m g oo d co nd it ion and are g eo m etr ica lly c or re ct fo r v alv e
stem app lication if app licable.
b . V e ri fy r eq u ir ed m ou n tin g p os i tio n o f th e dr iv e b us h in g ( 7, 22 ) an d i ns e rt in to
th e g earcase base insid e o f th e c enter co lum n ( 8) .
c . E ns ur e th e s l ot s of th e d ri v e bu s h in g ( 7 , 2 2 ) a re f u ll y en g ag ed w it h t he
ac tu at o r's c en te r co l um n s ha ft dr i ve d o g s .
d . I n s t al l a n d t ig h t en d r iv e b u s h i n g r e ta in er ( 5 , 23 ) .
e . U s i ng a fe el er g au g e, ve ri fy ga p b et w een d ri ve b u s h in g r eta in er (5 , 2 3 ) an d
bu shin g (7 , 22 ) do es no t e xceed 0 .0 18 in ch .
f . I ns ta ll an d t ig h t en d r iv e b u s h in g r e ta in e r s cr e w ( 6 5 ) .
g . P re- 1 97 8 on ly : rei ns er t re dca p pl ug ( 59 ) in to g ear cas e ( 1) .
23 .3.2 Sy nc ro se t A sse m b ly
1 . W i rin g L o o m I nt ern al C on ne ctio ns to T e rm i nal B un g
a . C o nn ect h eater w ire s to t erm ina ls 4 a nd 5 on b ack o f te rm i na l b lo ck ( 15 2)
fr om th erm os tat lo om ( 18 5) .
b . C on nect m o tor w ir es to t erm i nals 1, 2 , and 3 o n bac k of ter m in al b lo ck (1 52 )
fro m m o to r l oo m (1 8 4 ).
c. C on n ect nu m b ered sw it ch m ec han is m and add -o n- p ak lo om (1 7 2) to
co rr espo nd ing n um ber ed ter m in als o n back o f ter m in al b lo ck (1 52 ).
d. P er for m c ont inu ity check w ith m et er f ro m f ield s ide of ter m ina l bl ock (1 52 ) to
eac h sw itch c on tact to en su re co rr ect sw itch is w ir ed to co rr ect te rm i nal .
2 . A s s em b ly of T erm inal B lo ck in to S ync ros et
a. S m ear O - ri ng ( 16 4 ) an d ter m in al bl ock ou ter b o re w ith g r ease an d pl ace O -
ring (164 ) into low er rad ial gro ove o f s yncro set.
b. C a ref ul ly p os iti on t erm ina l b u ng in s id e s y nc ro s et bo dy (1 50 ) tak in g car e n o t
to p inch o r dam ag e an y w ir es or th e O -r ing ( 164 ).
c. S e cu re t erm in al b lo ck ( 1 52 ) b y p la cin g r et ain in g r in g ( 17 4 ) in to ou te r r adi al
groove of th e s yncros et body (1 50).
d. In sta ll g ro un di ng lu g as s em b ly (1 58 , 15 9, 1 60 , 16 5, 1 66 ) int o si de of
s yncroset bo dy (150 ).
3. A s sem b ly of Syn cros et M o dule to G earcase
a. E ns u r e he ate r as s e m b ly ( 1 87 ) , ( P os t -1 9 78 ) , is s ec ur ed to g ea rc as e w it h tw o
s cr ew s i nt o p re tap p ed ho le s d i re ctl y b en eat h s y n cr os e t en tr y o p en in g i n th e
g ea rc as e .
23-13
b. I ns pe ct g e ar ca s e an d s y n cr o s et s e al in g s ur f ac es f o r a ny d am ag e t ha t w o u ld
h ind er p ro p er s eali ng .
c. E n su re O -r ing (1 70 ) is f itted pr op erly a rou nd b od y (1 50 ) a nd fit in to gear cas e
(1 ) o pe n in g .
d. S ecur e w ith fo ur capscre w s ( 16 7) and spr ing w ash ers ( 17 1). T o rqu e cap screw s
to 10 - 12 ft. lbs .
1. P re-1 978 and P os t- 1 978 A ctuator s

a. If lim it s w itch w h eel o r d riv e as s em bly (1 22) is d efectiv e or h as been rem o ved
in or de r to r ep lace to r qu e sw i tch m ech an is m , i t m ust b e rep lac ed o n lim it
sw it ch m ech ani sm sha ft.
b . E n su re lim it sw i tch w he el and d ri ve as s em b ly (1 2 2) is fu lly in s ert ed ha rd
aga ins t th e sw itch m ech ani s m ( 2 61 ) br ass b u s hin g .
c. U s in g th e ho le in the li m it d ri ve as s em bl y (2 6 ) as a te m p late , dr ill a 1 /8 in ch
hole throu gh the s w itch m echanism ass em bly (261 ) shaft's bras s bu shing.
d . S ecu re lim it s w it ch dr ive as s em b ly ( 12 2) o n s w i tch m ec han is m as se m bl y by
ins er tin g sp ir ol pin ( 12 4) th ro ug h 1/ 8 inch h ole d rill ed in s tep 3.
e. C lip h eat er to b ack of r ep lace m en t sw i tch m e ch ani s m a s se m b ly if P r e- 19 78
h ea ter (o b s ol ete ) is s til l in s tal led . ( P r e- 19 7 8 s w i tch m ec ha ni s m s ha d h eat er
clip s po p-r iveted to the back of the m echan is m .)
f. G rease O - ring (2 71) o n sw itch m echanis m .
N O T E : T he follow ing step s cann ot b e per for m ed u nles s m o tor m odu le

has been insta lled .
g. In s tall tor qu e s w itc h s h aft ( 11 7) in to op eni ng in g earc as e in s ur ing s h akep ro of

w ash er end is faci ng sw itch m ec han is m .
h. C aref ully p us h sw itch m ech ani sm (2 61 ) in to gear cas e (1 ) un til g ears m at e.
l. R eplace on e capscrew (26 4) in to sw itch m echan is m b ackplate (2 63) and
t ig ht en i n or d er t o v er if y to r qu e ad ju s tin g f r on tp la te ( 27 0 ) tu r ns to w ar d th e
v erti cal p os itio n (p oin ter align s w ith ar row ) .
j. If n ot i n v erti cal p os itio n, re m ov e cap s crew ( 26 4) an d w ith dr aw s w itch
m echan ism (26 1) aw ay fr om g earcase (1 ).
N O TE : I ncr eas in g th e s ha fts (l1 7) ove ra ll len gth w ill cau s e the
fron tplate (27 0) to rota te clockw is e w h en view ing the sw itch m echa nis m
(2 61) from the front.
k . R em o ve torq ue s w i tch sh aft (1 17) an d adju st cap scr ew ( 25, 9 1) in or der to

cen ter p oin ter o n to rq ue ad ju s ting fr on tpl ate (2 70 ).
l. T ig hte n aer o tig ht s ti ff nu t (1 1 9) a fte r ad ju s tin g to rq u e s w i tch s h af t ( 1 17 ),
t akin g car e no t t o ov er tigh ten a nd d am a ge cap screw (1 1 8) .
23-14
m . R ep ea t S tep s h an d i. I f a lig n m en t is ach ie ve d g o to S t ep n . I f n ot r ep ea t

S teps j thro ugh m .
n. R ep lace tw o capscrew s (26 4) and to rqu e to 4 .5 - 5 .5 f t. lbs.
o. C on n ect a ll in ter n al w ir in g t o th e ap p ro p ri ate t er m in al s a nd s ecu re w iri ng
lo om to sw it ch m echan is m w ith S co tch T he rm o se tting T ap e 2 7.
N O T E : T he cover o rien tatio n is im por ta nt o n the 1 2 sw itch add -o n-p ak

a ss em bly. A n a dd- on -pa k s u ppo r t is w elded to the ins id e of the cove r
(252 ).
p. G rease O -rin g (2 54 ) and in st all o n gear case ( 1) . In sta ll lim it sw itch co ver
( 250 , 25 1, 2 52 ) a nd s ecur e w ith th ree cap sc rew s ( 25 7) and w as h ers ( 28 8) .
G reas e and tor qu e caps cr ew s (25 7) to 10 - 12 ft. lb s. ( 4.5 - 5.5 f t. lbs . on P re-
1 97 8).
q. R ef er to Sect ion 20 .0 f or sw it ch m echan is m ad justm en t p ro cedu re.
2. M od ula r R ep lace m en t o f S w itch B ank s o n M ech an is m
a. P re -1 9 78 A c tu ato rs w it h N O desi gn S w itch M ech an is m s I nst alle d
• C om pres s w ash er (26 6) and s prin g ( 265 ) by m ov ing sw itch tow ard s the
fro n tp la te (2 7 0 ).
• P u ll s w itc h ban ks (2 60 ) ou t o f th e s w itch m ech anis m re arp late (2 7 2) .
• I ns ta ll re pla cem e nt s w itc h ba nk s ( 26 0) , d ep res s in g w as h er ( 26 6 ) and
spr ing ( 265 ) and snap pin g sw itch b ank (2 60 ) i n p lace.
b. P o s t -1 9 78 A ctu a to rs
• S crew lockin g h ex nu t (2 69) tow ards s w itch bank (2 62) .
• M ove s w itch ban k (2 62) tow ards fr ont p late (270 ), far eno ugh to r eleas e
sw it ch ban k ( 26 2) f rom sw itch m ech anis m 's r earp late (2 72 ).
• I nsta ll r ep lace m en t sw itc h ba nk s ( 26 2) in to f ra m e and h o ld in p lace.
.• E n s ur e s m all b ar re l nu t is p o s itio n ed in ro un d ed ar ea o f s lo t on f r on t
p late (270 ).
• S cr ew lock ing h ex nu t ( 26 9) fir m ly aga ins t in side su rf ace o f fr ont pl ate
(270).
1 . P o s t -1 9 7 8 A d d -o n - pa k
a . I n s pe ct ad d -o n -p ak fo r d am ag e
b . E n s u re al l po w er ha s b een re m o ve d f ro m ac tu ato r.
c . V e rif y t hat t he r ep lace m en t ad d- on - pa k ge ar cl us t ers ( 32 5) an d spa cer s ( 32 6 )
m atc h th e da m ag ed add - on - pa ks .
d . I f ad d- on -p ak is be ing i ns tal led f or th e fir s t t im e ref er enc e E nclo s ur e 20 .3 i n
S ection 2 0.0 f or co rre ct n um b ers o f gear clu s ters ( 32 5) and s p acers ( 32 6) fo r
s pe cif ic v alv e tr av el.
23-15
N O T E : N e ver m i x a n d m atc h ge ar in g th at is pin n ed, w ith gea r in g th at

is in ves tm ent cas t.
e. R e m ov e tw o ca ps cre w s (3 12 ) t hat reta in sw it ch ho ldin g pla tes (3 13 ) to th e

ad d- on -pa k fro nt plate .
f . R em o ve s w itch h o ldi ng p late s ( 31 3) , s pr in gs ( 3 10 ), an d w as h ers (3 09 ) h eld
b e h in d th e se p lates .
g . In s tall th e thr ee m o un tin g pi llar s ( 33 0) to th e s w it ch m ec han is m (2 6 1) . S cre w
u p ti gh tl y to th e n ut s r et ain in g t he s w i tch m e ch an is m s f ro n tp lat e (2 7 0 ) an d
to rqu e to 5 - 5.5 f t. lbs .
h . I f p o tent iom eter ( 30 8) is fit ted, sli de it on th e pill ar.
i. I n st all th e add - on -p ak o nt o th e p ill ars (3 3 0) .
j. M ov e s w itches (3 03) to th e s id e to allo w in stal lation o f the caps cr ew s (31 5)
an d w as h er s ( 3 16 ) to pi llar s (3 30 ) . T o rq u e to 5 - 5.5 f t. lb s .
k. R ep lace sw itch es (3 03 ) in ad d- on -pak f ram e.
l. R ep lace sp rin gs ( 31 0) , w ashe rs ( 309 ), h old ing pl ates (3 13 ) and tw o capscr ew s
( 31 2 ) th at w e re r em o ve d in s tep f.
m . C o nnect w iring fr om the lo om (17 2) to the s w itches ( 30 3).
n . S e cur e th e l oo m to th e pi llar s u s in g S co tch T he rm o s et tin g tap e 27 .
o . R efer to S e ctio n 20 .0 f or ad jus tm ent p ro cedu re .
2 . P r e - 1 97 8 A d d - o n - p ak
a. I n s p ec t ad d -o n - p ak f o r d a m a ge
b. E n s ur e al l p ow e r h as be en r em o ve d f ro m ac tu ato r .
c. V er if y th at th e r ep lac em en t ad d -o n -p ak gea r cl us t ers ( 32 5 ) an d s p ace rs ( 32 6 )
m a tc h th e d am ag e d ad d - o n -p a k s .
d. I f add - on -p ak i s b ein g in s tal led f or the f ir st t im e, r ef er en ce E nc lo su r e 2 0 .3 i n
S ectio n 20 .0 f o r cor rec t n um ber s o f ge ar clu s ters (3 25 ) an d space rs (3 26 ) fo r
sp eci fic va lve tr avel .
N O T E : N e ver m ix a nd m a tch g ear in g th at is n ylo n w it h gea r ing tha t i s

investm ent ca st.
e. L oo sen tw o fr ont plate m ou nting nuts (3 24) .

f. S crew lock ing h ex n ut (3 22) tow ards s w itch bank (3 19).
g. M ov e s w itch ba nks (3 19) to w ard s fr on tplate (3 14 ) far en oug h to rele ase
sw i tch ban ks (3 19 ) fro m add -o n- pak f ram e .
h. In s tall th r ee the t hr ee m o un tin g p illa rs (3 21 ) to the s w it ch m e cha nis m ( 25 9 ).
Screw up tightly to the nuts retaining the sw itch m echanism s fron tp late
(2 70) an d to rqu e to 5 - 5.5 f t. lb s.
i. I f pot entio m eter ( 30 8) is fitted , s lide it on th e p illar .
j. I nstal l th e add -o n- pak o n to the pi llar s (3 21 ).
k. I ns tal l al ien s crew (3 20 ) in to up per h ol e o f add -o n -p ak fr am e and t igh ten in to
th e en d o f th e u pp er s up p or t p ill ar ( 3 21 ) . T i gh te n to 5 - 5 .5 f t. lb s .
23-16
1. L o c a tin g th e b o tto m tw o p illars (3 2 1 ) in to th e a dd -o n -p a k fra m e an d d riv e

a da pt er ( 3 27 ) on to th e s w it ch m ech a ni s m (2 5 9 ), tig h ten th e tw o bo tt o m ali en
s cre w s (3 20 ) to 5 - 5. 5 ft. lb s.
m. Install sw i tches ( 31 9) int o ad d- on -pa k f ram e and h old in pl ace.
n. T ig hten t w o f ro nt plat e m ou ntin g nu ts ( 32 4 ).
o. E ns u re s m all h ex nu t (3 23 ) is p os iti on ed in r ou nd ed ar ea o f s lot o n fr on tpl ate
( 3 1 4 ).
p. Sc rew lock ing h ex n ut (3 22 ) fir m ly ag ains t the in side sur face of t he fr on tplat e
( 31 4 ) en su r in g tw o h ex n ut s ar e jam m ed to g eth er ( 32 2 , 32 2) .
q. C onn ect w ir ing to the lo om (1 72) to the sw itches (31 9).
r. S ecur e t he loo m t o t he pilla rs u s ing S co tch T he rm o s ettin g T ape 27 .
s. R efer to S ection 20.0 f or ad jus tm ent p roced ure.
1 . P o s t-1 9 7 8 A ct u at o r
N 0 T E : A ll N A 1 m ot or s a r e su p plie d in a m od u lar for m . S tat or s a r e

alrea dy fitted into the m otor cover and the r otor onto the w or m sh aft pr ior
to leaving the fa ctor y.
a. In spect m ach ine d su rf aces o f m oto r and m o tor w or m shaf t ( 24 ) for d am ag e.

b . I ns p ect f or da m age and g reas e O - rin g (9 1); en su re cor rect po s ition o n m oto r
co ver h ou s ing .
c. V erify to rqu e s w itch s haft (1 17) is in s talled in g earca se (1) .
d . E ns u r e m o to r le ad s a re co n ne cte d to ap pr op r iat e ter m i na ls o n b ac ks i de o f
ter m in al b lo ck (15 2) as follow s :
• I n s ta ll f ib r eg l as s s le ev in g ov e r 3 S yn c ro s e t m o to r le ad s .
• S tr ip in s u l at io n f r o m e nd s o f S yn c r os e t a nd m ot o r l ea ds .
• P us h w i re s in to ap p r ov e d b u tt c on n ec to r an d c r im p w i th ap p ro v ed to o l.
• P u s h f ib r e gl as s s le ev i n g o v er m o to r le ad s an d b u tt c o n n ec to r s an d ta p e i n
p lace w it h S co tch T her m o sett ing T ap e 2 7.
N O TE : A cor rectly po sitioned m o tor w ill have a s ta tor locking s crew on

the s ide next to the s yncros et hous ing.
e. A lign m oto r as fo llow s:

• W hile keepin g m o tor leads clean of oil and gr ease, feed spliced m otor
lead s i nto p assag ew ay o n th e r ig ht side o f th e g ear case (1 ) an d car efu lly
slip m oto r w orm sh aft (2 4) p art w a y i nto ge arcase (1) . T he fib reg lass
s lee vin g s h o uld ke ep th e m o to r lea ds s tr aig ht a nd a w ay f ro m th e m o to r
shaf t.
23-17
• U nles s res is ta nce is e nco un ter ed be tw een th e w o rm s ha ft (2 4) an d

w orm w heel (21 ), con tinu e f eedin g the m otor lead s into p assag ew ay a nd
caref ully p ush m oto r flus h w ith gear case ( 1).
• If t eeth of g ea rs do n o t m es h to g eth er e as ily , r em o ve m oto r an d t ur n
w or m sh af t (2 4) slig ht ly an d r ep eat ste ps 1 an d 2 a s n ece ss a ry .
f . L u b r ica te a n d i ns tal l t hr ee ca ps c r ew s ( 7 1) an d s p ri n g w a s h er s (2 0 ) to re ta in
m o to r t o ge ar ca s e ( 1 ) .
g . T o rq u e bo l ti n g t o 2 0 - 22 f t. lb s .
2 . P re -1 9 7 8 A c tu ato r
N O T E : A L L N A 1 m oto r s ar e s upp lied in a m o du lar for m . S tator s ar e

alr eady fitted in to the m o tor cover a nd the r oto r onto the w or m s ha ft pr ior
a . In sp ect m a ch in ed su rf ace s o f m o to r an d m ot or 's w o r m sh aft ( 2 4) f o r da m ag e.

b . I ns p ec t f o r da m ag e an d g rea s e O -r in g (9 1 ); en s u re co r re ct po s iti on on m ot or
c o v er h o u s i n g .
c. V e rif y to r qu e s w itch s haf t ( 11 7) is i ns ta lled in g ear cas e ( 1) .
d . E ns u r e m ot o r le ad s ar e c on n ec te d to ap p r op r ia te t er m i n als o n ba ck s id e o f
te rm in al b lo ck (1 5 2) .
N O T E : A corr ectly pos itioned m oto r w ill have a stato r lo cking s cr ew o n

the side next to the s yn cr os et h ousing (150).
e . A lig n m o to r as fo ll ow s :
• W hile k eeping m otor leads clean of oil and grease, feed sp liced m otor
lea ds int o pa ssa gew a y on t he r igh t side o f th e g ear case an d car ef ull y slip
m o tor w or m shaf t ( 24 ) p art w ay int o g ear case (1 ).
• U n less resi stan ce is en cou n ter ed b etw e en th e w o rm sh af t (2 4 ) an d
w or m w heel (2 1) , co ntin ue feedi ng the m oto r leads in to pas s agew ay and
car efull y p ush m oto r flus h w ith gear case (1 ).
• I f teet h o f ge ars do no t m es h t og eth er e as ily , r em o v e m ot or a nd tur n
w o rm sh af t ( 2 4) sli gh tly a nd r ep eat step s 1 ) an d 2) a s n ecessar y .
N O T E : P r e- 197 8 actu ato r s utili zed a s m aller m o tor m o un ting b olt

than the P os t- 1978 gear cases . IF r eplacing a new P ost-1 978 m oto r
on a P re-1 978 g ea rcas e, ensu re pr oper bus hings and w ash er s are
in stalled.
f. In stal l bu sh in g an d f la t w ash er w h en in stal lin g a P o st- 1 97 8 m ot or on a P re -

1 978 gear case.
23-18
g. L u br ica te an d in stal l t hr ee ca ps cr ew s (7 1 ) an d sp rin g w a sher s (2 0) to r eta in

m o tor to g earcase (1 ).
h . T or que 1/4 - 20 U N C x 1 1 /2" bo lting to 1 0 - 1 2 f t. lb s . T o rqu e 5 /16 - 1 8 U N C
x 1 1/2" bo lting to 20 - 2 2 ft. lb s.
1 . T o p M o u n t ed
a. A pp ly a thin coat of E xxo n U n irex N 2 g rease to O -rin g ( 10 8), and oil seals
( 50) an d pr ess int o p lace us in g top ha nd w h eel se al to ol.
b . P o sit ion ha ndw h eel a ss em b ly to pr even t cap s crew s ( 72 ) fro m b ein g d ire ctly
over or aligned w ith clutch key s ( 27) on clutch ring (2 6).
c. C oat n ylo n h and w he el r eta ine r (1 03 ) w ith g ear case oil an d fe ed in to g earc ase
w h ile ro tating hand w h eel h oop (8 7) coun terclock w is e.
d . In s tall han d w h eel re tain er s ealin g p lug ( 10 0) a nd to rq ue to f ol low in g
specif icatio ns:
•
I f o ld s ty le p lu g w it h ph il lip s s c re w , to rq u e t o 1 5 ft . lb s .
•
I f n ew s t yl e ex tr a cto r p l ug , t o rq u e to 20 - 2 2 f t . lb s .
e. T ig hten phillip s s crew if ins talled.
f. V eri fy ha nd w heel op er ation i n m anu al m od e.
2. S id e M o un te d
a. A pp ly a t hin co at o f E xx on U n irex N 2 gr ease t o O - rin g (4 6) an d fit on to
han dw h eel as s em b ly sp ig ot.
b . G reas e ha nd w heel o il s ea ls ( 50 ) and p re ss int o plac e u s ing s id e han dw h eel
seal to ol.
c. P os ition h and w h eel as s em b ly c arefu lly and lo cate d ow el p ins (11 1) int o h oles
in u pp er f ace o f ge arc ase a nd t ap in to p lac e u s in g a ru bb er m alle t.
d. C oa t n y lo n ha nd w he el re tain er ( 1 03 ) w it h ge arc as e oi l a nd fee d in to g ear cas e
w hile rotatin g h andw heel hoo p ( 80) cou nter clo ckw is e.
e. I n st all ha nd w hee l r etai ner s e alin g pl ug ( 10 0) a nd to r qu e t o fo llo w ing
specifications :
• If ol d s ty le p lu g w i th p h ill ip s s c re w t or q ue t o 1 5 f t. l bs .
• I f ne w s ty le ex tr ac to r p l ug to r q ue to 2 0 - 2 2 ft . l bs .
f . T igh ten p hilli ps s cr ew if in s talled .
g . V er ify h and w h eel op eratio n in m anu al m od e.

1. U si ng ap pro pria te fit tin g s, in sta ll p re ssure g au ge a nd co n nec t ai r su pp ly to
gear case hou s ing (1) aft er r e-as sem bly of all m o dule s is com p lete.
2. S lo w ly ap pl y pr es s ur e to g ear cas e un til g aug e re ads be tw een 2 8 - 3 0 ps i g.
3. I s ol ate p r es s u re s o u rc e an d r ec or d a ir p r es s u re .
4. A ft er 1 5 m i nu tes r eco rd fin al ai r p res s u r e and re cor d p r es s ur e dr o p if a ny .
5. I f p re s s ur e dr o pp ed m o re th an 2 p s ig , de ter m i ne s o ur ce o f le ak a nd rep ai r p er
th e a p pr o p r ia te s u b s e ct io n s .
6 . I f ge arc as e d id n ot d ro p pr es s ur e ov er 2 p s ig, co n tin ue to n ext s tep .
7. R eliev e pr es s ur e fr om g ear cas e.
8. F ill gear cas e w ith oil thr oug h oil fill plu g h ole up to on e in ch of ho le b ase
th r e a d s .
23-19
9. Inc rease air p ressure to gear case slow ly to 18 - 20 p si g.

10 . Is o late pr essur e so ur ce a nd r eco rd p ressur e.
1 1. A ft er fif teen m inu tes r eco rd f ina l air p re ss u re an d reco rd p re ss u re dr op i f any .
12 . If g ear case p r essu re d ro pp ed m o re th an 2 ps i g, d eter m in e so ur ce of lea k and
rep air pe r t he app ro pr iate su bs ecti on s.
1 3. If g earcas e did n ot dro p pr ess u re ov er 2 p s ig, co ntin ue to nex t s tep.
14 . R em ov e f ittin gs , pr es s ur e s u pp ly and r eliev e gear cas e pr ess u re.

C om po nent T o rq u e F u n c t io n a l T im e * D ia g n o s tic
R e p a ir e d T e st V e r ific a tio n R e sp o ns e T e s tin g
B ench
M oto r M odule X X X X
W o rm ge ar X X X X
G earcase M odu le X X X X
D riv e B u shi ng X X X
H an dw h eel M o du le X
S yncroset M o dule X
A dd -on-pak M odu le X X
* R efe r to S e ction 2 6 .0 fo r tes ting g uid elin es .

1 . E n s u r e a ct u at or f ee d er b r ea k er is op e n .
2 . I f req u ire d re m ov e ol d dr iv e b u s hin g f ro m old actu ato r ( 7, 2 2) p er S e ctio n
2 3.2 .6.3 a n d r ei ns t al l on r ep la cem en t a ctu at o r p er S ec tio n 23 .3.1 .4.
3 . E n s ur e v alv e s te m is p ro p er ly s ecu r ed t o av o id pe rs o n ne l in ju r y o r eq u ip m e nt
d am a g e.
4 . L u b r ic at e v a lv e s te m a s n ec es s ar y .
5 . I n s ta ll r ig g in g as n ec es s a r y t o s u p p or t t h e w ei g ht of th e a ct ua to r .
6 . I n s t a ll a c tu a to r as f o l lo w s :
a. F or p res s ur e se al ty pe v alves , lo os en y ok e c lam p b olts , r otat e y ok e an d
actu ator as n ecessar y to pro vid e ac cess to yok e b olts .
b. F or k ey ed s ha ft s tem ap pli catio n s , po s itio n act uato r s o k eyw a ys lin e u p an d
p u s h a ctu a to r s t ra ig ht o n to ge ar b ox s h af t.
c . F or thr ead ed sh af t v al ve stem ap p lica tio ns , p osi tio n act uat or so d r ive
b us h in g a nd va lv e s t em m ate. O pe ra te h an dw h ee l ho o p ( 87 ) t ow a rd o p en
d ir ectio n u nti l a ctu ato r is f lus h a gai ns t va lve y ok e.
d . Fo r glo be val ve app licatio ns a fter p erfo rm ing step c) , en sur e k eys a re
i ns t all ed i nt o y ok e an d s t em an d k ey r et ain er s ar e rep la ced pe r v alv e
d raw ing s.
e. A li gn ac tua tor to m at chm ark s a s ap pl icab le.
7 . S e cu re ac tu ato r to yo k e o r g ear b ox us i ng a pp r op r iate b o ltin g h ar d w are .
8 . E n s ur e p r op e r to r q ui n g r eq u ir em en ts ar e m et p er va lv e d r aw in g s .
9. R em o ve tem p o rar y ri gg ing .
23-20
10. R em ove syncroset co ver (15 1).

11. C o nn ect field cabling to term inal block (15 2) as requ ired.
12. In stall s yn cros et ho us ing co ver (15 1).
13. R em ov e valve gag device f rom s tem as applicable.
14 . P er for m s w itch setu p per S ection 20 .0 .
23-21
- -

F ig u r e 2 3 -la
30 G ea r ca s e A s se m b ly
(S e e F ig u re 2 3 -1 b fo r P a rts D e sc rip tio n )
23-22
F ig u re 2 3 -lb
3 0 G e ar c as e A s se m b ly
23-23
F ig u r e 2 3 -2
3 0 D r ive B u s h A s se m b ly
23-24
F ig u r e 23 -3
30 M oto r A ss em b ly
23-25
F ig u r e 2 3 -4
30 T o p H a n d w h ee l A ss em b ly
23-26
T h is p ag e i nte ntio n ally le ft bl ank .
F ig u r e 2 3 -5 a
3 0 S id e H an d w h ee l A s se m b ly
(S ee F ig u re 2 3 -5 b for P a rts D e scrip tio n )
23-28
F igu r e 2 3- 5b
3 0 S id e H a n d w h e el A sse m b ly
23-29
F ig u re 2 3 -6
S p rin g P a k S h e et 3 0 N A T
23-30
Th is pag e in ten tion ally left b lan k.
EPRI Licensed Materia l
N u cle ar M a in ten an ce A p pl ica tion s C e nte r
F ig u re 2 3-7a
S yncro set A ssem bly
(See F igure 2 3-7 b for P arts D escription)
23-32
-

Ro tork M aintenanc e M an ual
PAR T ID PAR T D ESCR IPTIO N NOTES

1 50 B ody
1 51. C o ve r
15 2. T e rm in a l B lo c k
15 3. C o n t ro l T e rm in a l P art o f 183
154. P o w e r T e rm in a l P art of 1 83
15 5. P o w e r T e rm in a l S c re e n
156. S h a ke p ro o f W a s h e r
157. T e r m in a l N u t
158. T e rm in o l N u t
159. B ra s s W a sh e r
160. S p rin g W a s h e r
161. Nut
16 2. S p rin g W a s h e r
163. B ra s s W a sh e r
165 . E a rth L a b e l
166. B ra s s S c re w
167. C a p sc re w
170. "O " R ing
171. S p rin g W a sh e r
172. S w it ch M e ch a n is m L o o m
17 3. In se rt
174. R e t a in in g R in g
175. Sh a ke p ro o f W a s h e r
17 6. T a p it e S c re w
177. T e rm in a l L in k
178. L o be l
17 9. 1 1/2 " C on duit P lug
180. 1 1/4 " C ondu it P lug
181. S cr e w - H a m m e r D r ive
182. C o d e C a rd
183. T e rm in a l B lo c k S u b a s s e m b ly
184. M otor Lo om
185. T h e r m o s ta t L o o m P os t - 19 7 8 O n ly
186. N y lo n W a sh e r
187. L o o m -H e a te r * P re - 1 9 78 is O bs o le te
188 . S cre w
190. L o c k n u t S te e l
F ig u re 2 3- 7 b
S yncroset A ssem bly
2 3- 33
Nuc lear M aintena nce Ap plica tio ns Ce nte r
F igu re 2 3-8
A dd-on-pak A ssem blies
2 3 -3 4
E P R I Licensed M aterial
R o tork M ainte nance Man ual
F igu re 2 3-9
T ype "A " and T ype "N A " O ld V ersion A dd-o n-pak
Pre-19 7 8
2 3- 35
Nuclea r Main tena nce Ap plica tion s Cen ter
Fig ure 2 3-1 0

T ype "N A " N ew V ersion A dd-on-pak
P o st -19 7 8
23-36
Ro tork M aintenanc e M an ual
Figure 23-11
A dd -on -p ak M od ular R ep lacem ent o f Sw itch B an ks
P ost-19 78
2 3 -3 7
EPPI Licensed Material
F igure 2 3-1 2
A dd -o n-p ak M o dular R e placem ent of S w it ch B anks
Pre - 1978
23-38
E P R I License d M aterial
Rotork Mainte nance Manua l
Fig ure 23 -13

A dd -o n-p ak T y pical A O P I G ear A rrang em en t
23 - 39
E P R I L ic ensed M aterial
Nucle ar Main ten ance Applicatio ns Ce nte r
F igu re 23-14
N A T and N A 2 S w itch M echanism A ssem bly
P re-19 78
23-40
F ig u re 2 3 -1 5
N A T S w itch M e ch a n ism A ss em b ly
23-41
F ig u r e 2 3- 1 6
S w it c h M e c h a n i s m M o d u l e ( N A 1 )
(F r on t V iew C r os s S ection )
23-42
F ig u r e 2 3 -1 7
R ep la c e m en t S w itc h M e ch a n is m S w it ch P a k s
23-43
F igu r e 2 3 -1 8
F a b r i c a t e d C o v e r A s s e m b ly f o r S w i t c h M e c h a n is m
23-44
F ig u re 2 3 -1 9
23-45
F ig u r e 2 3 -2 0
F a b r i c a t e d C o v e r A s s e m b l y f o r 1 2 S w it c h A d d - o n - p a k 1
23-46
24.0 40 NA1 ACTUATOR

N um b er ed re f er en ce s in p a re nt h es e s , ( ), co r re s p on d to F ig u re s 24 - la t hr o u g h 2 4 -2 0 .
N O T E : T his pr oced ur e h as been w r itten u tiliz ing a m od ula r ap pr oa ch to

m ain tenan ce activities . D ue to this a ppr o ach, cer tain step s w ill be r epea ted
w ith s pecific m o dule m a in tenan ce in m ind .
1 . E n s ur e a ct ua to r f e ed er br e ak er is in o pe n p o s it io n .
W A R N I N G : A d dition al cir cuits m ay need to b e iso lated by r em oving fus es ,

lifting lead s, op ening s liding links , etc.
W A R N IN G : I f th e s ys tem i s pr es s ur iz ed, th e va lve s tem m a y s lip r es ultin g

in s eriou s injur y to p ers onn el per form ing m aintena nce on the actu ator .
2 . G ag v alve stem as req ui red by secu rin g valv e stem to y ok e.

3. T o rem ove s yncro set cov er (15 1), r em ove fo ur s crew s (1 88).
4 . D is con nec t an d r em o ve field w irin g fr om sy ncr os et bod y (1 50 ). M ark w irin g fo r
re co nn ec tio n , a s n ec es s ar y .
5 . R ep lace syn croset co ver (15 1) .
6. R eplace four s crew s (188).
7 . T o r em o ve the lim it s w itch co ver (2 50 , 25 1,25 2) , r em o ve thr ee c aps cre w s (2 57 ),
and sp rin g w ash ers (2 58 ).
8 . D iseng ag e th e pr im ar y lim it sw it ch and l oo s en ad d- on -p ak clu tch n ut , if
app lica ble (r ef er to S ectio n 2 0.0 fo r deta ils ).
9 . R ep la ce li m it s w i tch c ov er (2 5 0,2 51 ,25 2 ) w it h ca ps c rew s ( 25 7 ) an d s p r in g
w a sh e rs (2 5 8 ).
C A U T IO N : W h en r igg ing th e actu ator fo r r em oval / r eplacem ent, car e

shou ld be ta ken to a void con necting to either the han d a uto lever (11) ,
han d w heel hoop (82, 75), o r handw heel spo kes (80, 73).
10 . I n stall r ig g in g as n ece ssary to su p po r t th e w eig h t of t he a ctu at or an d p rev en t

s te m d a m a g e d u ri n g r e m o v a l.
11 . M a tch m ar k a ctu ato r as s e m b ly a nd v al ve y o ke to es tab li s h o rig in al in s ta lla tio n
position.
12 . R em o ve th e m o un tin g bo lt s o r s tud nu ts f ro m b elo w th e val ve y ok e or g ear bo x
fl a ng e .
24-1
1 3. R em ov e actuator fro m valve as follow s :

a. G lob e V alv es
- E ns ur e v al ve s t em k ey s ar e r em ov e d an d pr o pe r ly m ai nt ain e d u nt il t he
a ctu ato r is r ep lac ed/ rei ns ta lled .
b . G ate V alv es
- F or th r ea d ed s h af t v al v e s t em a p pl ic at io n s , ro t ate o pe r ato r h an d w h ee l
to w ard clo s ed di re ctio n u nti l t he act uat or u n sc re w s fr o m the v alv e st em .
c . Q ua rte r T u rn V alv es
- F o r k ey ed s h af t ap pl ica tio ns , en s ur e th e actu at or is p u lle d s tr aig h t o f f o f
t he va lve stem o r ge arb ox sp lin e shaf t to av oid val ve stem d am ag e.
14 . T ra ns p or t ac tua to r to p r op er a re a fo r s to ra ge a nd /o r r ep air .
W A R N IN G : If the actu ator h as no t been r em o ved fr om th e valve pr ior to m o tor

as sem bly rem oval, ens ur e actuator feed er b reaker is in o pen pos ition.
A d ditio nal cir cuits m ay als o need to be iso lated by r em o ving fu ses , lifting
lead s, open ing s lidin g links , etc.
1. C heck m o tor w inding s ( 90) f or d am ag e as fo llo w s :

a. U s in g a d ig ita l m u lti- m e ter , m e as u re w in d ing re s is tan ce b etw e en e ach
ph a s e. N o w in d in g re s i s ta nc e s h o u ld r ead o p en an d th e r es is t an ce va lu e s
sh ou ld be ap pr oxi m ately b alan ced.
b. U s in g a m egg ar ( 10 00 v olt scale ), m e asur e t he resist ance b etw een o ne m o to r
w in d in g to th e m o to r h o us i ng . T he r es i s tan ce v al ue s h o ul d b e 2 1 .5
m eg ohm s .
c. I f r esistan ce va lu es v ar y fr om r esul ts i nd icat ed ab ov e, co n tact th e
ap p r o pr ia te e n gi n eer i ng r ep re s en t ati v e or a R o to r k r ep r es e nt at iv e.
2 . D rain o il f ro m g earca se (1 ) by rem ov ing lo w er p lug ( 86 ).
3 . P l ace t h e act u ato r in t h e ha n d o p er ati o n m od e b y d e pr es s in g h an d a u to lev er
( 1 1 ) t o th e m an u a l m o d e .
4 . If t he m o to r is ha ng in g v er tica l fr om t he ac tua to r re fer to S ec tio n 2 4.2.2 , S w itc h
M ech anis m R em o val to e ns u re s w itch m e cha nis m ( 25 9, 2 61 ) an d tor qu e s w itch
pl un g er (1 1 4) ar e r em o v ed pr io r t o m ot or re m o v al. P r oc eed to S tep 24 .2 .1 .4, if
th e m o to r is ho r izo n tal t o th e act ua to r.
C A U TIO N : Im prop er rem ova l o f the m otor cover (4) fr om the gear case (1)
cou ld res ult in d am a ge to o il s eal (5 5) a nd bea ring (42,43).
5 . R e m ov e fo ur c aps c rew s (8 5) a nd s p rin g w as h ers (8 1) t hat r etain the m o to r cov er

(4 ) to the g earcas e (1 ).
6. R em o ve the m otor co ver (4 ) slo w ly f rom the gearcase (1).
24-2
7 . L o cate bu tt co nn ecto rs un der f ib erg lass slee vin g an d cut m o to r lead s o n bo th

s ides of butt conn ector s.
8 . R em ov e the m otor cov er O -r ing (91 ) an d in spect f or dam age. R ep lace as
n ecessar y.
N O T E : If th e oil sea l (55) is d eter m ined to need r eplacem en t, the circlip ( 5)

a nd sea l ba ckup w as her ( 7) m u st b e r em o ved fir s t on P os t-19 78 m o dels
o n ly.
9 . R ep lace o il seal (55 ), sno ut bear ing ( 42) an d need le b earin g (43 ) as req uir ed by
ind ication s of oil leakag e or dam age.
NOTE: Section 24.2.1.10 pertains to pre -1978 actuators only.
10 . In spe ct w o rm shaf t sh ro ud ( 29 ) fo r d am ag e a nd r epl ace as n ecessar y.
1 . P o s t-1 9 78 A c tua tor s

a . E n s ur e ele ctri cal p ow er i s is ola ted or d is con ne cted .
b. V i su all y insp ect fo r pr op er m o ve m en t o f the sw itch m ech anis m ( 26 1) as the
v alv e is m an u all y o per at ed . If th e s w itch m ec ha ni s m (2 61 ) s h o ul d n eed
a dj us t m e nt r ef er t o S ec tio n 2 0 .0 of th is m an u al. I f d am ag e is in di cat ed ,
rep lace the sw itch m echa nis m (2 61 ) as n ecessar y.
N O T E : S ection 2 4.2.2 .1 , Step c) is n ot req uir ed if r epla cing s w it ch

ba nks only.
c. D ra in o il fr om g ea rc as e (1 ) b y r em o v in g lo w e r plu g ( 86 ) .
d. R em ov e the th ree cap s cre w s (2 57 ) an d sp ri ng w as h ers (2 58 ) that r etain th e
lim it s w itch co ver (25 0, 251 , 2 52) and pu ll cov er s traig ht of f.
e. I f th e a ctu ato r is to rq ue d ou t in e ith er th e op en o r cl os ed po s itio n , th e t or qu e
ad ju s tin g f r on t p la te's p oi nt er w i ll n ot b e v er ti cal . I n th is in s ta nc e, m o ve t he
ha nd au to l ev er ( 1 1) in to t he h an d po s it io n to cen te r th e to r qu e ad ju s ti ng
fr on t p late a s n ece ssar y.
f. D isco nn ect th e sw it ch m ech an ism lead s f ro m t he sw itch b an ks (2 62 ) on t he
sw itch m echa nis m assem b ly (2 6 1) . M a rk w ir ing f or r eco nn ecti on , as
necessar y.
g. T o r em o ve s w itch b ank s (2 62) , scr ew lo ckin g hex nu t ( 26 9) tow ar ds s w itch
ban k (26 2).
h. M ov e s w itch b ank ( 262 ) tow ar ds f ro nt plate (2 70 ) far en oug h to relea se
sw itch ban k ( 26 2) fro m sw itch m echan ism rear plate (2 72) .
24-3
i. R em o ve t w o cap scr ew s (26 4) on the sw itch m ech anis m baseplate (26 3) .
C A U TI O N : U se car e w h en rem o ving s w itc h m ech an is m (2 61) to a void

da m age to the O -ring ( 271).
j. C ar efu lly re m ov e the sw itch m e chan is m (2 61 ) fr om th e g ear case ( 1) .

k. R em o ve th e li m it sw it ch dr iv e g ear as s em b ly (1 13 , 12 1 , 12 2) f ro m th e sw i tch
m e ch an is m s h af t (2 6 1 ) b y d r iv i ng o ut t h e s p ir ol pi n ( 1 19 ) lo ca ted n ear th e
li m it sw it ch rea r plat e ( 27 2) .
1 . R em o ve the tor qu e s w itch plu ng er (1 14 ).
N O TE : If r eplacem ent of o il sea l (57 ) is req uired, circlip (13) and s ea l

ba ckup w a sh er (2 0) m us t b e r em oved pr ior to r epla cem ent in 2 4.2.2 .1, S tep
m ).
m . V isua lly in sp ect oi l seal ( 57 ) fo r leak age or d am ag e. R epl ace as n ecessary .

n . V is ually i ns pe ct to rq ue s ha ft sh ro ud ( 60 ), s n ou t b eari ng ( 42 ), an d need le
b ear in g ( 43 ) f or w ear o r d am a ge . R e pl ace p art s a s n ece ss a ry .
2 . P r e- 1 9 78 A ct u ato r s
a. E nsu re elec trical p ow er is is olated o r d isconn ected.
b . V is u ally ins p ect f or pr op er m ov em ent of th e s w itch m ech ani sm (2 59 ) a s the
v alv e is m a nu al ly o p er ate d. If t he s w i tch m e ch an is m ( 25 9 ) s h ou ld ne ed
a dj u s tm e n t re fe r to S ec tio n 20 .0 o f t hi s m an u al . I f d am ag e is in d ic ate d,
r epl ace the sw itch m ech an is m ( 25 9) as nece ss ar y.
N O T E : 24 .2 .2 .2 , S tep c) is no t r eq uir ed if r ep lacin g s w itch b an ks on ly.
c. D rain o il fro m gearcas e (1 ) by rem ov ing lo w er plug (86 ).

d. R e m ov e the th ree cap screw s (2 57 ) and sp rin g w ashe rs ( 25 8 ) that r etain th e
lim it s w itch cover (2 50, 251 , 2 52) and pull co ver s traig ht of f.
e. If th e act uat or i s to r qu ed o ut in eith er t he o pen or c los e d po s iti on , th e to rq ue
ad ju s ti ng fr o n t pl ate 's p o in ter w ill n o t b e ve rt ica l. I n t hi s i ns t an ce , m o v e th e
h an d a u to le v er ( 11 ) i nt o th e h an d p o s iti on to c en ter t h e t or q u e a d ju s tin g
f ro nt p lat e as n ec essar y.
f. D is co nn ect the s w itch m ech anis m lea ds f ro m the s w itch b an ks (2 60 ) on th e
s w itch m echa nis m as s em b ly ( 25 9) . M ark w ir in g fo r rec on nec tion , as
n ecessar y.
g. T o rem o ve s w itch ban ks (26 0), com pr ess w ash er (2 66) and sp ring (265 ) b y
m ov ing s w it ch ban k (2 60 ) to w ard s th e f ro nt p late (2 70 ) pu llin g s w itch b ank s
( 26 0) o ut of the sw i tch m echa nis m rear pl ate ( 27 2).
h. R em ov e tw o capscrew s (2 64 ) o n t he sw itch m echan ism basep late (2 63 ).
24-4
C A U T IO N : U s e car e w hen rem ovin g s w itch m ech anis m (2 59) to a void

d am ag e to th e O -r ing (27 1).
i. C a ref ully r em ov e the sw i tch m ech anis m (2 59 ) fr om the gea rcase (1 ) and slip
ge arcase hea ter ou t o f clip lo cated o n th e b ack of th e sw itc h m ech anis m .
j . R e m ov e th e l im it sw it ch dr ive gear a ss em b ly (1 13 , 12 1, 1 22 ) fro m the s w i tch
m ec han is m s haf t ( 25 9 ) by d riv in g ou t the s pi ro l p in ( 11 9) lo cat ed ne ar the
k . R em ov e th e to rq ue s w i tch p lu n ger (1 14 ) .
l. V i su ally in sp ect oil seal ( 57 ) f or lea kag e o r d am ag e. R ep lace as n ecessa ry.
m . V is u all y in s p ect n eed le b ea ri ng (4 3 ) fo r w e ar o r d am ag e. R ep la ce pa rt s a s
n ecessar y.

1 . P os t -1 9 78 A c tu ato rs
a. E nsu re ele ctrical pow er is is olated o r d isconn ected .
b . R em ov e th e th ree ca ps c rew s ( 25 7 ) an d spr in g w ash er s ( 2 58 ) th at r etai n th e
lim it s w itch co ver (25 0, 251 , 2 52) and pu ll co ver s traig ht o ff.
c. D isco nn ect the add -o n-p ak lead s, w ith in the sw it ch m echan is m l oom (1 72 ),
fr om th e ad d- on -p ak s w itch es ( 30 3) . M ark w ir ing f or r econ ne ctio n, as
n ecessar y.
N O T E : I f r ep lacin g add -o n- pak s w itch b an ks (3 03) , of the rem a inin g

s teps in Section 24.2 .3.1, p erfo rm Step s d ) a nd e) on ly.
N O T E : If r em ovin g th e ad d-o n- pak as sem b ly (3 00, 30 1, 30 2) for r epa ir

/ in s pectio n o f th e a ctuat or elim ina te S teps d ) and e) an d per for m th e
r em a ining s teps in Section 24 .2.3.a .
d . R em ov e the s w itch h oldin g p lates (3 13 ), com p res sio n s p ring s (3 10) and
w ash ers (3 09 ).
e. P ul l a dd -o n- p ak s w itch p ak s h af t ( 31 1 ) tow a rd s th e fr on t pla te (3 14 ) an d
rem o ve sw itch ban ks (3 03 ).
f. R em o ve tw o caps crew s (31 2), w ash ers (3 09) and com p res sio n s prin gs (3 10)
tha t r eta in s w itc h ho ld in g pl ates (3 13 ) to the f ro nt p lat e ( 31 4 ).
g. R em ove sw itch ho ld ing p lates (3 13).
h. M ov e s w itch b ank s (3 03 ) t o th e s id e to all ow en tran ce o f allen ke y in to the
s oc ket cap sc rew s ( 31 5) t hat ret ain ad d- on -p ak (3 00 , 30 1, 3 02 ) to m o un ting
pillar s ( 330) .
i. R em ove the th ree sock et cap scr ew s ( 315 ).
j. R em ove add- on- pak (30 0, 30 1, 302 ) f rom the s w itch d riv e s haft (27 3).
24-5
k . L oos en set s crew (3 28) in lo cking plate (3 29) , th en rem o ve lock ing plate (3 29),
sp acers ( 32 6) and g ear clus ters (32 5) .
l . P er fo r m v isua l i nsp ectio n o f gear clust ers (3 25 ), sp acer s ( 32 6) , d riv e adap ter
( 327 ), lockin g p late (3 29) , m o untin g p illars (3 30) and s et s crew (3 28) fo r
d am a ge an d ab n o rm al w e ar .
m . If m ou nti ng p illar s (3 30 ) ar e d am ag ed, u ns cr ew f ro m s w i tch m ech an is m
as sem bly ( 261).
n. R ep lace par ts a s ne cessary .
2 . P re -1 9 7 8 A ct u ato r s
a. E n su re e lectrical p ow er is iso lated or discon nected.
b . R e m o v e th e th re e cap s c re w s ( 2 57 ) an d s p ri ng w as h er s (2 5 8 ) th at r et ain th e
lim it s w itch cov er ( 250 , 2 51, 25 2) and p ull co ver str aight off.
c. D i sco nn ect t he a dd -on -p ak leads, w ithi n th e sw itch m ec han ism lo om (17 2) ,
f ro m the add -o n- pa k sw it ches (3 19 ). M ar k w i rin g fo r reco nn ectio n , a s
nece ss ar y.
N O T E : I f r ep lacin g add -o n- pak s w itch b an ks (3 19) , of the rem a inin g

s teps in Section 24.2.3 .2, per form S teps d) thr oug h f) only.
N O T E : If r em oving the ad d-o n-p ak a ss em bly (30 0, 301 , 3 02 ) fo r rep air

/ ins pec tion of the actu ato r, elim in ate Step s d) thr o ugh f) an d per for m
the r em ainin g s teps in Section 24.2.3.2.
d. L o os en t w o fr on t m o un tin g n uts (3 2 4) n ear es t to s w itc h ba nk s ( 31 9 ).

e. S cre w loc kin g hex n ut (3 22) to w ard s s w itch b ank s (3 19 ).
f. M ov e s w itc h ban ks (3 19 ) tow ar ds f ro nt p late (3 14 ) far en ou gh to r elea se
s w itch ban ks ( 319 ) fr om add -on -p ak m ain fr am e.
g. L oo s en th r ee al ien s cr ew s ( 32 0 ) th a t re tai n th e ad d - on - pa k m ain fr am e to th e
m o un ting p illars ( 32 1).
h. R em o ve ad d- on -p ak (3 00 , 30 1, 3 02 ) fr om th e s w itch m ech anis m dr iv e s ha ft
(2 73 ).
i. L o os en s et s crew (3 28) in lo cking plate (3 29) , th en rem o ve lo cking plate (3 29) ,
sp acers ( 32 6) and ge ar clu s ters ( 32 5).
j. Pe rfo rm v isu al insp ectio n of ge ar clus ter s ( 32 5) , sp acer s (3 26 ), d riv e ad ap ter
(3 27) , lo cking plate ( 329 ), m oun ting pillars ( 321 ) an d s et s crew (3 28) fo r
d am ag e an d a bn o r m al w ear .
k. I f m ou nti ng p illar s (3 21 ) ar e d am ag ed, u ns cr ew f ro m sw it ch m ech ani sm
ass em bly (25 9).
l. R ep lac e par ts as n ece ssary .

1. E ns u re ele ctr ical p ow er i s is o late d or dis co n nec ted .
2. R em o ve f ou r s crew s ( 188 ) f ro m the s yncr os et b ody (1 50 ) an d rem ov e co ver (1 51) .
24-6
3. R em o ve O - rin g (1 6 4) an d v is ual ly in s pect f or d am a ge.

4. D is co n n ect a nd r em o v e al l ex ter n al w i ri ng . M ar k w i ri ng fo r r ec o nn ec tio n , a s
necessar y.
N O TE : To r eplace d am a ged ter m inal b lock (1 52) only, com plete 24 .2.4
Steps 5 throug h 7 . T o rem ove the en tire syncroset a ssem bly p ro ceed to
Section 24 .2.4 S tep 8 .
5 . R e m o ve gr o un di ng l ug c on ne ctio n s ( 15 8, 1 5 9, 1 6 0, 1 65 , 1 66 ) an d r etai nin g r ing

( 17 4) f ro m i ns id e th e sy n chr os et bo dy (1 50 ).
C A U T IO N : W h en rem ovin g th e ter m inal block (15 2) do no t pu ll on the br as s

ter m in al s tud s .
6. P u ll th e te rm in al b lo ck (1 52) s tr aigh t o ut of th e s y ncr os et bo dy (1 50 ) us in g tw o

pair s o f pl iers by g ri pp ing a nd p ull ing o n ter m in al blo ck s ep arat or s .
7. R em o ve int ern al w ir ing f ro m t he back o f ter m ina l b lock ( 15 2) . M ark w ir ing f or
re co n ne ct io n , a s n e ces s ar y .
8. R em ov e fo ur cap scr ew s ( 167 ) b etw een the s yn cros et bo dy (15 0) and gearcas e (1 ).
9. R e m ov e s yn cro set and v is ually in sp ect O - ring ( 17 0).
10 . O n ce th e syn cro set assem b ly is rem o ved f rom the gear case (1 ), the w i re lo om s
(1 72 , 1 84 , 18 5) m a y be dr aw n ou t th ro ug h the ge arcas e (1 ) op enin g.
N O T E : Sectio n 2 4.2.4 S teps 1 1 thr ou gh 13 a re to be per for m ed on ly if

rep airin g d am aged term ina l block (152 ) a fter th e s ynchr os et has b een
re m o ve d .
11. R em ov e gr ou nd ing lug co nnec tion s (15 8, 15 9, 16 0, 16 5, 1 66) an d r etainin g rin g

(174 ) fr om ins ide th e sy nchro set b ody (15 0).
C A U T IO N : W hen r em o ving the ter m inal block (15 2) do no t pu ll or a pply

for ce to th e br as s term inal stu ds .
1 2. P ull the term inal blo ck (1 52 ) str aig ht out of th e s y ncr os et bod y (1 50 ) us ing tw o
p airs of p lier s b y gr ipp in g and p u llin g on ter m in al blo ck s ep ara tor s .
A dd itio na lly , th e te rm i nal b lo ck (1 5 2) m a y be ta pp ed f ro m t he re ar to ai d in
rem ov al.
1 3. R e m ov e in tern al w i rin g f ro m t he back o f term i nal blo ck (1 52 ). M ark w ir ing f or
reco nnection , as necessary.
24-7
N O TE : P r ior to r em oving ha nd w heel m odu le, n ote the p os ition of the a ctua tor
to determ ine if d ra inag e of oil fr om gea rca se (1) is necessa ry. If th e ha ndw heel
is in a tw elve o'clo ck pos itio n 24 .2.5 .1, Step a) is not r equir ed.
1 . T o p M o u n te d H an d w he e l
a. D r ain o il by r em ov in g low er p lu g (8 6) fr om g ear cas e ( 1) .
b . R em o ve h an d w he el re tai ne r s eal in g p lug (9 7 ) fr o m th e ge arc as e ( 1) .
N O T E : T he ha nd w h eel m ust turn in a clo ckw is e d irectio n w h ile

rem oving the n ylo n h andw heel r etainer (1 47) .
c. R em ov e th e han dw h eel reta iner ( 10 3) .

d. Ins p ect n ylo n hand w heel retai ner (1 03 ) f or d efects .
e. L i ft th e ha nd w he el m o du le s tr aig ht o ff u s in g ca re n ot to d am age t he O - rin g
( 98) o r the oil seals (99).
f. R em ove and ins pect O - ring (9 8).
g. V isu ally i nsp ect o ils ea ls ( 9 9) f or leak ag e or d am age . R e pl ace pa rt s as
nece ss ar y b y pr es si ng o il se als ( 99 ) in to han d w h eel s ub as s em b ly w ith to p
han dw h eel s ea l t oo l.
2 . S id e M o u nt ed H an dw h e el
a. D r ain oil b y rem o ving lo w er plug (86) fro m gearcas e (1).
b. R em ov e h and w heel ret ainer s ealin g plu g (9 7) fr om the gea rcas e (1) .
N O T E : U s e sn ipe no sed pliers to gr ip the en d o f the r etainer w h ile

r em o vin g th e nylon han dw heel retainer ( 103) .
c. R em o ve the h and w hee l r etain er (1 03 ).

d . In spect ny lon han dw h eel r etainer ( 103 ) for d efects.
N O T E : S ide m o un ted ha ndw heel cas in gs a re do w elle d a t th e to p of t he

g ear cas e ( 1), an d m a y r equ ire gen tle ta ppin g u pw ar ds w ith a r ub ber
m allet to rem o ve.
e. L i ft th e ha nd w he el m o du le s tr aig ht o ff us in g ca re n ot to dam ag e t he O - rin g

(10 8) or the oil seals (99).
f. R em ov e and ins pect O -rin g ( 108 ).
g. V isu ally insp ect o il seals ( 99 ) fo r le aka ge o r da m ag e. R ep lace p ar ts a s
n eces s ar y b y ins er tin g o ils eals (9 9 ) int o han d w h eel s u bas s em bly w i th s id e
h and w heel seal too l.
24-8

1 . G ea r ca s e R em o v al a n d I n s p ec ti o n
a . R em o ve actu ator f ro m valv e per S ect ion 2 4.1.
b . D rain all oil fr om actua tor gear cas e ( 1) by lo os eni ng low er m o st plu g (8 6).
c . R e m ov e th e f ol low in g actuat or co m po nen ts p er app licab le sec tion s :
• M o to r: S e ctio n 2 4 .2 .1
• S w itc h M ec ha ni s m : S e cti on 24 .2.2
• S y n cr o s et: S e cti on 2 4.2 .4
• H a nd w h e el : S ec ti o n 2 4 .2.5
d . R em o v e r em ain in g gea rcas e in ter nal co m po ne nts per t he fo llo w ing s ect ion s :
• C lu tc h an d W or m g ea r: S e cti on 24 .2.6 .2 .
• D riv e B u s h ing : S ect ion 24 .2 .6.3.
• H and A uto L ev er : S ecti on 2 4 .2 .6 .4.
• O il S e al: S ec tio n 2 4.2 .6 .5.
• W o rm s haf t B u s h ing : S ecti on 2 4 .2 .6 .5, S te p c) .
2 . C lu tc h an d W o r m g ear R e m o val
a . R em o ve actu ato r f ro m valv e per S ect ion 2 4.1.
b . R em o v e h an dw h eel as s em bl y fr om t he act uat or p er S ec tio n 24 .2.5.
c. D r ain all o il f ro m ac tuato r gear case ( 1) by lo os en ing lo w er m ost p lug ( 86 ).
d . R e tu r n a ctu a to r t o a ut o p o s it io n b y u s in g a s cr ew d r iv er to th e g en t ly n u d g e
th e han d a uto fin g er (1 2 ) on the y ok e as s em b ly ( 1 0) u n til it an d th e clu tch
ring (26) dr op b ack do w n on to the w o rm w heel (21 ).
W A R N IN G : T h e clutch s pr in g ( 25) in the follo w in g s tep is s till u nder

loa d a nd could cau se ser iou s injur y if car e is no t taken w h en r em ovin g
the clutch retaining O -r ing (52 ).
e. R em ov e the clu tch r etain in g O -r ing ( 5 2) , sp eci al w a sh er ( 31 ), an d clu tch

spring (25) from top of center colum n (8 ).
f. Slid e the clutch ring (2 6) and yo ke assem bly (1 0) off the center colum n ( 8)
tak ing car e n ot to dr op clu tch key s ( 27) in to the ge arcas e (1 ).
g . R e m o ve t he c ap s cre w s ( 7 0) re tai ni ng the t hr u s t pa d ( 15 ) .
h. L ift ou t th rus t p ad (15 ) and w orm w h eel ( 21) f rom gear cas e (1 ).
i. R e m o v e ca p s cr ew s ( 7 1 ,6 1 ) r e tai n in g t hr u s t b as e (2 ) to ge ar c as e. S t an d
gea rca se ( 1) s o t ha t th e ha nd a uto lev er (1 1 ) is u p per m o s t.
C A U TIO N : U se a piece of w ood o r a r ubber m a llet to tap the center

co lum n ( 8) an d b ase a ssem bly free in the fo llow ing step to p reven t
dam age to the center colum n (8) .
j. T ap cente r c olu m n (8 ) as sem bly f ro m to p to dr ive it o ut of th e g ear cas e(l) .

k . T o w ith dra w ba se as s em b ly fro m the cen ter colu m n ( 8), s u pp or t th e
base/ cen ter co lu m n assem b ly so th at th e m ou nt ing h ol es ar e up pe rm o s t.
24-9
l. U s in g a s ta nd ar d b en ch p re s s o r j ack in g s t ra p p re s s ou t th e ce nt er c ol um n ( 8 )
an d lim it sw itch w o rm ( 19) .
m . S u p po rt th e lim it s w itch w or m (1 9) and pr es s t hr ou g h th e c en ter co lu m n ( 1 ).
n . T o w it h dr aw th e t hr u s t be ar in g ( 4 1) f ro m th e t hr u s t ba s e ( 2) re m o v e eig h t
s crew s c aps cr ew s (6 9) , li ft off th ru s t r ing ( 3) and l ift bear ing ( 41 ) o ut .
o . U s in g t he d r iv e bu s h in g r eta in er ( 2 3, 33 ) a s a p r es s to ol , lo ca te ag ain s t th e
b ear in g s top r in g (9 ), p o si tio n as s em b ly un d er be nch p re s s an d pr es s o ut .
p . R em o ve a ll O -r ing s and in sp ect and rep lace a s necessary .
3. D riv e B u s hing R em ov al an d Ins p ection s
N O TE : T he actua tor m us t b e r em o ved fro m the va lve p rio r to d rive

bus hing rem oval per Section 2 4.1.
N O T E : S om e ac tua to r s h av e a ho le w h ich is n ot p lu gg ed . In th is ca se
om it Step 24 .2 .6.3, Step a) .
a. U n scr ew and rem ove plu g ( 59) o n s ide of actuato r bas e.

b . U s ing h an d au to lev er ( 11 ), po s itio n act uat or to h an d op er atio n .
c. R o tat e th e h an dw h e el as s e m b ly un t il th e b us hi ng re ta in er s e ts cr e w ( 6 5) is
v is ible th ro ug h th e h ol e in t he gea rcas e (1 ) ba se .
d. R em o ve s ets crew (6 5).
e. U ns c rew d ri ve b us h in g r etai ne r (2 3 , 33 ) b y u s in g a s pa nn er w r en ch i ns e rte d
int o the tw o h ol es p ro v ided on th e dr iv e b us h in g re tain er (2 3 , 33 ).
N O T E : F or type A dr ive b us hing (36) , r eco rd the po sition of the drive

bu shing (36) p rior to rem oval.
P o sition 1- D rive B u sh ing (36 ) is ins er ted into the center colum n (8) .
P o s ition 2 D r ive B us hin g (3 6) pr o tru des fr om th e cen ter co lum n ( 8).
W hile P er fo rm ing 24 .2.6 .3, Step f) , r em ove the d rive bus hing (22 , 3 6)
by pulling it str aigh t ou t of the cen ter co lu m n (8) .
f. V is u ally in s pec t th re ads of th e d r ive bu s hin g ( 22 , 36 ) fo r dam age .

g. V is u all y in s pe ct m ac hi ne d s ho u ld ers o f th e dr iv e bu s hi ng (2 2, 36 ) at th e
con tact p oin t w ith th e c ente r col um n ( 8 ) do gs fo r cra cks or s h ear s.
h. R ep lace da m ag ed pa rts as n ecessar y.
24-10
4. H and A uto L e ver R em ov al an d Ins p ection s
N O TE : To ga in a ccess to the h and au to lever com po nents , th e actu ator

h and w heel as sem bly m u st fir s t be r em oved per Section 24 .2.5; access w ill
a ls o b e im pr oved by r em oving th e center colum n (8) p er 24 .2.6.2 .
a. F r om in side th e g ear case (1 ), h an dw h eel en try u pp er m os t lo cate seal lo ck pi n

( 62 ).P o siti on dr ift p un ch and tap ou t an d r em ov e f ro m ge arcas e ( 1) .
b. P ul l o ut han d a uto lev er (1 1) .
c. U n h oo k s p lit p in ( 63 ) f ro m cam r etu r n s pr in g ( 89 ) an d r em o v e h an d au to cam
(1 7).
d. C ar ef ull y m an ip ulat e c am ret ur n s pr in g (8 9) a nd r em o ve it fr o m l oca tin g pin
(16).
5. O il S eal R em ov al
a. O n P os t- 19 7 8, r em o ve b ack up w a sh er s ( 7, 2 0) on th e m o tor w o rm s haf t bo re
a nd tor q ue s h af t b o re .
b. R em ove old o il s eals.
c. O n P re- 1 97 8, in s pe ct, r em o ve & re pla ce w o rm s haf t s hr ou d (2 9 ) as r equ ir ed .
6 . T o r q u e S h af t S h r ou d an d W o r m s h af t B e ar in g R e m o v al
a . P osi tio n g ear case ( 1 ) so th at sw it ch m ech an is m en tr y is u pp er m o s t.
b . L o ca te d rif t p un ch in to to r qu e s h af t s h r ou d ( 6 0) and s no u t be ar in g (4 2 ) an d
d ri ve d o w nw a rd s u nt il th ey are p u s h ed i nt o th e g ear ca s e (1 ) a nd th en
r em ov ed .
c . P o s it ion gea rc as e (1 ) s o th at th e m o to r bo r e is u p per m o s t.
d . L o cat e dr if t pu n ch in to m ot or bo re t o r es t ag ain s t the e nd of t he n eed le
be arin g ( 43 ) and dr ive o ut in to ge arca se ( 1) an d r em o ve.
1 . B e ar i n g A s s em b l y
a. F it nee dle b earin g (4 3 ) on to the w or m s h aft ne edle b eari ng /fla m epr oo f s hr ou d
tool ; loc ate in g earcase ( 1) at m oto r w o rm bo re, and p ress ho m e.
b . P r e-1 9 78 o nly : F it w or m s h aft s hr ou d (2 9) o nto t he pr es s w or m s ha ft nee dle
bear ing /flam epr oof sh rou d too l; l ocate in gear case ( 1) at m oto r w or m b ore an d
pr es s ho m e.
c. C o at t he ou ts ide of t he on e w o rm sh aft oi l seal (5 5) w it h H y lo m ar an d pre ss
int o g earcas e ( 1), (d yn am ic s ide to in s ide), w ith w o rm s haf t o il s eal to ol;
rep eat fo r the secon d seal (55 ), (dy nam ic sid e ou tsi de).
d. Po st-19 78 o nly : F it seal back up w asher (7 ) a nd circl ip ( 5) in to g earca se (1 ) at
m oto r w orm b ore.
e. F it sn o ut be ari ng ( 42 ) on to th e w or m s ha ft ne edle b ear ing /f lam ep r oo f s hr ou d
to ol; lo cate in gea rcase (1 ) at t or qu e sw itch sh aft bo re, an d pr ess h om e .
f. F it to rq ue s h aft s h ro ud ( 60 ) o nto tor qu e s haf t s hr ou d to ol ; lo cat e i n
g ear case( 1) at to rq u e sw it ch sha ft bo re , and pr ess h om e.
24-11
g . L o cate the to rq ue shaf t's o il se al ( 57 ) on t or qu e sh aft seal to ol and pr ess

hom e.
2 . H and A uto L ever A ss em b ly
a. F it o il s eal ( 56 ), u s in g ha nd a uto se al too l, o n to ha nd a uto lev er ( 11 ) s ha ft.
b. F it loca ting p in (1 6) an d O - rin g (5 3) in to gea rcas e (1 ); fit cam retu rn s pr in g
(8 9) to en d o f lo c atin g p in (1 6) .
c. S m ear E xx o n U n ire x N 2 g re as e an d in s ert h an d au to l eve r ( 11 ) th ro u gh oil
s e al (5 6 ), so th at th e ha nd le o f th e lev er ha ng s d o w n to w ar d s th e b as e en tr y
o f the gearcase (1).
d. In s er t t he s p lit p in ( 63 ) in to th e cam ( 17 ) an d lo cat e the ca m on t he h and
au to lev er s haf t.
e. H oo k the en d of the sp ring ( 89) into th e eye of the s plit p in (63 ).
f. L if tin g th e ha nd le o f the h an d au to le ve r (1 1 ) to th e lef t, li ne u p th e ho le in
th e cam ( 1 7) w ith th e ho le i n th e ha nd au to l ev er sh af t an d d ri ve h o m e th e
seal lo ck p in (62).
3. C ent er C o lum n and C lut ch and W or m gea r A s s em b ly
a . S m ear O -rin g gr oo ve and bo re of th rus t bas e (2) u si ng E xx on U ni rex : N 2.
b . S m ea r tw o O - ri ng s ( 5 1) w i th g re as e an d lo cate in th ru s t bas e ( 2) .
c . W or kin g f ro m the to p o f th e b as e, lo cat e b ear in g s to p rin g ( 9) an d p re ss in to
p lace s o t ha t t he to p f ace o f th e be ar in g s to p ri ng (9 ) is lev el w it h th e bea ri ng
s h e lf .
d . F i t th r u s t b ear in g (4 1 ) i n to t h ru s t b as e (2 ) .
e . A s s e m bl e thr u s t r in g ( 3) t o th ru s t bas e ( 2) u s in g tw e lve ca ps c rew s (6 9 ) an d
to rq ue to 42 - 4 7 f t. lb s .
f . A pp ly lock tite to the k nu rl on th e cen ter co lum n ( 8) ; lo cate lim it s w i tch w or m
( 19 ) on to the ce nt er co lu m n ( 8) a nd p r es s o n u s ing ben ch p r es s a nd l eng th o f
tu b in g .
N O T E : E ns u re cor r ect r atio lim it s w itch w or m is f itted and n o g ap

exists b etw een w orm and center colu m n shou lder w h en assem b led.
g . G rease lo w er sectio n of center col um n and O -r ing gr oov e.

h . G re ase and f it O - rin g ( 47 ) to center co lum n ( 8) .
l . L o ca te cen te r co lu m n ( 8) th ro ug h t hr us t b ea rin g ( 4 1) a nd int o b ear in g s to p
r ing (9 ) u nd er a b en ch p r es s . P r es s ho m e u nt il s ho u ld er o n th e cen ter co lum n
co m es to r est a gai ns t th e t op su rf ace o f the b ear in g.
N O T E : D ur ing as s em bly o f th e center colum n into th e thr u st bas e the

bea ring s top r ing w ill m ove a w ay fr om the bear ing.
j. I n v er t a s s e m b ly . U s i n g a s u it a bl e s iz ed t ub e an d m al le t t o g e n tl y ta p t h e
b ear i ng s to p r in g b ac k i nt o p la ce. In s e rt d r iv e b us h in g an d ti g ht en r et ai ne r
s ecu rin g w ith s crew .
k . F it tw o s pir ol pin s ( 34 ) to thr us t bas e.
24-12
l. G r eas e to p s pig ot on t hru s t b as e a ss em bly an d fit O -r ing ( 46 ).

m . G re ase b ase en tr y bo re o n g ear case an d assem b le ba se a s se m b ly in to
g earc ase, locat e spi ro l p ins (34 ) int o ho les an d se cur e b ase to g earc ase u si ng
f our caps crew s (7 1). T igh ten to 20 - 22 ft. lbs .
n. S lide w o rm w heel (21 ) o nto center colum n (8 ), allo w in g w h eel to s it o n s helf
a cro s s c ent er o f gea rca s e e ns u ri ng d ri ve p ins ar e up pe rm o s t.
o. P os iti on t hr us t p ad (1 5 ) s o th at the b lin d ho le in t he up p erm os t lev el o f the
p a d is n ea r es t t he s yn cr o s et en tr y o n th e g ea rc as e . S e cu r e us i n g f o ur
ca ps crew s ( 70 ). T o rqu e t o 1 0 - 12 ft. lb s .
p. M an ip ul ate y ok e as s em bl y (1 0 ) in to p lac e ens u r in g th at th e ha nd a ut o fi ng er
assem b ly li es f lat o nto the w o rm w h eel an d th e adj ustin g g ru b scr ew l oca tes
in to th e bl in d h o le in th e th ru s t p ad .
N O T E : C lu tch key's (2 7) or ien tatio n is cr itical . W ide s ide of keys an d

clutch r ing (26 ) m u st be u pper m os t, n ot a ga ins t w o rm w heel.
q . In st all c lutch k ey s (2 7) in to clu tch rin g (2 6) an d pl ace a ssem b ly o n the cen ter
colum n (8) .
r . Pr es s clu tch s pr ing ( 25) , w as her (3 1) , and O - rin g ( 52 ) do w n o nt o c enter
co lum n (8) ens urin g th e O - ring (5 2) lo cks into center co lum n's (8 ) gr oov e
u sin g clutch sp ring com p res s or tool.
4 . D ri ve B ush in g A ssem b ly
a . V erif y thr eads ar e in g ood co nd ition an d ar e g eom et rically co rrec t fo r valv e
stem ap plication if app licable.
b . V erif y req ui red m o un tin g po si tion o f the dr iv e b us h ing ( 22 , 3 6) a nd in se rt
int o the gear case b ase in side of th e ce nter co lum n ( 8) .
c . E n su r e t he s lot s o f the d riv e bu s hi ng ( 22 , 3 6) ar e fu lly en g age d w ith th e
a ctu ato r's c ent er co lu m n sh aft d riv e do gs .
d . I n s ta ll an d tig h te n d r iv e bu s h in g re tai n er ( 2 3 , 3 3) .
e . U s ing a fee ler g au g e, v er ify ga p be tw ee n dr iv e bu s h in g re tai ner (2 3 , 33 ) an d
bu sh ing (2 2, 36 ) d oes n ot e xceed 0.052 in ch.
f . I n s tall a nd tig h ten dr iv e b u s hi ng re tain e r s cr ew (6 5 ).
g . P r e-1 97 8 on ly: rei nsert re dcap p lug ( 59 ) into g ear case ( 1) .
1. W i rin g L o om I nt ern al C on ne ctio ns to T e rm i nal B un g

a. C on nect h eater w ir es to ter m in als 4 an d 5 on b ack o f term inal b lock ( 15 2)
f ro m ther m os tat l oom (1 85) .
b. C onn ect m oto r w ir es to term i nals 1 , 2, and 3 on b ack of term inal blo ck (15 2)
fr o m m o to r lo o m ( 1 8 4 ).
c. C o nn ect n um bere d sw itch m e chan is m an d add -o n-p ak loo m ( 17 2) to
c orr es po nd ing nu m be red term inals on bac k o f term in al blo ck ( 15 2) .
d. P erfo rm co ntin uity check w ith m eter f rom field s ide of term in al blo ck ( 15 2) to
eac h sw it ch co ntac t to e ns u re cor re ct s w it ch is w ir ed o ut to co rr ect ter m ina l.
24-13
2. A s sem bly of T erm inal B lo ck into Sy ncro set

a. S m ea r O -r in g (1 6 4) a nd t er m in al bl ock ou ter b o re w ith gr eas e an d p lace O -
rin g ( 16 4) into low er radial gr oov e of s yn cros et.
b . C ar efu lly p o s itio n ter m in al b un g in s ide s y ncr o se t b o dy ( 15 0 ) tak ing car e n o t
to pin ch or d am ag e an y w ires or th e O -r ing ( 16 4) .
c. S e cu re te rm in al b lo ck ( 1 52 ) b y p la cin g r eta in in g r in g ( 17 4 ) in to o u ter ra di al
gro ove of th e s yncr os et bod y ( 150 ).
d . I ns ta ll gr ou nd in g lu g as s em b ly ( 15 8 , 15 9, 1 6 0, 1 65 , 1 66 ) in to s id e of
s yn cros et b ody (1 50) .
3 . A s s em b ly of S y nc ro s et M o d ule to G ear cas e
a . E n s ur e h ea ter as s em bly (1 87 ), ( P os t -1 97 8) , is s ecu red to ge arc as e w ith tw o
s cr ew s in t w o pr e- tap ped h o les d ir ectly ben eat h s yn cro s et en try o p enin g in
th e ge ar case.
b . I n s p ec t g ear c as e a n d s y n cr o s et s ea lin g s u r fa ce s f o r an y d a m ag e t h at w o u l d
hin de r pr op er s ea lin g.
c . E n s ur e O - rin g ( 17 0) is fitted p ro per ly aro un d bo dy (1 50 ) and f it i nto ge arcas e
(1 ) o p e nin g .
d . S ecu re w ith f our cap scr ew s (1 67) an d s p ring w as her s (1 71) . T orq ue caps crew s
to 1 0 - 1 2 ft. lb s.
1. P r e-1 9 78 and P os t- 1 97 8 A ct ua to rs
a. If lim it s w itch w heel or driv e as s em bly ( 122 ) is defe ctive o r has b een r em ov ed
in o rd er to rep la ce to rq u e sw itch m e c ha n ism it m us t b e rep la ce d o n lim it
s w itc h m ec han is m s h aft .
b . E n su re li m it s w itch w h eel and dr ive as s em b ly ( 12 2) i s f ully ins er ted h ar d
ag ain s t th e sw itch m ech an is m ( 26 1 ) br ass bu shi ng .
c. U s in g th e ho le in th e l im it d riv e as s em b ly (2 6 ) as a tem pla te, d rill a 1 /8 in ch
ho le th ro u g h th e sw itch m e ch a n ism a ss em b ly (2 6 1 ) s h aft's b ras s bu s hin g .
d . S ecu re lim it sw itch d riv e as s em b ly ( 12 2) on s w itch m ech ani sm as s em bly b y
in ser ting s p irol pin ( 11 9) thr ou gh 1/ 8 in ch ho le d rilled in S tep C .
e. C lip he ater to b ack of r epl acem en t sw it ch m ech anis m assem b ly if P re- 19 78
he ate r ( ob s o let e) i s s t ill i ns t all ed . ( P re -1 9 7 8 s w it ch m ech an is m s ha d h eat er
clips po p- riveted to the back of the m echanis m ) .
f . G r ease O -rin g ( 27 1) on sw itch m echa nis m .
N O T E : T he fo llow ing steps ca nno t be per for m ed un less m oto r m o du le

has been insta lled .
g. I ns t all t or qu e s w it ch p lu ng er (1 1 4) i nt o o pe ni ng i n g ear ca se i ns u r in g
sha kep roo f w asher en d is faci ng sw itch m ech anis m .
h. C are fu lly pu s h s w itc h m ech an is m ( 26 1) int o ge arc as e (1 ) u nti l gea rs m at e.
l. R ep lace on e ca ps cre w (2 64 ) into sw itch m e chan is m b ack plate (2 63 ) and
t ig ht en i n o rd e r to ve ri fy to rq u e ad ju s ti ng fr o n tp lat e (2 7 0) tu r ns to w ar d t h e
v ertical p os ition . ( poin ter alig ns w ith arro w ) .
24-14
j. I f n ot in ver tical po s ition r em ov e c aps cre w (2 64 ) a nd w ithd raw sw it ch

m ech anis m (2 61) aw ay f rom gearcase ( 1).
N O T E : Incr eas ing the s ha fts ( 114 ) o verall length w ill ca us e the
fron tplate (27 0) to rota te clockw ise w hen view in g the sw itch m echan ism
(26 1) from the fr ont.
k. R em ove to rqu e s w itch s haf t ( 11 4) and ad jus t caps cr ew (2 5, 91 ) in or der to

cen ter p oin ter o n to rq ue ad ju s tin g fr on tp late (2 7 0) .
1 . T i gh ten c aps c rew (1 1 8) af ter adj us tin g to r qu e s w i tch s h aft ( 11 4) , tak in g car e
n ot to ove rtig hten an d d am ag e cap s crew ( 11 8).
m . R epe at S tep s l and J . I f alig nm en t i s ach ieved g o to S tep o. I f no t r epea t
S tep s k th r ou g h n .
n. R ep lace tw o caps crew s (26 4) an d to rque to 4 .5 - 5.5 ft. lbs .
o. C on n ect a ll in ter n al w ir in g t o th e ap p ro p ria te te rm in als an d s e cu re w ir in g
loo m to s w itch m ech anis m w ith S cotch T h erm o s ettin g T ape 27 .
N O TE : T he cover o ri entati on is im por ta nt o n the 12 sw itch ad d-o n- pak

a ss em bl y. A n a dd -on -p ak su pp or t is w elded to th e in sid e o f th e co ver
(252).
p. G reas e O -r ing (2 54 ) and in s tall o n gea rcas e (1) . In st all li m it s w itch co ver
(2 50 , 2 51 , 2 52 ) and secur e w ith th ree capscre w s ( 25 7) an d w ash ers ( 288 ).
G r ease and tor que caps crew s (25 7) to 1 0 - 12 ft. lbs ., (4 .5 - 5 .5 ft. lbs . o n P r e-
19 78 ).
q. R ef er to Sec tion 20 f or sw i tch m echan is m ad justm en t p ro cedu re.
2 . M od ular R ep lacem en t of S w itch B ank s on M echa nis m
a. P r e-1 9 78 A ctu ato rs w ith N O d esig n Sw i tch M ech ani sm s I nstal led
• C om p res s w as h er (26 6) an d sp rin g (2 65 ) b y m ov ing s w itch to w a rds the
fr on tplate (2 70 )
• P ull s w itch b an ks (2 60 ) ou t of th e sw it ch m ec han is m rear p late (2 72 )
• I nst all re pl acem en t sw i tch b an ks (2 6 0) , de pr essin g w ash er ( 26 6 ) an d
s pri ng (2 65 ) and s nap pi ng s w itch ban k (2 60 ) i n p lace
b . P o s t - 1 9 7 8 A c t u at o r s
• S crew lockin g h ex n ut ( 269 ) tow ard s sw itch bank (2 62)
• M o ve s w itch ban k (26 2) tow ar ds f ron t p late ( 270 ), far en ou gh to releas e
sw i tch ban k (2 62 ) fr om sw itch m ech an ism 's rear pl ate ( 27 2)
• I ns t all re pla cem e nt s w itch ban k s ( 26 2) i nto fr am e an d ho ld i n pl ace
• E n s ur e s m al l b ar re l nu t is p o s itio n ed in ro u nd ed a rea o f s lo t on fr on t
plate (27 0)
• S crew l ock ing he x n ut (2 69 ) f irm ly a gain st ins id e s u rfac e o f f ro nt plate
(2 70 )
24-15
1 . P ost-19 78 A dd-on- pak

a. I n sp ec t ad d - on - p ac k f o r d am ag e
b. E n s u re a ll p ow e r ha s b ee n r em o v ed f ro m ac tu ato r .
c. V er ify t hat th e re pla cem e nt ad d- on -p ak g ear c lus t ers (3 25 ) an d sp acer s ( 32 6)
m a tch th e d am ag ed a dd -o n -p ak s .
d. If ad d- on -p ak is b eing i ns talled f or th e f ir st tim e re fer ence E n clos u re 20 .3 in
Sectio n 20 fo r co rr ect n um b ers of g ear c lus ters ( 32 5) and spacer s (3 26) fo r
specific valve tr av el.
N O T E : N ever m ix an d m a tch g ea ri ng t ha t is p in ned w it h ge ar in g th at

is inves tm ent cas t.
e. R em o ve tw o caps cr ew s ( 312 ) th at r etain s w itch h old ing p lates (3 13 ) to the

a dd - o n -p a k f r o nt p lat e.
f . R em o ve sw it ch ho ldin g plat es (3 13 ), s p rin gs ( 31 0) , and w as he rs ( 30 9) h eld
b e h in d th es e p lates .
g . In s tal l th e th ree m o un tin g p illa rs ( 3 30 ) to th e sw i tch m e cha nis m ( 26 1) . S cr ew
up tig htly to the nuts retain in g the s w itch m echanism s frontplate (27 0) and
to rq u e to 5 - 5 .5 f t. lb s .
h . I f p ote ntio m eter (3 08 ) is fitted , slid e it on th e p illar.
i. In st all th e a dd -o n- pa k on to th e pil lars (3 3 0) .
j. M ov e s w itch es (3 03 ) to the si de to allow i ns tallati on of th e cap s crew s ( 31 5)
an d w as her s (3 16 ) to pill ars ( 33 0) . T or qu e to 5 - 5 .5 ft. lb s .
k . R e place sw itc hes ( 30 3) in add -o n- pak fr am e.
l. R e place spr ing s (3 10 ), w ash ers (30 9) , ho ldin g plates (31 3) an d tw o c aps crew s
( 3 12 ) t ha t w er e re m o v ed i n S te p f .
m . C o nnect w irin g to the loo m (17 2) to the sw itches (30 3).
n . Se cur e th e loo m to t he pill ars u s ing S co tch T h erm os ettin g T ap e 2 7.
o . R efer to Secti on 20 fo r ad jus tm en t pr oced ur e.
2. Pr e-1 978 A dd-O n-P ak
a. In spect ad d-o n- pak f or d am age
b . E n su re all p ow er h as b een r em o ve d fr om actu ato r.
c. V e rif y th at t he re pla cem en t add - on -p ak g ear clu s ter s ( 32 5) an d spa cer s (3 2 6)
m atch the d am a ge d ad d- on - pa k's .
d . I f add -o n- pak is bein g ins tal led fo r the fir s t tim e, ref eren ce E nclo s ur e 2 0.3 in
Sec tion 20 fo r co rr ect nu m ber s of gear clu ster s (3 25) an d spa cers (3 26 ) f or
specific valve travel.
N O T E : N ever m ix an d m atch g ea r ing t ha t is nyl on w ith g ear in g th at is

investm en t cast.
2 4-16
e. L oos en tw o fr on t p late m oun ting n uts ( 32 4) .

f. Scr ew lo ckin g h ex nut (3 22 ) to w ards sw itch b ank (3 19) .
g. M ov e s w itch b ank s (3 19 ) t ow ard s f ron tpl ate ( 31 4) fa r en ou gh to r eleas e
s w itch ban ks (3 19 ) f ro m ad d- on- pak fr am e.
h. In s ta ll th re e th e thr ee m ou n tin g p ill ar s ( 32 1 ) to th e s w i tch m ec ha nis m ( 2 59 ) .
S cr e w u p t ig h t ly to t h e n u ts r e ta in i n g t h e s w i tc h m e ch a n is m s f r o nt p la te
(2 70 ) an d tor qu e t o 5 - 5 .5 ft . l bs .
i. I f po ten tiom eter ( 30 8) is fit ted, s l ide it on th e pil lar.
j. I ns tall th e ad d- on -p ak on to th e p illar s (3 21 ).
k I n s tall ali en s cr ew ( 32 0 ) in to up p er h ole o f ad d- on -p ak f ra m e an d tig ht en in to
th e end of th e up pe r s up po rt p illar (3 21 ). T igh ten t o 5 - 5.5 f t. lb s .
l. L oc ate the b otto m tw o pi llar s (3 21 ) in to th e ad d- on - pak f ram e, an d dr ive
ada pte r (3 27 ) o nto t he s w itch m ech ani s m ( 25 9 ), ti gh ten th e tw o b otto m alie n
screw s (3 20) to 5 - 5.5 ft. lbs .
m . I nstall sw itch es (3 19 ) i nto add -o n- pak fr am e a nd ho ld in place.
n. T i gh ten tw o fr on tp late m o un ting n u ts (3 2 4) .
o. E n s ur e sm all hex n ut ( 32 3) is po s itio ned i n ro un ded a rea of s lo t on f ro ntp late
(3 14).
p. S cre w lo ckin g hex n ut (3 22 ) fir m ly ag ains t the in si de su rf ace of th e f ro ntp late
(3 14 ) en s ur ing tw o hex n uts are jam m ed to geth er (3 22 , 3 23 ).
q. C o nnect w iring from the loo m (17 2) to the s w itches (3 19) .
r. S ec ur e th e loo m to th e p illa rs u s in g S cotc h T he rm o s etti ng T a pe 27 .
s . R efer to S ectio n 20 fo r adju stm ent pr oced ur e.
1 . P o s t- 1 9 7 8 A ct u at o r
N O T E : A ll N A 1 m o tor s a re s up plie d i n a m o du lar fo r m . S tat or s a re

alr eady fitted into the m o tor cover an d th e r otor on to th e w o rm s haft pr ior
to leaving the factor y.
a . I ns p ec t m ac hi ne d s u rf ac es of m o to r an d m ot or 's w or m s h af t ( 24 ) f o r d am a ge .
b . I ns p ect f or da m ag e an d gr eas e O - ri ng (9 1) ; en s ur e co rr ect p os i tio n o n m o to r
c o v e r h o u s in g .
c . V er ify tor q ue sw it ch p lu ng er ( 11 4 ) is in st all ed m g ear case ( 1) .
d . E n s u re m o to r l ea ds a re c o nn e cte d t o a pp r o pr ia te t er m i n als o n ba ck s id e o f
term in al b lock (1 52) as f ollow s :
• I ns tal l f ib r e gl as s s l ee v in g ov e r 3 S y n cr o s et m o t or le ad s .
• S tr ip in s u l ati o n f r o m en d s o f S y n cr o s et a n d m o to r l ea ds .
• P us h w ir e s i nt o a pp r o ve d b u tt c on n ec to r a nd cr im p w i th ap pr o v ed to ol .
• P u s h fi b re g la s s s le ev i ng o v er m o to r le ad s an d b u tt c o nn e ct or s a nd t ap e i n
place w ith S co tch T her m osettin g T ape 2 7.
24-17
N O T E : A corr ectly pos itioned m oto r w ill have a stato r locking s cr ew o n

th e side next to the s yncros et hous ing.
e. A lign m oto r as f ollow s :

• W h ile k eep ing m o tor lead s clean o f o il and gr ease, feed spl iced m oto r
l ead s in to p as s age w a y on t he ri gh t s i de of t he ge arc as e ( 1) and c are fu lly
s lip m oto r w o rm s h aft (2 4) pa rt w ay in to gea rcas e (1) . T he fib reg las s
sl eev in g sh ou ld k eep th e m ot or lead s st ra igh t an d aw a y fr o m th e m ot or
sh aft.
• U n le ss r esista nc e i s en co u nte re d be tw een th e w o r m sh aft ( 24 ) a nd
w o rm hee l ( 21 ), c on tin ue fe edi ng th e m ot or lea ds into pas s ag ew ay an d
c arefu lly pu sh m o tor flu s h w ith g earcas e ( 1) .
• I f te eth o f g ear s d o n ot m es h to ge th er ea si ly , re m o ve m o to r an d tu rn
w o rm s haf t (2 4) s li gh tly a nd r epe at S tep s 1) and 2 ) as nec es s ary .
f. L u b ric ate an d in s tal l fo ur cap s cre w s ( 85 ) a nd s p ri ng w as he rs (2 0 ) to r eta in
m o to r to gea rca se ( 1) .
g. T or qu e b oltin g to 20 - 22 ft . lb s .
2 . P re -1 9 7 8 A c tu a to r
N O T E : A l l N A 1 m o to r s a r e s up p lie d in a m o du la r fo r m . S ta to r s a r e
alr ead y fitted in to th e m otor cover a nd the r oto r o nto the w or m s ha ft pr ior
to leaving the facto ry.
a . In spe ct m a chi ne d sur f aces o f m o to r an d m o to r's w o rm sh af t (2 4 ) fo r d am a ge .

b . I ns p ec t fo r d am ag e an d g re as e O -r in g ( 9 1) an d en s u re co r re ct p os i tio n o n
m o to r c ov er h o us in g .
c. V eri fy to r qu e s w i tch p lu ng er ( 11 4 ) is i ns ta lled i n ge arc as e (1 ).
d . E n s u re m o to r l ea ds ar e c o nn ec te d t o a pp r o pr ia te t er m i n als o n b a ck s id e o f
te rm in a l b lo ck ( 1 52 ) .
N O TE : A corr ectly pos itioned m otor w ill h ave a s tator locking scr ew on
th e side next to the syncro set hous ing (150 ).
e. A lig n m o to r as fo llo w s :
• W hile keeping m otor leads clean o f oil and greas e, feed spliced m otor
leads i nto pa ss ag ew ay o n the rig ht side of the gea rcase a nd care ful ly slip
m o tor w o rm shaft ( 24) part w ay into gearcase(1) .
• U nless resistan ce is en cou n tered b etw ee n the w or m sha ft (2 4) an d
w o rm h eel ( 21) , con tinue feed ing th e m o tor leads into passagew ay an d
caref ully p ush m oto r flus h w ith gearcase (1).
24-18
• I f teet h o f ge ars d o no t m es h tog eth er eas ily , r em o v e m ot or a nd tur n

w or m s h af t (2 4 ) s lig h tly an d re pe at th e ab ov e ste ps as ne cessar y .
f . L ub r icat e a nd ins t all f ou r ca ps cr ew s (1 1 4) a nd s pr in g w as h er s ( 20 ) to ret ain
m otor to g ear case (1).
g. T or qu e bo ltin g to 2 0 - 2 2 ft. lbs .
24.3.6 Handwheel Asembly
1 . T o p M o un ted
a. A p ply a th in coa t o f E xx on U n ire x N 2 gr ease to O - rin g (9 8) , an d oil seals (9 9)
an d pr e s s in to p lac e u s in g to p ha n dw he el s eal to o l.
b . P os i tio n h an dw h eel as s e m b ly to p r ev ent c aps c re w s ( 72 ) f ro m be in g di rec tly
ov er o r alig ned w i th clu tch k eys (2 7) o n clu tch r ing ( 2 6) .
c. C oa t ny l on ha n dw h ee l r eta in er ( 1 0 3) w it h g ear ca se o il an d fe ed i nt o g ea rc ase
w h ile ro tati ng h and w h eel ho op ( 82 ) co un ter clo ckw is e.
d . I n s tal l h an dw h e el r eta in er s eal in g p lu g (9 7 ) an d to rq u e ex tr ac to r p lu g to 2 0 -
2 2 ft. lb s .
e. T i gh t en p h il lip s s cr ew i f in s ta ll ed .
f . V er if y h an d w h ee l o p er a ti on i n m an u al m o d e .
2 . S id e M ou n ted
a. A p p ly a thin coa t o f E x xo n U ni rex N 2 g re as e t o O -r ing (4 6) an d f it on to
han dw h eel as s em bl y sp ig ot.
b. G re as e h an d w he el o il s ea ls (9 9 ) a nd pr es s in to pl ace u s in g s id e ha nd w h ee l
se al to o l.
c. P o s ition h an dw h eel as se m bly c aref ul ly and l ocat e s p iro l d ow el p ins (1 00 ) into
ho les in u pp er fa ce of g ear case an d tap in to p lac e u s in g a r u bb er m al let.
d. C o at n yl on h an d w he el re tain er (1 03 ) w i th g ear case o il an d f eed in to g ear case
w h ile ro tating han dw heel h oo p ( 75) cou nterclo ckw is e.
e. I ns t all h an d w he el r eta in er s e ali ng pl ug (9 7 ) an d t or q ue e xt ra cto r p lu g t o 2 0 -
22 f t. lbs .
f. T i gh ten P hil lip s s c re w if ins t alle d.
g. V er ify h and w heel op erat ion in m an ual m o de.
1 . U s in g ap pr o pr iat e f itt ing s , in stal l p r essur e gau g e and con n ect air su p ply to
g earcas e ho us ing (1 ) after r e-as s em bly o f all m o du les is co m plet e.
2 . Sl ow ly ap ply p res s ur e t o gear case u nt il g aug e r ead s be tw een 28 - 3 0 ps ig .
3 . Is o late pr essur e so ur ce and r eco rd a ir pr essur e.
4 . A fte r 15 m inu tes rec or d fin al air p res s u re an d re cor d pr es s ur e dr op i f any .
5 . I f pr es s ur e dr o pp ed m o r e t han 2 ps ig det erm in e s o u rce o f lea k and rep air per the
ap p r o pr i at e s u b s e ct io n s .
6 . If gear case did no t dr op pres s ur e ov er 2 ps ig, co ntinu e to nex t: s tep.
7 . R eli eve p ressure fro m g earcase.
8 . F ill gear case w ith o il thr oug h o il fill plug h ole u p to on e inch o f h ole b ase
th r ea ds .
9 . Incr ease air pr essur e to gearcase slow ly to 18 - 20 ps ig.
1 0. I s ola te p re ss u re s ou rc e a nd r ecor d p res s u re.
1 1. A fter fif teen m inu tes r ecord f inal air pre ssur e an d reco rd pr essu re d ro p if an y.
24-19
1 2. I f gea rcas e p res s u re dr op pe d m o re th an 2 ps ig , d eter m in e s o ur ce of le ak an d

rep ai r p er t he ap p ro p ri ate s u b s ect ion s .
13 . I S gear cas e did no t d rop p res su re over 2 ps ig, con tinu e to nex t s tep.
14 . R em ov e fitti ng s, p re ss u re s up ply an d re liev e g ear cas e p res s u re.
C o m p o n en t Torque F u n c t io n a l T im e * D ia g n o s tic
R ep a ir e d T e st V e r ific a tio n R e sp o n s e T e s tin g
B en c h
Sw itc h M e chan is m X X X X
W o r m g ea r X X X X
G ear case M o du le X X X X
D riv e B u s hi ng X X X
H an dw h eel M o du le X
Sy ncros et M od ule X
A dd- on-pak M odule X X
*R efer to S ection 26 for testin g guidelines.
1 . E n sur e a ctu ato r fe ede r br eak er is op en .

2 . I f r equ ired rem ove old d rive bu s hing f rom old actu ator ( 22, 3 6) per S ectio n
24 .2 .6 .c an d r ein s tall on rep lace m en t a ctu ato r per Se ctio n 2 4.3.1.4.
3 . E n su re v alv e s te m i s pr o per ly s ecu re d to av oid p er s on nel in jur y o r equ ip m en t
dam ag e.
4 . L u br icate v alv e stem as ne cessary .
5 . I ns ta ll ri gg in g as nec es s ar y to s u pp o rt th e w eig ht o f th e actu ato r .
6 . I nstall actu ator as fol low s:
a. F o r pres s ur e s eal typ e v alve s, lo os en yo ke clam p bo lts , ro tate y ok e an d
actu ator as n ecessary to pr ov ide access to yo ke bo lts.
b. F or k ey ed s haf t s tem ap pl icatio ns , p os itio n actu ato r so k ey w ays l ine up a nd
p u s h ac tu at or s tr ai gh t o nt o g ea rb o x s h af t.
c. F o r th rea de d s haf t va lve s te m app lic atio n s, po s itio n ac tua tor s o dr iv e
bu s hi ng a nd v alv e s tem m a te. O p er ate h and w h eel ho o p (7 5 , 82 ) to w ar d op en
dir ect ion u n til actu ato r is f lu s h ag ains t v alv e y ok e.
d. F or g lob e v alve ap plica tion s af ter per fo rm in g S tep c), en s ur e k eys are
in s tal led in to y o ke , an d s te m an d k ey r et ain er s ar e rep la ced pe r v alv e
dr aw in gs .
e. A lig n ac tua tor to m at chm ar ks as ap p licab le .
7 . S ec ur e act ua tor to y ok e o r ge arb o x u s ing ap pr op r iate b o ltin g h ar dw a re.
8 . E n s u re p r op e r to r qu in g re qu ir em en ts ar e m et p er v a lv e dr aw in gs .
9. R em ove tem porary rig gin g.
1 0 . R em o v e s yn c ro set c o ve r (1 5 1 ).
11 . C onn ect field cabling to term inal b lo ck (1 52) as r eq uired.
24-20
12 . I ns tall sy ncro set h ous ing cover (1 51) .

13 . R em o ve valv e gag d evice fro m s tem as ap plicable.
1 4. Per fo rm s w itch se tup per S ection 20 .0.
24-21
F ig u r e 2 4 -la
4 0 G e a rc a se A ss em b ly
(Se e Fig u re 2 4 -lb for P a rts D esc rip tio n )
24-22
Rotork Maintenance Manua)
F ig u r e 2 4 -lb
40 G ea r c as e A ss em b ly
24-23
PART ID PA RT D ESC RI PTI O N N OTES

22. D r iv e B u sh ing T ype AZ
23. D r iv e B u s h in g R etain e r T ype A Z
3 3. f iv e B u shi ng R et ai ne r T ype A
36 . D r iv e Bu sh in g T ype A
65. Set sc re w
84. R eta in er L ab el
F ig u r e 2 4 -2
4 0 D r iv e B u sh A ss em b ly
24-24
F ig u r e 24 -3
4 0 M o tor A sse m bly
24-25
PA R T ID P A R T D E SC R I PT IO N NO TE S
58 . C o ve r T ub e Su b-A sse m bl v
59. Sc re w ed B l an kin g Pl ug
72 . C a pscre w
77 . W a sh er C o u nt e r - C l oc k w ise O nl y
78 L ab el C ou n t e r- C lo c k w i se O n ly
8 0. Spo ke
8 2. H oo p
9 6. S ea li ng W a she r
97 . H a nd wh e el R et ai ne r Se a lin g P lu g
98. "O " R in g
99 . O ilseal
103. H a nd wh e el R et ai ne r
11 2. H an d w h e el H u b
F ig u re 2 4 -4
4 0 T o p H a n d w h ee l A ss em b ly
24-26
T h is pag e inte nti on ally le ft bl ank .
F ig u r e 2 4 -5 a
4 0 S i d e H a n d w h e e l A s se m b ly
(Se e F igu re 2 4 -5 b fo r P a rts D e sc rip tio n )
24-28
F igu r e 24 -5 b
40 S id e H a n d w h e el A ss e m b ly
24-29
F ig u re 2 4 - 6
S p r in g P a k S h e e t 4 0 N A 1
24-30
T his pag e int ent ion ally l eft b lank .
F ig u r e 2 4 -7 a
S y n cr o s et A s se m b ly
(See F igure 24-7b for P arts D escription)
24-32
P A R T ID P A R T D E SC R I PT I O N N OT ES
150. Bo dy
151. Cover
152. T e rm in a l B l oc k
153. C o n tr o l T e rm i na l P art o f 1 8 3
154. P ow er Terminal P art of 1 83
155. P o w e r T e rm in a l S c re e n
156. S h a k e p r o o f W a sh e r
157. Term inal N ut
158. Term inal N ut
159. B ra ss W a s h e r
160. S p ri n g W a sh e r
161. N ut
162. S p ri n g W a s h e r
163. B ra ss W a s h e r
165. E a r th L a b e l
166. B r a s s S c re w
167. C aps crew
170. "O " R i ng
171. S p r in g W a sh e r
172. S w it c h M e c h a n ism L o o m
173. I n se rt
174. R e t a i n in g R i n g
175. S hak eproof W as her
176. T a p it e S c re w
177. T e rm i n al L i nk
178. L a be l
179. 1 1/2 " C o n d u it P lu g
180. 1 1 /4 " C o n du it P lug
181. S c re w - H a m m e r D ri v e
182. C o d e C a rd
183. T e r m i n a l B lo c k S u b a sse m b l y
184. M o to r L o o m
185. T h e r m o st a t L o o m P o st - 1 9 7 8 O n l y
186. N yl o n W a sh e r
187. L o om -H e ate r * P r e - 1 9 7 8 i s O b so le te
188. S cr e w
190. L o c k n u t S te e l
F ig u re 2 4-7 b
S yn c r os et A s sem b ly
24-33
F ig u r e 2 4 - 8
A d d - o n - p a k A s s e m b li e s
24-34
F ig u re 2 4 -9
T y p e " A " a n d T y p e " N A " O l d V e r s io n A d d -o n -p a k
Pre- 1978
24-35
F igu re 2 4 -1 0
T y p e " N A " N e w V e r si o n A d d - o n -p a k
24-36
R o tork M ainte nance M an ual
Fig ure 24 -11

A d d-on-pak M odu lar R ep lacem ent of S w itch B anks
2 4 -3 7
EPIC Licensed Material
Nu clear M aintena nce Ap plica tion s Cen ter
Fig ure 24 -12

A d d-on-pak M o du lar R eplacem en t of S w it ch B anks
P re-1 97 8
24-38
E P R I L ic en s ed M a te ria l
Rotork Maintena nce M anua l
Fig ure 24-13

A d d-o n-pak T y pica l A O PI G ear A rrang em en t
24-39
Nucle ar Mainte nan ce App lication s Center
F igu re 24-14
N A 1 and N A 2 Sw itch M echanism A s sem b ly
2 4 -4 0
Ro tork M ain tena nce M anua l
Fi gure 24 -15
N A 1 Sw itch M echanism A ssem bly
2 4 -4 1
N u clear M aintena nce A pplica tion s C en ter
Fig ure 24 -1 6
S w itch M ech anis m M o d u le ( N A 1 )
(F ront V iew C ross Section)
24-42
R otork M aintenan ce M a nual
F ig ure 24-17
R e plac em en t S w itch M ec han ism Sw it ch P aks
24-43
Nu clear M aintena nce Applic atio ns Ce nte r
Fig ure 24 -18

F abricated C ov er A ssem bly for Sw itch
2 4 -4 4
R o tork M ain tena nce M anu al
F igu re 2 4-1 9
F abricated C over A ssem bly fo r 6 S w itch A dd-on-pak 1
24-45
N uc lea r M a inte na nc e A pp lic atio ns C en ter
F igu re 24-20
F abricated C o ver A ssem b ly for 12 Sw itch A d d-o n-p ak 1
2 4 -4 6
25.0 70/90 NA ACTUATOR

N u m b er ed r ef er en ce s in p a re nt h es es , ( ) , c o rr es po n d t o F i gu r es 2 5 -l a th r ou g h 2 5 - 20 .
N O T E : T h is pr os ed a re has b een w r itten u tilizin g a m od ular a ppr oa ch to

m ainten ance activities . D u e to this ap pr oach , cer tain s teps w ill be rep eated
w it h s p ecific m odu le m a int ena nce in m i nd.
1 . E n s u r e ac tu at or fe ed er b re ak er is in o pe n p o s it io n.
W A R N IN G : A dd itiona l cir cuits m ay need to be is ola ted by rem ovin g fu ses ,

liftin g lead s, op ening s liding links , etc.
W A R N IN G : If t he s ys tem is pr es s ur iz ed, the va lve s tem m a y s lip r esu ltin g

in s erio us injur y to p ers onn el per form ing m a intenan ce on the actua tor .
2. G ag v alv e stem as req ui red by sec ur ing val ve stem to y o ke.

3. T o r em o ve s yncro set co ver ( 151) , rem ov e fou r s crew s ( 188) .
4. D isc on nect and r em o ve field w ir ing f ro m s y ncr os et bod y (1 50 ). M ar k w ir ing f or
re co n n e c tio n , a s n e c es sa ry .
5. R ep lace sy ncro set cover (15 1).
6. R ep lace fo ur scr ew s ( 188 ).
7. T o rem ov e th e li m it s w itch c ove r ( 25 0, 2 51 ,2 52 ), re m ov e th ree cap s crew s ( 25 7) ,
an d spr ing w ash ers (2 58 ).
8 . D i se ng ag e th e pr im a ry l im i t sw i tch a nd l oo s en a dd - on -p ak clu tch n u t, if
ap plic able (re fer to S ection 2 0.0 f or de tails ).
9. R ep lace li m it s w itc h co ver (2 50 ,25 1,25 2 ) w ith c ap sc rew s (2 5 7) a nd s p r ing
w a sh e rs (2 5 8 ).
C A U T IO N : W hen riggin g th e actua tor for rem oval/r eplacem ent, care
sh ould be taken to avoid connecting to either the han d au to lever (11),
hand w heel hoop (88), or h andw h eel s pokes (8 7).
1 0. I n s tal l ri gg in g as n ece s s ar y to s u p po r t th e w eig h t o f t he a ctu ato r a nd pr ev en t

s t em d am a ge d ur in g r em o v al.
1 1. M a tch m a rk a ctu at or a s s em b ly and va lv e y o ke t o es ta bl is h o ri gi na l i ns t alla tio n
p os it ion .
12 . R em ov e th e m ou ntin g bo lts o r s tu d nu ts f ro m b elow the val ve yo ke or g earb ox
flan ge .
25-1
13 . R em o ve actuator T om valv e as follow s:

a. G l o b e V a lv e s
- E n s u re v a lv e s te m k ey s a r e re m o v ed an d p r op er l y m a in ta in ed un t il th e
actu at or i s r epl aced /r ein s tal led .
b . G a te V a lv e s
- F or th r ead e d s h af t v alv e s t em a pp li ca tio n s , r o tat e o pe ra to r h an d w h ee l
tow a rd c los e d di rec tio n un til th e actu ato r u ns c rew s fr om t he v alv e s te m .
c . Q u a rter T u rn V a lv e s
- F or ke yed sha ft a pp lic ati on s , en su re t he ac tu ato r is p ul led st ra ig ht o ff of
the v alv e s te m or g ear bo x s pl ine s ha ft to av o id va lve s tem d am ag e.
14 . T r an s p or t act ua to r to p r op er a re a fo r s to r ag e a nd /o r r ep air .
W A R N I N G : I f the a ctua tor ha s not been rem oved fr om the valve p rio r to m oto r
a ss em bly r em oval, en sur e actuator feed er br eaker is in op en pos itio n.
A d ditio na l cir cuits m a y a lso n eed to b e is ola ted by r em ovi ng fus es , li fting
lea ds , op ening s lid ing links , etc.
1. C heck m otor w indin gs ( 90) f or dam age as follow s:

a. U s in g a dig it al m u lti- m e ter , m e as ur e w in di ng r es is t anc e bet w een e ach
p h ase . N o w in di n g r esi stan ce sho u ld re ad op en an d t h e re sist an ce v al ue s
s h ou ld be app ro xim ately ba lance d.
b. U s in g a m e gg ar ( 1 00 0 v ol t s c ale ), m eas u re th e r es is ta nce b etw e en o ne m ot or
w in d in g to t he m o to r h ou s in g . T h e r es i st an ce va lu e s h o ul d be ≥ 1 .5
m ego hm s.
c. If r es i s tan ce v al ue s v ar y f ro m r es u lts in d ica ted a bo v e, c on ta ct th e
a pp r op r ia te en g in ee ri ng re pr e s en tat iv e o r a R ot or k re pr es e nt at iv e.
2. D rain o il from gearcase ( 1) b y rem ov in g low er p lu g (8 6).
3. P la ce th e act ua to r in t he h an d o p er atio n m o de b y d ep re s s in g h an d au to l ev er
( 11 ) to the m an ua l m o de .
4. I f th e m oto r is h an gin g v ert ical fr om th e actu ato r ref er to S ec tio n 25 .2 .2 , S w itch
M ech ani sm R em o val to e nsu re sw itch m e chan is m (2 59 , 2 61 ) and t or qu e sw it ch
pl un g er ( 11 4 ) ar e rem ov ed pr io r to m ot or r em ov al . P ro ce ed to S tep 2 5 .2 .1 .5, i f
th e m o to r is h or izo n tal t o th e act ua to r.
C A U T IO N : Im pr oper r em oval of the m otor cover (4) fro m the gearcas e (1)
could r esu lt in dam ag e to oil s eal (55 ) and bear ings (42 , 43) .
5. R em ov e f our cap s crew s ( 71 ) and w as her s (6 7) th at r etain the m o tor co ver (4 ) to

th e g earc ase (1 ).
6. R em ove th e m otor co ver (4 ) s lo w ly from th e gearcase (1 ).
25-2
7. L ocat e b utt co nn ecto rs un de r fib erg las s s le evi ng an d cut m o to r lead s o n bo th

s ides of bu tt con nector s.
8 . R em o ve the m oto r cov er O - rin g (9 1) and in spect fo r d am ag e. R ep lace a s
n e ces sar y .
N O T E: If the oil sea l (55 ) is determ ined to need r eplacem ent, the cir clip
(5 8) a nd backu p w ash er (54 ) m us t be rem oved firs t on P os t-1 978 m o dels
o nly .
9. R ep lace o il s eal (5 5) and n eedle bear ing ( 42, 4 3) as r equ ired by in dica tion s of oi l
le a k a g e o r d a m a g e .
N O TE : Section 2 5.2 .1.1 0 per tains to P re-1 978 actuato rs on ly.
1 0. I nspect w orm sh aft sh ro ud (2 9) for d am age and rep lace a s necessary .
1 . P os t-19 78 A ctuator s
a. E n sur e electrical p ow er is is olated o r disconnected.
b. V is ually in spect f or p roper m ovem ent of th e sw itch m echanis m (2 61) as th e
va lv e is m an u all y o pe ra ted . I f th e s w i tch m ec ha ni s m (2 6 1) s ho u ld n ee d
ad ju s tm e nt r ef er to S e cti on 20 .0 o f th is m an ua l. I f d am ag e is in di cat ed ,
rep lace the sw it ch m echa nis m (2 61) as nece ss ar y.
N O T E : 2 5.2 .2 .1 , S tep c) is n ot r eq uir ed if rep lac ing s w itch b an ks on ly.
c. D r ain o il f rom gearcas e (1) by rem o vin g lo w er p lug (86 ).

d. R em ov e th e t hr ee c ap s cr ew s (2 5 7) an d s p r in g w as h er s (2 5 8) th at r eta in th e
lim it s w itch cove r ( 250 , 251 , 2 52 ) an d pul l cov er str aigh t of f.
e. I f the actuat or is to rqu ed ou t in eith er the op en or clo se d p os itio n, th e to rqu e
ad ju s tin g f r on t p la te's p oi nt er w i ll n ot b e v er ti cal . I n th is in s ta nc e, m o ve t he
ha nd au to l ev er ( 1 1) in to t he h an d p o s iti on to c en ter th e to rq u e ad ju s tin g
fr on t p late a s n ece ssar y.
f. D i sc on nec t th e sw i tch m ec han ism lead s f ro m t he sw itch b ank s ( 26 2) o n th e
sw it ch m ech an is m a ssem bly ( 26 1 ). M ar k w irin g fo r re con ne ctio n, as
n ecessar y.
g. T o r em o ve sw it ch ban ks ( 26 2) , s cr ew lo ckin g hex n ut (2 69 ) t ow ard s s w itch
ban k ( 262 ).
h. M ov e sw i tch ba nk (2 6 2) to w ard th e fro n t p late (2 70 ) far e no ug h to rel eas e th e
sw itc h b an k (26 2) f ro m s w itch m e chan is m r ear pl ate ( 27 2) .
i. R em ov e tw o c aps crew s (2 64 ) o n t he sw itch m echan is m basep late ( 263 ).
25-3
C A U TI O N : U se care w he n rem ovin g sw itch m echa nis m (2 61 ) to a void

da m age to the O -ring (271).
j. C aref ully rem ove the sw it ch m echan ism (2 61 ) f ro m th e gea rcase ( 1).
k . R em o ve the lim it s w itch d rive gea r as s em b ly (11 2, 1 13) f ro m th e s w itch
m ec ha nis m s h af t (2 61 ) b y d riv in g o ut th e s pi ro l pi n (1 2 4) l oc ated nea r th e
lim it s w itch r ear pla te ( 27 2) .
l. R em ov e th e to rqu e s w itch plu nger ( 114 ).
N O T E : If replacem ent o f oil s eal (57) is requ ir ed, tw o s et screw s (38 )

and s eal b ackup w as her s (49 ) m us t be rem oved pr ior to r eplacem ent in
25 .2.2.1 , S tep m ) .
m . V isu ally insp ect o il seal (5 7) f or leak age or d am age . R ep lace as necessar y.
n . V i su ally in s pect tor qu e s h aft s hr oud ( 39 ), n eedle be arin g (4 2) , a nd ne edle
b ear ing ( 43 ) fo r w ear o r dam age. R ep lace pa rts as n ecessary .
2. P re-1 97 8 A ctu ator s
a. E nsur e electr ical po w e r is is olated o r d isco nn ected.
b . V is u ally ins pe ct f or pr op er m ov em ent of th e s w itch m ech anis m (25 9) as th e
v alv e is m an u all y op er at ed . If th e sw i tch m ec ha nis m ( 2 59 ) sh o ul d ne ed
ad ju s tm en t re fer to S e cti on 20 .0 o f th is m a nu al . I f da m a ge is in d ica ted ,
re place th e sw itch m echan is m (2 59 ) a s nec essa ry .
N O T E : Se ction 25 .2 .2 .2, S tep c) is no t r equ ir ed if r epla cing s w it ch

ba nks o nly.
c. D r ain oil fro m gearcas e (1) by r em o ving lo w er plug ( 86).

d . R e m o ve t he t hr ee c ap s cr ew s ( 25 7 ) an d s p r in g w as h er s (2 5 8) th at r eta in t he
lim it s w itch cov er ( 250 , 2 51, 25 2) and pull co ver str aight off .
e . If the ac tua tor is to r qu ed o ut in e ith er th e op en o r clo s ed p os it io n, th e to rq ue
a d ju s tin g f r on t p lat e's p o in te r w il l no t b e ve rt ica l. I n th i s in s t an ce, m o ve t he
h an d a ut o le ve r ( 11 ) i nt o th e h an d p os i tio n t o ce nt er th e to r qu e ad ju s ti ng
f r on t pl ate as n ecessar y .
f . D is co nn ect the s w itch m ech anis m lea ds fr om th e s w itch b an ks (2 60 ) on th e
sw itch m echa nis m assem b ly (2 59 ). M a rk w ir ing f or r eco nn ectio n , as
ne cessar y.
g. T o r em ov e s w i tch b anks ( 26 0), com p res s w ash er ( 266 ) and sp ring (2 65 ) b y
m o vin g s w itch b ank ( 26 0) to w ard s th e f ro nt p late (2 70 ) pu lling s w itc h ban ks
( 26 0) o ut o f the sw itc h m echan is m r ear plate (2 72 ).
h. R em o ve tw o caps crew s (2 64) on the sw itch m echan is m bas eplate (26 3) .
25-4
C A U T IO N : U se car e w h en r em o ving sw itch m echan ism ( 259) to avoid

d am ag e to the O -ring (271).
i. C are ful ly rem o ve the sw i tch m ech anis m (25 9) f ro m th e g earc ase (1 ) and slip
ge arcase hea ter ou t o f clip lo cated o n the bac k of th e sw itch m e chan is m .
j. R e m ov e th e li m it s w itch d riv e g ear as s em bl y ( 11 2, 1 13 ) f ro m t he sw itc h
m e cha ni sm s h af t (2 59 ) b y d ri vin g o ut t he s p iro l p in ( 99 ) lo cat ed n ear t he
k . R em o ve th e t or qu e s w itch p lu ng er (1 14 ).
l . V isuall y insp ect oil seal ( 57 ) fo r leak age o r dam age . R ep lace as nece ss a ry .
m . V is ua lly i ns p ect n ee dle b ear in g ( 42 , 4 3 ) fo r w ea r or da m ag e. R ep lac e pa rts as
n ecessary .
1 . P o s t- 1 9 7 8 A c tu a to r s
a. E n su re electr ical p ow er is iso lated o r disconn ected.
b. R e m ov e th e th ree ca ps c rew s (2 5 7) a nd sp r in g w as h ers (2 5 8) t ha t r et ain th e
lim it sw itch cover (2 50, 25 1, 2 52 ) and pu ll cov er s traig ht of f.
c. D isco nn ect th e ad d- on -pa k l eads, w ithin th e sw itch m ech anis m loo m ( 17 2) ,
fr om the ad d- on -p ak s w i tches (3 03 ). M ar k w i rin g fo r reco nn ectio n, as
necessary .
N O T E : If r epla cing a dd -o n- pa k s w i tch ba nks ( 30 3) , per fo rm Step s d) ,

and e o nly of the r em aining s teps in S ection 25.2.3 .1.
N O T E : I f r em o ving the add -on -pa k a ss em bly ( 300 , 301 , 3 02) for
r epa ir /in s pec tion o f the a ctu ato r el im ina te St eps d) a nd e ) an d
per for m the rem ain ing s teps in Sectio n 2 5.2 .3.1.
d. R em ov e the s w itch ho ldin g p lates (31 3) , co m pres s ion s prin gs ( 310 ) an d

w ash ers (3 09 ).
e. P u ll a dd -o n- p ak s w itch p ak s h aft ( 31 1) tow ar d s th e f r on t p lat e ( 31 4 ) and
rem ov e s w itch b ank s (30 3) .
f. R em ov e tw o cap screw s (3 12) , w as hers ( 309 ) and com p res sio n s pr ings (3 10 )
tha t r eta in s w itch h o ldi ng p lat es ( 31 3 ) to th e f r on t p lat e ( 3 14 ).
g. R em ove sw itch hold in g plates (31 3).
h. M ove s w itch ban ks ( 303 ) to the si de t o al low en tran ce o f allen key in to the
so ck et ca ps cr ew s (3 15 ) tha t r etain ad d- on -p ak (3 0 0, 30 1, 3 02 ) to m o un tin g
pillar s ( 330) .
i. R em ov e the three sock et capscrew s (3 15) .
j. R em ove add- on- pak (30 0, 301 , 3 02) fro m th e sw itch driv e s haft (27 3).
25-5
k. L o os en s et s crew (32 8) in lock ing p late (32 9), then rem ov e lockin g p late (32 9),
spacer s (3 26 ) and ge ar c lus ters (32 5) .
l . P e rf or m v is u al ins p ectio n o f gea r clu st ers (3 25 ), s p ace rs ( 32 6 ), d riv e ada pte r
( 3 27 ), lo ck in g pla te (3 29 ), m ou nt ing pill ars (3 3 0) an d s et s cre w ( 32 8) f o r
d a m a g e an d a b n o rm a l w e ar.
m . If m o un tin g pil lars (3 30 ) are da m age d, u ns cr ew f ro m s w itch m ech anis m
ass em bly (26 1).
n . R ep lace pa rts as n ecessary .
2. Pr e-1 97 8 A ctu ato rs
a. E nsure electrica l po w er is is o lated o r discon nected .
b. R em ov e th e t hr ee ca ps cr ew s (2 5 7) a nd sp r ing w ashe rs (2 5 8) t hat r eta in th e
lim it s w itch cov er ( 25 0, 25 1, 25 2) and pu ll co ver s traig ht o ff .
c. D iscon nect the ad d- on- pak leads, w ithin the sw itch m ech anis m lo om ( 17 2),
fr om th e a dd -o n- pa k s w itch es ( 31 9 ). M ar k w ir ing f or r eco n nect ion , as
ne ce ssa ry.
N O T E : If r epl acin g ad d- on -p ak sw itch b an ks ( 31 9) , p er for m Step s d )

thr oug h f) only of th e r em a ining s tep s in S ection 25.2.3 .2.
N O T E : I f r em o ving the add -o n-p ak a s sem bly (30 0, 30 1, 30 2) for

r epa ir / ins p ec tio n o f t he a ctu a tor , elim i na te 2 5.2.3 .2 , S tep d ) th r o ug h f
and pe rfo rm th e r em ainin g s tep s in S ection 25 .2.3.2 .
d. L oo sen tw o fro nt m o unting nuts (3 24) neares t to sw itch ban ks (31 9).
e. Screw L ocking H ex nut (32 2) tow ar ds s w itch banks (31 9).
f. M ove s w itch b an ks (319) from add -on-pak m ain fram e.
g. L oo s en thr ee alie n screw s (3 20 ) th at reta in th e ad d -o n- pak m ain f ram e t o the
m o un tin g pilla rs ( 32 1)
h. R em ove add- on- pak (30 0, 301 , 3 02) fr om th e s w itch m echan ism driv e s haft
(2 73 ).
i. L oos en s et s crew (3 28) in lo cking plate ( 329 ), th en r em ove lo cking plate ( 329 ),
sp acers (32 6) an d g ear clus ter s (3 25 ).
j. Pe rf or m v isual in sp ectio n of g ear clu s ters (32 5) , space rs ( 32 6) , dr ive ada pter
(32 7), lock ing plate ( 329 ), m oun ting pillars ( 321 ) an d s et s crew (3 28 ) fo r
d am ag e an d ab n or m a l w ea r .
k. If m ou ntin g pillar s (3 21 ) ar e d am age d, un scr ew fr om s w it ch m echan ism
as sem bly (259) .
1. R e pla ce par ts as n ec essary .
1 . E n s ur e elec tri cal po w er i s is o late d or dis co n ne cted .

2 . R em ov e fo ur s crew s (1 88 ) f rom the sy ncr os et bo dy (1 50 ) an d rem ov e co ver (1 51) .
3 . R e m ov e O -r ing (1 64 ) an d vis u ally ins p ect fo r d am ag e.
25-6
4 . D is co n ne ct an d r em o ve a ll ex ter n al w ir ing . M a rk w iri ng fo r r eco nn ec tio n , as

n e c e s sa ry .
N O T E : To rep lace da m a ged term inal block ( 152) on ly, com plete 2 5.2 .4
S teps 5 thr oug h 7 . T o rem ove the entir e s yncr os et a ss em bly p ro ceed to
2 5.2.4.8.
5 . R em o ve g ro un din g lug c on nect ion s ( 15 8, 1 59 , 16 0, 1 65 , 16 6) an d re tain ing r ing

( 17 4) f ro m i ns id e th e s y ncr os et b od y (1 50 ).
C A U TI O N : W hen r em o ving the ter m ina l blo ck (1 52) do n ot p ull o n th e

b r as s ter m ina l s tu ds .
6 . P ull the ter m inal b lock ( 15 2) s trai gh t o ut of th e s yn cro s et b od y (1 50 ) us in g t w o

pa irs o f plier s by g rip pin g a nd pu llin g o n term inal blo ck se par ator s.
7 . R em ov e in ter nal w irin g fr om th e b ack o f t erm i nal blo ck ( 15 2). M ar k w irin g fo r
recon nection , as necessar y.
8 . R em o ve f our caps crew s (16 7) betw een the sy ncro set bod y (1 50 ) and gear case (1).
9 . R em o ve sy ncr os et and vis u ally ins pe ct O -r ing (1 70 ).
1 0. O nce the sy ncr oset assem bl y is rem o ved fr om t he g earcase (1) , the w ir e lo om s
( 17 2 , 18 4, 1 8 5) m a y be d raw n o u t th r ou gh t he ge arc as e ( 1) op eni ng .
N O T E : Sect ion 25 .2.4 Step s 11 thr o ug h 1 3 ar e to be per fo rm ed on ly if

r epair ing dam aged term ina l block (152 ) a fter th e syn cro set h as been
re m o v ed .
1 1. R e m ov e gr ou nd ing lug co nne ction s (1 58, 1 59, 1 60, 1 65 , 1 66 ) an d retain ing rin g
( 17 4) fro m in s ide t he s y ncro s et bo dy (1 50 ).
C A U T IO N : W h en r em oving the term ina l blo ck (1 52) do no t pu ll or a pp ly

for ce to the br as s ter m ina l s tuds .
1 2. P ull the term inal blo ck ( 15 2) str aigh t ou t of th e s yncr os et b od y ( 150 ) u s ing tw o
pa irs of pl iers by g rip pin g an d pu llin g on ter m in al b lo ck s epar ato rs .
A dd itio n ally , the ter m in al bl ock ( 15 2) m ay b e ta pp ed fr om th e rear t o aid in
rem o val.
1 3. R em o ve inter na l w iri ng fr om th e b ack of ter m in al b loc k (15 2) . M ark w ir ing fo r
r eco nnection, as necessary.
25-7
N O T E : P rior to r em oving hand w heel m od ale, note the p osition o f th e actu ator
to determ ine if dr ainag e of oil fr om gear ca se ( 1) is necess ar y. If the h and w heel
is in a tw elve o'clock p os itio n) Step 25.2 .5.1 Step a ) is not r equir ed.
1 . S id e M ou nt ed H a nd w h eel
a. D rain oil by rem ovin g low er plu g (8 6) f rom gear cas e (1 ).
b. R em ove cap screw s (7 0) f rom hand w h eel gearcas e (9 7) r im .
c. L ift th e ha nd w he el m o du le s tr aig ht o ff u s in g ca re no t to d am a ge th e O -r in g
(4 4) or the oil seals ( 50).
d. R em ove and insp ect O -rin g (44 ).
e. V isua lly in sp ect oi l seal s (5 0) f or l eaka ge or d am ag e. R epla ce p ar ts as
n eces s ar y by p res s in g oi l s eal s (5 0 ) i nto h an dw h eel as se m bl y ho us in g us in g
sid e han dw h eel seal to ol.
1 . G ear case R em o v al an d In sp ecti on

a. R em o ve actu ato r fr om val ve per S ect ion 2 5.1.
b. D r ain all o il f ro m actu ator g earcase (1) b y loo sen ing lo w er m ost p lug (8 6) .
c. R em ov e th e f ollo w ing act uato r com p on ent s per ap pli cable sectio ns :
• M o to r: S e c tio n 2 5 .2 .1
• S w it ch M e ch a n is m : S ec ti o n 2 5 .2 .2
• S y n c ro se t: S e c tio n 2 5 .2 .4
• H a n d w h ee l: S e ctio n 2 5 .2 .5
d . R em o ve re m ain ing g ear case int ern al com p o nen ts p er th e f oll ow in g sectio ns :
• C lu tc h an d W o r m ge ar : S ec ti o n 2 5 .2 .6 .2 .
• D r iv e B u s h i n g: S ec ti o n 25 .2 .6 .3 .
• H an d A u to L ev e r: S ec ti o n 2 5 .2 .6.4 .
• O i l S e al : S e ct io n 2 5 .2 .6 .5 .
• W o r m s h af t B us h in g : S e c ti on 2 5 .2 .6.5 , S t ep c )
2. C lu tch and W o rm g ear R em o val
a. R em ove actuato r f rom valv e per S ection 25 .1.
b. R em o ve han dw h eel a ss em bly f ro m th e a ctuat or pe r Sec tion 2 5.2.5.
c. D rain all o il fr om actuator gear case (1 ) b y lo os ening lo w er m ost p lug (8 6).
d. R e tur n ac tu ato r to au to p o s itio n b y u si ng a s cr ew d ri ve r to g en tly n ud g e t he
f in ger as s em b ly ( 12 ) on th e yo ke as s em b ly (1 0) u nti l it an d the clu tch r in g
( 26) d rop back dow n o nto the w orm w heel (21 ).
W A R N IN G : T he clutch s pr ing (2 5) in the follo w ing s tep is s till un der

loa d a nd could cau se s er ious in jur y if ca re is not taken w hen r em o ving
the clu tch retaining O -r in g (52) .
25-8
e. R em ov e t he c lutch r etainin g O -rin g (5 2) , w as he r ( 31 ), an d cl utch s pr ing (2 5)

from top of center colum n (8).
f. S lide the clu tch r ing (26 ) an d y oke assem bly (1 0) off the center colum n (8 ),
tak ing car e n ot to dr op clu tch key s (2 7) in to the gea rcas e ( 1) .
g. R em o v e th e cap s cre w s ( 36 ) th at ret ain th e thr u st p ad ( 15 ).
h. L i ft o ut thru s t pad ( 15) an d w o rm w heel (2 1) fro m g earcas e ( 1) .
i. R em ov e cap s crew s (7 0) retain ing ge arbo x bas e ( 3) to thru st bas e (2) .
j. R em o ve co m ple te gea rbo x (3) , o il s eal (51 ), bea ring s top r ing (9 ) an d thru s t
bearin g ( 41) .
k. R e m ov e ca ps cre w s (3 6) an d w as her s (8 1) , reta inin g thr us t bas e (2 ) to
gearcase (1).
1. U s in g a s tan d ar d b enc h p re ss o r jac ki ng st ra p p res s o ut th e cen te r co lu m n ( 8 )
an d lim it sw itch w or m (1 9).
m . S u pp or t th e lim it s w itch w or m (1 9) an d pr es s th ro ug h the cen ter co lu m n (1 ).
n. R em o ve a ll O -r ing s; inspect and r eplace as nec ess ar y.
3 . D r ive B us h in g R e m ov al an d In s p ectio n s
N O TE : T he actua tor m us t b e r em o ved fro m the va lve p rio r to d rive

bus hing rem oval per Section 2 5.1.
N O T E : S om e ac tua to r s h av e a ho le w h ich i s n ot p lug g ed. In th is ca se

om it Step 25.2.6.3 , S tep a).
a . U ns cr ew a nd r em ov e plu g (5 9) o n s ide of ac tuat or b as e.

b . U s i ng han d a ut o lev er ( 1 1) , p os i tio n ac tu ato r to h an d o p era tio n .
c. R o ta te t he ha nd w h ee l as s em b l y u nt il t he bu s h in g re tai n er s e ts c re w (6 5 ) i s
visib le thr ou gh t he ho le in the g ear case ( 1) b ase.
d . R em o ve sets crew (65 ).
e. U n s cr ew d r iv e b u s h in g re ta in er ( 13 ,2 3 ) b y u s i ng a s p a nn e r w r en c h i ns er te d
in to the tw o ho les p ro vi ded o n the dr ive bu s hin g ret aine r ( 13 , 23 ).
N O T E : F o r typ e A dr ive bus hing (20) , r eco rd the pos ition o f the dr ive
bush ing (20) p rior to rem oval.
P o si tion 1 D riv e B u sh ing ( 20) is ins er ted into th e cen ter co lum n (8 ).
P o si tion 2 D ri ve B u sh ing ( 20 ) p r otr ud es fr om the center c olu m n ( 8).
W h ile per for m in g 2 5.2 .6.3 , S tep f) rem ove th e dr ive bu sh in g ( 20, 22) by
pu lling it str aig ht o ut o f the cen ter co lum n ( 8).
f. V is u ally in sp ect thr eads of th e d riv e b us h ing ( 20 , 22 ) for d am ag e.

g . V isu ally in sp ect m ach ined sh ou lder s of th e dri ve bu sh in g ( 20 , 22 ) at t he
co ntact po int w ith the center co lum n ( 8) do gs f or cr acks o r shear s.
h . R e pla ce d am age d par ts as n eces s ar y.
25-9
4. H an d A ut o L ev er R em ov a l an d I n s p ec tio n s
N O T E : T o gain access to the ha nd auto lever com po nents , th e actu ator

ha nd w heel as sem bly m u st firs t b e r em o ved p er Sectio n 2 5.2 .5, acces s w ill
als o be im pro ved by rem oving the center colum n (8) p er 25 .2.6.2.
a. F ro m insid e th e g ear case ( 1) , h and w he el en try , lo cate th e up p erm os t spi ro l

pin ( 62 ). Po s itio n d rif t p u nch , tap o ut an d re m o ve fr om g ear cas e (1 ).
b . P u ll o ut han d auto le ver (1 1) .
c . U n ho o k s p lit p in ( 6 3) fr o m ha nd au to r etu r n s p ri ng ( 8 9) an d r em o v e ha nd
aut oca m (1 7) .
d . C ar ef ul ly m a ni pu la te ha nd aut o r etu rn s pr in g ( 89 ) an d r em o v e it fr o m
locating pin (16).
5. O il S eal R em oval
a. O n P o st- 19 78 : r em ov e back up w as her s ( 54, 4 9) o n the m oto r w or m s haf t b ore
an d to r qu e s ha ft b or e.
b. R em ove o ld oil seals .
c. O n P re -19 78 : i ns pect , r em o ve & r epla ce w or m s haf t s h ro ud (2 9) as req uir ed.
6 . T or q u e S h af t S h r o ud an d W o r m s h af t B e ar in g R e m o v al
a. P os i tio n g ear ca s e (1 ) s o t ha t s w i tch m ec ha nis m e nt ry is u p pe rm os t .
b. L o ca te d ri ft p un ch in to t or q ue s h af t s hr o ud (3 9 ) an d d ri ve d o w nw a rd s u n til i t
is p us h ed int o the g earc as e ( 1) , the n rem ov e.
c. P osit io n ge arc ase (1 ) so t hat th e m o to r b or e is u p pe rm o st.
d. L oc ate d r if t pu n ch i nt o m o t or bo r e to r es t a ga in s t th e en d o f th e s n ou t an d
ne ed le b ea ri ng ( 42, 4 3) and dr ive out into g earcas e ( 1) and rem ove.
1. B earing A s s em bly
a. F it sn ou t an d ne edl e bea rin g s ( 42 , 4 3) o n to th e w or m sh aft n eed le b ear in g
too l, l ocate in gear case (1 ) at m o tor w or m b or e, an d pr ess hom e.
b. P re- 19 78 o nly : F it w orm sh af t s hr ou d (2 9) on to th e f lam ep roo f s hr ou d a nd
bea rin g m an dr el; lo cate in g earc ase ( 1) a t m o to r w or m b o re and p r ess ho m e.
c. C o at the ou ts ide o f t he on e w o rm sh aft o il seal ( 55 ) w i th H ylo m ar an d pr ess
in to gear cas e ( 1) (d yn am ic s ide to ins id e) w ith w o rm s h aft oil se al to ol; rep eat
fo r the secon d s eal (55 ), ( dynam ic s ide o utsid e).
d. P o st- 197 8 only : F it seal b acku p w asher (5 4) and circlip ( 58) into g earcase (1 )
at m o tor w or m b ore .
e. F it tor qu e s h af t s h ro ud ( 34 ) on to p res s t or qu e s h aft s hr ou d /oil s eal to ol;
lo cat e m g ear case( 1) a t t or qu e sw i tch sh aft b or e, an d pr ess h o m e.
f. L oca te th e tor qu e s h aft's o il se al ( 57 ) on to rq ue s haf t s h ro ud /oi l s eal to ol and
pr ess hom e.
g. P o s t-1 9 78 o nl y: F it s eal ba cku p w as h er (4 9 ) on to to rq ue s h aft s h ro ud /o il s e al
too l an d pr es s h o m e. I ns t all tw o s ets c rew s (3 8) .
25-10
2 . H and A uto L eve r A s sem bly

a. F it o il se al) ( 56 ), us in g h and a uto se al too l, o n to ha nd a uto lev er (1 1 ) s haf t.
b. F it lo cat ing pin (1 6) a nd O - r ing (5 3) int o ge arc as e (1 ); f it ha nd a uto ret ur n
spring (8 9) to e nd o f lo catin g p in (16 ).
c. S m ea r w i th E x x on U n ir ex N 2 g r ea s e an d i n s er t h an d a ut o l ev er (1 1 ) t h ro u g h
oil s eal ( 56) s o th at the hand le of the lever h ang s dow n tow ards th e bas e
en tr y o f th e g ear case ( 1 ).
d. I n ser t th e spl it p in ( 6 3) i nt o th e h an d au to cam ( 1 7) an d lo ca te th e ca m on
th e h a n d a u to le v e r sh aft.
e . H oo k t he en d o f t he h an d a ut o r etu r n s p rin g ( 8 9) in to t he e ye o f t he s p lit p in
(63 ).
f. L ift ing t he h and le o f the h an d aut o lev er ( 11 ) to th e lef t, li ne up the h ol e i n
t he c am ( 17 ) w it h th e h ol e in t he h an d au to lev er s ha ft a nd dr iv e ho m e t he
s pirol pin (62).
3 . C ent er C ol um n , C lu tch and W o rm g ear A ssem b ly
a. A pp ly lock tite to th e k nu rl o n the cente r co lum n ( 8) , l ocate lim it sw itch w o rm
(1 9) o nt o the cen ter c olu m n ( 8) an d p res s o n , us in g ben ch p res s and l eng th o f
tu bi ng .
b . U s i ng a s u ita b le b en ch p re s s , p o s it io n b ea ri ng s to p r i ng ad ap te r to o l. P os iti on
b earing sto p r ing (9) on to bear ing sto p rin g ad apter tool so that th e largest
d iam eter is u pper m os t. P os ition thr us t bear ing (41 ) o ver bearin g s top rin g
(9 ) an d fin a lly, p lac e th e th ru s t b as e ( 2) o v er the c o m ple te as se m b ly .
N O T E : E n su r e c or r ect r atio l im it s w itch w or m is fit ted. N o ga p s ho ul d

exis t betw een lim it sw itch w o rm an d center colu m n w hen as s em bled .
c. G r ease lo w er sectio n o f center co lum n an d O - ring g ro ove.

d. G rease an d fit O - ring (47 ) to center colum n (8) .
e. C arefu lly lo cate center colu m n assem bly .
f. C over as sem bly w ith lim it sw itch w orm pr es s adapter tool, or suitable leng th
o f tu b ing , o pe rat e b en ch pr es s and pr es s a s se m b ly to ge th er.
g. Ins tall oil s eal (5 1) in to gear box bas e (3) us ing w o rm s haft o il seal to ol.
h. G re ase bear ing s top rin g (9) , alread y as s em b led t o cen ter colu m n.
i. G r ea se u p pe r m ac hi ne d s p igo t o n th ru s t b as e (2 ) . G re as e an d lo ca te O -r in g
( 44) and fit dow el pins (34).
j. I n st all cen ter col um n/b ase assem bly int o ge arc ase and secu re u si ng sc rew s
(3 6) a nd s p rin g w as her s ( 81 ). T igh ten to 2 0 - 22 f t. lb s .
k . G rea se u pp er m ach ine d spi go t o n g ear bo x b ase ( 3 ). G r ease an d lo cate O -r in g
(45).
1 . I n s ta ll g ear b ox b as e in to th r us t b as e tak in g e x tr em e c ar e n ot t o d am ag e oi l
s eal (5 1) as it pas s es o ver bea rin g s to p ring ( 9) .
25-11
N O T E : U s in g tw o st uds diam etr ica lly o pp os ed w ill ens ur e m o un ting h oles

are aligned w ith cleara nce ho les.
m . Se cur e g earb ox b as e to th ru s t b as e u si ng s cre w s (7 0).

n. S lid e w or m w h eel ( 21 ) o nto center co lum n and allo w w heel to sit o n sh elf
ac ro ss cen te r o f ge ar case . E n su re d r iv e pi ns ar e up p er m o s t.
N O T E : E n sur e co rr ect ra tio is fitted. I f w o rm w h eel dr ive pins ( 28) ar e

not fitted, fit befor e ass em bly into gearcas e.
o . P os it ion t hr us t p ad (1 5 ) so tha t t he bl ind h o le in th e u p per m o s t l eve l o f th e

pa d is n ea re s t th e s y n cr os e t en tr y o n th e g ear cas e . S e cu re us i ng 4 o f f
caps crew s (36 ) tighten ed to a to rq ue o f 2 0 - 22 ft. lb s.
p . M an ip ul ate y ok e as s em bly (1 0) int o p lace en s u rin g th at th e h and /a uto fin g er
as s em bly l ies f lat o nto t he w or m w h eel an d the ad ju s tin g gr ub s c rew loc ates
in to th e bl in d h o le in th e th ru s t p ad .
N O T E : P o sitio nal adju stm ent of th e yoke (10 ) is m ad e by scr ew in g th e

gr ub s crew up or dow n.
q. A ssem ble the cl utch key s (27 ) i nto the clutch rin g ( 26 ), secu re w ith screw s
(7 0) a nd ti gh ten to 20 - 2 2 f t. lb s. S l ide th e com pl ete as s em b ly o nto t he
center colu m n (8) .
N O T E : Tu rn center co lum n if necessa ry before sliding do w n the clu tch

ring as sem bly so th at the clutch ring keys co m e dow n clear of the tw o
clutch yoke lugs .
r. E n sur ing tha t t he clu tch k ey s ( 27 ) ar e f lat o n th e w o rm w hee l, fi t t he clu tch

sp ring (2 5) ov er th e cen ter co lum n.
s. S li de th e c lut ch spr in g ov er th e cen ter co lu m n so th at it re sts o n to p of t he
clu tch r ing.
t. Plac e the clutch spr ing w asher (3 1) on top o f th e spr ing .
N O T E : T he la rg e cha m fer o n th e clu tch spring w a sh er sh ou ld b e

u p p e r m o st.
25-12
u . U si ng th e s lid e han dw h eel se al to ol , com p re ss the s pr ing /w as he r s u ff icien tly

to c lear th e g r ov e at th e top of t he ce nt er co lu m n . M ai nta in in g pr essu re o n
th e s p r ing a s se m b ly w ith o n e h an d, u s e th e o th er to r ol l o n th e O -r in g (5 2)
an d lo cate i nto gr oo ve . R e leas e p re ss u r e o n th e s pr in g as s em bly sl ow ly un til
th e sp r ing as s em b ly c om e s to res t ag ain s t th e O - ri ng .
4 . D riv e B u sh ing A ss em bly

a. V e rify th read s are in g oo d con ditio n an d are geom etrically co rr ect f or valv e
ste m ap pl icatio n.
b . V er ify r equ ired m oun tin g po si tion o f the dr ive bu s hin g (20 , 22 ) and in s ert
i nto th e g earcase base insid e o f t he center co lum n (8) .
c. E ns u re th e s lo ts of th e dr ive b us h ing (2 0, 2 2) a re fu lly e ng age d w ith th e
actu ato r's c ente r c olu m n s ha ft dr ive d og s.
d . In s tal l and tig hte n d riv e bu s hi ng ret ain er ( 13 , 2 3) .
e. U s in g a feel er ga ug e, ve rif y ga p bet w e en dr iv e b us h in g ret aine r (1 3, 2 3) a nd
bu shin g (2 0, 2 2) d oes not ex ceed 0.043 inch.
f . I n s tall a nd tig h ten dr iv e b us h in g r et ain er s c re w ( 6 5) .
g. P re-1 978 o nly: reins ert red cap p lug (5 9) into gear case (1) .
1 . W irin g L oo m I nter nal C o nn ectio ns to T er m ina l B ung

a. C on nect h eater w ir es to ter m in als 4 a nd 5 o n back o f ter m ina l b lock ( 15 2)
fro m th erm o stat lo o m (1 8 5 ).
b . C onn ect m otor w ire s to term in als 1, 2 , an d 3 o n back of ter m inal blo ck (1 52)
from m otor loo m (1 84).
c. C o nn ect n um b ered sw itch m ech anis m and ad d-o n- pak lo om (1 72) to
co rres p on din g n um b ered ter m in als on b ack of term inal blo ck (15 2) .
d. P erfo rm co ntin uity check w ith m eter fr om f ield sid e of term in al b lock (15 2) to
eac h sw it ch con tact to en sur e co rr ect sw itch is w ir ed o ut to co rr ect t erm inal.
2. A s sem b ly of T erm inal B lock in to S yncro set
a. S m ear O - rin g (1 64 ) and t erm i nal blo ck o uter b or e w it h gr ease an d pl ace O -
ring (164 ) into low er rad ial gro ove o f s yncro set.
b . C ar efu lly po s itio n t erm i nal bu ng in s ide s yn cro s et b od y (1 50 ) takin g car e n ot
to pin ch or dam age any w ires o r t he O - ring ( 16 4).
c. S ecur e t erm i nal bl ock ( 15 2) b y plac ing r etain ing r in g (1 74 ) i nto o ute r rad ial
gro ove of the syn cr oset body ( 150).
d . In s tall g ro und ing lu g a ss em b ly (15 8, 15 9, 1 60, 1 65, 1 66 ) in to sid e o f
s yncroset body (150).
3. A s sem b ly of Sy ncros et M o dule to G earcase
a. E n sur e h eate r a ssem bly ( 18 7) , (P o s t-1 97 8) , is secu red t o gear case w ith tw o
s cre w s in p re -ta pp ed h ole s d ire ctly b en eath s yn cro s et en try op en ing i n th e
g earcase.
b . I nsp ect g ear case an d syn cr ose t se alin g su rf aces fo r an y d am a ge th at w ou ld
h ind er p ro pe r s ealin g.
c. E ns ur e O - rin g (17 0) is fitted p ro per ly aro un d bo dy (1 50 ) and f it in to gear cas e
(1 ) o p en in g .
25-13
d . S ecu re w ith f ou r c aps cr ew s (1 6 7) an d sp rin g w asher s ( 17 1) . T or qu e ca ps cr ew s

to 1 0 - 1 2 ft. lbs .
1. P r e- a nd P os t -1 9 78 A c tu ato r s
a. I f lim it s w itch w h eel o r driv e as s em bly ( 112 , 113 ) is def ective or has b een
r em o v ed in o rd er to r ep lace to rq ue s w itc h m ech an is m , it m u s t be re pla ced o n
l im it s w it ch m ec ha nis m s h aft .
b . E ns u re lim it s w it ch w heel (1 13 ) and d riv e as s em b ly (1 12 ) is fu lly in ser ted
h ar d ag ai ns t t he s w i tch m ec ha ni s m (2 6 1 ) b ra s s b u s hi ng .
c. U s in g th e h o le i n the li m it dr iv e a ss e m bl y (2 6) a s a tem p lat e, dr ill a 1/ 8 inc h
h ol e th ro u gh th e sw itc h m e ch an is m asse m b ly ( 2 61 ) sh af t's br ass b ush in g .
d. S ecu re l im it s w itch d riv e as s em b ly (11 2) o n s w itch m e chan ism as s em bl y b y
ins er ting s pir ol p in (12 4) th rou gh 1/8 in ch hole dr illed in Ste p c) .
e. C lip he ater to b ack of r epl acem en t sw it ch m ech ani sm assem b ly if P re -1 97 8
h eate r (o b s ol ete) is s t ill in s tal led ; P re- 1 97 8 s w it ch m e ch ani s m s had he ater
clips pop -r iveted to the b ack of the m echan is m .
f . G rease O -r ing (27 1) on sw it ch m ech anis m .
N O T E: T he follow in g s tep s ca nnot b e per fo rm ed u nless m otor m o d ale

ha s b een ins talled.
g . I ns ta ll tor q ue s w itc h p lun g er ( 11 4) int o op en in g in g ear ca se e ns u ri ng

sh akep ro of w asher en d is f acing sw itch m ec han ism .
h .. C ar efu lly p us h s w itc h m e chani sm (2 61) in to gearca se (1 ) u ntil gear s m ate.
i. R ep lace o ne cap screw ( 264 ) in to sw itch m ech anis m b ackp late (2 63 ) an d
t ig ht en i n o rd er to v er if y t or q ue a dj us t in g f ro n tp lat e ( 2 7 0) t ur n s t ow a rd th e
ve rtical po s ition , (p oin ter align s w ith arr ow ) .
j . I f no t in v ertica l p os itio n, rem ov e cap s crew ( 26 4) an d w it hdr aw s w itch
m echanis m ( 261 ) aw ay fr om g earcase (1 ).
N O TE : In crea sing the sh afts (1 14) over all len gth w ill cau se the
fro ntpla te (2 70) to ro tate clo ckw is e w h en view ing the sw itch m echa nis m
(261) fro m the front.
k. R em o ve tor qu e s w itch plu ng er ( 11 4) an d a djus t caps cr ew (6 8) in or der to

cen ter p o int er on tor qu e ad justi ng f ro n tpl ate (2 70 ).
1. T ig h ten ca ps cr ew (6 8) af ter adj us tin g to rq u e s w it ch pl un ge r (1 14 ), tak ing
car e n ot to o ver tig hten an d da m age cap screw (6 8) .
m . R ep eat S tep s h ) an d i). I f ali gn m en t is ac hiev ed g o to S te p n) . If n o t
r epe at S tep s j ) th ro ug h m ).
n. R ep lace tw o caps crew s ( 264 ) an d tor que to 4.5 - 5.5 ft. lbs .
25-14
o. C o n ne ct al l in ter n al w ir in g to th e ap pr o pr ia te te rm in als an d s e cu re
w ir ing lo om to s w it ch m echan is m w ith S co tch T her m o set ting T ap e 2 7.
N O TE : T he cover or ienta tion is im po rta nt on the 12 s w itch ad d- on- pa k

a s sem b ly. A n add -o n- pak s up por t is w eld ed to the ins ide of the cover
(252 ).
p . G re ase O - ri ng ( 25 4) a nd in stall o n ge arca se ( 1) . In stall lim it sw i tch co ve r

( 25 0, 2 51 , 2 52 ) and secu re w ith thr ee ca ps crew s (25 7) an d w asher s (2 88 ).
G r ease and tor que caps crew s (2 57 ) to 10 - 12 ft. lbs . (4 .5 - 5 .5 ft. lbs . on P re-
1 97 8 ).
q . R ef er to S ecti on 20 f o r sw itch m ech an is m ad ju stm e nt p ro ced u re .
2. M o dul ar R eplacem ent o f Sw itch B anks on M echan ism
a. P r e- 19 7 8 A ctu at or s w i th N O d esig n S w it ch M ec ha ni s m s I n stal led
• C o m pr es s w as her ( 26 6) and s p rin g ( 26 5) b y m ov ing s w itch to w a rds the
f ro ntp late (27 0)
• P u ll sw itch b ank s ( 26 0) o u t o f th e sw itc h m ech ani s m r ear pla te ( 2 72 )
• I n stall r epl acem en t sw it ch b an ks (2 60 ) d ep ressin g w ash er ( 26 6 ) an d
s p rin g (2 65) an d s nap pin g sw itc h b an k ( 26 0) in p lace
b. P o s t- 1 97 8 A c tu ato r s
• S crew lo cking hex nu t (26 9) to w ard s s w itch bank (26 2)
• M o ve s w itch bank (2 62 ) to w ar ds fr ont plate (27 0), far eno ug h to releas e
sw itc h ban k (2 62 ) f ro m sw it ch m ech anis m 's r ear plate ( 27 2)
• In s tall re pla cem e nt s w itch ban k s ( 26 2) i nto f r am e an d ho ld in pla ce
• E ns u r e s m all b ar rel n ut i s p os it io ned in r ou n ded are a of s l ot o n fr o nt
plate (2 70)
• Scr ew lo ckin g hex nu t ( 26 9) fir m ly aga ins t in side su rf ace o f fro nt plat e
(2 70 )
1. P o st- 19 78 A dd -o n- pak
a. I n spe ct ad d- o n- p ak f o r d am a ge
b . E n s ur e all p o w er h as be en r em ov ed f r om a ctu ato r .
c. V er if y th at th e r epl ace m en t ad d- on - pa k g ear c lus t er s ( 32 5 ) an d sp acer s (3 26 )
m a tch the d am age d ad d -o n- p ak s .
d . I f a dd -on -p ak is be ing in sta lled fo r t he firs t tim e ref eren ce T a ble 20 .4- 1 in
S ection 2 0.0 fo r corr ect n um b ers of ge ar clu st ers (3 25 ) an d sp acers ( 326 ) f or
specific valve tr av el.
N O T E : N ever m ix an d m at ch g ear i ng th a t i s p inn ed w ith g ea r in g tha t

is inves tm en t cas t.
25-15
e . R em o ve tw o cap s crew s (31 2 ) t hat ret ain s w itch h old ing p lates (3 13 ) to the
a d d- o n -p a k f r on t pl at e.
f . R em o ve sw itch h oldi ng plates ( 31 3), s pr ing s (3 10) , and w ash ers ( 30 9) held
be hi nd th es e p late s .
g . I ns tal l th e thr ee m o un tin g pi llar s ( 33 0) t o the s w itch m ech an is m ( 2 61 ). S cr ew
u p tightly to th e nuts retaining the sw itch m echanism s fro ntplate ( 270) an d
torq ue to 5 - 5.5 ft. lb s.
h . If po tentiom eter (30 8) is fitted, slid e it on the pillar.
i. I ns tall the ad d-o n-p ak o nto the p illars (3 30) .
j. M o ve s w itch es ( 303 ) to th e s id e to allow in stallation of th e capscr ew s (3 15)
and w as hers (31 6) to pillar s ( 330) . T orq ue to 5 - 5.5 ft. lb s.
k . R eplace sw itch es (30 3) in add- on-pak f ram e.
l. R ep lace springs (31 0), w ash er s (3 09), holding plates (313 ) and tw o capscrew s
(312) th at w ere rem oved in S tep f).
m . C onn ect w ir in g to the loom (1 72) to the s w itches ( 303).
n. S ecur e the loo m to the pillar s us ing S cotch T her m os etting T ap e 2 7.
o . R efer to Section 20 f or ad ju stm ent p rocedu re.
2. P re -1 97 8 A dd -o n- p ak
a. I ns pec t ad d- on- pak f or d am ag e
b . E n su re all p ow er h as b een r em o ved f ro m actu ato r.
c. V er ify t hat th e r ep lacem ent ad d- on - pak g ear cl us ter s ( 32 5) a nd sp acer s ( 32 6)
m atc h th e dam ag ed a dd -o n -p ak s .
d. If ad d- on -p ak is bein g ins tal led for th e f irs t tim e, re fer ence T abl e 2 0.4 -1 in
S ectio n 2 0.0 f or cor rect n um b ers o f g ear clus ters ( 325 ) and sp acers ( 32 6) for
specific valv e travel.
N O T E : N eve r m ix an d m atch g ea r ing th at is nylo n w ith ge ar in g tha t is

investm ent ca st.
e. L oo sen tw o fr ont p late m oun ting n uts (32 4).

f. S crew lock ing hex n ut (3 22) tow ards s w itch bank (3 19) .
g. M ove sw itch ban ks (3 19) tow ar ds fr ontp late (3 14) far eno ug h to releas e
s w itch ban ks ( 319 ) f ro m add -o n-p ak f ram e.
h. In stall th e t hr ee m ou n ting pil lars (3 2 1) to t he sw itch m ech ani s m ( 25 9 ). S cr ew
u p tig h tly t o th e n uts r eta ini ng th e sw itch m ec ha nis m s f r on tp lat e (2 7 0) a nd
tor que to 5 - 5.5 f t. lb s.
i. I f po tentio m eter (3 08 ) is fit ted, s lide it on the pil lar.
j. I nstal l th e add -o n- pak o nto t he pil lars (3 21 ).
k. I ns tal l all en s crew (3 20 ) into u pp er h ole of ad d- on -p ak f ram e an d tig hten in to
th e en d of th e u pp er s up po rt pil lar (3 21 ), tig ht en to 5 - 5.5 ft. lb s .
1. L o catin g th e b ott om tw o p illar s ( 32 1) in to th e a dd -o n- pak f ra m e a nd d riv e
ad ap ter ( 32 7) o n to th e sw i tch m ech ani sm ( 25 9 ), t igh ten t he tw o b o tto m a llen
screw s ( 320) to 5 - 5 .5 ft. lbs .
m. Install s w itches (319) into add- on-pak fram e and h old in p lace.
n. T i gh ten tw o fr on tp late m ou nt ing n uts (3 24 ).
25-16
o . E ns u re s m all he x nu t ( 32 3) i s p os itio ne d in ro un de d are a o f s lot on f ro n tpla te

(3 14 ).
p . S cr ew lo cki ng h ex nu t ( 32 2) fi rm ly ag ain s t th e in s ide s ur face o f t he fr on tplat e
(3 14 ) ens u rin g tw o he x nu ts ar e j am m ed t og ethe r (3 22 , 32 3.).
q. C onnect w iring fro m the loo m (17 2) to the s w itches (3 19).
r . Se cur e the lo om to t he pi llar s u si ng S co tch T her m o se ttin g T ap e 27 .
s . R efer to S ectio n 20 fo r adju stm ent pro cedu re.
1 . P o s t - 1 9 7 8 A c t u at o r
N O T E : A ll N A Y m o tor s ar e su pp lied in a m odu lar for m . S tat or s ar e

alr eady fitted into the m oto r cover an d the ro tor on to th e w o rm s haft p rio r
to leaving the factor y.
a. In spect m ach ined sur face s of m o tor an d m oto r w o rm sh aft (2 4) fo r dam a ge.
b . I ns p ect fo r dam a ge and g rea se O -r ing ( 91 ) and e ns ur e c or rect po s itio n on
m otor co ver h ous ing.
c. V er ify tor qu e s w itch p lun ger (1 14 ) is in s talled in g earcas e ( 1) .
d . E n s ur e m o tor lead s a re co nn ect ed to a pp ro p ria te ter m in als on bac ks id e of
term inal block (152) as f ollo w s :
• I nstall fib regl ass sleev ing o ver 3 S yn croset m oto r leads.
• S tri p ins ul ation f ro m en ds of S yn cro s et a nd m o tor lea ds .
• P u sh w ir es in to app rov ed bu tt c on necto r and cr am p w ith app ro ved to ol.
• P us h f ib reg las s s leev in g o ver m o tor l ead s an d b ut t c on ne cto rs an d tap e in
place w ith S cotch T h erm o setting T a pe 27.
N O TE : A cor rectly pos itioned m o to r w ill have a sta to r lo ckin g s crew on

the side next to the s yncros et hous ing.
e. A lig n m otor as fo llow s:

• W hile k eeping m oto r leads clean of oil an d gr ease, feed sp liced m o tor
le ads in to pa ssa gew a y on t he ri gh t si de of t he g earc ase (1 ) and care fu lly
sl ip m oto r w or m shaf t ( 24 ) p art w ay int o gear case(1 ). T h e f ibr egla ss
sle ev ing sho u ld k eep t he m oto r le ad s str ai gh t an d aw ay fr om t he m o to r
shaf t.
• U n less re sistan ce is en co un te re d be tw een th e w o r m sh af t ( 2 4) a nd
w or m w h eel (2 1) , c ontin ue feed ing the m ot or leads in to pas s agew ay and
car efu lly pus h m o tor flu sh w ith gea rcase ( 1).
• If t eeth of g ear s d o n ot m esh to ge th er easi ly, rem ov e m o to r an d tu rn
w or m sh aft ( 24 ) slig ht ly r epe at the ab o ve step s as ne cessar y.
f. L u b ri cate an d in stal l f o ur c aps c rew s ( 71 ) an d spr in g w ash er s ( 67 ) to r et ain
25-17
g . T o rq u e b o lt in g t o 8 0 - 9 0 f t. lb s .
2 . P re - 1 97 8 A ct u at or
N O T E : A l l N A 1 m o to r s a re s u pp lie d in a m o du la r fo r m . Sta to r s a r e
a lrea dy fitted into the m oto r cover an d the ro tor on to th e w o rm s haft pr ior
to leaving th e factory.
a. I nspec t m ach in ed su rf aces o f m oto r and m o tor w or m shaf t ( 24 ) fo r d am ag e.

b . Ins p ect for d am ag e an d gr eas e O - rin g ( 91 ), en s ure co rre ct p os itio n on m o tor
cov er hous ing.
c. V erify to rqu e s w itch plu nger ( 114 ) i s ins talled in gearc ase (1) .
d . E n s u re m o to r lea ds ar e c on ne cted to ap pr o pr iate te rm ina ls o n b ack s id e o f
te rm in a l b lo c k (1 5 2 ).
N O T E : A corr ectly pos itioned m o tor w ill have a s tator locking scr ew on the
s ide next to the syncr oset ho using (150) .
e. A lign m otor as fo llow s :

• W hile keepin g m otor lead s clean o f oil an d g rease, feed spliced m o tor
l ead s in to p as s ag ew ay o n th e r ig ht s id e of th e ge arc as e a nd c are fu lly s li p
m oto r w o rm s h aft (2 4) pa rt w a y i nto ge arcas e( 1) .
• U n less re si stan ce is en co un ter ed bet w een t he w o rm sha ft ( 24 ) an d
w or m h eel (2 1) , con tin ue fe edin g th e m o to r lead s in to pa ss ag ew ay an d
car efull y p ush m ot or flu sh w ith ge arcase ( 1) .
• I f te eth o f g ear s do n o t m es h to g eth er e as ily , r em o v e m ot or a nd t ur n
w o r m sh aft ( 24 ) sli gh tly a nd r ep eat th e ab ov e step s a s n ecessa ry .
N O T E : P re- 19 78 actu ato rs utiliz e a s m aller m o tor m o unti ng bo lt

th an the P o st-19 78 g ea rcas es. IF r ep lacing a new P os t-197 8 m otor
on a P r e-1978 gear ca se, ens ur e prop er bu shing s an d w as her s ar e
in stalled.
f. In s t all bu s h i ng an d fl at w as h er p er ap p ro p r ia te d r aw i n g w h en in s t al lin g a
Po st-1 97 8 m oto r on a P r e-1 97 8 gear case.
g . L u b ri cat e an d in sta ll th r ee ca p s cr ew s (7 1 ) an d spr in g w a she rs ( 2 0) to r et ain
m otor to gearcase ( 1).
h. T o rqu e 1 /2 U N C x 1 3/4" bo lting to 80 - 90 f t. lb s . T o rq ue 5/16 - 18 U N C x 1
3/4 " b oltin g to 20 - 2 2 f t. lbs .
1. C le an o il s e al b or e, m ak in g s u r e i t is fr ee f r om r u s t.
25-18
N O T E : If oil s eal b or e is b adly co rr oded and can not b e cleaned sufficiently

to p reven t seal dam a ge w hen new seals a re fitted, do no t a ttem p t to fit n ew
s ea l s . T H E O N L Y S O L U T I O N I S T O R E P L A C E T H E C O M P L E T E
SID E H AN D W H EEL M O D U LE.
2 . S m e ar o il s eal s ( 50 ) w it h g rea s e and pr es s in to p lac e u s in g s id e h and w h eel s ea l

to o l.
3 . G r eas e ha nd w hee l as s em bly sp ig ot an d fit O - rin g (4 4) .
4 . G rease b or e and t op f ace o f gea rca se ( 1) a nd seal lo cat ion d iam eter o n ce nte r
c o lu m n (8 ) .
5 . C are fu lly alig n cl ear an ce h ole s in ha nd w he el as s em bl y w ith t ap pe d ho le s in
g ear case ; g en tl y ease h an dw h ee l a ssem b ly i nt o p lace t aki ng car e no t to d am ag e
oil seal lips .
N O T E : O r ien tatio n o f h and w h eel a s sem b ly ca n va r y; b ut, m ake s ur e th e

han dw h eel can b e tur ned w ith out fou ling any other p ar t o f the gear cas e
ass em bly.
6. I ns ert eig ht s crew s ( 70 ) a nd tig hten to 2 0 - 22 ft.lb.

7. F it s cr ew ed bu ng ( 17 0) if r equ ire d. If co ve r t ub e as s em b ly (7 15 ) is f itted , s ea l
thr ead w ith H Y L O M A R or s uit able ap pr ov ed equ iva lent .
25 .3.7 P os t-m a inten an ce Tes ting - G earca se Pres su re C he ck
1. U s i ng ap pr o pr ia te f itt in gs , in s tal l pr es s u r e ga ug e an d c on n ect a ir s u p pl y to

ge arcas e h ou sin g (1) af ter re-as s em b ly o f all m o du les is co m plete.
2. S low ly a pp ly pr es su re to g earca se u ntil ga ug e r eads betw ee n 28 - 3 0 p s ig.
3. I s ol ate pr essur e sou rc e a nd r eco rd air p ressu re .
4. A f ter 1 5 m in ute s re cor d f inal ai r pr es s ur e a nd r eco rd p res s u re d ro p if an y.
5. I f pr es s u re dr o pp ed m o re th an 2 p s ig , de term in e s o ur ce of l eak an d r epa ir p er
th e ap pr o pr ia te sub s ect io ns .
6. If g earcas e did n ot dr op pr es s ure ov er 2 ps ig , c on tinu e to n ext s tep.
7. R elieve pres s ur e fr om gearcas e.
8. F ill gear case w ith oil thro ugh oil fill p lug hole up to o ne in ch o f h ole b ase
thread s.
9. Incr ease air p ressure to gear case slow ly to 18 - 20 p sig .
10 . Is ol ate p re ss u re s ou rce an d rec or d pr es su re .
11 . A f ter f ifte en m in ute s rec or d fin al air pr es s ur e a nd r ecor d pr es s ur e d ro p if an y.
12 . If g ear case pr essu r e d ro pp ed m o re th an 2 p s ig, d eter m in e so u rce of l eak an d
re p ai r p e r t h e ap p r o p r iat e s u b s e ct io n s .
13. I f gear cas e d id no t d rop p res s ur e o ver 2 p sig , con tinu e to n ext s tep.
14 . R em o ve f ittin gs , pr es s ur e s u pp ly and r eliev e g ear cas e p re ss u re.
25-19
25.3.8. Post-maintenance Testing - Requirements Matrix
C o m p on en t T o rque F u n c tio n a l T im e D ia g n o s t i c
R ep a ir e d T es t V e r ific a tio n R e sp o n se T e stin g
B ench
W or m g ear X X X X
G ear case M odu le X X X X
D r iv e B u s h ing X X X
H an dw hee l M od ule X
Sy ncros et M odu le X
A dd-on-p ak M odu le X X
*R efer to Section 26 for testing guidelines.
1 . E nsu r e ac tu ato r f ee d er b r eak er is o pe n.

2. If re quir ed rem o ve old dr ive bus h ing fr om old actuato r (7, 2 2) per S ectio n
25 .2 .6 .3 an d re ins tal l o n rep lac em en t ac tua tor p er S ectio n 2 5.3.1.4.
3. E n s ur e v alv e st em is p ro per ly s ecu re d to av oid p er s on nel in jur y o r equ ip m en t
dam ag e.
4. L u b rica te v alv e stem as n ecessar y.
5 . I ns ta ll rig g ing as n ec es s ary to s u pp or t th e w e ig ht o f th e a ctu ato r.
6 . I nstall actuat or as f ollo w s :
a. F o r pr essur e seal ty pe v alv es, lo os en y o ke cla m p b ol ts, ro tat e y ok e an d
actu ator as n ecessary to pr ov ide access to yo ke bol ts.
b . F or key ed s ha ft s te m ap pl icat io ns , po s iti on actu at or s o ke yw a ys li ne u p an d
p u s h ac tu at or s tr ai gh t o n to g e ar bo x s ha ft .
c. F o r t hr ea d ed s h af t v alv e s te m ap pl ica tio n s , p os i tio n act ua to r s o d r iv e
b us h in g an d v alv e st em m at e. O p era te ha nd w h eel ho o p (8 8 ) to w ard op en
d ire ctio n un til ac tuat or is fl us h ag ain s t v alv e yo ke .
d . F o r glo b e v alv e app lica tio ns afte r per fo r m in g S tep c) , en su re k eys ar e
in s tal led i nto yo k e a nd s t em an d k ey r etai ner s are r ep lace d p er v alv e
d raw ing s .
e. A l ig n actu ato r to m atch m ar k s as app lic ab le.
7. S ecur e actuat or to y ok e or g earbo x us ing app ro priate bo lting har dw are.
8 . E ns u r e p r op er to rq u in g re qu ir em en ts are m et p er v alv e d ra w in gs .
9. R em ove tem porary rigging.
10 . R em o ve sy n cro se t co v er (1 51 ).
11. C onnect f ield cablin g to ter m inal block (15 2) as required.
1 2. In sta ll sy n c ro se t h o us in g co v e r (1 5 1 ).
1 3. R e m o v e v alv e g a g d ev ic e fro m s tem as a p p lica b le.
14. Perform sw itch setup per Section 20.0.
25-20
T h is p ag e i nten tio na lly lef t bla nk .
F ig u r e 2 5 - la
7 0 /9 0 G e a rc a se A ss em b ly
( S ee F igu r e 2 5- 1 b fo r P a rts D es cr ip tion )
25-22
F ig u r e 2 5 -lb
7 0 /9 0 G ea r c as e A ss em b ly
25-23
F igu r e 2 5 -2
7 0 /9 0 D ri ve B u s h A s se m b ly
25-24
F ig u r e 25 -3
7 0 /90 M oto r A s sem b ly
25-25
F ig u re 2 5 -4 a
7 0 /9 0 H a n d w h e el A ss e m b ly
(S e e Fig ur e 2 5-4 b fo r P ar ts De scr ip tio n)
25-26
F ig u re 2 5 -4 b
7 0 /9 0 H a n d w h e el A ss em b ly
25-27
F ig u re 2 5 -5
S p r in g P a k S h e et 7 0 N A 1
25-28
F ig u r e 2 5 -6
S p r in g P a k S h e e t 9 0 N A 1
25-29
F ig u r e 2 5 - 7 a
S y n cr o se t A ss em b ly
(S e e F ig u r e 2 5 - 7 b f o r P a r ts D e s cr ip t io n )
25-30
PA R T ID P A R T D E S C R IP T I O N NO T ES
1 50 . B ody
1 5 1. C ove r
1 5 2. T er min a l B Io ck
1 53 . Co n tro l T e rm in al P a rt o f 18 3
15 4. P ow e r T er min a l P art of 18 3
15 5. P ow e r Te rm in a l S cr ee n
1 56 . S ha ke p ro of W as he r
1 5 7. T e rm in a l N u t
1 5 8. T e rm in a l N u t
1 59 . B ra ss W a sh er
16 0. S pr ing W a she r
16 1. Nut
1 62 . S p rin g W a she r
1 63 . B ra ss W a sh e r
1 64 . " O " Rin g
1 6 5. Ea rth la bel
1 66 . B ra ss S cre w
1 67 . Cap scre w
168 . Ca p scre w 7 0/90 Only
16 9. A d a pto r 7 0/90 O nly
17 0. "O " Rin g
1 71 . S prin g W a sh e r
1 72 . S w itc h M e ch a n ism l o o m
1 73 . In ser t
17 4. R etain ing Rin g
1 75 . S h a ke pr oo f W a sh e r
17 6. Ta pite S cre w
177 . Te rm in a l L ink
17 8. L ab el
1 7 9. 1 1 /2 " Co nd u it P lug
1 8 0. 1 1 /4 " Co nd u it P lug
1 8 1. S cr e w- H a m m e r D r ive
1 82 . Co d e C ard
18 3. Te rm in a l B lo ck S u ba ss em b ly
1 84 . M o to r L o o m
18 5. Th erm o stat loom P o st -1 9 7 8 O n ly
1 86 . N ylon W a she r
1 87 . L oom -H eater * P re - 1 97 8 is O bs ole te
1 88. S crew
18 9. S p rin g W a sh er P o st - 1 9 7 8 O n ly 7 0/9 0 On ly
1 90 . L ock nu t S te e l
F igu r e 2 5- 7b
25-31
F ig u r e 2 5 - 8
A d d - o n - p a k A s s e m b li e s
25-32
F ig u re 2 5- 9
T y p e " A " a n d T y p e " N A " O l d V e r si o n A d d -o n -p a k
P re -1 9 7 8
25-23
F ig u r e 2 5 -1 0
T yp e "N A " N ew V ersion A dd -on-p ak
P o s t- 1 9 7 8
25-34
F ig u r e 2 5 -1 1
A d d - o n - p a k M o d u l a r R e p l a c e m e n t o f S w i tc h B a n k s
P o st -1 9 7 8
25-35
F ig u r e 2 5 -1 2
A d d - o n - p a k M o d u l a r R e p la c e m e n t o f S w i t c h B a n k s
25-36
F ig u re 2 5 -1 3
A d d -o n - p a k T y p i c a l A O P I G e a r A r r a n g e m e n t
25-37
F ig u r e 2 5 -1 4
N A 1 a n d N A 2 S w it ch M e c h a n ism A sse m b ly
25-38
F ig u r e 2 5- 1 5
N A 1 S w itch M e c h a n ism A ss em b ly
25-39
F ig u r e 2 5 -1 6
S w it c h M e c h a n is m M o d u le ( N A 1 )
( F r o n t V i e w C r o s s S e c t io n )
25-40
F ig u r e 2 5- 1 7
R e p la c em en t S w itc h M ec h a n ism S w itc h P ak s
25-41
P A R T ID P AR T D E SC R IPT IO N NO TE
250. L imit Sw itch C over Th is cov er is u tilize d for
actu a to rs w itho u t a d d -o n
pa ks on ly.
253. A da ptor
254. " O ''-R in gs
255 C a p s cr e w
256. S p r in g W a sh e r
257 . C a p sc r e w
258 . S pring Washer
F ig u re 2 5 -1 8
F a b r ic a t e d C o v e r A s s e m b l y f o r S w i t c h M e c h a n i s m
25-42
PART ID PART DESCRIPTION N OT ES

251. Lim it S witch Co ver U se w ith 6 -s witch ad d -o n
p ak 1 on ly.
253. A dap to r
254 . "O "-R ing s
255 . C a p s cr e w
256 . Sp ring W asher
257 . C a p sc r e w
258 . Sp rin g Po sh er
F ig u r e 25 -1 9
25-43
PAR T ID P AR T D E SC R IP T I0 N N OT ES
252. L imit Sw itch Co ver Use w ith 2-S witch add-on
p ak 1 on ly.
2 53. A d aptor
254. " O " -R in g s
255 . C a p s cr e w
256. S prin g Wa she r
25 7. C a p s cr e w
258. S prin g Wa she r
F ig u r e 25 - 20
F ab r ica ted C o v er A ss em b ly fo r 12 S w itc h A d d -o n-p a k 1
25-44
.
26.0 PRE-OPERATIONAL/POST-MAINTENANCE TESTING
P o s t- m a in ten an ce an d p re -o p er atio n t es ti ng c on d uc ted on a R o to rk actu at or s ho ul d b e

b as e d on th e t yp e of re pai r/ rep la cem en t p er fo r m ed . T a bl e 26 .0 - 1 p ro vi de s te s tin g
.
r eco m m en dat ion s fo r the m aj or R oto rk m o du les .
T a b le 2 6 .0 - 1
P o st-m a in te n a n c e /P r e -o p e r a tio n T e s tin g
C om po nent T o rq u e F u n c t io n a l T im e D ia g n o s tic
R e p a ir ed T e st V e r ific a tio n R e sp o n s e T e s tin g
B ench
S w i tch X X X X
M ech ani s m
W o rm G e ar X X X X
G ear case M od ule X X X X
D r iv e B u s h in g X X X
H an d w h ee l X
M odule
S yncr os et M o dule x
A dd- on-pak X X
M o d u le
In the fo llo w ing sec tion s , basic g uid elin es a re pr ov id ed to m eet th e t estin g/r ecer tif icatio n
r eq u i r em en t s .
26.1 Rotork Torque Test Bench Certification Guidelines
R ef er to Section 10 .0 f or discu ss ion of cer tification proced ures .
26-1
26.2 Functional Verification
26.2.1 Functional Verification of Open Torque Bypass Switch
N O TE : Th is section verifies cor r ect w ir ing and s etu p o f tor que bypa ss fun ctio n
b y m an ually a ctuatin g o pen tor que sw itch co ntacts a nd electr ically open ing
v alve. If w ir ing an d setu p a r e cor r ect, valve sh ou ld o pen an d sto p at p os ition
to rqu e bypa ss sw itch w as s et to actua te.
1 . E n sur e va lv e w a s e lect ri call y o per at ed to fu ll sea ted p o s itio n .

2 . R o ta te t o rq u e s w it ch fr o n tp l at e u n til o pe n to r qu e s w it ch co n t act s ac tu a te . H o l d
f ro nt p late in t his p os iti on a s v alv e is el ectr ica lly o pe ned .
3 . H av e a pp r o pr i ate pe r s on n el at R em o te P u s h b u tto n el ect r ica ll y o p er at e v al ve i n
open directio n.
4 . V er ify valv e op en s an d s top s b etw e en ap pr ox im at ely 2 5% a nd 7 5% o f to tal va lve
tr av el ( o r at the p osit ion desig n ated i n M O V setu p cal cul atio ns ) .
26.2.2 Operational Verification of Rotork Actuators
N O T E : T em p or ar y cir cuit alter atio ns as id entified in this p ro cedu re m a y be

per for m ed on ly on valve actua tor s w hich a re cons ider ed ino pera ble (o ut of
s er vice for r epair, m aintenan ce, testing, etc.).
N O T E : P e rm is sive s ar e de fined as co nditio ns w hich m us t b e s atis fied to

perm it O peration of electr ically operate valves .
N O TE : Inter locks ar e defined as conta cts lo cated in oper ator u nder tes t w hich
affect oth er equ ipm en t. T h ey a re fou nd in s w itch co ntac t dev elop m en t o n
a pp r o pr ia te ele c tric a l e lem e nta r y.
N O TE : A uto m a tic actu ati on is d efin ed as a co nd itio n w h ich w h en sa tis fied

w ill ca use valve to electrically o per ate ind ep end ent of O perator action.
1. B E F O R E p er f or m i ng a ny tem po r ar y ci rcu it a lte ra tio ns ( pe r S te p 26 .2.2 ,2 ) ,

p erf o rm fo llo w in g actio ns to en s ur e a ll req ui red co n diti on s ar e sa tis fi ed:
a . I n s p e ct p h y s i ca l c on d i ti o n o f v al v e an d a ct ua to r . E n s u r e ac tu at o r
co m po nen ts ap pear to b e in pr op er w ork ing o rd er.
26-2
b . R ev i ew ap p r op r ia te D e s ig n do cu m en ts . E n s u r e in te n de d f u n cti o n o f a ll
e lec tr ica l i nt er lo ck s , p er m is s iv es , an d co n tr ol s a re f ul ly u n de rs t oo d .
c. IF p er m i s s iv es ar e re q ui re d to be b y p as s ed , r ev ie w co nt ro l ci rc u it w it h
a p p ro p ria te O p era tio n s p e rso n n el. E n s u re th e y a re a w are o f in te n d e d
co n di tio n to b e s im ul at ed a nd an y l im i ted co nt r ol a lte ra tio n w ill c au s e.
d . I F a n a ut o m a ti c ac tu at io n f un c ti on is r e qu i re d t o be by p as s ed , ob t ai n
ap pr ov al fr om ap p ro pr iate O p era tion s p er s on ne l.
e. I F O p en /C lo se T or qu e or L im i t c on tr ol s w itc h is r eq u ire d to b e by pa s se d,
o b tai n ap p ro v a l f ro m re s p o ns ib le pe r s o nn e l. B yp a s s f un c ti on i s r e q ui r ed to
b e p e r f o r m e d o nl y at v al v e a c tu a to r .
f . I F S tep d ) o r S t ep e) w a s pe rf o r m ed , es ta b lis h ap p ro p r iat e co n tr o ls to m o n ito r
m o to r cu r re nt d u ri ng va lv e s tr ok e A N D to im m ed ia tel y r em o v e po w e r f ro m
m oto r o r oth erw is e stop act uato r if n eed occu rs .
g . C o n s u l t O p er a ti o ns a s n ec es s ar y an d ve r if y th at an y v al ve ac tu a to r or o th e r
c om po n en t a ff ect ed b y p ro po s ed alte ra tio n is co ns id er ed i no p er abl e.
2 . P er fo r m tem p o ra ry cir cu it alt era tio n s as n ece s sa ry to f ul ly cl os e /o pe n va lv e.
C A U TIO N : R epeated cycling of actuator can caus e excessive heat and

r esu lt in m o tor da m a ge. A llow to co ol w hen it becom es h ot.
3 . H av e ap pr op r iate p er s on n el ele ctr ica lly o p er ate v alv e to o pe n an d cl os e p os i tio n

as necessary A N D verify follow in g:
a . V e r if y ac tu at o r o pe n s a n d/ or cl os e s on to r qu e a s s pe ci fi ed b y ap p ro p r iat e
m an uf act ur er 's d oc um e nt s.
b. V er if y act u ato r op en s an d /o r clo s e s o n lim it a s s pe ci fi ed by ap p r op r ia te
m a n u f ac tu r e r 's d o c um e n ts .
N O T E : O pen ing to rq ue cur r ent is cur r en t r equir ed to lift valve o ff its

clo s ed sea t. T his o pe n c ur r ent re ad ing s ho uld b e ta ken im m edia tely
a fter ini tial sta r ting cu rr en t. C lo se cur r ent r ead ing s ho uld be take n a s
valve to rques into its s ea t.
N O T E : I f p rev iou s m ain tena nce activi ty in volved M O V tes tin g w h ich
in clud ed m o tor cur r ent da ta tra ces , Step c) m ay be N /A 'd.
26-3
c. R e co rd op en in g an d cl os i ng cu r re nt .
N O T E : E lectr ical s ho rt circu its ar e a poten tial p ro blem w ithin R otor k

ter m inal bun g d ue to con tact b etw een term ina l lug (s ) o f on e ter m in al
a nd b ar r el nu t o f a n ad ja cent ter m in al. P o ten tia l is hig hes t w h er e
m o re th an o ne ter m in al lug m u st b e la nd ed on s a m e te rm in al w hich i s
o ften r equ ir ed fo r M / O a nd M / C to r qu e s w i tch ter m ina ls . If M / O a nd
M / C tor qu e s w itch term ina ls ar e s ho rted tog ether , th is pr ob lem w ou ld
n ot be d etected dur ing n or m a l oper ation from O pen and C los e
pu s hbu tton s b ut w ou ld cau s e salve to cycle re pea tedly if a m ain tai ned
con tact sig na l (s uc h a s a sa fety s ign al) w er e app lied. Sh or ted con ditio n
can be detected by having O per ator d epr ess appr opriate O pen o r C los e
pus hb utton a s econd tim e a fter valve r eaches full o pen o r fu ll clos e
pos ition.
N O T E : S tep d ) m a y als o be u sed for o per ation al verifica tion of

antih am m er con tact, if a pplicab le.
d . A ft er valv e reach es f ull C los ed p ositio n, h ave O pe rato r dep res s C L O S E

pu s h bu tto n an d h ol d fo r at le as t on e (1 ) s eco n d. V e rif y v alv e re m ain s i n
clos ed po si tion and d oes n ot h am m er .
e. A fte r va lve r each es fu ll op en p osi tio n, h av e O p er ato r de pr ess O P E N
pu s hb u tto n an d ho ld f or a t l eas t on e (1 ) s eco nd . V er if y va lve r em ai ns in o pen
position.
f . V erif y p ro per ind icatio n or op eratio n of all R em o te I ndic ating L ig hts , M oni tor
L ig h ts , A n nu n cia tor s and ex ter na l lim i t s w itch es as re qu ir ed f ro m
ap pr op r iate el ectr ica l e lem ent ary .
g. V erify pro per in dication o f co m puter in dications .
h. V erif y p rop er in dication of B y pas s Pan el ligh ts.
i. I F I nte rlo ck m o nito r po in ts ar e p re se nt, v erif y pr op er o per atio n of I nte rlo ck
co nta ct(s) b y u s ing m on ito r po in ts li sted o n app r op ria te elect rica l
ele m e nt ar ies .
N O T E : A ntiha m m er co ntact, if a pplica ble, is oper atio na lly ver ified b y

pr o vidi ng a m ain tai ned p ath to A n tih am m er co nta ct, w h ile electr ica lly
op er atin g valve clos ed . M ain tai ned pa th can u su ally be pr ovi ded by
ho ld ing M / C p us hb utt on do w n . In s om e ca ses a jum p er is r efer en ced a nd
m ust be p laced . R efer ence the appr opr iate electrical elem en ta ries.
26-4
N O T E : M /C s tar ter at ap pr o pr ia te br ea ker m u s t b e m o nit or ed d ur in g

A ntih am m er co nta ct ve rif icatio n an d a pp r op ria te actio n sh ou ld be taken in
event of m otor stall or m o to r starter ch atter.
j. I F A n tih am m er co nta ct is b ein g us ed , v erif y p ro pe r op era tio n of A n tih am m er

co nta ct b y u s ing C ont rol R o om M /C pu sh bu tton o r by plac em ent of ju m per
l is te d o n d at a s he et.
26.3 Time Response

V alv es ar e te s ted af ter in s tal lat io n an d p r io r to s er v ice a s w e ll as af te r m a jo r m a in ten a nc e.
W he n a va lv e o r it s co n tro l s y st em h as b een rep la ced o r r ep air ed o r h as u n der g on e m aj or

m ai nt en an ce th at c o ul d af f ect i ts pe rf o rm an ce , an d p r io r to th e tim e it i s r et ur n ed t o
s e rv ice , it is tes te d to d em o n s tra te it w ill s til l op er ate acc ep tab ly . M ajo r m a int en anc e
i nc lu des ad ju s tm e nt o f s tem p ack in g, lim i t s w itch or t or qu e s w itc h ad ju st m en t, r em ov al o f
t he bo n net , st em assem b ly, o r actu ato r, and d isco nn ecti on o f hy dr au lic or e lectr ical lin es
a re ex am ple s o f m a int en anc e tha t cou ld a ff ect v alv e pe rf or m a nce p ar am e ter s .
A s a gen er al ru le, ti m e res p o ns e tes ts are p erf o rm e d to en s ur e the f oll ow in g :

• V erif y th e a bility o f t he v alv e to m o ve fro m a no n sa fety po s ition to its saf ety
p os ition
• M o ni tor va lve s t ro ke t im e as a m ea ns to p r ed ict p ote nt ial f ailu r es i n ad v anc e of
ac tu al fa ilu r es
• P r ov ide per iod ic v eri ficatio n that co ntr ol roo m ind icatio ns r eflec t actu al v alv e
po s itions as verif ied by field o bs ervat ion
F u ll s t ro k e ti m e i s t ha t ti m e in t er va l f ro m in i tia tio n of th e ac tu ati n g s ig n al t o th e e nd o f

th e actu at ing cyc le. T he v alv e d isk m ov em e nt is ve ri fie d by eith er o bse rv in g a par am eter
w hic h s ig nals chan ge of d isk p os itio n, o r o bs er vin g ind irect evi den ce, su ch as ch ang es in
s y s tem p re s s ur e, f lo w r at e, le vel , o r tem pe rat ur e.
A f un ctio nal ve rif icatio n st ro ke tes t s h ou ld be per fo rm ed f or th e f ol low in g m ain tenan ce

activ ities:
• R em o val /re pla cem e nt of t he va lve ac tua tor
• A d ju st m ent o f t he valv es p os iti on in dic ating l im it sw it ches
• R ep air a nd /o r ad ju s tm en t o f th e val ve p ack in g
• R e pai r, rep la cem en t a nd /o r ad ju s tm en t o f a v alv e o pe rat or 's tor q ue s w i tch
• R e pa ir, re pl acem en t an d/ or adj ust m en t o f a va lv e's reg u lat or
• A d justm e nt of stan ch ion g ui des fo r M ain S team Iso lati on v alve s
• R epair o r rep lacem e nt of safe ty relate d so len oid s
26-5
26.4 Diagnostic Testing
D u e to t he p o ten tia l ef fec ts s ub co m p on en t m a int en an ce m a y h av e o n a ctu at or

t hr u s t o u tp u t, i t m ay b e n e ces s ar y t o r ev e ri fy / re es t ab li s h t he va lv e's t hr u s t
r eq u i r em en ts .
T his c an be a ccom p lis hed u tilizin g o ne of s ever al a vailab le v alve dia gno s tic s y ste m s.
N ot o nly do t hes e s y s tem s pr o vid e th ru s t v er if icat ion c ap abi liti es , bu t th ey als o are
abl e t o id ent ify add iti on al pr o ble m s w i thi n th e v alv e or a ctu ato r.
26-6
27.0 SPARE PARTS HANDLING AND STORAGE REQUIREMENTS

27.1 Spare Parts Handling
O n e o f the m o s t c riti cal fac tor s in d eter m in in g the re liab ility o f R oto rk a ctua tor s is
th e q u ali ty o f bo th pr e ve nt iv e an d c or r ect iv e m a in te na nc e. I n o r d er f o r p la nt
m ain ten an ce p er s on n el to pe rf o rm q ua lit y p re ve nti ve a nd co rr ect iv e m ai nt en an ce, i t
i s im p er a ti v e t h at th e y h av e q u a li t y m at e ri a l s u p p o r t. Q u a li t y m a te r ia l s u p p o r t
co n s is ts o f an a de qu ate q u an tit y of du p lic ate, un d am a ge d an d ac ces s i ble m ate ri al
an d sp aces ne cessar y to p er fo r m r o uti ne an d em erg en cy m ain ten an ce fu n ctio ns .
R o to rk va lv e act u ato r s a nd th eir asso cia ted r ep air pa rt s a re p r eci sio n eq u ip m e nt .

H a nd lin g a nd s to ra ge in acc or d an ce w ith m an u fa ctu r er's g ui de lin es an d ap p ro v ed
p lan t p ro ced u re s w i ll en s ur e p ro pe r o pe rat io n at in s ta lla tio n.
27.2 Receipt of Material
T he u tility P r oc ur em en t D ep ar tm en t s h ou ld d evel op a s pec ific r eceiv ing d o cum e nt

fr om t he v en do r s h ip pi ng d o cu m en t. U t ilit y pe rs o n nel s h o uld pe rf or m th e fo llo w in g
par ts re ceip t che cks :
• C h eck f or d am a ge to th e sh ip pin g car ton

• C o m p are v en do r s hi pp ing do cum en ts w it h the u tili ty p ur cha s e o rd er f or
var iances an d verif y inclu sio n of all r equ ired C er tificates of C o m plian ce
• I nv en to ry s hip m e nt f or ov er ag es a nd s ho rt ag es
• In itiat e d oc um enta tio n ide ntif y ing s h ipm en t d is cr epan cie s fo r r es olu tio n.
• T he po rt ion o f the s hip m en t id ent ified to c on tain di scr ep ancie s s ho uld b e
contr olled un til res olu tion is effectiv e
• U p d a te s p a r e p a r ts in v e n to ry
27.3 Storage Requirements

R o to r k ac tua to rs ar e to tal ly sea led fr om t he e nv ir o nm en t w h en shi pp ed fr om t he
m an u fa ctu r er . A ll i nt er na l co m p on en ts , ele ctr ic al an d m ech an ic al ar e p ro te cted .
S t or ag e in s id e a dr y w a re ho u s e, i n a ca rt on i s s u g ge s ted fo r l on g t er m s to ra ge . W i th
lo n g- ter m st or ag e, th ere ar e no p er io dic m a int ena nce p ro ced u res.
27.3.1 O-rings and Oil Seals

O - rin g s an d oi l s ea ls s h ou ld b e s to r ed in a cle an, d ry atm o s ph er e f re e f ro m du s t a nd
g r it . T em p er at u r es s h o u ld b e m a in t ai ne d b e tw e en 5 0 °F an d 6 8 °F . C o ld er
at m o s p h er es t en d t o h a rd e n t he s y nt h et ic r u b be r , w h il e e lev a te d t em p e r atu r es m ay
cau se d egr ad at io n of th e m ate ri al pr o pe rt ies. S e als also sho u ld n ot b e ex po sed to
lig htin g, p lace d near r ot atin g equ ipm ent , or ex po s ed to s ou rce s of o zo ne or r adi atio n
du r in g s to rag e.
27-1
S e als and O -r in gs m u s t n ev er b e thr ead ed o n s tr in g o r w ire , or pil ed in h ea ps .

I m pr o pe r s to r ag e w ill c au s e da m a ge t o th e s ea lin g e dg e s . N ea tly s tac ki ng th e s eal s ,
w h ile av oid ing any k ind of da m age to t he lip s of s eals is r ecom m end ed.
27.3.2 Used Parts Control
D am a g ed p ar ts s h o ul d b e d is p o s ed o f in a m an n er t ha t p re ve n ts re -e nt r y in to th e
s pa r e p ar ts s ys t em . S al va g ed p ar ts m u s t b e co n t ro l le d i n a m an n e r s i m i la r t o n e w
p a rt s . A p ro g ra m m u s t b e es t ab lis he d p ro v id in g tr ace ab ili ty to t he o r ig in al
p u rc ha s e or d er w h en us e d in a nu cl ear e nv ir o nm en t.
27-2
APPENDIX A
References
1. R oto rk C ont rol s In c., R oto rk M ainte nan ce M an ual. V ol um es 1 t hro ug h 3, R evis io n 0 ,
0 9 /0 1 /8 9
2. D u ke P o w er C om p an y, C at aw ba N u clea r S tatio n , M em o ra nd um to F ile, I W V R et es t

P h ilo so ph y , Fe br uar y 13 , 1 99 1
3. D uk e P ow er C om pan y, R o tork M O V S w itch S etup P hilos op hy , 1 0/22 /94
4. D u ke P ow er C om pan y, D esig n E n gin eer ing D ep art m en t, E lect rica l D iscip lin e
D esign M anu al, M o tor O per ated V alv e ( M O V ) C o ntro l an d P o sitio n Ind icatio n,
R ev is ion 0 , 06/06 /9 1
5. D u k e P ow e r C om pa ny , C ata w b a N u cl ear S tat io n, R o to rk A ctu at or P re ve nt ativ e

M ain tenan ce, R ev is ion 3, 0 4/2 1/9 4
6. D u ke P o w er C om p an y, C at aw ba N u clea r S tati on , R o o t C au s e F a ilu re A n aly si s o f

M O V s, R evision 0, 01/28/93
7. D u k e P ow e r C om p an y, C a taw b a N u cle ar S t ati on , R em o va l R e pl ace m en t an d F i eld

S et-U p o f R o tork A ctu ators , R evis io n 6 , 04 /19/9 4
8. D uk e P o w er C om pan y, C a taw ba N u clear S tatio n, F ield R eplace m ent of R oto rk N A B

an d N A 2 A ctu ator Sw itche s, R ev isio n 2 , 0 7/0 6/92
9. D u ke Po w er C o m pa ny , C ataw b a N u clear S tatio n, M O V T es tin g W ith V O T E S ,

R ev is ion 8, 04 /2 6/94
10. D u ke P o w er C o m p an y, C a taw b a N uc lear S tati on , R ot or k A ct ua to r T est in g an d

C ertification , R evis ion 5, 04/2 6/94
11. D u ke P ow er C o m pa ny , C a taw ba N u clear S ta tio n, T r ou b les ho ot ing a nd M ai nten an ce

of R o tork A ctu ato rs , R ev isio n 4, 04 /2 7/94
12. D u ke P ow er C om p any , M cG uir e N u clear S tati on , R o tor k A ctuat or T r ou blesh oo ting

an d R epa ir, R ev is ion 15 , 07/0 7/9 4
13. D u ke P o w er C om pa ny , M cG u ir e N u cl ear S ta tio n, I n s tall atio n. R em ov al an d S et up

of R o tork A ctuato rs, R ev is ion 15, 07 /0 5/94
14. D uk e P ow er C om p any, T rain ing C en ter, L ess on P lan I E -T C -B E - R L -0 1, C er tification

M echanical, 05/2 2/89
A-1
15. D u ke P ow er C om p an y, T r ain ing C en ter, L es so n P lan I E -T C - B E - R L -0 2, I niti al

C er tification O bjectives , 0 5/22 /89
Regulatory Documents
1. L icen see E vent R epo rt 4 14 /92- 004 (A dd -on -P ak A d jus tm ent)
2. N uc lear R eg ulato ry C om m is s io n G en eric L etter 8 9-1 0
3. O per ating E x per ience R ep ort II R -C 88 -0 81- 2 (L im it Sw itch S etu p)
4. O p eratin g E x per ience R epo rt V I L - 089 -1 3 (V en do r In for m atio n L etter , S tem

T ran siti on A rea )
5. O perating E xper ience R epo rt V IL -0 93-1 0 ( O il L evel/O il S eals )
6. O per ating E x per ience R ep ort V IL - 093 -0 5 ( T or qu e S w itch R epe atability )
7. O p erat ing E x pe rien ce Pr og ra m D o cum ent N o.: I IR -C 88 -0 81 -2
A-2
APPENDIX B
Rotork General Arrangement Drawings
C o n tai ne d in th is A pp en d ix a re g en er al a rr an g em e nt d r aw in g s f o r R ot or k S i ze 7 t hr o ug h
90 ac tu ato r s . E ach dr aw i n g p ro v id es a d eta ile d c ro s s - s ect io n o f a p ar t icu la r ac tu at or
m o du le . W h er e m o du le s a re co m m on to a ll act ua tor s ize s , on ly on e dr aw i ng is p r ov id ed . I n
th e pa s t, g en er al ar ra ng em en t dr aw i ng s hav e b een us e d fo r t he f o llo w in g p ur p os e s :
1. T r ain i ng M a nu a ls an d C ur r ic u lu m M a te r ial s
V i sua l aid s ar e ke y e lem en ts of a go o d tr ai n in g p ro g ra m . T h ese ai ds ar e u s ed t o

e xp la in m od es o f o pe ra tio n , an d t he o ri en tat io n an d a rr an g em e nt o f t he v ar io u s
a ctu at or s p ar ts. T he att ach ed ge n er al ar r an ge m e nt d r aw i ng s pr o v id e de tai led cr o ss-
s e ctio n al v iew s n eces s a ry to d ev elo p s u ch v is u al t ra ini ng aid s . E a ch p ar t o f a
p ar tic ul ar R ot or k a ctu ato r m od ul e is s h o w n o n th es e d ra w ing s .
2. P r oc edu re D ev elo pm ent
G oo d pro cedu res p rov ide clear, con cise gu idanc e, alo ng w ith visual aids w hich
i llu s tr at e an d cl ar if y th e t ex t. P r o vi de d in th is A p pe nd ix ar e th e cr os s -s e cti on al
v iew s n ecessar y f or p r ov id in g suc h vi sua l a ids . T he s e d r aw in gs sho w each par t of a
R o to rk a ctu at or m o du le an d p r ov id e th e ne ces s a ry d et ail to ex tr act p ro ce du r al
in f or m atio n f ro m t he en tir e d ra w i ng , or f ro m a p o rtio n o f the d raw in g .
3. T ech nica l P a per s , L ice ns ee E v en t R ep or ts , P r ob lem In v es tig atio n R epo rt s, R o ot

C au s e F ailu re A n aly s is R ep o rt s
I ll us t ra tio n s a re o f ten s tr at eg ica lly pl ace d in cer ta in p a pe rs an d r ep o rt s t o cl ar if y

t ech ni cal p oi nts , m o des o f op er at ion , an d /o r ex pl ain f ai lur e m e cha ni s m s . E a ch
g en er al ar ra ng em ent c ro s s -s e ctio n d r aw in g p ro v ide s t he in f or m at io n n eces s a ry t o
d ev elo p th es e i llu st rat ion s .
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
B-9
EPRI Licensed Maferial
B-10
B-11
B-12
B-13
B-14
B-15
B-16
B-17
B-18
B-19
B-20
B-21
B-22
B-23
Nuclear Maintenance Applications Genter
B-24
B-25
B-26
B-27
B-28
APPENDIX C
Glossary
a cti ve d u ty D e s ig n ate s t ha t an M O V i s r eq u ir ed t o o p er ate d u ri ng /f o llo w i ng a s af ety ev en t
a c tu a t o r t o r q u e c e r t ific a tio n A test p erf or m ed to ver ify ov erall accep tance crit eria for a
sp ecif ic size an d spee d actu ator
a v e r a g e lo a d m o to r c u r r e n t A pp ro xim ately 1 /3 to 1/2 th e f ull lo ad cur ren t d epe ndi ng o n

th e ty pe o f va lve an d p ack in g
b a r r e l n u t S p ec ial n ut u s ed o n R o tor k t erm in al b un g s cr ew ed ter m in al s f or att ach in g ri ng

t e rm i n a ls
c a p s c r e w s A lso call ed a lle n cap scr ew s or so ck et h ea d ca p scr ew s , st an dar d m eta l

f a s te n e rs
c a s e h a r d e n e d P r oce s s f or h ar de nin g th e s ur fa ce of a c om p o ne nt fo r im pr o ved w ear o r

an ti- g allin g p er fo rm a nc e
c e n t e r c o lu m n T h e ou t pu t d ri v e s ha ft w h i ch r o tat es th e d ri ve b u s h in g a nd pr o du c es
t or q u e
c e n te r c o lu m n d r i v e d o g s L oc ated o n t he w o rm w h eel, the s e st eel p ins o r cap sc rew s m a te

w it h the b ott om of the clu tch k ey s to o pe rat e th e cen ter co lu m n in m oto r m o de
c ir c li p S pr i ng lo a d ed re ta in er r in g
c lu t c h k e y s T h es e m et al k ey s co n tac t th e h an d w h eel d r iv e d o gs w h en u p an d th e
w or m w heel dr ive do gs w he n d ow n
c l u tc h r in g O n R o tor k M o de ls 1 4 an d la rg er , th is m etal r ing ho ld s th e clu tch key s a nd i s

li fte d by t he clu tch y ok e to en ga ge ha nd o p erat ion
c l u t c h s p r in g T h is larg e coi l sp rin g ap pli es th e do w nw ar d fo rc e to the clu tch r in g to ke ep

t he a ctu at or in m ot or o pe ra tio n m od e
c o e ff ic ie n t o f fr ic t io n T h e r atio o f: th e f rict ion al fo rce, p ar allel to th e su rf ace of stem an d

s tem n ut th rea ds ( o pp os in g th e s lid in g m o tion ) , to the f or ce no rm a l to the s ur fa ce o f co nta ct
d r i v e b u s h in g A lum in um -b r on ze n u t w hic h in te rf ace s w i th th e v alv e s tem t o d ri ve th e

v alve
d r i v e b u s h i n g r e t a in e r T h e m etal r in g w h ic h th r ead s ov er th e stem n u t on to th e cen ter

c ol um n t o r et ain th e s te m n ut in p la ce a nd ca rr ie s th e th r us t l o ad s d u r in g v al ve o p en in g
C-1
d u ty c y c l e R at io o f w o rk in g tim e t o to tal ti m e fo r i nte rm itte ntl y o per at ed d ev ices

(n or m ally 15 m in utes per ho ur f or R o tor k m oto rs )
fu ll lo a d c u r r e n t A p pr ox im at e m oto r cu rr en t ex p ected w h en th e actu ato r is p r od uci ng

n o rm a l ra te d to rq u e
h a m m e r b lo w e ff e c t L o s t m otio n g ear hy s ter ys is betw e en op eni ng an d clo s ing o pe rati on

w hich allo w s the m o tor to be at f ull s peed b efo re torq ue loa d is app lied
h a n d a u t o fin g e r O n R oto r k M od els 14 and lar ger , th is s pr in g loa de d cam m a int ain s th e
act ua to r in m an u al m o de o n ce en g ag ed u n til th e n ex t m o to r op er at io n
h a n d a u t o ja c k O n R oto rk M o dels 7, 1 1 and 1 3, a cam lo cated o n the en d of th e h and lau to

lev er w h ich k ee ps the ac tu ato r in m a nu al o per ati on m od e on ce en ga ged
h a n d w h e e l E x ter na l, r im p ul l w he el fo r m an ual ly o p era tin g a n M O V
h a n d w h e e l d r iv e d o g s L oc ated on th e h an d w he el, t he s e s teel p in s o r c ap s cr ew s m a te w ith

th e to p o f the cl utch key s to o p era te t he cen ter co lu m n in h an d m o de
h e lic a l g e a r A ls o cal led he lix g ear, l oca ted in th e sw it ch m ec han is m and p ro vi des a
con ve rs io n f ro m line ar m oti on to r otat ing m o tio n fo r the tor qu e s w itc h
lim it s w i tc h w o r m g e a r T hi s ge ar is p res s ed t o the cen ter co lu m n an d pr ov ide s a

m ec han ic al int erf ace t o dr iv e t he li m it s w itc h s haf t
lo c k e d r o to r c u r r e n t A p pr ox im ate m o tor c ur re nt ex pec ted w h en th e m o tor i s f irs t s tar ted

or w he n s tal led a t fu ll to r qu e
w ir in g l o o m A ls o cal led w ir in g h arn ess, p ref ab ri cate d ha rn ess
m a in t h r u s t b e a r in g B all b eari ng in th e bas e of th e a ctua tor w h ich pr ov id es a fr ictio nl es s

co n tac t p oi n t du r in g s i m u lt an eo u s th ru s t a nd to r qu e l oa di n g
m o t o r s h a f t I nt eg ra l w or m an d m o to r s h af t rig id l y at tac he d to th e m o to r r ot or
n a 1 , n a 2 , n a 4 , n a 5 R o to rk d es ig na tio ns fo r va rio u s n ucl ear q ua lif ied ac tu ato rs
o i l s e a l N it ril e or v it on m ate ria l dev ic e w h ic h pr ev en ts ge arc as e oi l fr om l eak in g at

lo ca tio n s w h er e m o v in g p ar ts p en etr at e th e oi l ba th ed c om p ar tm e nt
o v e r lo a d h e a t e r R esist an ce el em e nt i n ser ie s w ith th e m o to r le ad s w hi ch h ea ts up as th e

m o to r c ur r en t in cr ea s es
o v e r lo a d r e la y s E l ectr ic al co nt ro l de vic es th erm all y act ua ted b y a dja cen t o ver lo ad h ea ter s
s ized to p rote ct m o tors in th e ev ent o f m oto r o ver load con ditio n
C-2
p r im a r y s w itc h m e c h a n is m B as ic m ech an is m p ro vid ed o n all R o tor k actu ator s w ith 3

op enin g co ntro l s w itches an d 3 clo sin g co ntr ol s w itches ( contr ol can b e s et fo r torq ue o r
lim it op eratio n)
q u a li fie d c a b l e e n t r a n c e s e a lin g S p ecif ic s ite req u ire m en t f or p r ov idi ng h ar s h

en vir onm ent electr ical seali ng fo r electri cal en clos u res
r a d ia ti o n c la s s H T yp e o f m ot or w in din g ins u latio n sp ecif ied f or hi gh ra diat ion ar eas
R P M R e vo lut ion s p er m i nu te - us u ally r efe rs t o the o utp u t d ri ve s pee d
s y n c r o s e t h o u s in g R o to rk de s ign at io n f or th e fie ld c ab le te rm in atio n e nc lo s ur e
te r m in a l b u n g A ls o call ed ter m in al h o us in g, lo cate d ins id e the s yn cr os et ho u si ng an d ha s

scre w e d term inal s fo r attach m en t o f fi eld cab les
te r si l 1 8 T yp e o f elect rica l co nd uct or in sulati on spe cifi ed fo r hig h rad iatio n ar eas
t h r u s t b a s e T he b ase o f th e act ua to r (b et w een t he g ea rca se an d th e va lv e y o ke ) w h ich

ab s or b s th e th ru s tin g f or ce in r is in g, no n- ro ta tin g s tem v alv es .
t h r u s t c o m p e n s a t o r A s pe cial th r us t b as e pr ov id ed f or hig h s p eed R o to rk a ctu ato rs w ith

b ellev ille s pr ing w a sh er ar ran ge m en ts to al low a cu s hi on ed (le ss rig id ) s eatin g loa d.
t h r u s t p a d H o rs e sh o e sh ap ed m et al p lat e th at r et ain s th e w o rm w h ee l in pl ace i n t he

g ear case
t o r q u e s h a f t A l so ca ll ed t or q ue p lu n g er , p ro v id es th e n on - ro t ati ng co nt act po in t b etw e en

th e m o to r s h af t an d t he s w itc h m e ch an is m h eli cal g ea r
w o r m w h e e l A l s o cal led w o r m ge ar, th is a lu m in u m br on ze g ear m at es w i th th e m o to r

w o rm sh aft to p r ov id e t he m o to r to rq ue a nd g ear r ati os fo r m o to r op er ati on
y o k e O n R o to rk M od el s 1 4 a nd lar ge r, th is m eta l ri ng lif ts th e clu tch ri ng an d k ey s to

en g ag e h an d o pe r ati on
C-3
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About EPRI
EPRI creates science and technology solutions for
the global energy and energy services industry.
U.S. electric utilities established the Electric Power
Research Institute in 1973 as a nonprofit research
consortium for the benefit of utility members, their
customers, and society. Now known simply as EPRI,
the company provides a wide range of innovative Program: TR-104884
products and services to more than 1000 energy- Nuclear Power

related organizations in 40 countries. EPRI’s
multidisciplinary team of scientists and engineers
draws on a worldwide network of technical and
© 1995 Electric Power Research Institute (EPRI), Inc. All rights reserved. Electric Power Research
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EPRI. Electrify the World Printed on recycled paper in the United States of America
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Technical Repair Guide for Rotork Valve

Actuators NA Range Models

Please read the Export Control

Agreement on the back cover.

Technical Repair Guide for Rotork

BACKGROUND A number of valves in nuclear power plants are equipped with

EPRI 104884s Electric Power Research Institute December 1995

EPRI PERSPECTIVE This document provides a guideline for utility

Work Order 2814-94

EPRI Project Manager

ORGANIZATION(S) THAT PREPARED THIS REPORT:

Duke Engineering & Services, Inc.

The purpose of this set of manuals is to provide a maintenance document aimed at

Due to the variety of valve/actuator configurations available, care should be taken to

Technical Contributors include:

Tim Cline, Duke Power Company

Detailed review of the draft was completed by:

Paul Albares, Northern States Power (Monticello)

2.0 MECHANICAL OPERATIONS 2-1

3.0 ACTUATOR MOTOR 3-1

4.0 PRIMARY SWITCH MECHANISM, ADD-ON-PAK AND

5.0 THRUST COMPENSATOR AND TORQUE LIMITER FUNCTION 5-1

6.0 BASIC ELECTRICAL CONTROL DESCRIPTION 6-1

7.0 GENERAL NAMEPLATE DATA 7-1

Rotork Maintenance Manual

7.1.2 Revolutions per Minute (RPM) .....................................................7-2

9.0 ENVIRONMENTAL QUALIFICATION SUMMARY 9-1

10.0 ACTUATOR CERTIFICATION PROGRAM 10-1

Nuclear Maintenance Applications Center

11.0 ACTUATOR UPGRADE NOTES (PRE-1978 VS. POST-1978) 11-1

12.0 ACTUATOR PERFORMANCE DATA 12-1

13.0 ACTUATOR MOUNTING BOLT SPECIFICATION 13-1

14.0 PREVENTIVE MAINTENANCE INSPECTIONS 14-1

Rotork Maintenance Manual

14.2 Procedure ............................................................................................14-1

15.0 ACTUATOR INTERNAL WIRING DIAGRAMS 15-1

16.0 SPECIAL TOOLS 16-1

17.0 ACTUATOR FAILURE MODES/TROUBLESHOOTING 17-1

18.0 VALVE PROBLEMS AFFECTING ACTUATOR OPERABILITY 18-1

Nuclear Maintenance Application Center

18.2 Valve Stem ...........................................................................................18-1

19.0 ROOT CAUSE AND CORRECTIVE ACTION GUIDELINES 19-1

20.0 PROCEDURES FOR SETTING SWITCHES 20-1

21.0 7/11/13 NA1 ACTUATOR 21-1

Rotork Maintenance Manual

21.2.1 Motor Assembly Removal and Inspection ..................................21-2

22.0 14/16 NA1 ACTUATOR 22-1

22.2.6 Gearcase Module Removal and Inspection ...............................22-9

23.0 30 NA1 ACTUATOR 23-1

23.3.4 Add-on-pak Assembly ..............................................................23-15

24.0 40 NA1 ACTUATOR 24-1

25.0 70/90 NA ACTUATOR 25-1

26.0 PRE-OPERATIONAL/POST-MAINTENANCE TESTING 26-1

26.3 Time Response ...................................................................................26-5

27.0 SPARE PARTS HANDLING AND STORAGE REQUIREMENTS 27-1

Figure 1.2-2 Drive Bush Assembly - Type A ................................................................... 1-4

Figure 1.2-3 Drive Bush Assembly - Type AZ ................................................................. 1-5

Figure 1.2-4 Type AX ...................................................................................................... 1-6

Figure 4.1-1 NA1 Electrical Actuator ............................................................................... 4-1

Figure 4.1-2 Primary Switch Mechanism ......................................................................... 4-2

Figure 4.1-3 Primary Switch Mechanism Selector ........................................................... 4-3

Figure 4.1-4 Switch Mechanism ...................................................................................... 4-4

Figure 4.2-1 Post-1978 Add-on-pak Assemblies............................................................. 4-5

Figure 4.2-2 Add-on-pak ................................................................................................. 4-6