Emerson Hytork XL26 Instruction manual

Installation, Operation & Maintenance Manual
MAC050515 EN Rev. D
February 2018
Hytork XL Pneumatic Actuator

Table of Contents
February 2018
Installation, Operation and Maintenance Manual
MAC050515 EN Rev. D
I
Table of Contents
1 Important Safety Procedures ........... 1
2 ATEX instructions for use in (potential)
explosive areas ....................................2
2.1 Intended use...............................................2
2.2 Safety Instructions......................................2
2.3 Temperature range for (potential)
explosive areas............................................2
3 Operating Media, Pressures and
Temperatures .................................. 3
3.1 Operating media ........................................3
3.2 Operating Temperature range ...................3
4 Actuator to Valve Installation........... 3
4.1 Bi-directional Travel Stops ..........................3
4.2 Travel Stop Adjustments.............................3
5 Piping Instructions........................... 3
6 Solenoid Valves on
Spring Return Actuators ......................4
7 Position Feedback............................ 4
8 Spares Recommendations................ 4
9 Disassembly Procedure.................... 4
9.1 End cap and springs disassembly on
Spring Return actuators..............................4
9.2 Changing spring sets on XL26 to XL681 .....5
9.3 End cap disassembly on
Double Acting actuators ............................5
9.4 Piston disassembly .....................................5
9.5 Pinion disassembly .....................................5
9.6 Inspection...................................................5
10 Assembly Instructions...................... 6
10.1 Pinion Assembly .........................................6
10.2 Alignment of pinion for correct piston
assembly ................................................ 6
10.3 Piston Assembly .........................................6
10.3.1 Clockwise rotation ........................................6
10.3.2 Counter-Clockwise rotation ..........................6
10.4 Travel stop assembly...................................7
10.5 End cap assembly on double acting
actuators ....................................................7
10.6 Spring Return Actuators .............................7
10.6.1 Spring set adjustments..................................7
10.6.2 Installing the Springs.....................................8
11 Testing the Hytork Actuator............. 8
11.1 Testing and Cycling of Infrequently
Used or Stored Actuators ...........................8
12 Retractor Rods ................................. 8
12.1 Spring Removal System Board....................8
13 Service............................................. 8
14 Grease Specification......................... 8
15 Parts and Materials .......................... 9
Contents

1
Installation, Operation and Maintenance Manual
MAC050515 EN Rev. D
Hytork XL
February 2018
1 Important Safety Procedures
Table 1. Applicable Models
XL 26 XL 281 XL 2586
XL 71 XL 426 XL 4581
XL 131 XL 681
XL 186 XL 1127
XL 221 XL 1372
Hytork XL actuators are only intended for use in
large-scale xed installations excluded from the
scope of Directive 2011/65/EU on the restriction of
the use of certain hazardous substances in electrical
and electronic equipment (RoHS 2).
Installation, adjustment, putting into service, use,
assembly, disassembly and maintenance of the
Actuator is strictly reserved to qualied personnel.
Before installation, operation and maintenance, read
the relevant sections of:
- This manual
- Quick Reference Guide: DOC.QRG.XL
!CAUTION - BEFORE YOU START
• Always disconnect the Air and Electrical
supplies before carrying out any form of
maintenance on an Actuator.
• When removing any ball valve or plug valve
assemblies from a pipe system, isolate the
piping system on which the Actuator is
installed and relieve any media pressure
that may be trapped in the valve cavities
before removing the Actuator for
maintenance.
• Always contain the Spring tension with
Hytork Retractor Rods as explained in
Section 9 (Disassembly procedure).
Follow instructions for using the Retractor
Rod carefully. Only Hytork manufactured
or approved Retractor Rods are to be used
for Spring removal. As with any threaded
tool that is frequently used Retractor Rods
should be checked to ensure that the
threads are not worn or damaged in any
way and greased regularly. Any damaged
or worn Rods must not be used and must
be destroyed.
• Never attempt to ‘BLOW OUT’ the Pistons
or the End caps from the Actuator Body by
using air pressure.
• Never turn the stop screws completely out
when the actuator is under pressure.
Numbers in brackets (#) refer to parts on the exploded
view drawing (Chapter 15). All Hytork XL Spares Kits
are supplied with SAFEKEY assemblies (13/14) cut to an
exact length which will t the circumference of the End
Cap (21) when fully assembled into the Actuator.
Any shortened SAFEKEY must not be used.
If in doubt contact Emerson or your local Hytork
Stocking Distributor. Read the relevant sections
carefully before continuing.
IMPORTANT - STORAGE
• Failure to follow proper storage guidelines
will void warranty.
• Warehouse storage: Hytork Actuators
should be stored in a clean, dry warehouse,
free from excessive vibration and rapid
temperature changes. Actuators should not
be stored on any oor surface.
• On site storage: Hytork actuators should be
stored in a clean, dry warehouse, free from
excessive vibration and rapid temperature
changes. Prevent moisture or dirt entering
the actuator. Plug or seal both air connection
ports.
!WARNING - LIFTING INSTRUCTIONS
• Use lifting equipement as required by
national or local legislation.
• Use lifting straps to lift the assembly of
actuator and valve.
• Do not attach lifting straps to only the
actuator, to lift the assembly of actuator and
valve.
Table 2. Weight of Actuators
Model Double Acting Spring Return with S80 Springs
Kg Lbs Kg Lbs
XL26 1.39 3.06 1.53 3.37
XL71 2.39 5.27 2.78 6.13
XL131 3.90 8.60 4.76 10.49
XL186 4.77 10.52 5.45 12.02
XL221 6.19 13.65 7.76 17.11
XL281 7.02 15.47 9.90 21.83
XL426 7.30 16.10 12.50 27.56
XL681 8.80 19.40 22.50 49.60
XL1127 22.00 48.50 36.00 79.37
XL1372 27.00 59.52 46.60 102.73
XL2586 46.00 101.41 79.00 174.16
XL4581 83.00 182.98 142.00 313.05

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Hytork XL
February 2018
Installation, Operation and Maintenance Manual
MAC050515 EN Rev. D
2 ATEX instructions for use in (potential) explosive areas
2.1 Intended use
The Hytork XL series pneumatic actuators are a Group II category 2 equipment and intended for use in areas
in which explosive atmospheres caused by mixtures of air and gases, vapours, mists or by air/dusts are likely to
occur. Therefore it may be used in (ATEX) classied Zones 1, 2 (Gasses) and/or 21, 22 (Dust).
2.2 Safety Instructions
a. Assembly, disassembly and maintenance, is only allowed at the actuator, when, at the time of the
activity, there is not an explosive mixture.
b. Prevent entry of explosive mixtures into the actuator. We suggest utilizing a solenoid with a
“breather” function on spring return actuators when used in potentially explosive atmospheres.
c. The plastic position indicator caps are approved for ATEX gas group IIB areas.
- In areas where ATEX gas group IIC requirements apply, the plastic indicator for actuator sizes
XL26 to 281 is approved for use.
- In areas where ATEX gas group IIC requirements apply, do not use the plastic position
indicator cap of sizes XL426 up to XL4581, to avoid build up of static electricity.
d. In order to avoid increasing dust explosion risk, periodically clean dust deposits from all equipment.
e. When equipment is installed in a hazardous area location (potentially explosive atmosphere), prevent
sparks by proper tool selection and avoiding other types of impact energy.
f. Proper care must be taken to avoid generation of static electricity on the non-conductive external
surfaces of the equipment (e.g. rubbing of surfaces, etc.).
g. Hytork XL actuators do not have an inherent ignition source due to electro-static discharge, but
explosion hazard may be present due to the discharge of static electricity from other valve assembly
components.
- To avoid personal injury or property damage, make sure that the valve is grounded to the
pipeline before placing the valve assembly into service.
- Use and maintain alternate shaft-to-valve body bonding, such as a shaft-to-body bonding
strap assembly.
h. The paint protection must not exceed 200 μm if the actuator is used in a group IIC atmosphere.
For group IIA or IIB atmospheres the paint protection must not exceed a thickness of 2 mm (0.08”).
!WARNING - SURFACE TEMPERATURE
• The actuator’s surface temperature is dependent upon process operating conditions. Personal injury
or property damage, caused by fire or explosion, can result if the actuator’s surface temperature
exceeds the acceptable temperature for the hazardous area classification. To avoid an increase of
instrumentation and/or accessory surface temperature due to process operating conditions, ensure
adequate ventilation, shielding, or insulation of these actuator components installed in a potentially
hazardous or explosive atmosphere.
2.3 Temperature range for (potential) explosive areas
Table 3.
Temperature Valid for
actuator model
Ambient range ATEX
class
TX
(ATEX surface temperature)
-20..75°C T6 T85°C (185°F) Standard Temperature
models
-20..80°C T5 T90°C (194°F)
-20..80°C T1...T4 T90°C (194°F)
-20..75°C T6 T85°C (185°F) High Temperature
models
-20..90°C T5 T100°C (212°F)
-20..120°C T1...T4 T130°C (266°F)
-40..75°C T6 T85°C (185°F) Low Temperature
models
-40..80°C T5 T90°C (194°F)
-40..80°C T1...T4 T90°C (194°F)
-20..250°C for
2 hours T2 T260°C 500°F) Tunnel application models
NOTE:
a. The specied values are
valid with the following
conditions:
- Maximum working
frequency of the actuator is
1Hz at a maximum of 50
cycles per hour and at
maximum load.

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Installation, Operation and Maintenance Manual
MAC050515 EN Rev. D
Hytork XL
February 2018
3 Operating Media,
Pressures and
Temperatures
3.1 Operating media
a. Use clean, dry or lubricated air or inert gas.
b. Maximum pressure : 8 barg / 116PSI.
NOTE:
On applications where the spring stroke of single
acting actuators is pneumatically operated, the
maximum pressure is 6.5 bar / 95PSI.
c. Dew point 10 K below operating temperature.
d. For subzero applications take appropriate
measures.
3.2 Operating Temperature range
Using standard seals and greases the operating
temperature range is -20°C to + 100°C (-4°F to
+212°F) as is indicated on the product label.
Other medias and temperatures may be used but
consult your local Hytork supplier for conrmation as
to suitability.
4 Actuator to Valve
Installation
The Pinion drive, coupling device and Valve Stem should
be centered and concentric to prevent any side loading
to the Pinion Radial Bearing and Valve Stem Seat area.
Ensure that the coupling shaft to be operated is a tight
but free sliding t into the female drive in the Actuator
Pinion (19).
4.1 Bi-directional Travel Stops
Hytork XL actuators have two travel stops (22, 23 and
24) for setting acurately the travel and the open and
closed positions. XL2586 and XL4581 can be tted with
the optional Bottom Stop Block for setting the travel.
The actuator has a factory set stroke of 90°. The
adjustable stroke range of the actuator is :
- at closed (0°) position : -3° to +7°
- at open (90°) position : -83° to +93°
NOTE:
If the actuator is assembled for reverse operation,
instead of standard operation, Stop “1” will adjust the
“open” position and stop “2” the “closed” position.
“2” “1”
Stop marked Stop marked
View from above
Fig. 1 Travel Stops
4.2 Travel Stop Adjustments
1. Operate valve/actuator assembly to the
open position.
2. Remove air supply.
3. Slacken locknut (24) on the “closed” stop
(marked “2”).
4. Turn the “closed” stop clockwise to reduce
or counter clockwise to increase the travel.
5. Tighten the lock nut.
6. Connect air and check that the position is
correct. If not repeat from 2.
7. Operate valve/actuator assembly to the
“closed” position.
8. Remove air supply.
9. Adjust “open” travel stop (marked “1”) as
from step 3 to 6.
5 Piping Instructions
All Actuators can be either piped with solid or
exible tubing with the solenoid valve 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. (See Fig. 2)
Spring return
actuator operation
Double acting
actuator operation
Fig. 2 Solenoid Operation

4
Hytork XL
February 2018
Installation, Operation and Maintenance Manual
MAC050515 EN Rev. D
6 Solenoid Valves on
Spring Return Actuators
It is recommended that on Spring Return Actuators,
the Hytork “CATS” Solenoid Valves are used.
These Valves are specially designed to prevent
contamination of the internals of the Actuator by dirt
from the atmosphere. This increases the working
life of the Actuator which reduces down time and
maintenance periods. (See Fig. 3)
Spring stroke operation Air stroke operation
Fig. 3 Hytork “CATS” Solenoid Valve
7 Position Feedback
All position feedback or positioning accesories, that
comply to the VDI/VDE 3845 (NAMUR) standard, can
be mounted easily on top of Hytork XL actuators. To
access the pinion top, remove the position indicator.
8 Spares
Recommendations
When disassembling and carrying out maintenance work
on the XL Actuator, a Hytork Spares Kit must be used
to replace all ‘O’ Rings, DURASTRIP Bearings, Washers
etc. This Kit is available from Emerson or its Stocking
Distributors.
9 Disassembly Procedure
9.1 End cap and springs disassembly on
Spring Return actuators
1. Release Locking Nuts (24) and remove both
Travel Stops (22) and Thread Seals (23) or
‘O’-rings (23a).
2. Remove the Indicator (7) from the top of the
Pinion (19) For XL26 to XL221 use an Allen
key size 4mm. For the larger sizes the
Indicator can by pulled from the pinion top.
3. Remove both Sealing Bolts (28) and seals
(29) from the End Caps (21).
4. Place both the Hytork Retractor Rods
through the hole in the End Caps and screw
the Rods into :
- For XL 26 to XL 681 the Pistons (20)
- For XL 1127 to XL4581 the Retractor
plate (20a, see also Fig. 4) until
travel is stopped (DO NOT
OVERTIGHTEN) and take care the
nut and washer being free of the
End Cap face.
5. Turn back the Rod 1/2 turn.
6. Screw the adjusting nut and washer by hand
clockwise down the Retractor Rod until they
come up against the face of the End Cap.
7. Prevent the “hold-nuts “ to rotate by one
wrench. Use another wrench, to screw both
adjusting nuts half turn at a time (see Fig. 4)
clockwise down the Rods until the end cap
loosens (Maximum; approximately two
complete turns). This draws the:
- For XL 26 to XL681 the Pistons (20)
- For XL 1127 to XL4581 the Retractor
plate (see also Fig. 4) to the
end caps (21) and compresses the
springs. This Spring-compression,
releases the Spring force and
unlocks the SAFEKEY for removal.
8. Rotate the Caps to ensure that the Springs
are retracted; if the Cap will not turn easily,
a gentle tapping with a plastic hammer
against the endcap will loosen the end cap.
9. Unscrew the two slotted SAFEKEYS (13/14),
and gently pull each SAFEKEY from the Body.
If the SAFEKEY resists removal, gently tap
the End Cap with a soft hammer to assist
release.
10. When both SAFEKEYS have been removed,
use a wrench to rotate the Pinion, driving the
pistons (20) apart until they partially push
the End Caps from the Body.
- For XL 26 to XL681 the Pistons (20),
springs and end cap will come out.
- For XL 1127 to XL4581 the Retractor
plate, springs and end cap will come
out.

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Installation, Operation and Maintenance Manual
MAC050515 EN Rev. D
Hytork XL
February 2018
11. To keep the Spring Pack Assembly intact (see Fig. 4), leave the Retractor Rod in place. To disassemble
the Spring Pack, unscrew the adjusting nut on the Retractor Rod relieving the Spring force, while
preventing the rod from turning with a wrench on the hold nuts.
1
2/3
4
5
6
7
1
2/3
4
5
6
4
4
End cap disassembly steps
XL26 to XL681
End cap disassembly steps
XL1127 to XL4581
Extractor rods
Extractor
plates
Hold nuts
Adjusting nut
Fig. 4 End Cap Disassembly
9.2 Changing spring sets on XL26 to XL681
If only the springs set of the actuator has to be changed, perform steps 1 to 9. These steps can be performed at
both end caps simultaneously or at one end cap only. After step 9 unscrew the adjusting nut on the Retractor
Rod relieving the Spring force, while preventing the rod from turning with a wrench on the hold nuts.
9.3 End cap disassembly on Double Acting actuators
Remove the SAFEKEY as described previously. The Retractor Rod 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.
9.4 Piston disassembly
Rotate the Pinion using a wrench to drive the Pistons apart and remove from the Body by pulling the Pistons.
9.5 Pinion disassembly
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.
9.6 Inspection
Clean and examine all parts for damage and wear. Emerson recommends ‘O’ Rings, DURASTRIP Bearings,
SAFEKEYS, Washers, etc. are replaced using a Hytork XL Spares Kit.

6
Hytork XL
February 2018
Installation, Operation and Maintenance Manual
MAC050515 EN Rev. D
10 Assembly Instructions
NOTE:
Check the product coding on the actuator’s product
labels to dene which type of grease to use.
For standard actuators
(-20°C to +80°C / -4°F to +176°F):
Castrol High Temperature Grease or
Rocol Sapphire Premier grease (or equivalent)
For low temperature operation
(-40°C to +80°C / -40°F to +176°F):
Castrol Tribol GR TT 1 PD
(previously known as Castrol OPTITEMP TT1)
or LG2 grease (or equivalent).
For high temperature operation
(-20°C to +120°C / -4°F to +250°F):
Castrol High Temperature Grease or
Rocol Sapphire Premier grease (or equivalent)
10.1 Pinion Assembly
1. Lightly grease all ‘O’ Rings, ‘O’ Ring grooves,
bearing grooves and Pinion.
2. 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).
3. Lightly grease the Pinion bores in the
Body (11) and insert the Pinion being
careful not to damage the ‘O’ Rings.
4. 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 ts properly
into the groove).
5. 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.
10.2 Alignment of pinion for correct
piston assembly
Standard rotation is clockwise with the Pistons
moving towards each other (When viewed from
above the slot at the top of the Pinion, see Fig. 5).
Piston assembly for
“Standard” operation
Pinion dot
One body dot for
standard mode
Piston assembly for
“Reverse” operation
Two body dots
for reverse mode
Pinion dot
Fig. 5 Pinion Alignment
10.3 Piston Assembly
10.3.1 Clockwise rotation
(Pistons moving inwards, Fig. 5).
6. Align the Pinion by lining up the center of the
NAMUR slot in the top of the Pinion with the
single dot on the Body. The top of the Pinion is
marked with a single identication dot to indi-
cate the correct orientation of the stop faces.
7. Lightly grease all Piston grooves, gear form
and Piston ‘O’ Rings (4) and t the ‘O’ Ring
(4) and Wear Ring (3) to the Piston.
8. Fit the Bearing Block (10) to the back of the
Piston.
9. Grease the Actuator body bore.
10. 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).
11. 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 ats should be at right angles to
the axis of the Body.
10.3.2 Counter-Clockwise rotation
(Pistons moving inwards, Fig. 6).
12. Align the NAMUR slot in the top of the Pinion
with the two dots on the Body and assemble
the pistons so that the Pinion rotates anti-
clockwise as the Pistons are drawn together.
Length
Diameter
Length tolerance : 0 to +5mm / 0” to 0,197”
Diameter tolerance : ±0.05mm / ±0.002”
Fig. 6 SAFEKEY Dimensions

7
Installation, Operation and Maintenance Manual
MAC050515 EN Rev. D
Hytork XL
February 2018
Length
Thread
Length tolerance : 0 to +1mm / 0” to 0.04”
Fig. 7 Retractor Rod Dimensions
Table 4. SAFEKEY Dimensions
Model (in mm) (in inches)
Length Diam. Length Diam.
XL26 157 3.175 6.18 0.125
XL71 217 3.175 8.54 0.125
XL131 267 3.175 10.51 0.125
XL186 282 3.175 11.1 0.125
XL221 317 3.175 12.48 0.125
XL281 367 3.175 14.45 0.125
XL426 377 3.175 14.84 0.125
XL681 437 3.175 17.2 0.125
XL1127 517 3.175 20.35 0.125
XL1372 572 3.175 22.52 0.125
XL2856 707 3.175 27.83 0.125
XL4581 937 4.978 36.89 0.196
Model Thread Length
mm. inch.
XL26 1/4-20 UNC 215 8.46
XL71 1/4-20 UNC 215 8.46
XL131 1/4-20 UNC 215 8.46
XL186 1/4-20 UNC 215 8.46
XL221 5/16-18UNC 225 8.86
XL281 M10 210 8.27
XL426 M8 278 10.94
XL681 M12 363 14.29
XL1127 M12 416 16.38
XL1372 M12 416 16.38
XL2856 M20 500 19.69
XL4581 M20 600 23.62
10.4 Travel stop assembly
(See Fig. 1)
13. 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.
14. Rotate the Pinion through 90ø 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 see
chapter 4.
10.5 End cap assembly on double acting
actuators
15. Install the SAFEKEY ‘O’ Ring seals (12) to the
SAFEKEY heads (13).
16. Lightly grease the End Cap ‘O’ rings (2), the
End Cap grooves and the ends of the Body
bore.
17. Taking one of the EndCaps install its ‘O’ Ring
and insert it into the Body.
18. 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.
19. 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.
20. Repeat the operation for the other End
Cap. With the Pistons together,
mount the Position Indicator (7) to the top
of the Pinion.
10.6 Spring Return Actuators
10.6.1 Spring set adjustments
The actual selection of the correct spring set can be
done by either referring to the torque charts given
in the literature on Spring Return Actuators or by
consulting your local Hytork representative. After
selecting the appropriate spring set arrange the
springs as indicated below.
Table 5. Spring Rating Chart
Spring set Side of actuator Outer Inner
S40 Left S20
Right S20
S50 Left S30
Right S20
S60 Left S30
Right S30
S70 Left S20 S20
Right S30
S80 Left S20 S20
Right S20 S20
S90 Left S30 S20
Right S20 S20
S1C Left S30 S20
Right S30 S20
Spring Colour Coding
S20 Inner = Green
S20 Outer = Pink
S30 Outer = Brown

8
Hytork XL
February 2018
Installation, Operation and Maintenance Manual
MAC050515 EN Rev. D
10.6.2 Installing the Springs
1. For XL 1127 to XL4581 place the Retractor
plate on top of the piston.
2. Insert the Springs (26/27) into the face of the
Piston and then the End Cap onto the Springs.
3. Pass the correct Hytork Retractor Rod
through the End Cap (Fig.6) and screw it into
- For XL 26 to XL681 the Pistons (20)
- For XL 1127 to XL4581 the
Retractor plate.
4. Line up the End Cap so that the safety
symbol is correctly positioned for easy
reading.
5. Prevent the “hold-nuts “ to rotate by one
wrench. Use another wrench, to screw the
adjusting nut on the Hytork Retractor Rod in
until the End Cap is completely engaged in
the Body.
6. It will be necessary to push the End Cap into
the Body to overcome the ‘O’ Ring
compression.
7. When the End Caps are in place and the
SAFEKEYS tted correctly, remove the
Hytork Retractor Rods and replace
the Sealing Bolts (28) and seals (29).
11 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.
11.1 Testing and Cycling of Infrequently
Used or Stored Actuators
Actuators not in current use (i.e. 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.
12 Retractor Rods
12.1 Spring Removal System Board
Hytork’s “SPRING REMOVAL SYSTEM BOARD”
contains a full set of Retractor Rods so that any size of
Actuator can be disassembled on site.
Standard spare parts kits for XL26 to 221 contain
the required Retractor Rods. For XL281 to XL4581
seperate Retractor Rod kits are available. These
Rods are not included in the spare parts kits but are
seperately available.
Ask your local Hytork representative or Stocking
Distributor of Hytork Products for details.
!WARNING - USE APPROVED TOOLS
• The Hytork Retractor Rod tools are specially
designed for the safe removal of the Spring
Return End Cap modules. Only Hytork
manufactured or approved rods are to be
used for Spring End Cap removal.
• As with any threaded tool that is used
frequently, Retractor Rods should be
checked to ensure that the threads are not
worn or damaged in any way and greased
regularly. Any damaged or worn Rods must
not be used and must be destroyed.
• Retractor Rods must be made to the design
specification for safety reasons.
Emerson can not take any responsibility for
any other design.
13 Service
It is the policy of Emerson 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 or other Hytork Products please do not
hesitate to contact any Actuation Technologies Center
of Emerson or your local Hytork Stocking Distributor.
14 Grease Specification
Check the product coding on the actuator’s product
labels to dene which type of grease to use.
* For standard actuators
(-20°C to +80°C / -4°F to +176°F):
- Castrol High Temperature Grease or
Rocol Sapphire Premier grease
(or equivalent)
* For low temperature operation
(-40°C to +80°C / -40°F to +176°F):
- Castrol Tribol GR TT 1 PD
(previously known as Castrol
OPTITEMP TT1)or LG2 grease
(or equivalent).
* For high temperature operation
(-20°C to +120°C / -4°F to +250°F):
- Castrol High Temperature Grease or
Rocol Sapphire Premier grease
(or equivalent)

9
Installation, Operation and Maintenance Manual
MAC050515 EN Rev. D
Hytork XL
February 2018
15 Parts and Materials
567891019 23252627 22 24 20
11 214 15 21 282913
41213161718
Fig. 8 Hytork XL Actuator Parts
Table 6. Parts and Materials
Pos. Description Material Qty Note:
1 Ball Bearing Chromium steel 2 -
2 ‘O’ Ring (End Cap) Nitrile 2 -
3 Wear Ring (Piston) Acetal M90 2 -
4 ‘O’ Ring (Piston) Nitrile 2 -
5 Thrust Bearing (Circlip) Acetal M90 1 -
6 Circlip Springsteel 1 -
7 Indicator Nylon 1 -
7a Indicator screw Stainless steel 1 3
8 ‘O’ Ring (Pinion top) Nitrile 1 -
9 Bearing (Pinion top) Acetal M90 1 -
10 Bearing block (Piston) Acetal M90 2 -
11 Body Aluminum alloy 1 -
12 ‘O’ Ring (SAFEKEY) Nitrile 2 -
13 SAFEKEY Head Grivory 2 -
14 SAFEKEY Wire Stainless steel 2 -
15 Thread Insert Steel 2 -
16 Location Ring Acetal 1 -
17 ‘O’ Ring (Pinion bottom) Nitrile 1 -
18 Bearing (Pinion bottom) Acetal M90 1 -
19 Pinion Steel 1 -
20 Piston Aluminum alloy 2 -
20a Retractor plate Aluminum alloy 2 1
21 End Cap (DA & SR) Aluminum alloy 2 2
21a End Cap DA Aluminum alloy 2 1
22 Travel Stop Stainless steel 2 5
23 Thread Seal Steel/Rubber 2 3/6
23a ‘O’ Ring (Travel Stop) Nitrile 2 4
23b Washer (Travel Stop) Stainless steel 2 4
24 Locking Nut Stainless steel 2 5
25 Thrust Washer (Circlip) Stainless steel 1 -
26 Spring Outer Spring steel 2 -
27 Spring Inner Spring steel 2 -
28 Sealing Bolt (End Cap) Steel 2 -
29 ‘O’ Ring (Sealing Bolt) Nitrile 2 -
Notes:
1 on XL 1127 to 4851 4 on XL 281 to XL 1372
2 on XL 26 to XL 681 5 on XL 26 to XL 1372
3 on XL 26 to XL 221 6 on XL 26/71 equipped with extra nylon washer

For complete list of sales and manufacturing sites, please visit
www.emerson.com/actuationtechnologieslocations or contact us at
[e-mail]
World Area Configuration Centers (WACC) offer sales support, service,
inventory and commissioning to our global customers.
Choose the WACC or sales office nearest you:
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Houston TX 77065
USA
T [phone]
F [phone]
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325 Iporanga Sorocaba
SP 18087-105
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T [phone]
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T [phone]
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T [phone]
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T [phone]
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Jubail 31961
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T [phone]
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Longmeadow Business Estate East
P.O. Box 6908 Greenstone
1616 Modderfontein Extension 5
South Africa
T [phone]
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EUROPE
Berenyi u. 72- 100
Videoton Industry Park
Building #230
Székesfehérvár 8000
Hungary
T [phone]
F [phone]
www.emerson.com/hytork
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