cashco 48 Series Instruction manual

I. DESCRIPTION AND SCOPE
Models 48D and 48R are multi-spring, single acting,
spring opposed, rotary actuators used with Cashco
rotary control valves. Regardless of final installed
failure action, the actuator is always pressurized on
“top” of the traveling diaphragm plate.
Cashco has adopted a convention as follows in identi-
fying its rotary actuators:
“D” = Direct Action = ATC-FO Action
“R” = Reverse Action = ATO-FC Action
The Model 48 actuator is field reversible by arrange-
ment of actuator with respect to valve stem and valve
plug/disc orientation. Some disassembly is required,
but no new parts are required.
Reference the technical bulletin of the valve body these
actuators are unitized with for operating/installation/
selection specifications; i.e. available bench settings,
strokes, etc.
MODEL 48
SPRING/DIAPHRAGM ROTARY ACTUATORS
INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-48
12-13
SECTION I
Figure 1
Model 48 Actuator
SECTION II
4 8 R - 0 1
Basic Model No.
48 in2size
Reverse Action
(ATO-FC)
Modifier
Valve Modifier
Product Series No.
Ranger QCT -00 through -09
Premier EZO -00 through -09
Premier Unlined -00 through -09
II. MODEL NUMBERING
The basic Model Number identifies the actuator size and action. To identify a unique Model Number, another series
of 2-character modifiers is added to the basic number. This number will identify which basic valve body the actuator
may be used on. See Table 1.
TABLE 1

IOM-48
2
Full Actuator Model No.
Basic Available Air Supply
Actuator Modifier Bench Settings Pressure Unitized Products *
Model No. Number psig (Barg) psig (Barg)
48R 1"-2" (DN25-50) Ranger QCT
or -01 5-15 (.34-1.03) 20 (1.4) 3"-4" (DN80-100) Premier EZO
48D or Premier Unlined
148R 3"-4" (DN80-100) Ranger QCT
or -01 5-13 (.34-0.90) 20 (1.4) 6" (DN150) Premier EZO
148D or Premier Unlined
148R 4"-8" (DN100-200) Ranger QCT,
or -02 10-26 (.69-1.79) 36 (2.5) 10" (DN250) Premier EZO
148D
148R 8" (DN200) Premier EZO,
or -03 7.5-19.5 (.52-1.34) 27 (1.9) 8"-10" (DN200-250) Premier
148D Unlined
* Metric body size in parenthesis.
ACTUATOR MODEL NO. vs. VALVE BODY MODEL
(Model 148 included for clarity)
III. INSTALLATION
A. Orientation:
1. Recommended actuator major axis orientation
with any model of Cashco rotary control valve
is upwards with the valve in a horizontal pipe
and the valve stem also horizontal; i.e. position
“A” for ATO-FC, or position “B” for ATC-FO.
2. Both Ranger QCT and Premier EZO/Unlined
control valve products incorporate an extended
SECTION III
FIGURE 2: Mounting position of Ranger QCT to
Model 48 Actuator with Model 73N-B P/P Positioner.
FIGURE 3: Mounting position of Ranger QCT to
Model 48 Actuator w/Model 9540R or Smart Positioners.
valve body bonnet and a mounting yoke to
allow the actuator to be far enough away
from the valve body or mounting flanges to
incorporate a minimum of 2" (50 mm) thick-
ness of insulation. It should not be necessary
to install thermal insulation to any portion of
Model 48 actuator. The maximum ambient
temperature for installation is 180°F (83°C);
the minimum ambient temperature is -20°F
(-29°C).
Position A
Position B
Position A
Position B

IOM-48 3
3. A 1/4"–NPT female connection for pneumatic
LOAD is located on the side of the actuator’s
upper diaphragm casing near the casing
flange joint. Reference specific Ranger-TB or
Premier-TB for location of the connection.
4. Reference the valve body instructions — IOM-
Ranger, IOM-Premier EZO or IOM-Premier
Unlined — for additional instructions on in-
stalling unit in the process piping.
B. Air Supply:
1. Recommendation is that a desiccant dried,
instrument quality air supply be used. Such
a supply is recommended for outdoor instal-
lations, and is required in areas of freezing
weather conditions.
FIGURE 4: Mounting position of Premier EZO or Pre-
mier Unlined to Model 48 Actuator with Model 73N-B
P/P Positioner
FIGURE 5: Mounting position of Premier EZO or Pre-
mier Unlined to Model 48 Actuator with Models 9540R
or Smart Positioners
2. If air supply contains moisture and/or lubri-
cating oil, the air should be filtered with a co-
alescing type of filter prior to use in stroking
the actuator.
3. Connection for the air loading pressure is 1/4"
female NPT. A suitable pipe thread sealant is
recommended to be used when installing the
pipe or tube fitting. Exhibit care to prevent the
sealant from getting inside the tube/pipe.
4. If an alternate gaseous fluid is used as a source
of loading pressure (i.e. natural gas, nitrogen,
etc.), this gas MUST NOT BE CORROSIVE
to the aluminum casing material.
IV. OPERATION
A. General:
1. Actuators supplied with 5-13 psig (0.34-0.90
Barg) benchset range are designed to operate
with or without a positioner. A 3-15 psig (0.21-
1.03 Barg) instrument output signal would be
required to operate without a positioner.
2. On larger valve body sizes the benchset
range is essentially 1.5–2.3 times that of the
5-13 psig (0.34-090 Barg); i.e. 7.5-19.5 psig
(0.52-1.34 Barg) or 10-26 psig (0.69-1.79
Barg) for Model 148’s. Either a signal booster
or a positioner will be required for full rotation
(0°–90°) by the actuator.
SECTION IV
3. If an “installed characteristic” other than the
“inherent characteristic” is desired, a positioner
plus a “characterization cam” is required. The
inherent characteristic of Ranger QCT control
valves is linear; for Premiers the inherent
characteristic is equal percent.
4. See Tables 2 through 4 for available actuator
models with benchset ranges per valve type
and body size. (Note: Model 148 actuators
included for clarity.) Proper MAXIMUM air
supply pressures are also indicated.
Position A
Position B
Position A
Position B

IOM-48
4
TABLE 2
RANGER QCT
ACTUATOR BENCHSET RANGES
TABLE 3
PREMIER EZO
ACTUATOR BENCHSET RANGES
TABLE 4
PREMIER UNLINED
ACTUATOR BENCHSET RANGES
* Model 148 included for clarity.
Valve Body Size
In. (DN)
Actuator
Model
*
Failure
Action
Benchset
Range
psig (Barg)
Supply
Pressure
psig (Barg)
Qty of Range
Springs
1", 1-1/2" & 2"
(25, 40 & 50)
48R-01 ATO-FC 5-15
(.34-1.03)
20
(1.4) 6
48D-01 ATC-FO
3" & 4"
(80 & 100)
148R-01 ATO-FC 5-13
(.34-.90)
20
(1.4) 4
148D-01 ATC-FO
4", 6" & 8"
(100,150, & 200)
148R-02 ATO-FC 10-26
(.69-1.79)
36
(2.5) 8
148D-02 ATC-FO
Valve Body Size
In. (DN)
Actuator
Model
*
Failure
Action
Benchset
Range
psig (Barg)
Supply
Pressure
psig (Barg)
Qty of Range
Springs
3" & 4"
(80 & 100)
48R-01 ATO-FC 5-15
(.34-1.03)
20
(1.4) 6
48D-01 ATC-FO
6"
(150)
148R-01 ATO-FC 5-13
(.34-.90)
20
(1.4) 4
148D-01 ATC-FO
8"
(200)
148R-03 ATO-FC 7.5-19.5
(.52-1.34)
27
(1.9) 6
148D-03 ATC-FO
10"
(250)
148R-02 ATO-FC 10-26
(.69-1.79)
30
(2.1) 8
148D-02 ATC-FO
Valve Body Size
In. (DN)
Actuator
Model
*
Failure
Action
Benchset
Range
psig (Barg)
Supply
Pressure
psig (Barg)
Qty of Range
Springs
3" & 4"
(80 & 100)
48R-01 ATO-FC 5-15
(.34-1.03)
20
(1.4) 6
48D-01 ATC-FO
6"
(150)
148R-01 ATO-FC 5-13
(.34-.90)
20
(1.4) 4
148D-01 ATC-FO
8", 10"
(200, 250)
148R-03 ATO-FC 7.5-19.5
(.52-1.34)
27
(1.9) 6
148D-03 ATC-FO

IOM-48 5
V. MAINTENANCE
A. General:
1. Hereafter, all maintenance, disassembly, etc.,
is assumed to be done in an indoor shop.
2. Most actuators are a sub-assembly that is
unitized with a body sub-assembly. Reference
should be made to the IOM for the correct
body utilized.
3. Where the body is not being disassembled,
special care MUST be exhibited to prevent
valve stem rotation during any disassembly
or reassembly for all types of valves. Follow-
ing this procedure will ensure not damaging
seating surfaces.
4. Remove all instrument tubing and intercon-
nected electrical wiring. Label “ends” to ensure
proper reconnection.
5. All indicated Item Numbers that are with re-
spect to IOM-Ranger, IOM-Premier EZO or
IOM-Premier Unlined will be in parenthesis
and underscored; i.e. (20); the same is true
for Model 73N-B P/P positioner parts.
6. All Item Numbers that are with respect to this
IOM-48 are not underscored; i.e. (19).
7. Item Numbers that relate to the Model 9540
or Smart positioners ((PA)) are in a double
set of parenthesis and are underscored; i.e.
((3)).
B. Separation of Body Assembly (BA) from Ac-
tuator Assembly (AA):
1. Place completely joined valve assembly (AA)
(BA) upon a flat work surface with sufficient
room to move the individual sub-assemblies
(AA) (BA) around. Place matchmarks on valve
yoke (12), arm housing (4) and actuator lower
casing (2) to use as references.
2. Remove cover plate (20) away from arm
housing (4) by removing four machine screws
(36).
3A. Units with Model 73N-B P/P Positioner or No
Positioner, and No Travel Limit Switch:
a. Using a 3/16" allen key wrench, remove
the three cap screws (31) securing the
dial lens (14), travel indicator dial (15)
and coverplate (13).
b. Remove cap screw (32) and lock tooth
washer (55) securing the bright orange-
colored travel indicator (16) to the upper
end of valve stem (Ranger (7)), (Premier
(3.2)) using a 7/32" allen key wrench. Re-
move travel indicator (16) off of protruding
locator pin (51).
c. If equipped with a Model 73N-B P/P po-
sitioner, remove the four cap screws (33)
that secure the positioner assembly (PA)
to the arm housing (4) using a 3/16" allen
key wrench. Remove positioner assembly
(PA) and feedback range spring (102).
Loop a 6" piece of fine wire around the
feedback linkage subassembly (72). Place
one screw (33) back into a tapped opening.
Pull wire taut and wrap around protruding
screw (33) to keep the linkage (72) from
interfering with further disassembly.
3B. Units with End-of-Shaft Model 9540R Posi-
tioners:
a. Remove clear indicator cover ((22)) by
removing two cap screws ((A3)).
b. Remove red plastic pointer ((34)) by pull-
ing outwards from hub of post-end screw
((23)).
c. Make a matchmark on the characteriza-
tion cam ((24)) at the point where the cam
follower ((31)) touches. Using a wrench
remove post-end screw ((23)) that secures
characterization cam ((24)). Pull feedback
lever ((13)) downwards; remove cam
((24)) and adhered to lock toothed washer
((28)) and shouldered washer ((27)).
d. Remove the positioner unit ((I/P)) ((P/P))
from the baseplate ((26)) by removing cap
screws ((11)) with lock washers ((12)) from
side and back of baseplate ((26)).
e. Remove the four cap screws ((78)) secur-
ing the bracket ((76)), baseplate ((26))
assembly and coverplate (13) to the arm
housing (4).
3C. Units with End-of-Shaft Model 991 or PS2 I/P
Positioners:
a. Remove cap screws (31) securing the
positioner mounting bracket ((9)) to coverplate
(13).
b. Set positioner/bracket assembly to the
side.
c. Remove set screw ((16)), washer ((17))
from end of valve stem (Ranger (7)), (Premier
(3.2)) securing carrier linkage ((3)) to stem.
d. Remove linkage ((3)) from end of stem.
SECTION V

IOM-48
6
4. For ATO-FC valve action, it is necessary to
remove the “stem windup”.
a. Rotate manual handwheel operator
(MHWO) handwheel (58.1) approximately
1-3 revolutions CW (viewed from above
handwheel) until interconnecting arm and
stem linkage (5, 10) of actuator “relax”.
b. Pressurize actuator casing (1) only
until the interconnecting arm and stem
linkage (5,10) “relax”. DO NOT OVER-
PRESSURIZE.
NOTE: Do not remove the drive coupling ((32))
unless required.
5. Remove ball bearing (18), both bearing flanges
(19) and indicator spacer (17) over shaft-end
(Ranger (7)), (Premier (3.2)).
6. For actuator with a handwheel (58), rotate
handwheel CW (viewed from above), driv-
ing the arms (5) down until the shoulder bolt
(40) clears the ears on the arm housing (4). If
actuator does not include a handwheel (58),
loosen jam nut (44) and, using a 9/16" open
end wrench, rotate the hex portion of the push
rod (10) until the shoulder bolt (40) clears the
ears on the arm housing (4).
7. Remove lock nut (46) that secures shoulder
bolt pin (40) through lever arms (5). Remove
shoulder bolt pin (40).
8. Grasp lever arms and rotate stem (Ranger
(7)), (Premier (3.2)) as required to pull down
and away from the lower rod end-L.H. (9) to
allow clearance to remove arms (5). Slide
subassembly consisting of both arms (5),
spacer (12) or characterization cam (Model
73N-B (12)), and two spring pins (50) outwards
and away from the arm housing (4) and over
shaft-end (Ranger (7)), (Premier (3.2)).
9. While securely holding the actuator assembly
(AA) with an overhead sling support, and the
body assembly (BA) to prevent movement,
remove the four bolts (24) that secure the
body yoke (12) to the actuator arm housing
(4). Slide the actuator assembly (AA) over the
stem-end (Ranger (7)), (Premier (3.2)). Lay
body assembly (BA) aside.
C. Changing Actuator Mounting Position (With
No Change in Failsafe Action).
1. Determine the desired mounting position of
actuator assembly (AA) with respect to valve
body assembly (BA) from Figures 6-9, follow-
ing pages.
2. The valve body/bonnet (1) to valve body
yoke (12) can be rotated in four 90° incre-
ments around the centerline of the valve shaft
(Ranger (7)) (Premier (3.2)).
3. Separate the actuator assembly (AA) from
the body assembly (BA) as described in this
Section, V.B.1. through V.B.9.
4. Determine if it is necessary to interchange
packing studs (21) on Ranger or Premier
Unlined, and yoke (12) attachment hex head
cap screws (19) on Ranger or Premier Unlined
per following:
5. If required, remove both packing flange stud
nuts (22) on Ranger or Premier Unlined, and
any external live-loaded packing components
(Ranger (27) (28) (29)), and set both aside
carefully to prevent an “inadvertent mixing”
of the component’s “stack-up”.
Degrees Packing Studs
Rotary Valve Rotation Yoke Attach Studs
Position Change Switch of Position
Ranger, 90°, 270° Required
Premier Unlined 180° Not Required
Premier EZO 90°, 180°, 270° Not Required
6. Place matchmarks between yoke (12) and
valve bonnet/body (1). While holding yoke
(12) with hand, remove two cap screws (19)
and pull yoke (12) over end of stem (Ranger
(7)) (Premier (3.2)) and set aside.
7. If necessary, remove studs (21) from Ranger
or Premier Unlined body assembly (BA) and
relocate/interchange as required.
8. Reposition yoke (12) back onto body bonnet
(1), shifted/rotated the number of degrees
required (i.e. 90°, 180° or 270°), using the
matchmarks to guide to correct position. Se-
cure yoke (12) to body bonnet (1) by engaging
two cap screws (19). Torque per following:
1" & 2" Rangers — 35-40 ft-lbs (47-54
N-m)
3" & 4" Premiers, lined & unlined —
75-80 ft-lbs (101-108 N-m).

IOM-48 7
FIGURE 6:
ORIENTATION – RANGER QCT ACTUATOR MOUNTING POSITIONS
WITH MODEL 73 P/P POSITIONER
NOTES: 1. Flangeless valve design indicated; integral flanged units follow same orientation.
2. Dimension tables are included in the Ranger-TB.
REVERSE ACTION DIRECT ACTION

IOM-48
8
FIGURE 7:
ORIENTATION – RANGER QCT ACTUATOR MOUNTING POSITIONS
WITH MODELS 9540R P/P or 991 or PS2 I/P POSITIONERS
NOTES: 1. Flangeless valve design indicated; integral flanged units follow same orientation.
2. Dimension tables are printed in the Ranger-TB.
REVERSE ACTION DIRECT ACTION

IOM-48 9
FIGURE 8
PREMIER ACTUATOR MOUNTING POSITIONS – 73
Position "A" is standard for fail closed action. Position "B" is standard for fail open action.
Position "C" and "D" covers vertical piping.
FIGURE 9
PREMIER ACTUATOR MOUNTING POSITIONS – 9540R/991/PS2
Position "A" is standard for fail closed action. Position "B" is standard for fail open action.
Position "C" and "D" covers vertical piping.
Note: All basic valve dimensions are printed in the Premier-TB

IOM-48
10
9. Reposition packing flange (Ranger (14))
(Premier Unlined (5)) over packing studs (21)
for Ranger and Premier Unlined. Reinstall
live-loaded packing components (Ranger (27)
(28) (29) 2 sets). Reengage both packing stud
nuts (22) for Ranger and Premier Unlined. Set
torque level on packing stud nuts as indicated
in IOM-Ranger QCT, IOM-Premier EZO, or
IOM-Premier Unlined body assembly (BA)
instructions.
10. Reorient body assembly (BA) with respect to
the actuator assembly (AA). Rejoin the body
assembly (BA) to the actuator assembly (AA)
as described in this section, V.I. Ensure proper
plug (Ranger (6)) or disc (Premier (3.1)) posi-
tion prior to reinstalling lever arms (5). Ensure
that the lever arms (5) are “centered” within
the arm housing (4), and with respect to the
actuator stem linkage (8) (9) (10) (43) (44).
11. Recalibrate the unit (AA) (BA) and its positioner
((PA)).
D. Changing Failsafe Action:
1. The Model 48 actuator (AA) is field-reversible
for failsafe action with no additional parts
required.
2. It is possible that both of the following can
occur together for the degree of disassembly
undertaken:
a. Failsafe action reversed.
b. Change in actuator mounting position.
NOTE: This section will be limited to the procedures
for 2.a. above. If 2.b. is also desired, then it will be
necessary to reference Subsection C. herein for
the added procedural steps as required.
This subsection will thus be limited as indicated as
follows (reference Figures 6 – 9 herein for begin-
ning and end graphic orientations).
3. To reverse actuator (AA) failsafe action basi-
cally requires:
a. Moving lever arms (5) from left side of
valve’s stem (Ranger (7)) (Premier (3.2))
to right side, or vice versa. This is accom-
plished by removing actuator assembly
(AA) from body assembly (BA) and rotating
actuator (AA) 180° about the actuator’s
stem linkage (8) (9) (10) (43) (44). See
Figure 10 and Figure 11.
b. Rotating plug (Ranger (6)) or disc (Premier
(3.1)) by 90°; ie. from “closed” position to
“open” position, or vice versa.
c. Reconnecting actuator (AA) to body (BA)
with lever arms (5) also rotated 180°.
NOTE: Valve stem always goes CW to “close”,
viewed from stem-end.
4. Separate the actuator assembly (AA) from
the body assembly (BA) as described in this
Section, V.B.1. through V.B.9.
5. Rotate plug (Ranger (6)) or disc (Premier (3.1))
position 90° to new failsafe position.
6. Slide actuator assembly (AA) that has been
rotated 180° back over the stem-end (Ranger
(7)) (Premier (3.2)). Align bolt holes between
arm housing (4) and valve yoke (12).
7. Reengage bolting (24) securing arm housing
(4) to yoke (12). Torque bolting (24) to 17-20
ft-lbs (23-27 N-m).
8. Ensure that the reinstalled lever arms (5) are
also rotated 180° in the same reference as the
actuator assembly (AA) was rotated. (NOTE:
The repositioned arms (5) will appear to have
only changed relative position by 90° in another
plane.) Ensure the lever arms assembly (5)
is “centered” within the arm housing (4), and
with respect to the actuator stem (8) (9) (10)
(43) (44).
9. Rejoin the body assembly (BA) to the actuator
assembly (AA) as described in this Section,
V.I.
E. Diaphragm Replacement:
1. Place unit assembly (AA) (BA) onto a flat work
bench with actuator upper casing (1) on top
side; i.e. handwheel (58), if supplied, on top
side.
2. Ensure that all air pressure is released from
actuator assembly (AA) casing (1).
Product Begin End
Position Action Position Action
“A” ATO-FC “B“ ATC-FO
“C” ATO-FC “D” ATC-FO
“E” ATO-FC “F” ATC-FO
Ranger QCT “G” ATO-FC “H” ATC-FO
“B” ATC-FO “A” ATO-FC
“D” ATC-FO “C” ATO-FC
“F” ATC-FO “E” ATO-FC
“H” ATC-FO “G” ATO-FC
Premier EZO “A” ATO-FC “B” ATC-FO
or “C” ATO-FC “D” ATC-FO
Premier “B” ATC-FO “A” ATO-FC
Unlined “D” ATC-FO “C” ATO-FC

IOM-48 11
3. Ensure that manual handwheel (58) operator
is fully rotated upwards by loosening locking
lever (59) and rotating CCW (viewed from top
side) as far as possible.
4. Place a matchmark between actuator casings
(1) (2).
SPRING UNDER COMPRESSION. Prior to removing
flange bolting (27, 28, 41, 42) relieve range spring
(11) compression by rotating the handwheel or
adjusting screw assembly (58) CCW (viewed from
above handwheel (58) until all spring compression
is relieved. Failure to do so may result in flying
parts that could cause personal injury.
CCW-TO-OPEN
ATC-FO
(DIRECT)
Push Down-to-Close
CCW-TO-OPEN
ATO-FC
(REVERSE)
Push Down-to-Open
CCW-TO-OPEN
ATC-FO
(DIRECT)
Push Down-to-Close
CCW-TO-OPEN
ATO-FC
(REVERSE)
Push Down-to-Open
Figure 10
Ranger Plug vs. Lever Arm vs. Actuator Orientation
Figure 11
Premier Plug vs. Lever Arm vs. Actuator Orientation
NOTE: To switch “action” requires locating actuator stem
to opposite side of valve stem.
NOTE: To switch “action” requires locating actuator stem
to opposite side of valve stem.
5. Loosen all casing (1,2) flange bolting (27, 28,
41, 42) two revolutions. Pry apart the casings
(1,2) if “stuck” together.
6. In one revolution increments loosen all op-
posing nuts (41, 42) until the short bolting
(27, 41) disengages and can be removed.
Continue loosening extension nuts (42) in
the alternating, one revolution pattern ensur-
ing that the casings (1, 2) are being “pushed
apart”, until the extension bolting (28, 42) is
disengaged and removed.
7. Lift the upper casing (1) upwards and away
from the lower casing (2). Set upper casing
(1) aside.
8. Remove pivot screw (25) by rotating CCW
(viewed from above), and seal (56).
9. Pry diaphragm washer (52) loose. Clean
washer (52) of any rubberized sealant.
10. Prior to diaphragm (6) removal, inspect to see
where a diaphragm (6) leak may have been
caused by wearing against the upper case (1)
at any point. Inspect the upper case (1). NOTE:
The diaphragm (6) is a rolling diaphragm and
should NOT touch the upper case (1) at any
point of the piston’s (3) upwards/downwards
travel. If there is side movement of the piston
(3), further disassembly for inspection of range
springs (11) is mandatory. If there is topside
wear, uptravel stop washer (54) is not properly
adjusted.
11. Remove diaphragm (6) and discard.
12. Clean surface of piston (3) of any foreign
material that could cause a premature failure
of diaphragm (6) if covered. Turn diaphragm
(6) “inside-out”. Place diaphragm (6) onto
piston (3) centered over the center bolt hole
in piston (3); ensure that the smooth black
surface of diaphragm (6) is on the “pressur-
ized air-side”.
13. Place silicone sealant, Dow-Corning “Silastic”
#732 RTV or equal, around the diaphragm’s
(6) center bolt hole opening. Lay diaphragm
washer (52) onto sealant and centered over
bolt hole. Replace seal (56) on top of washer
(52).
14. Place a tool around the skirt circumference
of the piston (3) to secure during tightening;
use tape or similar material to prevent this tool
from leaving sharp edges that could damage
WARNING

IOM-48
12
the new diaphragm (6). Place Locktite #242,
or equal, thread sealant onto the threads of
pivot screw (25); engage and tighten screw
(25) to 15-20 ft-lbs (21-27 N-m) torque. NOTE:
Piston (3) must be held from rotating to prevent
the multiple nested range springs (11) from
tilting away from a common vertical centerline
between hubs of lower case (2), piston (3) and
range spring (11).
15. Fold the diaphragm (6) skirt from its inside-
out orientation, down and around the piston’s
(3) skirt. Using a rounded-end tool, push the
diaphragm (6) down between the lower casing
(2) sidewall and the piston’s (3) skirt, forming
a “valley”. Work diaphragm (6) to ensure that
all folds or “puckers” are taken away. Press
the diaphragm’s (6) lower/outer beaded edge
into the groove. Again, smooth out all folds or
puckers in diaphragm (6).
16. Place a light coating of graphite powder
lubricant, (dry molybdenum disulfide) on the
skirted areas of diaphragm (6), and into the
“valley”. This lubricant will prevent the dia-
phragm (6) from “sticking together” or abrading
itself during piston (3) travel.
17. If actuator (AA) is supplied with a manual hand-
wheel operator (MHWO), place a heavy-duty
wheel bearing grease, Lubriplate No. 130-AA,
or equal, into the v-notch in the head of the
pivot screw (25).
18. Inspect working of manual handwheel opera-
tor (MHWO) located within the upper casing
(1) for signs of wear. Go to Subsection F. for
maintenance of manual handwheel operator
(MHWO).
19. Place properly oriented upper casing (1) down
onto the lower casing (2) with matchmarks
aligned and all casing flange bolt holes cen-
tered. NOTE: The casing flanges (1) (2) will
not touch together.
20. Insert both extension bolts (28) through two
upper casing (1) bolt holes that are located
180° across from each other; these bolts
should extend through the lower casing (2)
flange enough to engage its companion exten-
sion nut (42). Place a friction-reducing thread
lubricant on the lower exposed threads of the
extension bolts (28).
21. Place the same friction-reducing thread lubri-
cant into the threaded portion of both extension
nuts (42). NOTE: Only one end of extension
nut (42) is threaded. It is not possible to en-
gage the extension bolting (28) (42) with the
extension nut (42) upside down; the threads
of the nut (42) will not engage.) Engage both
extension nuts (42) until they draw tight to the
lower casing (2) flange’s underneath side.
Place one short bolt (27) through a bolt hole
of upper flange (1) to serve as an indicator. In
one-revolution increments and an alternating
cross-pattern, draw the casing (1) (2) flanges
towards each other. When there is at least
one-half of the indicator short bolt (27) threads
exposed through the lower casing (2) fl
ange,
engage nut (41) until the short bolting (27)
(41) is finger-tight.
22. Place all short bolts (27) through the remaining
upper casing (1) flange bolt holes, and engage
each ones nut (41) until the short bolting (27)
(41) is finger-tight.
23. In an alternating cross-pattern, tighten all
flange bolting (27) (28) (41) (42) in one-
revolution increments. When all bolting (27)
(28) (41) (42) is hand-wrench tight, torque to
levels indicated below:
Item Torque Req’d
Nos. Description ft-lbs N-m
27, 41 Short Bolting 15–18 20–24
28, 42 Extension Bolting 8–12 11–16
24. Connect a temporary instrument air source
directly to the 1/4" FPT connection in the up-
per casing (1). Pressurize to the “Air Supply
Pressure” level as indicated in Table 2-4 of
WARNING
1. Elongated extension bolting (28) (42) is a safety
feature to allow relaxation of range springs (11)
to the piston’s (3) mechanical uptravel stop at
disassembly.
2. Extension bolting (28) (42) should ONLY be
replaced with factory replacements; do NOT
substitute conventional bolting.
3. Extension bolting (28) (42) MUST be located
180° opposite of each other in the flange bolt-
ing array. Failure to heed could cause personal
injury at a later disassembly.

IOM-48 13
Section IV.A.4. for the corresponding actual
benchset range of the actuator being serviced,
and test for leakage at upper casing (1) to
lower casing (2) joint. Also test for leakage at
manual handwheel operator (MHWO), rotat-
ing handwheel (58) in and out several times
during the test.
25. Release all air pressure into actuator upper
casing (1); remove air source from 1/4" FPT
connection.
wheel (58.1) end) back into the handwheel
gland (67). When stem (58.2) protrudes far
enough through gland (67), relocate locking
pliers to opposite end and rotate stem (58.2)
until stem (58.2) fully disengages.
12. Remove O-ring (62) from handwheel gland
(67).
13. Remove O-ring (63) from handwheel stem
(58.2).
14. Place parts (58.2) (59) (60) (64) (67) into a
suitable solvent and clean as much as pos-
sible, remove parts and allow to dry.
15. Inspect handwheel stem (58.2) with embedded
ball (64) for wear on ball (64). If ball (64) is
worn, or threads of stem (58.2) are damaged,
replace handwheel sub-assembly (58); i.e.
parts (58.1) (58.2) and (64).
16. If handwheel gland (67) shows signs of wear
in female threads (i.e. loose gauging), replace
handwheel gland (67) and self-tapping slot-
ted-head screw (65). NOTE: A replacement
handwheel gland (67) will require drilling a
new 5/32" x 1-1/16" (4mm x 25.5mm) deep
hole into the lip of the upper casing (1).
17. Install new O-ring (63) onto handwheel stem
(58.2).
18. Install new O-ring (62) onto handwheel gland
(67).
19. Place a thin coat of lithium grease on the
handwheel stem O-ring (63) and the immedi-
ate surrounding area of the handwheel stem
(58.2).
20. Engage the handwheel stem (58.2) into the
gland’s (67) underneath side. When the hand-
wheel (58.1) end of the stem (58.2) protrudes
through the gland’s (67) upper side, place a
new threadseal washer (61) over the stem’s
(58.2) upper end. Continue engaging stem
(58.2) until the O-ring (63) is pulled into the
gland (67).
21. Install washer (60) and locking lever (59) onto
stem (58.2).
22. Place handwheel stem (58.2) into a soft-jawed
vise. Position handwheel (58.1) onto stem
(58.2) with holes for pin (66) aligned. Insert
pin (66) and drive through stem (58.2) and
handwheel (58.1) far side. Remove handwheel
assembly (MHWO) from vise.
F. Manual Handwheel Operator:
1. Reference Item Number drawing at end of IOM
for details of the manual handwheel operator
(MHWO) sub-assembly.
2. Place unit (AA) (BA) on a flat work surface
with the handwheel (58) on topside.
3. Ensure all air pressure has been released from
actuator casing (1). Ensure handwheel (58)
is fully “backed-out” by rotating CCW (viewed
from above); i.e. is as “high” as possible.
4. Remove slotted-head screw (65) securing
handwheel gland (67) to upper casing (1).
5. Place a smooth-jawed wrench onto handwheel
gland (67) and rotate CCW (viewed from
above) to removal of the manual handwheel
operator sub-assembly (MHWO).
6. Place the sub-assembly (MHWO) into a vise,
grasping with leaded jaws on the coarse-
screwed handwheel stem (58.2) near the
base of the handwheel (58.1), oriented to
allow driving-out the rolled pin (66) securing
the handwheel (58.1) to the handwheel stem
(58.2).
7. Drive pin (66) out using a suitable punch and
locking pliers. Set pin (66) aside for reuse. Re-
move handwheel (58.1) from stem (58.2).
8. Rotate locking lever (59) CCW (viewed from
handwheel-end) to removal.
9. Slide washer (60) and threadseal washer
(61) off handwheel stem-end (58.2). Discard
threadseal washer (61).
10. Remove remaining engaged parts (67) (58.2)
from vise. Reorient horizontally in vise along
flats of handwheel gland (67).
11. Place stick punch in drive-pin hole and rotate
handwheel stem (58.2) CW (viewed from hand-

IOM-48
14
Benchset Free
Part Range Qty. of Height * Coating
Number psig (Barg) Springs in (cm) Color
830-H2-5-R9069-95 5-15 6 5.60 Grey
(0.34-1.03) (14.23)
* Acceptable ± 1/8" (± 3 mm)
23. Place heavy duty wheel bearing grease as
specified previously onto the stem-end ball
(64). Engage the gland (67) into the upper
casing (1) female opening. Align tapped open-
ing for self-tapping slotted-head screw (65).
24. Install slotted-head screw (65) fully.
G. Adjusting Screw Assembly and Actuator Plug
Maintenance:
1. Reference Item Number drawing at end of the
IOM.
2. Determine the portion of the text of Subsec-
tion F. above that would apply to the adjust-
ing screw assembly (ASA) counterpart of the
manual handwheel operator (MHWO) assem-
bly, and complete maintenance in a similar
procedure. NOTE: Adjusting screw assembly
(ASA) is ONLY applied to reverse-action,
ATO-FC Ranger QCT units (AA) (BA).
3. Determine the portions of the text of Subsection
F. previous that would apply to the actuator
plug (67) counterpart of the manual handwheel
operator (MHWO) assembly, and complete
maintenance in a similar procedure. NOTE:
Actuator plug (67) may be applied on all Pre-
mier units (AA) (BA) and ONLY direct-action,
ATC-FO Ranger QCT units (AA) (BA).
H. Replacement of Range Springs:
1. Replacement of actuator assembly (AA)
range springs (11) requires what is essen-
tially a complete actuator (AA) disassembly.
It is recommended that the range spring (11)
replacement should include:
a. diaphragm (6) replacement
b. O-ring(s) (62) (63) replacement
c. threadseal (61) replacement.
2. Separate the actuator assembly (AA) from
the body assembly (BA) as described in this
Section, V.B.1 through V.B.9.
3. Push piston (3) downwards by:
a. manual handwheel operator (MHWO)
being rotated CW (viewed from above
handwheel (58.1)) approximately one-half
of full travel.
b. pressurize actuator to approximately one-
half of the stated benchset range; i.e. for
5-15 psig (.34-1.03 Barg) pressurize to
approximately 10 psig (.69 Barg).
Do NOT stick hand or fingers into the arm housing (4)
when the actuator is pressurized. ONLY USE TOOLS
WITHIN ARM HOUSING (4).
4. Place a wrench on the hex surface of the ac-
tuator’s stem/pushrod (10). Rotate the push
rod (10) CCW (viewed from lower L.H. rod
end (9)); keep track of number of revolutions
to disengage from upper R.H. rod end (8) in
box below.
Number of revolutions of push
rod (10) required to disengage
from upper R.H. rod end (8). ___________
5. Allow piston (3) to travel upwards by:
a. manual handwheel operator (MHWO)
being rotated CCW (viewed from above
handwheel (58.1)) fully out/up.
b. releasing air pressure as applied per 3.b.
above; remove the air supply from actuator
upper casing (1).
6. Orient actuator assembly (AA) with upper cas-
ing (1) on top side. Disassemble the actuator
assembly (AA) to the point of diaphragm (6)
replacement as described in this Section V.E.1
through V.E.11.
7. Place a matchmark at flange of lower casing
(2) and correspondingly at piston (3). Lift off
piston (3) in a vertical direction to prevent
tipping range springs (11) over. Set piston
(3) on work surface upside down.
8. Remove all range springs (11) and set in a row
side-by-side. Inspect for any difference in the
spring (11) height or verticality. Replace any
abnormal spring(s) (11). Replace any springs
(11) that show cracks, nicks, damaged epoxy
coating, corrosion, etc. Inspect springs (11)
using data in table below as the “normal”:
WARNING

IOM-48 15
Benchset Range Quantity
psig (Barg) of Springs Array
5-15 (0.34-1.03) 6
9. Inspect clevis (7), upper R.H. rod end (8), clevis
pin (48), washers (53) and hairpin (49) for signs
of looseness and/or wear; replace any worn
parts. Check bolting (26) for looseness; tighten
as necessary to 15-18 ft-lbs (20-23 N-m).
Hub w/NO
Spring (11)
Hub With
Spring
(11)
Figure 12
Piston & Clevis Close-up
12. Reinstall a new diaphragm (6) and reassemble
the upper casing (1) as described in this Sec-
tion, V.E.12 through V.E.24.
13. Using air pressure of V.E.24., pressurize
the actuator upper casing (1) to the upper
value of the stated benchset range plus 2 psi
(0.14 Bar); i.e. for 5-15 psig (0.34-1.03 Barg)
benchset range, pressurize to 15+2 = 17 psig
(1.03+0.14 = 1.17 Barg). This pressure level
should cause the piston’s (3) lower skirt-edge
to bottom out on the lower casing (2).
14. Using only tools (i.e. no fingers within arm
housing (4)) to grasp the actuator stem/push
rod (10), insert push rod (10) with intercon-
nected parts (9) (43) (43) (44) (54) into arm
housing (4) and engage into dangling upper
R.H. rod end (8) by rotating CW (viewed from
lower L.H. rod end (9)). Count number of
revolutions of push rod (10) engagement to
match those recorded in Article 4., previous,
at removal.
15. Release all air pressure into actuator upper
casing (1); remove air source from 1/4" FPT
connection.
16. Join the actuator assembly (AA) to the body
assembly (BA) as described in this Section,
V.I.
I. Joining of Body Assembly (BA) to Actuator
Assembly (AA):
1. Determine proper orientation of actuator
(AA)-to-body (BA) for the following consid-
erations:
• failsafe action
• installed piping orientation.
Reference Sub-sections V.C. and V.D. to see
schematics of orientations available.
2. Position body assembly (BA) on a flat work
surface. Orient such that the actuator as-
sembly (AA) can be oriented with the top of
the actuator upper casing (1) on topside; i.e.
manual handwheel operator sub-assembly
(MHWO) stem (58.2) vertically oriented, if
supplied.
3. Using an overhead hoist, lift the actuator
assembly (AA) (with position indicator ap-
paratus (13,14,15,16,17,31,31,34), lever arm
apparatus (5,5,12,40,46,50,50), end-of-shaft
10. Place range springs (11) back onto hubs of
lower casing (2) per following table:
NOTE: Every spring (11) has another spring (11) 180°
across/opposite.
11. Aligning matchmarks of Article 7. above,
reposition piston (3) back onto top side of
range spring (11) array. Using a mirror tool
and flashlight, look through the rectangular
opening in the lower casing (2) from within the
arm housing (4) to ensure that the piston (3)
hubs are centered within the ID of the range
spring (11) coil. It may be necessary to use
a tool to move the upper end of the range
spring (11) as necessary to be “captured” by
a piston (3) hub. Each spring (11) MUST be
captured by a hub on top and bottom ends.

IOM-48
16
bearing (18), bearing flanges (19) and cover
plate (20) removed) properly oriented and shift
laterally over the protruding stem (Ranger (7),
Premier (3.2)). Bring the round opening of
the arm housing (4) into position against the
mounting yoke (12). Raise/lower/tip/rotate the
actuator assembly (AA) to align at least one
bolt hole of the yoke (12) with one bolt hole
in the arm housing (4). Insert one cap screw
(24) from behind the yoke's (12) bolt hole and
engage with the tapped opening in the arm
housing (4); finger tighten cap screw (24).
4. Reposition actuator assembly (AA) as required
to align the remaining bolt holes securing
yoke (12) with arm housing (4). Insert the cap
screws (24) and finger-tighten.
5. (Wrench-tighten in one-half revolution incre-
ments and in an alternating cross-pattern
the three cap screws (24) securing actuator
assembly (AA) to body assembly (BA). Final
tightening should be by torque wrench to 17-
20 ft-lbs (23-27 N-m)
6A. For units (AA, BA) with Model 73N-B P/P
positioner:
a. Secure characterization cam (12) properly
oriented over the two rolled spring pins
(50) stuck into the inner lever arm (5).
b. Place the outer lever arm (5) over the
two spring pins (50) with the bolt holes
aligning. Press the apparatus (5,50,50,5)
together.
6B. For Units (AA, BA) with no positioner, Model
9540R P/P positioner or 991 or PS2 I/P:
a. Similar to 6A. above, except a spacer
washer (12) replaces the cam (12) of a
Model 73N-B P/P positioner.
7. Position valve plug (Ranger (6)) / disc (Premier
(3.1) in the proper “Full Closed” or “Full Open”
position. NOT FOLLOWING THIS ARTICLE
WILL CAUSE MECHANICAL DAMAGE TO
THE UNIT’S (AA, BA) LINKAGE MECHA-
NISM!
8. Place properly oriented lever arm apparatus
(5,50,12,50,5) over shaft’s (Ranger (7), Pre-
mier (3.2)) square end and push into place
while holding lower L.H. rod end (9) “swung”
aside so as to not interfere. NOTE: For units
(AA, BA) with 73N-B P/P positioner, it will be
necessary to “swing” the feedback linkage
subassembly ((72)) out of the way as the
lever arm apparatus (5,50,12,50,5) is pushed
into place. Center-align lever arm apparatus
(5,50,12,50,5) transversely within the arm
housing (4), directly over stop screw (35).
9A. For units (AA, BA) with Model 73N-B P/P po-
sitioner: Place indicator spacer (17) over end
of shaft (Ranger (7), Premier (3.2)) properly
oriented for travel indicator (16) to be “located”
by spring pin (51).
9B. For units (AA, BA) with Model 9540R P/P
positioner or 991 or PS2 I/P positioner: Ref-
erence the IOM-9540R or 991/PS2 IOM for
proper instructions on reinstallation of indicator
spacer (17) and drive coupling ((32)).
10. Align the bolt holes in lever arms (5) and lower
L.H. rod end (9). NOTE: For units (AA, BA)
with ATO-FC action it will be necessary to
offset “stem windup” by –
a. Rotating manual handwheel operator
(MHWO) handwheel (58.1) approximately
1-3 revolutions CW (viewed from above
handwheel) until the bolt holes of lever
arms (5) and lower L.H. rod end (9) are
aligned.
b. Pressurize actuator casing (1) only until
the bolt holes of the lever arms (5) and
the lower L.H. rod end (9) align.
11. Insert shoulder bolt (40) through the round
opening of the arm housing (4) and into the
bolt holes of lever arms (5) and lower L.H. rod
end (9).
12. Ensure that lever arm apparatus (5,50,12,50,5)
is transversely centered within the arm hous-
ing (4). Engage lock nut (46) together with
shoulder bolt. Wrench-tighten to a torque of
15-20 ft-lbs (20-27 N-m).
13. Position bearing flanges (19) with retainer ball
bearing (18) over the spacer (17). Align the
bearing flanges' (19) bolt holes with the arm
housing (4) bolt holes.
14A. Units (AA, BA) with Model 73N-B or without
postioner:
a. Insert rolled spring pin (51) into indicator
spacer (17). Pin (51) will protrude ap-
proximately 1/16" (1.5 mm).
b. Position travel indicator (16) onto end of
shaft (Ranger (7), Premier (3.2)) impaling
over protruding spring pin (51) and aligning
with shaft-end tapped opening with hole
in travel indicator (16). Align lock-tooth
washer (55) on spacer (17) and secure

IOM-48 17
travel indicator (16) to shaft (Ranger (7),
Premier (3.2)) with cap screw (32) using a
7/32" allen key wrench until firmly tight.
c. Position cover plate (13) over the bearing
flanges (19) aligning the cover plate (13)
bolt holes with those of the bearing flanges
(19). Hold cover plate (13) on outer edge
with fingers. NOTE: Ensure that the three
tapped holes in the coverplate (13) are
near the 1:o'clock, 5:o'clock and 9:o'clock
positions.
d. Position travel indicator dial (15) onto
cover plate (13) properly oriented.
e. Position clear plastic dial lens (14) over
indicator dial (15), aligning bolt holes of
lens (14), dial (15) and cover plate (13).
f. Secure lens (14), dial (15), cover plate
(13) and bearing flanges (19) to arm
housing (4) by engaging the three socket
Figure 13:
ATO-FC (Reverse) Action ATC-FO (Direct) Action
head cap screws (31) using a 3/16" al-
len key wrench and tighten firmly; do not
over-tighten and crack plastic lens (14).
NOTE: It may be necessary to rotate the
actuator manual handwheel operator (58)
downwards, or alternately supply a small
level of air pressure (5-7 psig (0.35-0.50
Barg) to assist in aligning bolt holes for
cap screws (31). Do not tighten one single
cap screw (31) until all cap screws (31)
are partially thread-engaged.
14B. Units (AA, BA) with Models 9540R or 991 or
PS2 positioners: Reference the IOM-9540R
or 991 or PS2 IOMs for proper instructions on
reinstallation of positioner ((PA)) assembly to
shaft-end.
SECTION VI
VI. CALIBRATION
A. General:
1. This section covers calibration of the actuator
assembly (AA) to a Ranger QCT, Premier EZO,
or Premier Unlined body assembly (BA).
2. Positioner, if installed, requires reference to
the specific positioner model IOM for proper
calibration procedure.
3. All indicated Item Numbers that are with re-
spect to this Model 48 actuator assembly (AA)
are in parenthesis but are not underscored;
i.e. (20). Item Numbers that relate to the body
assemblies (BA) are in parenthesis and are
underscored; i.e. (7). Item Numbers that relate
to the positioners ((PA)) are in a double set of
parenthesis and are underscored; i.e. ((3)).
4. This Section assumes that the actuator as-
sembly (AA) and body assembly (BA) have
been interconnected together as recorded in
Section V.
5. This Section assumes that the calibration is
performed with the valve unit removed from
its normal pipeline location, and is in a repair
shop located on a suitable work bench. Actua-
tor stem/push rod subassembly (8, 9,10, 43,
43, 43, 44, 54) should be oriented vertically.
6. Premier EZO (lined) body assembly (BA)
MUST be properly clamped between two ANSI
150# RF weld neck flanges. NOTE: Flanges
MUST be of weld neck type! Clamping of liner
(Premier (10)) will prevent false movement of
liner (Premier (10)) within body (1).

IOM-48
18
Do not pressurize actuator assembly (AA) beyond the
“MAX ACTUATOR PRESSURE” level/value indicated
on the unit’s nameplate (21). Failure to heed may
cause catastrophic failure of upper casing (1) leading
to flying parts.
WARNING
CAUTION
7. In this Section reference will be made to three
phrases –
a. “lower value of benchset range”,
b. “higher” value of benchset range”,
c. benchset range.
The meaning of these phrases is summarized
in the following table.
Benchset Lower Higher
Range Value of Value of
* Benchset Benchset
Range Range
5-15 psig 5 psig 15 psig
(.34-1.03 Barg) (0.34 Barg) (1.03 Barg)
* Identified on nameplate (21) as “Bench” or “Input Range”.
B. Actuator Stem/Push Rod Adjustment:
1. Actuator stem/push rod linkage (8, 9, 10, 43,
43, 43, 44, 54) when properly adjusted will-
a. Provide the proper benchset range.
b. Provide 90° rotation.
c. Provide proper valve stem (Ranger (7),
Premier (3.2)) “windup”.
2. Ensure that manual handwheel operator
(MHWO) has handwheel (58.1) backed fully
out by rotating CCW (viewed from above
handwheel (58.1)).
3. Remove cover plate (20) by removing four
screws (36).
4. Remove travel indicator dial (15), dial lens
(14), coverplate (13), bearing flanges (19) and
bearing (18) by removing three cap screws
(31) using a 3/16" allen key wrench.
5. Units with ATO-FC (Reverse) Action:
a. Disconnect the lower L.H. rod end (9) from
engagement with the lever arms (5) by
removing shoulder bolt (40) and lock nut
(46). It will be necessary to remove stem
(Ranger (7), Premier (3.2)) “windup” as
described in Section V.B.4.
b. Swing the lever arms (5) down against
the travel stop screw (35); this “opens”
valve plug (6)/disc (3.1).
c. Loosen lower upstop jam nut (43) from
securing upstop washer (54); back nut
(43) to the root of its threads on push rod
(10).
d. The upper R.H. rod end (8), lower L.H. rod
end (9), and push rod (10) act together as
a turnbuckle; the upper end is standard
right-hand threaded while the lower end is
left-hand threaded. To ensure maximum
and equal engagement of rod ends (8,9)
to the push rod (10), it is recommended
that the linkage (8,9,10) be fully engaged
and then readjusted as a safety precau-
tion.
Unequal engagement adjustment of rod ends (8,9) and
push rod (10) can cause failure of a rod end (8,9)-to-
push rod (10) connection.
a. If this occurs during bench maintenance, the
parts (8,9,10) could snap apart and cause
personal injury.
b. If this occurs during installed operation, con-
trol function would be lost.
RANGER QCT®
SERIAL NO.
BODY SIZE MATERIAL
BODY RATING CLASS
END CONNECTION
MAX ALLOWABLE WORKING PRESSURE
MAX.
MAX. WORKING ∆P PSIG
PLUGSTEM
SEAT MATERIAL
PACKING RATED Cv
INHERENT FLOW CHAR. RATED Kv
RATED TRAVEL TRIM NUMBER
FLOW TOWARD
FAILURE POSITION
OF PLUG
MTG. POSITION
PSIG
MAX ACTUATOR PRESSURE
INPUT RANGE PSIG
OPTIONS
PRODUCT CODE
TAG NO.
PSIG @ 100°F @ 38°C
90°
WARNING: REFER TO IOM PRIOR TO MAINTENANCE
CASHCO, INC.
ELLSWORTH, KS.
U.S.A.

IOM-48 19
e. Loosen lower L.H. rod end (9) jam nut (44)
by rotating CW (viewed from above); this
nut (44) is “left-handed”. Back nut (44) to
the root of its threads on push rod (10).
f. Using a suitable tool to prevent lower L.H.
rod end (9) from rotating, rotate push rod
(10) CCW (viewed from above) until upper
end of push rod (10) is fully engaged with
upper R.H. rod end (8). NOTE: If lower L.H.
rod end (9) reaches full engagement with
lower push rod (10) end first, remove tool
securing against rotation, and allow lower
L.H. rod end (9) to rotate with push rod
(10). Once upper end of push rod (10) is
fully engaged with upper R.H. rod end (8),
rotate lower L.H. rod end (9) CW (viewed
from above) until it is fully engaged.
g. Provide a temporary air supply with an
inline adjustable airset to the actuator
upper casing (1) connection.
h. Reference the nameplate (21) attached
to the cover plate (20) that is fastened to
the arm housing (4). Determine the bench
setting from the nameplate (21).
i. Pressurize the actuator (AA) to the lower
value of the benchset range pressure
indicated on the nameplate (21).
j. While holding lower L.H. rod end (9) out
of way, lift lever arms (5) up as far as
possible (this will close plug (Ranger (5))/
disc (Premier (3.1)).
k. Rotate lower L.H. rod end (9) as required
to orient the holes of the rod end (9) and
the lever arms (5) in the same plane.
Swing lower L.H. rod end (9) between
the lever arms (5).
l. Rotate the push rod (10) CW (viewed
from above) lowering the lower L.H. rod
end (9) until it’s hole is centered with the
lever arm (5) holes. Center lever arms (5)
within arm housing’s (4) transverse axis;
i.e. center over travel stop screw (35).
m. Reinstall the shoulder bolt (40) through
the lever arm (5) and lower L.H. rod end
(9) holes. Finger-tighten lock nut (46) onto
shoulder bolt (40). Using a 1/4" allen key
wrench to secure the head of shoulder
bolt (40), torque wrench-tighten nut (46)
to 15-20 ft-lbs (20-27 N-m).
n. Tighten lower L.H. jam nut (44) down until
locked against lower L.H. rod end (9); nut
(44) is “left-handed”.
o. Add approximately 6 psig (0.4 Barg) to the
actuator’s (AA) lower value of benchset
range. This will extend the actuator stem/
push rod sub-assembly (8, 9, 10, 43, 43,
43, 44, 54) downwards to allow loosen-
ing double jam nuts (43) on top side of
uptravel stop washer (54).
p. Release air pressure down to the lower
value of benchset range.
q. Rotate lower jam nut (43) to raise uptravel
stop washers (54) until the gap clearance
between the lower casing (2) and the
top side of the washer (54) is 1/8"±1/16"
(3mm±1.5mm).
r. Repressurize actuator (AA) to level as
indicated in Article 5.o. above. Tighten
the lower of the two upper jam nuts (43)
until it is tight, and secures the uptravel
stop washer (54). Tighten the upper of
the two upper jam nuts (43) down to
secure the double jam nut (43) locking
effect. Retighten lower jam nut (43) on
underneath side of washer (54).
s. Release all air pressure from actuator
upper casing (1). Repressurize slowly to
confirm that as the pressure reaches the
lower value of the benchset range (see
Article 5.i. previous), the actuator stem/
push rod sub-assembly (8, 9, 10, 43, 43,
43, 44, 54) begins to move. If movement
is prematurely occurring (i.e. movement
at less than the lower benchset range
value), the length of the actuator stem
sub-assembly (8, 9, 10, 43, 43, 43, 44,
54) must be shortened. Repeat procedure
from Article 5.a. through to this Article. If
movement is late (i.e. movement at more
than the lower benchset range value), the
length of the actuator stem sub-assembly
(8,9,10,43,43,43,44,54) must be length-
ened (i.e. increased). Repeat procedure
from Article 5.a. through to this Article. It
is recommended that adjustment of ac-
tuator stem sub-assembly (8, 9, 10, 43,
43, 43, 44, 54) be made in one revolution
of push rod (10) increments. Repeat as
necessary.
t. Slowly increase air pressure in upper cas-
ing (1) until reaching the higher value of
the benchset range; i.e. pressurize only
until plug (Ranger (5))/disc (Premier (3.1))
is in the full open position.
u. Release all air pressure in actuator upper
casing (1). Repeat Article 5.t above and
this article, cycling valve unit (AA, BA)
closed-open-closed-open-closed several
times.
v. With valve plug (Ranger (5)) / disc (Premier
(3.1)) in “full closed” position, reinstall
bearing (18), bearing flanges (19), cover-
plate (13), dial lens (14) and dial (15) with
three cap screws (31). NOTE: Position

IOM-48
20
Benchset Higher Value Adder Loading
Range of Benchset Value – Pressure –
Range - “A” “B” “C”
_____ psig ____ psig 2 psig ____ psig
____ Barg ____ Barg .14 Barg ____ Barg
dial (15) such that travel indicator (16)
shows “0°” travel before fully tightening
screws (31).
w. Completion to this point completes the
benchset range adjustment. Proceed
to Subsection VI.C. to adjust 90° travel
stop.
6. Units with ATC-FO (Direct) Action:
a. Disconnect the lower L.H. rod end (9)
from engagement with the lever arms (5)
by removing shoulder bolt (40) and lock
nut (46).
b. Swing the lever arms (5) down and as
close as possible to the travel stop screw
(35); this “closes” valve plug (6) / disc
(3.1). Ensure that the “closed” position
is reached by observing actual plug (6) /
disc (3.1) position.
c. Loosen lower upstop jam nut (43) from
securing upstop washer (54); back nut
(43) to the root of its threads on push rod
(10).
d. The upper R.H. rod end (8), lower L.H. rod
end (9), and push rod (10) act together as
a turnbuckle; the upper end is standard
right-hand threaded while the lower end is
left-hand threaded. To ensure maximum
and equal engagement of rod ends (8,9) to
the push rod (10), it is recommended that
the linkage (8,9,10) be fully engaged and
then readjusted as a safety precaution.
Unequal engagement adjustment of rod ends (8,9) and
push rod (10) can cause failure of a rod end (8,9)-to-
push rod (10) connection.
a. If this occurs during bench maintenance, the
parts (8,9,10) could snap apart and cause
personal injury.
b. If this occurs during installed operation, control
function would be lost.
e. Loosen lower L.H. rod end (9) jam nut (44)
by rotating CW (viewed from above); this
nut (44) is “left-handed”. Back nut (44) to
the root of its threads on push rod (10).
f. Using a suitable tool to prevent lower L.H.
rod end (9) from rotating, rotate push rod
(10) CCW (viewed from above) until upper
end of push rod (10) is fully engaged with
upper R.H. rod end (8). NOTE:If lower L.H.
rod end (9) reaches full engagement with
lower push rod (10) end first, remove tool
securing against rotation, and allow lower
L.H. rod end (9) to rotate with push rod
(10). Once upper end of push rod (10) is
fully engaged with upper R.H. rod end (8),
rotate lower L.H. rod end (9) CW (viewed
from above) until it is fully engaged.
g. Provide a temporary air supply with an
inline adjustable airset to the actuator
upper casing (1) connection.
h. Reference the nameplate (21) attached
to the cover plate (20) that is fastened to
the arm housing (4). Determine the bench
setting from the nameplate (21).
i. Rotate lower L.H. rod end (9) until the rod
end (9) and the lever arm’s (5) holes are
in the same plane.
j. Loosen jam nut (45) and rotate downtra-
vel stop screw (35) out by rotating CCW
(viewed from below screw’s (35) head)
until just barely engaged in arm housing
(4).
k. Pressurize actuator (AA) to the higher
value of the benchset range pressure
indicated on the nameplate (21), while
“guiding” the lower L.H. rod end (9) hub
to its proper position between the lever
arms (5).
l. Pressurize actuator (AA) to a level as
indicated by “C” pressure in table that
follows according to the formula: “A” +
“B” = “C”.
CAUTION
m. Adjust the push rod (10) by rotating CW
(viewed from above) until the holes of the
lever arms (5) and the lower L.H. rod end
(9) are centered and the valve is in the
“closed” position.
n. Reinstall the shoulder bolt (40) through
the lever arm (5) and lower L.H. rod end
(9) holes. Finger-tighten lock nut (46) onto
shoulder bolt (40). Using a 1/4" allen key
wrench to secure the head of shoulder
bolt (40), torque wrench-tighten nut (46)
to 15-20 ft-lbs (20-27 N-m).
o. Loosen double jam nuts (43,43) on top
side of uptravel stop washer (54).
p. With valve in “closed” position, reinstall
bearing (18), bearing flanges (19), cov-
erplate (13), dial lens (14) and dial (15)
with three cap screws (31). NOTE: Po-
sition dial (15) such that travel indicator