91-463389 Hytork XL Series 01

Hytork

Installation, Operating and Maintenance Instructions

Installation, Dossier
Operating and
Maintenance
Instructions MXL079703

XL 1 Important Safety
the Pinion drive, coupling device and Valve
Stem should be centred and concentric to
Series Procedures prevent any side loading to the bottom
Pinion Radial Bearing and Valve Stem
Actuators Qualified maintenance personnel Seal area.

should read and follow these

Ensure that the square coupling shaft
Contents straightforward instructions.
to be operated is a close, but free
Important Safety Procedures 1 sliding fit into the female drive in the
Mounting and 2 ALWAYS disconnect the Air and Electrical
Actuator shaft (4).
Operating Instructions Supplies before carrying out any form
Piping Instructions 3 of maintenance on an Actuator.
2.2 Maximum Operating Pressure.
Solenoid Valves on 4 XL models 45 to 2585
Spring Return Actuators Always contain the Spring tension with
Do not exceed 8.2 bar (120 psi).
Spares Recommendations 5 HYTORK Retractor Rods as explained in
Complete Disassembly- 6 Section 7.2. Follow instructions for using
XL model 4580
Double Acting Actuator the Retractor Rods carefully.
Do not exceed 7 bar (100 psi).
Complete Disassembly- 7
Spring Return Actuator Never attempt to remove the Pistons
2.3 Operating media.
Assembly Instructions- 8 from the Actuator body by using air
Use clean, dry or lubricated air. Other
pressure when the End Caps have

XL Series Actuators
Double Acting Actuator medias may be used, but consult your
Assembly Instructions- 9 been removed.
local HYTORK VALVE AUTOMATION
Spring Return Actuators CENTER for confirmation as to suitability.
Spring Adjustments 10 Do not shorten or distort the SAFEKEYS;
Testing and Cycling of 11 correct length SAFEKEYS are supplied
Infrequently Used or with the Maintenance Kit.
Stored Actuators
Spares Kits 12 When replacing items use only those
Retractor Rods 13 supplied by HYTORK or its Stocking
Service 14 Distributors.

Numbers in brackets (#) refer to parts

on the exploded XL diagram (Fig. 1).

Read the relevant sections

carefully before continuing.

Fig. 2a
2 Mounting and
Operating
MXL079703

Instructions (Refer to Fig. 1)

Quality
Assured 2.1 Actuator to Valve Installation.
registered The mounting hole sizes and bolt hole
circle are to ISO 5211. These holes are
management
USA

ISO METRIC COARSE on metric models

systems (UNC COARSE on imperial models for the
to ISO 9001 USA) as standard. When mounting the
Actuator to a Valve using a Mounting Kit, Fig. 2b

1
 91-463389 Hytork XL Series 01

Part Part
No. Component Quantity No. Component Quantity

1 Travel Stops & Seals 2 bl Piston ‘O’ Rings 2

2 bm
2 3
End Caps
Pistons
2
2 bn
End Cap ‘O’ Rings
Pinion ‘O’ Rings
2
2
4 Pinion 1 bo DURASTRIP Thrust Bearings 2
5 Body 1 bp Steel Thrust Washers 2
6 SAFEKEYS & ‘O’ Rings 2 bq Snap Ring (Circlip) 1
7 Springs* 2, 3 or 4 br Position Indicator 1
8 Retractor Caps* 2 bs Sealing ‘O’ Rings* 2
9 DURASTRIP Pinion Radial Bearings 2 bt Sealing Bolts* 2

bm bk DURASTRIP Piston Bearing Strips 2 *Spring Return Models only

bsbt br
bn 9 bm 2
bobpbq
1
2
Double
7 bl
Acting

8
bobp bm
2 Spring
Return
5
4 3
bn bs
9 bt
Fig. 1 bk
67
3 Piping specially designed to prevent
contamination of the internals of the
Instructions (Fig. 2a & 2b) Actuator by dirt from the atmosphere.
This increases the working life of the
Actuator which reduces down time and
All Actuators can be either piped with solid
maintenance periods.
or flexible tubing with the Solenoid Valve
(See Dossier DSL019601)
mounted remotely from the Actuator or
by mounting a NAMUR designed Solenoid
Valve DIRECTLY onto the NAMUR
Mounting Pad on the side of the Actuator.
(ALL Solenoids made to the NAMUR
Fig. 3a Fig. 3b
standard can be mounted in this way.)

4 Solenoid Valves
on Spring Return
Actuators (Fig. 3a & 3b)
It is recommended that on Spring Return
Actuators, the HYTORK “CATS” Solenoid
Valves are used. These Valves are

2
91-463389 Hytork XL Series 01
5 Spares
Recommendations
When disassembling and carrying out
maintenance work on the XL Actuator, a
HYTORK XL Spares Kit must be used to
replace all ‘O’ Rings, DURASTRIP Bearing
Strips, Washers etc. This Kit is available
from HYTORK or its Stocking Distributors.
Important: Read Safety Instructions
before starting (see Section 1).
6 Complete
Disassembly -
Double Acting
Actuator
6.1 Removal of Travel Stops.
(Fig. 4)
Release the lock nut and remove both
Travel Stops and Seals (1) (cast Identity
numbers 1 & 2), which are located at the
top of the Actuator body (5) on the side
opposite the Actuator air connections.
6.2 Removal of End Caps.
Unscrew the two slotted SAFEKEY screws
(6) (cast Identity letters C & D) located in
the body next to each End Cap (2), and
gently pull them from the body, removing
each SAFEKEY. If the SAFEKEY screw
tends to spring, then rotate the End Cap
slightly to assist release. For larger
models (1125 to 4585) use a wrench
(spanner) on the End Cap to turn it to
assist the release of the SAFEKEY
(ensuring the End Cap is always flush to
the body). When both SAFEKEYS have
been removed, detach the Position
Indicator (17) from the top of the Pinion
and use a wrench (spanner) to rotate the
Pinion (4), driving the Pistons (3) apart
until they partially push the End Caps from
the body. Remove the End Caps by pulling
them free from the body, keeping them
square to the end face of the body.
6.3 Removal of Pistons.
Rotate the Pinion using a wrench (spanner)
to drive the Pistons apart until the Pinion
rotates freely. Rotate the Pistons in the
Actuator approximately 10 degrees.
Rotate the Pinion carefully with a little
force and the Pistons will push free of the
Actuator body. On later models of XL
Viewed
from above
Travel Stop (1)
Pinion Slot
Body (5)
2 1
SAFEKEY C (6)
Actuators, the Pistons are provided with
cast extraction holes in the face of the
Piston. By screwing the Travel Stop Bolt
into this hole it can be used to pull the
Pistons from the Actuator body using
pliers or vice grips.
6.4 Removal of Pinion.
On XL models 680, 1125 & 1370 with
Location Rings to ISO 5211 (metric
versions only), the Location Ring is a loose
item and must be removed before the
removal of the Pinion. Remove the Snap
Ring (Circlip) (16), Steel Thrust Washer
(15) and Thrust Bearing (14) from the top
of the Pinion and CAREFULLY remove the
Pinion from the cylinder body through the
bottom. (If the Actuator is a 680, 1125 or
1370 gently tap the top of the Pinion with
a rubber hammer to remove the Location
Ring first.) Care MUST be taken to ensure
that the Pinion Radial Bearing Strips (9) on
the top and bottom of the Pinion do not
become trapped in the bores during this
operation. Take care that the Pinion does
not damage the Pinion bores on removal.
If necessary, remove any burrs, etc. from
the top of the Pinion before removing it.
6.5 Inspection.
Clean and examine all parts for
damage and wear. Check SAFEKEYS for
damage and length (Fig. 10). HYTORK
recommends that ALL ‘O’ Rings, Bearing
Strips, Washers etc. are replaced using a
HYTORK XL Spares Kit.
3
Double Acting
Fig. 4
End
Caps (2)
SAFEKEY D (6)
7 Complete
Disassembly -
Spring Return
Actuator
7.1 Removal of Travel Stops.
(Fig. 4)
Release the lock nut and unscrew both
Travel Stops and Seals (1) (cast Identity
numbers 1 & 2), which are located at the
top of the Actuator body (5) on the side
opposite the Actuator air connections.
7.2 Removal of Spring Pack Modules.
(Fig. 5)
Remove Sealing Bolts (19) and ‘O’ Rings
(18) from each End Cap (2). Place the
HYTORK Retractor Rod (see Section
13.10) through the hole in the End Caps
and screw the Rod into the Spring
Retractor Caps (8) until travel is stopped,
the nut and washer being free of the End
Cap face. Screw the nut and washer
clockwise down the Retractor Rod until
they come up against the face of the End
Cap. Using a wrench (spanner), continue
to screw the nut clockwise down the Rod
exactly two turns, to draw the Spring
Retractor Cap away from the Piston
head (3). This compression of the Springs
releases the Spring force and unlocks the
SAFEKEY for removal. Repeat for the
other End Cap. Rotate the Caps to ensure
that the Springs are retracted; if the Cap
will not turn easily, screw the nut further.
Once the Retractor Rods have
compressed the Spring and the Caps can
be rotated freely, unscrew the two
SAFEKEY slotted screws (6) located in the
body (5) next to each End Cap to which
the SAFEKEYS (cast Identity letters C & D)
91-463389 Hytork XL Series 01
Retractor Rod End Cap (2)
Nut
Insert
Retractor Rod
screw down nut
SAFEKEY
Remove
SAFEKEY and
then remove Spring
End Cap assembly
Relax
Springs if
required to
change Spring rating
are connected. Gently pull the slotted
screws from the body removing the
SAFEKEY. If the SAFEKEY slotted screw
tends to spring, rotate the End Cap
slightly to assist release. For larger
models (1125 to 4580) use a strap
wrench to turn the End Cap to assist the
release of the SAFEKEY (ensuring the
End Cap is always flush to the body).
When both SAFEKEYS have been
removed, detach the Position Indicator
(17) from the Pinion top and use a wrench
(spanner) to rotate the Pinion (4), driving
the Pistons (3) apart until they partially
push the End Caps from the body.
Remove the End Caps by pulling them
free from the body, keeping them
square to the end face of the body.
For normal maintenance when Spring
changes are not required, it is not
necessary to relax the Springs. The
Spring End Cap assembly can be left with
the Retractor Rod holding the assembly
together, ready for reassembly.
If it is necessary to change the Spring
rating refer to Section 10.1.
Piston (3)
Retraction Plate (8)
Fig. 5
Hytork’s
“Safety Spring
Removal System”
7.3 Disassembly of the
center module.
These operations are as described for
Double Acting Actuators, Sections 6.3,
6.4 and 6.5.
8 Assembly
Instructions -
IMPORTANT: All HYTORK XL
Spares Kits are supplied with
SAFEKEY (6) assemblies cut to an
exact length which will fit the
circumference of the End Cap (2)
when fully assembled into the
Actuator. Any shortened SAFEKEYS
must not be used. If in doubt
contact HYTORK or your local
Stocking Distributor.
Double Acting
Actuators
8.1 Inspection.
Check that all components are clean and
free from damage. HYTORK recommend
that ALL ‘O’ Rings, Bearing Strips,
4
Washers, etc. are replaced using only
a HYTORK XL Series Spares Kit.
8.2 Installing the Pinion.
Lightly grease the Pinion, ‘O’ Ring grooves
and Bearing Strip grooves of the Pinion (4)
and Pinion ‘O’ Rings (13) with Lithium
based grease. Install one Steel Thrust
Washer (15) over the top of the Pinion and
slide it down to the top of the gear form.
Take the top Pinion Radial Bearing Strip
(9) and fit it into the top Pinion location
groove and slide one Thrust Bearing
Washer (14) down over the DURASTRIP
Bearing Strip, holding the strip in position
around the Pinion shaft.
Fit the top ‘O’ Ring into the top Pinion
groove. Fit the bottom Radial Bearing
Strip (9) into the bottom Pinion location
groove and hold in position using the
bottom ‘O’ Ring. Lightly grease the Pinion
bores of the body before assembly.
Carefully insert the Pinion into the body (5)
until the top of the Pinion rests in the top
bore but the bottom Radial Bearing Strip
groove is still protruding from the bottom
of the Actuator. Gently slide the Pinion up
through the body making sure that the
ends of the bottom Bearing Strip are not
trapped and the ‘O’ Ring slides or rolls into
the ‘O’ Ring groove as the Pinion is pushed
home into the body.
With the Pinion in this position, install the
top Thrust Bearing Washer (14), then the
Steel Thrust Washer (15) and lastly the
Snap Ring (Circlip) (16) into the narrow
groove at the top of the Pinion (making
sure the Snap Ring fits properly in
the groove).
Standard mode
of operation
(8.3, 8.4 & 8.5).
THIS MODE IS USED FOR MOST FAIL
CLOSED SITUATIONS.
CLOCKWISE ROTATION OF THE
PINION WITH PISTONS MOVING TOWARDS
EACH OTHER. (Fig. 6)
8.3 Alignment of Pinion for
correct Piston installation. (Fig. 6)
Rotate the Pinion to the position shown in
Fig. 6 (when viewed from above the slot at
the top of the Pinion) ensuring that the
machined Stop Flats are in the correct
91-463389 Hytork XL Series 01
orientation. On later XL Actuators the top
of the Pinion is marked with an single
identification dot to indicate the correct
orientation. To install the Pistons for
standard air Fail Close operation, proceed
as follows. Rotate the Pinion so that the
dot on the top of the Pinion is positioned
close to the single dot on the top pad of
the Actuator body. Accurate Pinion
alignment can now take place by lining the
center of the slot on the top of the Pinion
with the single dot on the body.
(As indicated by the arrow on Fig.6.)
8.4 Installing the Pistons.
Ensure that the dovetail on the
Bearing Strip is correctly aligned to the
dovetail grooves machined into the Piston
with the tang, in the center of the Strip,
pointing away from the Piston head. Once
in the correct orientation, the small tang in
the middle of the Strip must be adjusted
to point away from the dovetail groove so
that the Strip can be pushed into the
Piston dovetail grooves. When the Strip is
fully in the dovetail groove, the tang must
be pushed into the retaining slot on the
Piston. Lightly grease the Piston ‘O’ Rings
(11) with Lithium based grease. Liberally
grease the Actuator body bore and the
Single Pinion Stop Flats
dot for
standard
mode
Three
dots for
Reverse
Action
Pinion
(dot)
Pistons (3) using Lithium based grease
and fit the ‘O’ Rings into the ‘O’ Ring
groove on the Pistons. Insert the Pistons
into the bore, one Piston in each end with
the teeth facing each other (see Fig. 6), to
ensure that the Piston rack lines up with
the Pinion gear. The alignment groove in
the front face of the Piston must be lined
up parallel to the Pinion and “gun sights”
cast in the body. Push both Pistons
together until they are both in contact with
the Pinion, so that when the Pinion is
rotated clockwise (see Fig. 6) the Pistons
are drawn together. When the Pistons are
together and the racks correctly engaged
with the Pinion, the top Pinion drive flats
should now be at right angles to the axis
of the body.
8.5 Installing the Travel Stops.
(Fig. 4)
With the Pistons together, screw in the
Travel CLOSING Stop assembly complete
with lock nut and seal (cast Identity
number 2) until it comes into contact with
the Pinion. Rotate the Pinion 90 degrees
only to drive the Pistons apart and screw
in the Travel OPENING Stop (cast Identity
number 1) until it comes into contact with
the Pinion. Final adjustment is easily made
Pinion
(dot)
Standard Operation Fig. 6
Pinion Stop Flats
Reverse Operation Fig. 7
5
when the Actuator has been mounted to
its Valve, damper or other device, to suit
individual requirements. Ensure the lock
nut is tightened. HYTORK Actuators
have an over travel of 3 degrees at
each end of the stroke. (See Dossier
ACT030503 for benefits)
Reverse action
mode of operation
(8.6, 8.7 & 8.8)
THIS MODE IS USED FOR MOST FAIL
OPEN SITUATIONS.
ANTI-CLOCKWISE ROTATION OF THE
PINION WITH PISTONS MOVING
TOWARDS EACH OTHER. (Fig. 7)
8.6 Alignment of Pinion for
correct Piston installation. (Fig. 7)
Rotate the Pinion to the position shown in
Fig. 7 (when viewed from above the slot at
the top of the Pinion) ensuring that the
machined Stop Flats are in the correct
orientation. On later XL Actuators the top
of the Pinion is marked with an single
identification dot to indicate the correct
orientation. To install the Pistons for
standard air Fail Open operation, proceed
as follows: rotate the Pinion so that the
dot on the top of the Pinion is positioned
close to the three dots on the top pad of
the Actuator body. Accurate Pinion
alignment can now take place by lining the
centre of the slot on the top of the Pinion
with the three dots on the body.
(As indicated by the arrow on Fig. 7.)
8.7 Installing the Pistons.
Assemble Bearing Strips and ‘O’ Rings and
grease as described in Section 8.4. Insert
the Pistons into the bore, one Piston in
each end with the teeth facing each other
as shown in Fig. 7. The alignment groove
in the front face of the Piston must be
lined up parallel to the Pinion and cast
“gun sights” in the body. Push both
Pistons together until they are both in
contact with the Pinion, so that when the
Pinion is rotated anti-clockwise (see Fig. 7)
the Pistons are drawn together. When the
Pistons are together and the racks
correctly engaged with the Pinion, the
top Pinion drive flats should now be
approximately parallel to the axis of
the body.
91-463389 Hytork XL Series 01
8.8 Installing the Travel Stops. S P R I N G R A T I N G
(Fig. 4)
For Actuator Models 45, 70, 185, 425, 680, 1370, 2585, 4580
With the Pistons together, screw in the
Travel OPEN Stop (cast Identity number 1) Left Spring Assembly
Inner Outer
until it comes into contact with the Pinion.
Spring Rating 15 psi 25 psi
Rotate the Pinion 90 degrees to drive the S30 15 psi none
Pistons apart and screw in the Travel S40 none 25 psi
CLOSING Stop (cast Identity number 2) S50 none 25 psi
until it comes into contact with the Pinion. S55 15 psi 25 psi
S65 15 psi 25 psi
8.9 Installing the End Caps. S80 15 psi 25 psi
Install the SAFEKEY ‘O’ Ring Seals to the For Actuator models 130, 280, 1125
slotted screws on the SAFEKEY Spring Inner Outer
Rating 20 psi 20 psi
assemblies (6). Lightly grease the End
30 psi
Cap ‘O’ Rings (12) with Lithium based
S40 none 20 psi
grease. Grease the ends of the body bore S60 none 30 psi
and the End Caps (2), making sure the S80 20 psi 20 psi
grease goes into the grooves. Install the
‘O’ Ring into the square bottomed groove
in the End Cap and insert the Cap into the 9 Assembly
body. Holding the SAFEKEY close to the
entry hole to prevent kinking, insert the
Instructions -
SAFEKEY into the hole and gently push
into place. For larger models (1125 to
Spring Return
4580) use a wrench (spanner) on the End Actuators
Cap, ensuring the End Cap is flush to the
body, to turn the End Cap to assist the 9.1 Assembly of Main
insertion of the SAFEKEY. With the slotted Body Module.
screw in contact with the body, tighten Assemble in accordance with the
with a screw driver to create a pressure instructions for Double Acting Actuators
seal by compressing the ‘O’ Ring. Repeat as described in Section 8.1 to 8.8.
the operation for the other End Cap. With
the Pistons together, replace the Position 9.2 Installing the Spring
Indicator (17) with the white and red pegs End Cap Module.
located as required to indicate the If the Springs have been completely
Valve position. relaxed on disassembly refer to
Section 10 before proceeding.
8.10 Location Ring. Lightly grease the End Cap ‘O’ Rings (12)
On XL models 680, 1125 and 1370 with Lithium based grease. Grease the
(metric versions only) press the loose ends of the body bore and the End Caps
Location Ring into the bottom of the (2), making sure the grease goes into the
Pinion bore in the body. grooves. Install the ‘O’ Ring into the
square bottomed groove in the End Cap
8.11 Testing the HYTORK Actuator. and insert the Cap into the body (5),
Using compressed air at 80 - 100 psi, (making sure that the Springs have been
check the seal areas with soapy water, sufficiently compressed so that the
ensuring no bubbles are produced and
that the Pinion rotates smoothly over
Retractor Cap locates in the Piston
recess). Install the ‘O’ Ring Seals to the
its full travel. slotted screws on the SAFEKEY
assemblies (6). Holding the SAFEKEY
close to the entry hole to prevent kinking,
insert the SAFEKEY into the hole and
gently push into place. For larger models
(1125 to 4580) use a strap wrench on the
End Cap, ensuring the End Cap is flush to
the body, to turn the End Cap to assist the
insertion of the SAFEKEY. With the slotted
screw in contact with the body, tighten the
screw with a screw driver to create a
pressure seal. Repeat the operation for
the other End Cap. Line up each End Cap
6
C H A R T Fig. 8
Right Spring Assembly
Inner Outer
15 psi 25 psi
15 psi none
15 psi none
none 25 psi
15 psi none
none 25 psi
15 psi 25 psi
Inner Outer
20 psi 20 psi
30 psi
none 20 psi
none 30 psi
20 psi 20 psi
so that the safety symbols are correctly
aligned for easy reading.
When the End Caps are in place and the
SAFEKEY is fitted correctly, remove the
HYTORK Retractor Rod completely. First
place a wrench (spanner) onto the double
lock nuts at the end of the Retractor Rod
to stop it turning while releasing the single
nut and washer that is against the End
Cap. When this nut is free, unscrew the
Rod by using the lock nuts at the end of
the Retractor Rod and replace the Sealing
Bolts (19) and ‘O’ Rings (18) in each End
Cap. With the Pistons together, in the Fail
position, replace the Position Indicator
(17) with the white and red pegs located
as required to indicate the valve position.
9.3 Testing the HYTORK Actuator.
Using compressed air at 80 - 100 psi,
check the seal areas with soapy water,
ensuring no bubbles are produced and
that the Pinion rotates smoothly over
its full Travel.
10 Spring
Adjustments
10.1 Spring selection. (Fig. 8)
Diverse types of quarter turn Valves have
significantly different operating torque
characteristics. Plants have requirements
for both Fail Open and Fail Close Valves.
The air supply pressure to the Actuator
also effects the Actuator size. HYTORK
Springs are designed to give the user
flexibility for whatever application is
required. The actual selection of the
correct Spring combination can be done
by either referring to the torque charts
91-463389 Hytork XL Series 01

given in the literature on Spring Return
Actuators or by consulting your local
HYTORK VALVE AUTOMATION CENTER.
10.2 Normal Maintenance
Requirements.
For normal maintenance when Spring
changes are not required it is not
necessary to fully relax the Springs. The
Spring End Cap assembly can be left with
the Retractor Rod holding the assembly
together ready for reassembly.
10.3 Spring Removal. (Fig. 5)
If it is necessary to alter the Spring
rating, the nut on the Retractor Rod next
to the End Cap is gradually unscrewed
ensuring that the Retractor Rod does not
turn by using a spanner (wrench) on the
lock nuts at the top of the Rod. Continue
until the Spring is in its relaxed position.
Once the Spring is fully relaxed the
Retractor Rod can be unscrewed from
the Retractor Cap and the Springs
changed as required.
10.4 Spring Module Assembly.
(Fig. 5)
To compress the Springs reverse the
process ensuring that the Retractor Rod is
screwed fully into the Retractor Plate
before compressing the Springs.
11 Testing and
Cycling of
Infrequently
Used or Stored
Actuators
Actuators not in current use (i.e. Actuators
in stores or stock and/or not operated for
at least a 3 month period), should be
cycled a minimum of ten times and tested
against the possible ‘pre-set’ of the Seals.
This is a safety precaution recommended
by the Seal manufacturers.

A 0.039/1.0
0.0
ExB
0.059/1.5
Full thread 0.059/1.5
0.0 ExC 0.0 Full thread

0.039/1 x 45°
Cham typical Dia. D

Model 45 70 130 185 280 425 680 1125 1370 2585 4580
A 7.09/180 8.07/205 6.30/160 9.05/230 6.70/170 11.22/285 14.17/360 10.63/270 16.53/420 19.68/500 21.26/540
B 2.99/76 3.45/90 3.94/100 3.94/100 3.94/100 5.31/135 6.50/165 6.30/160 7.09/180 8.66/220 9.92/252
C 0.24/6 0.51/13 0.55/14 0.51/13 0.63/16 0.51/13 0.51/13 0.91/23 0.59/15 0.79/20 0.79/20
D 0.20/5 0.31/8 0.31/8 0.31/8 0.39/10 0.31/8 0.47/12 0.47/12 0.47/12 0.47/12 0.79/20
E M5 M8 M8 M8 M10 M8 M12 M12 M12 M12 M20

Material Specification: Retractor Rod: High Tensile Steel; tensile strength of 55 - 65 tonf/in2 (850 - 1000 N/mm2).
Nuts: High Tensile Steel; tensile strength of 50.8 tonf/in2 (785 N/mm2).

Important: Retractor Rods must be made to this design specification for safety reasons.
HYTORK can not take any responsibility for any other design.

Dimensions are given in inches/mm RETRACTOR ROD DIMENSIONS Fig. 9

‘W’ dia.
‘L’

Model 45 70 130 185 280 425 680 1125 1370 2585 4580 4580AFS
L mm 166 201 251 281 351 361 421 501 556 691 821 1141
L inches 6.54 7.91 9.88 11.06 13.82 14.21 16.57 19.72 21.89 27.20 36.26 44.92
W dia mm 3.175 3.175 3.175 3.175 3.175 3.175 3.175 3.175 3.175 3.175 4.978 4.978
W dia inches 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.196 0.196

Length dimension L tolerance = +/- 1.0mm

Length dimension L tolerance = +/- 0.040 inches SAFEKEY DIMENSIONS Fig. 10

7
91-463389 Hytork XL Series 01

12 Spares Kits 13 Retractor Rods 14 Service

Contents List: 13.1 Spring Removal It is the policy of HYTORK to give
1 x I, O and M Instructions System Board. the best possible service to our
HYTORK’S “SPRING REMOVAL customers. We are happy to assist you in
2 x SAFEKEY Assemblies (6) SYSTEM BOARD” contains a full set of any way we can and if you have any
2 x SAFEKEY Seal ‘O’ Rings (6) Retractor Rods so that any size of questions about HYTORK Actuators or
2 x Piston DURASTRIP Bearing Actuator can be disassembled on site. Ask other HYTORK Products please do not
your local HYTORK VALVE AUTOMATION hesitate to contact one of HYTORK’S
2 x Strips (10) CENTER or your local Stocking Distributor VALVE AUTOMATION CENTERS or your
2 x Steel Thrust Washers (15) of HYTORK Products for details. local HYTORK Stocking Distributor.
1 x Pinion top ‘O’ Ring (13)
The HYTORK Retractor Rod tools are
1 x Pinion top DURASTRIP Radial specially designed for the safe
2 x Bearing (9) removal of the Spring Return End Cap
2 x DURASTRIP Thrust Bearing (14) modules. Only HYTORK manufactured
or approved rods are to be used for
1 x Pinion bottom ‘O’ Ring (13) Spring End Cap removal.
1 x Pinion bottom DURASTRIP Radial
2 x Bearing (9) Important: As with any threaded tool
that is used frequently Retractor Rods
2 x Stop Seals (1) should be checked to ensure that the
2 x Piston ‘O’ Rings (11) threads are not worn or damaged in
2 x End Cap ‘O’ Rings (12) any way and greased regularly. Any
damaged or worn Rods must not be
1 x Pinion Snap Ring (Circlip) (16) used and must be destroyed.

13.2 Retractor Rod dimensions.

(Fig. 9)
Important: Retractor Rods
must be made to this design
specification for safety reasons.
HYTORK can not take any Quality
responsibility for any other design. Assured
registered
management
systems
to ISO 9001

MXL079703

Hytork Controls Europe Hytork Controls Inc. UK Patents: Important:

Valve Automation Center Valve Automation Center Tel: [+1] (813) 630 2255 GB 2 102 887 B; We have endeavoured
6 Bracken Hill 9009 King Palm Drive Fax: [+1] (813) 630 9449 GB 2 123 517 B; in this publication to
Southwest Industrial Estate Tel: [+44] (0191) 5180020 Tampa, Florida 33619 Email: hcisales@hytork.com GB 2 138 505 B; make the contents as
Peterlee Fax: [+44] (0191) 5180032 USA http://www.hytork.com GB 2 216 229 B; accurate as possible,
GB 2 225 079 B; but being given as
County Durham Email: hcesales@hytork.com GB 2 229 254 B; general information, it
SR8 2LS UK http://www.hytork.com GB 2 253 459 B; is not to be taken as
Hytork Controls Australian Operations GB 2 268 574 B. binding unless
25 South Street Tel: [+61] (2) 9841 2414 specifically confirmed
Rydalmere Fax: [+61] (2) 9684 6439 US Patents: in writing. Due to
NSW 2116 Email: hcpsales@hytork.com 4,496,071; Hytork's continuing
Hytork Controls Europe 4,651,627; commitment to
Ryeford Road South Austalia http://www.hytork.com 4,716,815. engineered product
Kings Stanley Tel: [+44] (01453) 827710 advancement, the
Stonehouse Fax: [+44] (01453) 827714 Warranties: product specifications
Gloucestershire Email: hcesales@hytork.com Hytork Controls Indian Operations Unauthorised and data presented in
311 Mayfair Tower Tel: [+91] (12) 9251618 modification to this publication are
GL10 3HG UK http://www.hytork.com any Hytork subject to change
Charmwood Village Fax: [+91] (12) 9251618
Product totally without notice.
New Delhi 110044 Email: hndsales@hytork.com invalidates all
India http://www.hytork.com warranties.

Part of the Hytork International plc Group

8
91-463389 Hytork XL Series 02
P Installation, Operating and Maintenance Instructions.
Installation, 1. Important Safety
Operating and Procedures.
Maintenance Qualified maintenance personnel should read maintenance
Instructions. and follow these straightforward instructions. all 'O' rings, DURASTRIP Bearings, Washers
XL Series
Actuators
Contents
1. Important Safety Procedures.
2. Spares Recommendations.
3. Actuator to Valve Installation.
4. Operating Media, Pressures
and Temperatures.
5. Complete Disassembly and
Safe Compression of Springs.
6. Assembly Instructions.
7. Testing the HYTORK Actuator.
8. Testing and Cycling of
Infrequently Used or Stored
Actuators.
9. Service.
Quality Assured
registered
management
systems to
ISO 9001
The information contained within this document is copyright © Hytork International Plc. And subject to change without notice.
Updated data sheets can be obtained from our websight www.hytork.com or from your nearest Hytork Valve Automation Center.
USA: +1 813 630 2255 (fax 630 9449) UK: +44 191 5180020 (fax 5180032) AUSTRALIA: +61 2 9841 2414 (fax 9684 6439).
Sheet No. D52A
XL 26, XL 71, XL 131, XL 186, XL 221.
June 22, 1999 Sheet 1 of 4
2. Spares Recommendations.
When disassembling and carrying out
work on the XL Actuator, a
HYTORK Spares Kit must be used to replace
etc. This Kit is available from HYTORK or its
ALWAYS disconnect the Air and Electrical Stocking Distributors.
supplies before carrying out any form of
maintenance on an Actuator.
3. Actuator to Valve
Caution ; When removing any ball valve or Installation.
plug valve assemblies from a pipe system,
isolate the piping system on which the The Pinion drive, coupling device and Valve
Actuator is installed and relieve any media Stem should be centered and concentric to
pressure that may be trapped in the valve prevent any side loading to the Pinion Radial
cavities before removing the Actuator for Bearing and Valve Stem Seat area. Ensure
maintenance. that the coupling shaft to be operated is a tight
but free sliding fit into the female drive in the
Caution ; Always contain the Spring tension Actuator Pinion (19).
with HYTORK Retractor Bolts as explained in
Section 6 (Spring Return Actuators). Follow
4. Operating Media,
the instructions for using the Retractor Bolts
carefully. Only HYTORK manufactured or Pressures and
approved Retractor Bolts are to be used for Temperatures.
Spring removal. As with any threaded tool that
is frequently used, Retractor Bolts should be
Operating media :
checked to ensure that the threads are not
Use clean and dry or lubricated air.
worn or damaged in any way and are greased
regularly. Any worn or damaged Retractor
Operating pressures :
Bolts must not be used and must be
not to exceed 10 bar ( 150 psi ).
destroyed.
Operating temperature range :
Never attempt to 'BLOW OUT' the Pistons
Using standard seals and grease the operating
from the Actuator Body by using air pressure
temperature range is -
when the End Caps have been removed.
-20°C to +100°C ( -4°F to +212°F ).
Numbers in brackets (#) refer to parts shown
For operating media's, pressures and
in the sectioned drawing (Fig. 1).
temperatures outside these ranges please
consult HYTORK.
All HYTORK XL Spares Kits are supplied with
SAFEKEY assemblies (13 / 14) cut to an
exact length which will fit the circumference of
the End Cap (21) when fully assembled into
the Actuator. Any shortened SAFEKEY must
not be used. If in doubt contact HYTORK.
Read the relevent sections carefully before
continuing.
 91-463389 Hytork XL Series 02

P Installation, Operating and Maintenance Instructions.

Sheet No. D52A

XL 26, XL 71, XL 131, XL 186, XL 221

June 22, 1999 Sheet 2 of 4

Item Component Description Material Quantity Item Component Description Material Quantity
1 Ball Bearing Chromium Steel 2 16 Location Ring Acetal 1
2 'O' ring (End Cap) Nitrile 2 17 'O' ring (Pinion bottom) Nitrile 1
3 Wear Ring (Piston) DURASTRIP 2 18 Bearing (Pinion bottom) DURASTRIP 1
4 'O' ring (Piston) Nitrile 2 19 Pinion Steel 1
5 Thrust Bearing (Circlip) DURASTRIP 1 20 Piston Aluminium alloy 2
6 Circlip Spring Steel 1 21 End Cap Aluminium alloy 2
7 Indicator Nylon 1 22 Travel Stop Stainless Steel 2
8 'O' ring (Pinion top) Nitrile 1 23 Thread Seal Steel / Rubber 2
9 Bearing (Pinion top) DURASTRIP 1 24 Locking Nut Stainless Steel 2
10 Bearing Block (Piston) DURASTRIP 2 25 Thrust Washer (Circlip) Stainless Steel 1
11 Body Aluminium Alloy 1 26 Spring Outer Spring Steel 2
12 'O' ring (SAFEKEY) Nitrile 2 27 Spring Inner Spring Steel 2
13 SAFEKEY Head Grivory 2 28 Sealing Bolt (End Cap) Steel 2
14 SAFEKEY Wire Stainless Steel 2 29 'O' ring (Sealing Bolt) Nitrile 2
15 Thread Insert Steel 2

5. Complete Disassembly
and Safe Compression of
Springs.
Release Locking Nuts (24) and remove both
Travel Stops and Thread Seals (22 / 23)
which are located at the top of the Actuator
Body (cast identity numbers 1 & 2), on the
side opposite the Actuator air connections.
Remove both Sealing Bolts (28) and seals
(29) from the End Caps (21). Place the
HYTORK Retractor Bolt complete with
Washer (see Fig. 3a) through the hole in
the End Caps and screw the Bolt into the
Piston (20) until the Bolt Head touches the
End Cap. Now screw in a further 1/2 to 1
turn to compress the Springs (26 / 27).
DO NOT OVERTIGHTEN.
Repeat for the other End Cap.
Unscrew the two slotted SAFEKEYS (13 /
14) located on the Body (11) next
to each End Cap (cast identity letters C &
D),
and gently pull each SAFEKEY from the
Body. If the SAFEKEY resists removal,
gently tap the End Cap with a soft mallet
(hammer) to assist release. When both
SAFEKEYS have been removed, detach the
Indicator (7) from the top of the Pinion (19)
and use a wrench (spanner) to rotate the
Pinion, driving the pistons (20) apart until
they partially push the End Caps from the
Body.
Spring Return Actuators :
To keep the Spring Pack Assembly intact
(Fig. 3b), leave the Retractor Bolt in place.
To disassemble the Spring Pack, unscrew
the Retractor Bolt relieving the Spring force.
Double Acting Actuators :
Remove the SAFEKEY as described
previously. The Retractor Bolt is not
required for Double Acting Actuators.
Remove the End Caps by pulling them free
from the Body keeping them square to the
end face of the Body.
Removal of Pistons :
Rotate the Pinion using a wrench (spanner)
to drive the Pistons apart and remove from
the Body by pulling the Pistons.
Removal of the Pinion :
Remove the snap ring (Circlip)(6), Thrust
Washer (25) and DURASTRIP Thrust
Bearing (5) from the top of the Pinion and
CAREFULLY push the Pinion from the Body
through the bottom. Take care that the
Pinion does not damage the pinion bores on
removal. If necessary, remove any burrs,
etc. from the top of the Pinion before
removal. Carefully remove Pinion Top
Bearing (9) from the Body.
Inspection :
Clean and examine all parts for damage
and wear. HYTORK recommends 'O' rings,
DURASTRIP Bearings, SAFEKEYS,
Washers, etc. are replaced using a
HYTORK XL Spares Kit.

The information contained within this document is copyright © Hytork International Plc. And subject to change without notice.
Updated data sheets can be obtained from our websight www.hytork.com or from your nearest Hytork Valve Automation Center.
USA: +1 813 630 2255 (fax 630 9449) UK: +44 191 5180020 (fax 5180032) AUSTRALIA: +61 2 9841 2414 (fax 9684 6439).
91-463389 Hytork XL Series 02
P Installation, Operating and Maintenance Instructions.
6. Assembly Instructions.
Note : The grease used in ALL HYTORK
Standard Model Actuators is a Lithium
Based Grease. Check with HYTORK for
high and low temperature applications.
Double Acting Actuators.
Installing the Pinion.
Lightly grease all 'O' rings, 'O' ring
grooves, bearing grooves and Pinion.
Assemble the Top Pinion Bearing (9) to
the Pinion, ensuring that the recess
openings are facing away from the gear
form, then assemble items (8), (17) and
(18).
Lightly grease the pinion bores in the
Body (11) and insert the Pinion being
careful not to damage the 'O' rings.When
the Pinion is in place, install the
DURASTRIP Thrust Bearing (5), Thrust
Washer (25) and the snap ring (Circlip)(6)
into the narrow groove at the top of the
Pinion (ensuring the snap ring fits properly
into the groove). .
The information contained within this document is copyright © Hytork International Plc. And subject to change without notice.
Updated data sheets can be obtained from our websight www.hytork.com or from your nearest Hytork Valve Automation Center.
USA: +1 813 630 2255 (fax 630 9449) UK: +44 191 5180020 (fax 5180032) AUSTRALIA: +61 2 9841 2414 (fax 9684 6439).
Sheet No. D52A
XL 26, XL 71, XL 131, XL 186, XL 221
June 22, 1999
Only open the snap ring (Circlip) enough to
just clear the Pinion diameter as opening
too far will damage the snap ring. If
damage occurs replace with a new part.
Note : The snap ring (Circlip) has one
side with bevelled edges which must go
down onto the Thrust Washer (25) ; the
square edge side must face UPWARDS.
Alignment of Pinion for correct Piston
installation.
(When viewed from above the slot at the
top of the Pinion) (Fig. 2a & Fig. 2b).
Standard rotation is clockwise with the
Pistons moving towards each other.
Installing the Pistons.
Clockwise rotation with Pistons moving
towards each other (Fig.2a).
Align the Pinion by lining up the center of
the NAMUR slot in the top of the Pinion
with the single dimple on the Body. The top
of the Pinion is marked with a single
identification dot to indicate the correct
orientation of the stop faces.
Sheet 3 of 4
Lightly grease all piston grooves, gear form
and piston 'O' rings (4) and fit the 'O' ring
(4) and Wear Ring (3) to the Piston. Fit the
Bearing Block (10) to the back of the
Piston.
Grease the Actuator body bore. Insert the
Pistons into the bore, ensuring the piston
racks line up with the pinion gear. (the part
number in the front face of the Piston must
be lined up parallel to the Pinion). Push
both Pistons together until they are both in
contact with the Pinion, so that when the
Pinion is rotated clockwise the Pistons are
drawn together. When the Pistons are
together and the racks are correctly
engaged with the Pinion, the top pinion
drive flats should be at right angles to the
axis of the Body.
Anti-Clockwise rotation with pistons
moving towards each other (Fig. 2b).
Align the NAMUR slot in the top of the
Pinion with the multiple dimples on the
Body and assemble Pistons so that the
Pinion rotates anti-clockwise as the
Pistons are drawn together.
91-463389 Hytork XL Series 02
P Installation, Operating and Maintenance Instructions.
Installing the Travel Stops (Fig. 4).
With the Pistons together, screw in the
CLOSING (cast identity number 2) Travel
Stop (22), complete with Locking Nut (24)
and Thread Seal (23), until it comes into
contact with the pinion stop face. Rotate
the Pinion through 90° only, driving the
Pistons apart and screw in the OPENING
(cast identity number 1) Travel Stop (22),
complete with Locking Nut and Thread
Seal, until it comes into contact with the
pinion stop face. For individual position
requirements final adjustment is easily
made when the Actuator has been
mounted to its valve, damper or other
device. Ensure the Locking Nuts are
tightened. HYTORK Actuators provide an
over travel of 3° at each end of the
stroke.
Installing the End Caps.
Install the SAFEKEY 'O' ring seals (12) to
the SAFEKEY heads (13). Lightly grease
the End Cap 'O' rings (2), the End Cap
grooves and the ends of the Body bore.
Taking one of the End Caps install its 'O'
ring and insert it into the Body. Holding
the SAFEKEY close to the entry hole
(cast identity letter C or D) to prevent
kinking, insert the SAFEKEY into the
hole and gently push into place.
The information contained within this document is copyright © Hytork International Plc. And subject to change without notice.
Updated data sheets can be obtained from our websight www.hytork.com or from your nearest Hytork Valve Automation Center.
USA: +1 813 630 2255 (fax 630 9449) UK: +44 191 5180020 (fax 5180032) AUSTRALIA: +61 2 9841 2414 (fax 9684 6439).
Sheet No. D52A
XL 26, XL 71, XL 131, XL 186, XL 221
June 22, 1999
With the SAFEKEY Head in contact with the
Body, tighten with a screw driver to gently
compress the 'O' ring and create a pressure
seal. Repeat the operation for the other End
Cap. With the Pistons together, replace the
position Indicator (7) to the top of the Pinion.
Spring Return Actuators.
Installing the Springs.
(Other instructions are as Double Acting
Actuators).
Insert the springs (26 / 27) into the face of
the Piston and then the End Cap onto the
Springs. Pass the correct HYTORK
Retractor Bolt through the End Cap (Fig.3a)
and screw it into the Piston. Line up the End
Cap so that the safety symbol is correctly
positioned for easy reading. Continue to
screw the HYTORK Retractor Bolt in until the
End Cap is completely engaged in the Body.
It will be necessary to push the End Cap into
the Body to overcome the 'O' ring
compression. When the End Caps are in
place and the SAFEKEYS fitted correctly,
remove the HYTORK Retractor Bolts and
replace the Sealing Bolts (28) and seals (29).
IMPORTANT : HYTORK Retractor Bolts
are made to a HYTORK design
specification for safety reasons. HYTORK
can not take any responsibility for any
other design.
Sheet 4 of 4
7. Testing the HYTORK
Actuator.
Using compressed air at 80 - 100 psi (5.5 -
7 bar) check the seal areas with soapy
water, ensuring there are no leaks and
that the Pinion rotates smoothly over its
full travel.
8. Testing and Cycling of
Infrequently Used or
Stored Actuators.
Actuators not in current use (ie. Actuators
in storage or stock and / or not operated
for at least a 3 month period), should be
cycled a minimum of ten times and tested
against the possible 'pre-set' of the seals.
This is a safety precaution recommended
by the seal manufacturers.
9. Service.
It is the policy of HYTORK to give the best
possible service to our customers. We are
happy to assist you in any way we can and
if you have any questions about HYTORK
Actuators and other HYTORK products
please do not hesitate to contact any
HYTORK VALVE AUTOMATION
CENTER or your local HYTORK Stocking
Distributor.