DeZurik G-SERIES User manual

DeZURIK G-SERIES
HANDWHEEL AND
CHAINWHEEL ACTUATORS
Instruction D10083
August 2012

DeZURIK
G-Series Handwheel and Chainwheel Actuators
D10083 © 2012 DeZURIK, Inc.
Instructions
These instructions provide information about the DeZURIK G-Series Handwheel and Chainwheel
actuators. These instructions are intended for personnel who are responsible for the installation,
operation and maintenance of G-Series actuators.
Safety Messages
All safety messages in the instructions are flagged with an exclamation symbol and the word Caution,
Warning or Danger. These messages indicate procedures that must be followed exactly to avoid
equipment damage, personal injury or death. Safety label(s) on the product indicate hazards that can
cause equipment damage, personal injury or death.
Safety label(s) on the product indicate hazards that can cause equipment damage, personal injury or
death. If a safety label becomes difficult to see or read, or if a label has been removed, please contact
DeZURIK for replacement label(s).
Personnel involved in the installation or maintenance of valves should be constantly
alert to potential emission of pipeline material and take appropriate safety precautions.
Always wear suitable protection when dealing with hazardous pipeline materials. Handle
valves, which have been removed from service with suitable protection for any potential
pipeline material in the valve.
Inspection
Your G-Series actuator has been packaged to provide protection during shipment. Carefully inspect
the unit for damage upon arrival and file a claim with the carrier if damage is apparent.
Parts
Recommended spare parts are listed on the assembly drawing. These parts should be stocked to
minimize downtime.
Order parts from your DeZURIK sales representative, or directly from DeZURIK. When ordering parts,
please include the 7-digit part number and 4-digit revision number (example: 9999999R000) located on
the data plate attached to the valve assembly. Also include the part name, the assembly drawing
number, the balloon number and the quantity stated on the assembly drawing.
DeZURIK Service
DeZURIK service personnel are available to install, maintain and repair all DeZURIK products.
DeZURIK also offers customized training programs and consultation services.
For more information, contact your local DeZURIK sales representative or visit our website at
www.dezurik.com.

DeZURIK
G-Series Handwheel and Chainwheel Actuators
August 2012 Page 3D10083
Table of Contents
Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
4
Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
4
Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
5
Changing the Actuator Position - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
5
Disassembling the Actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
6
R
eassembling the Actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7

DeZURIK
G-Series Handwheel and Chainwheel Actuators
D10083 Page 4August 2012
Description
These instructions cover adjustments and maintenance for a DeZURIK G-Series handwheel or
chainwheel actuator. Two sizes, G12 and G16, are available. See Figure 1 to identify which unit you
have.
This actuator can be furnished with either cast iron or ductile iron gears.
The ductile iron gear is necessary for submerged or buried service valves or when a 2"
operating nut is installed on the input shaft. Breakage of the gear teeth will occur if cast
iron gears are torqued above 200 ft-lb's.
Cast Iron & Ductile Iron are similar in appearance: To determine if the gear material is ductile
iron, remove the cover as described in the ACTUATOR DISASSEMBLY Section. G12 & G16
gears have "M199" cast in raised letters on either the top or under side of the web between the
hub and the teeth, removal of the gear is necessary to see the marking. If there is no "M199"
on the gear, the material is cast iron.
Figure 1- Actuator Identification

DeZURIK
G-Series Handwheel and Chainwheel Actuators
August 2012 Page 5D10083
Lubrication
The G-Series Actuator has been lubricated at the factory and requires no routine lubrication. If the actuator is
disassembled, lubricate the
worm gear and bearings and pack the gear sector teeth using one of these
lubricants:
- Keystone Zeniplex-1 (recommended)
- Amoco Amolith Grease #1-EP (alternate)
- Amsoil GHD (alternate)
- Mobil Mobilux EP 1 (alternate)
- Petro-Canada Vultrex MPG EP 1 (alternate)
- Shell Alvania EP 1 (alternate)
- Texaco Multifak EP 1 (alternate)
Adjustments
The closed position stop is a set screw located in the side of the actuator housing on the G12 unit, and
is located in the end of the extension cap on the G16 unit.
Adjust the set screw to position the valve in the closed position when the gear or rack contacts the set
screw. (Read the instruction sheet for the valve. Additional information on the proper closed position
may be included.)
Changing the Actuator Position
The possible actuator mounting positions are shown on the customer drawing. To change the mounting
position:
1. Shut off line pressure and close the valve.
2. Remove the actuator cover screws and the cover.
3. Remove the screws that fasten the actuator to the adaptor.
Note: These screws are located on the underside of the actuator.
4. Remove the actuator from the valve.
5. Remove the gear sector.
Note: Rotate it in the same direction and for the same number of degrees as the actuator will be
rotated, and reinstall the gear sector in the actuator. Be sure the key and keyway are engaged.
6. Place the actuator on the valve in the desired position, and install the screws that fasten the
actuator to the adaptor.

DeZURIK
G-Series Handwheel and Chainwheel Actuators
D10083 Page 6August 2012
Disassembling the Actuator
G12 UNITS
1. Shut off line pressure if the actuator is mounted on an installed valve.
2. Remove the actuator cover screws and the actuator cover.
3. Note the position of the gear sector—it must be installed in the same position during
reassembly.
4. Remove the gear sector.
5. Remove the pipe plug in the housing, and drive out the pin that connects the worm gear to the
handwheel drive shaft.
6. Remove the drive shaft, handwheel, and bearing race.
G16 UNITS
1. Shut off pipeline pressure if the actuator is mounted on an installed valve.
2. Remove the actuator cover screws, the actuator cover, the screws and the pointer.
3. Mark the teeth on the gear and rack that are engaged.
4. Remove the four screws that fasten the drive shaft seal housing to the actuator housing.
5. Turn the handwheel to remove the drive shaft seal assembly complete with handwheel and
drive shaft.
6. To disassemble the drive shaft seal housing assembly:
a. To remove the collar and the set screw, and turn the threaded collar out.
Note: Because this collar retains the lower bearing, the bearing will also be removed.
b. To remove the seal housing, remove the handwheel pin and handwheel. Then lift the
seal housing off the shaft.
Note: This will allow access to the top bearing.
c. To remove the sleeve, remove the pin that connects it to the shaft.
7. Remove the gear sector, the rack, the pin and the rack guide.

DeZURIK
G-Series Handwheel and Chainwheel Actuators
August 2012 Page 7D10083
Reassembling the Actuator
G12 UNITS
1. Assemble the drive shaft and handwheel, worm gear, thrust bearing, and bearing race.
2. Install the pin that connects the handwheel drive shaft and the worm gear.
3. Install the pipe plug in the housing.
4. Lubricate the worm gear and the gear sector with Keystone Zeniplex-1, and place the gear
sector on the plug stem in the same position as it was when disassembled.
5. Fasten the actuator cover to the actuator housing.
G16 UNITS
1. Assemble the drive shaft seal housing assembly:
a. Pin the sleeve to the shaft.
b. Install the top bearing, seal housing, and handwheel.
c. Pin the handwheel.
d. Install the lower bearing and threaded collar.
e. Install the set screw in the collar.
2. Lubricate the rack guide, rack and gear sector with Keystone Zeniplex-1.
3. Pin the rack guide in place.
Note: Position the pin so it does not protrude into the housing.
4. Install the gear sector and rack with the proper teeth engaged.
5. Install the drive shaft seal housing.
6. Continue turning the handwheel until the drive shaft seal housing is in place against the actuator
housing flange (marked P), and install the screws.
7. Fasten the actuator cover to the actuator housing.
8. Install the pointer.