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        Emerson Fisher 685 Installation Instructions
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1.    MAXIMUM  VALVE TRAVEL APPROXIMATE WEIGHT FOR ACTUATOR SIZE  kg  Ibs      mmf inches    2        6   8   20   2   a         102  4 0     847  1866  168 370    26257    311  686  89  1961  375 2150    305  12 00 157  346  245  541  292  643  337  742 457  1008 535  1180       Instruction Manual 685 Piston Actuator  D103626X012 September 2014    Table 5  Approximate Weights for Constructions with Handwheels    MAXIMUM  VALVE TRAVEL APPROXIMATE WEIGHT FOR ACTUATOR SIZE  kg  Ibs     Ca   3       573  1924   555       1092                2308   508  20 00 252  555 397  876 331  729 495  1092 715  1576 794  1751  990 2182    1088  2398   610  24 00 264  583 415  914 350  773 516  1138 746  1644 827  1823    1029 2268    1129  2488     Table 6  Lifting Point Load Ratings    LIFTING MAXIMUM LOAD  ACTUATOR SIZE ORIENTATION NUMBER OF LIFTING POINTS USED  bs         12to 24 Actuator Centerline 3400  Horizontal 6300  12to 24 Actuator Centerline 8300  vertical 4000       Installation       WARNING    Always wear protective gloves  clothing  and eyewear when performing any installation operations to avoid personal  injury     To avoid personal injury or property damage caused by bursting of pressure retaining parts  be certain the cylinder  pressure or other pressure ratings do not exceed the limits listed in table 1  Use pressure limiting or pressure relieving  devices to prevent cylinder pressure or other pressures from exceeding these limits     Check with your process or safety engin
2.  8  Tie Bolt Torque  BOLT DIAMETER    O N   ee  21        8 328       1 8 7 488    Instruction Manual 685 Piston Actuator  D103626X012 September 2014    Parts Ordering    When corresponding with your Emerson Process Management sales office about this equipment  refer to the serial  numbers  there are two serial numbers located on the actuator  found on the actuator nameplate  key 22   Also   specify the complete 1 1 character part number from the following Parts List when ordering replacement parts        A WARNING    Use only genuine Fisher replacement parts  Components that are not supplied by Emerson Process Management should  not  under any circumstances  be used in any Fisher valve  because they may void your warranty  might adversely affect the  performance of the valve  and could cause personal injury and property damage     Parts Kits    Includes all soft seals and O rings required for seal and O ring replacement in standard operating temperature  constructions  Refer to figures 2 and 3     EE re         Temperature    Bearing O ring  Rey 15      R685X000032 R685X000112 R685X000192  Bearing Quad Seal  Key 12    Piston Pod O ring  Key 19 R685X000042 R685X000122 R685X000202  Piston Wear Ring  Key 6 R685X000052 R685X000132 R685X000212  Piston Quad Seal  Key 7 R685X000062 R685X000142 R685X000222   Upper Lower Head O ring  Key 2  Upper Lower Head O ring  Key 2 RO AEE Sige  R685X000082 R685X000162 R685X000242       11    685 Piston Actuator  September 2014    Parts List    
3.  key 21  and the lower head  key 9  assembly onto cylinder  key 4  taking care not to  damage threads on the tie bolts  key 3   Be sure the O ring  key 2  is in place during this step     31  Install lock washers  key 10  and tie rod hex nuts  key 11  onto tie bolts  key 4   Torque in a crisscross pattern  according to table 2     If the actuator has a handwheel manual override proceed to step 32  otherwise proceed directly to step 37     32  Re position the actuator so it is right side up with the yoke  key 21  flat against the ground  Cloth or wood should  be used to prevent against paint damage     33  Remove the hex head cap screws  key 20  and lock washers  key 10  that secure the yoke  key 21  to the lower  head  key 9     34  Using the same lifting eyes as in the Actuator Removal section attach appropriate rigging gear and remove the  cylinder assembly from the yoke  key 21   The rigging gear should allow the cylinder to be rotated freely  Rotate the  cylinder assembly to screw the engage disengage block  key 43  onto the piston rod  key 17  until the gap  measured in step 3 is achieved     35  Tighten the set screw  key 36  into the engage disengage block  key 43      36  Secure the cylinder assembly to the yoke using the hex head cap screws  key 20  and lock washers  key 10    Torque in a crisscross pattern according to table 8     37  Referto the Actuator Mounting section of this manual for instructions on mounting and installing the actuator  onto a valve     Table
4.  the piston rod to the specified valve  travel     5  Attach the stem connector  key 18   clamping the piston rod  key 17  to the valve stem  Be sure you also attach the  feedback arm and travel indicator     6  Cycle the actuator to check availability of desired total travel and that the valve plug seats before the cylinder  reaches the end of its stroke  You can make minor travel adjustments  if necessary  by loosening the stem    Instruction Manual 685 Piston Actuator  D103626X012 September 2014    connector slightly  tightening the locknuts together  and  with the valve plug off the seat  screwing the stem either  into or out of the stem connector by means of a wrench on the locknuts     7   f thetotal travel is adequate  tighten the stem connector  key 18  securely  lock the stem locknuts  if present   against the connector  and adjust the indicator scale  key 22  on the yoke  key 21  to show valve plug position     8  Provide a gauge  if necessary  to measure the pressure to the actuator  Make a final adjustment on the positioner to  set the starting point of valve travel and to obtain full travel for the given instrument range     Handwheel Operation    If manual operation is required  the actuator should be equipped with a manual handwheel     CAUTION    To avoid damage to actuator parts and difficult operation of actuator handwheels  open the bypass valve  key 66  before  using a handwheel     The bypass assembly is furnished only when a handwheel actuator is specifi
5. Instruction Manual 685 Piston Actuator  D103626X012 September 2014    Fisher  685 Piston Actuator       Contents Figure 1  Fisher 685 Piston Actuator                       2255                                                    1  Scope Of Manual                      DescrpboH                   db pe             aene 1  Specifications                                 2  Educational Services                           3  Principle of Operation                           3  SCAN                                     5  Three Way Valve Applications Note               6  Actuator Mounting                            6  Handwheel Operation                           7  Maintenant                                   8  Actuator Removal                             8  Seal and O ring Replacement                    9  Parts Ordening 25                                 11  PANES IE ae ois keira          Kane PRESA ES dd         11                ae               12  Introduction    Scope of Manual    This instruction manual provides information on the installation  maintenance  and parts ordering for Fisher 685  piston actuators  Refer to separate instruction manuals for information regarding other equipment and accessories  used with these actuators     Do not install  operate  or maintain a Fisher 685 actuator without being fully trained and qualified in valve  actuator   and accessory installation  operation  and maintenance  To avoid personal injury or property damage  it is important  to ca
6. Note  For part numbers not shown  contact your Emerson Process  Management sales office     Common Parts  fiqures 2 and 3     Key Description    1 Upper Head  2  Upper Lower Head O ring  3  TieBolt  4 Cylinder  5 Piston  6 Piston Wear Ring  7 Piston Quad Seal  9 Lower Head  10 Lock Washer  11 Tie Bolt Hex Nut  12 Bearing Quad Seal  13 Bearing O ring  14 Bearing  15 Piston Rod Wiper Seal  16 Bearing Retaining Ring  17 Piston Rod  18   Stem Connector  19 Piston Rod O ring  20  HexHeadCap Screw  21  Yoke  22  TravelScale  5  Stem Connector Hex Nut  58   Stem Connector Stud  100 Multi purpose Grease  MPG 2 or approved equivalent    12    Instruction Manual  D103626X012    Manual Handwheel Parts   figure 2     Key    Description    ACME Thrust Shaft  Override Guide Shaft  Worm Gear   Thrust Shaft Upper Bushing  Thrust Shaft Bushing  Thrust Bearing   Thrust Guide Block  Engage Pin Guide   Guide Block Engage Screw  Engage Pin Control Knob  Engage Spring Pin  Socket Head Cap Screw  Socket Set Screw   Key   Override Engage Pin  Position Indicator   All Thread Stud   Flat Washer   Yoke Adaption Bracket  Engage Disengage Block  Stem Connector Stud  Handwheel   Helix Housing Cap O ring  Helix Gear Shaft Bushing  Helix Gear Bushing   Helix Worm Gear Housing  Helix Worm Gear   Helix Gear Shaft Spacer  Helix Shaft Wiper Seal  Helix Worm Gear Shaft  Helix Gear Housing Cap  Ext  Tooth Lock Washer  Pointer    Instruction Manual 685 Piston Actuator  D103626X012 September 2014    Figure 2  Fishe
7. ST HANDWHEEL DIAMETER      TURNSPER mm TURNS PER MA MUVIRIMEORGE  OF TRAVEL i       685 Piston Actuator Instruction Manual  September 2014 D103626X012    Maintenance       WARNING    Avoid personal injury from sudden release of process pressure  Before performing any maintenance operations   e Do not remove the actuator from the valve while the valve is still pressurized     e Always wear protective gloves  clothing  and eyewear when performing any maintenance operations to avoid personal  injury     e Disconnect any operating lines providing air pressure  electric power  or a control signal to the actuator  Be sure the  actuator cannot suddenly open or close the valve        Use bypass valves or completely shut off the process to isolate the valve from process pressure  Relieve process pressure  on both sides of the valve  Drain the process media from both sides of the valve     e Use lock out procedures to be sure that the above measures stay in effect while you work on the equipment     e The valve packing box may contain process fluids that are pressurized  even when the valve has been removed from the  pipeline  Process fluids may spray out under pressure when removing the packing hardware or packing rings  or when  loosening the packing box pipe plug     e Check with your process or safety engineer for any additional measures that must be taken to protect against process  media     Instructions are given below for complete disassembly of the actuator  seal replacement  
8. and O ring replacement   When inspection or repair is necessary  disassemble the actuator only as far as is required to accomplish the job  Key  numbers referenced in the following steps are shown in figures 2 and 3     Actuator Removal  The following procedure is for the removal of the actuator from a valve     1  Disconnect the actuator tubing from the pressure connections on the upper and lower heads  keys 1 and 9  and  positioner     Note  Refer to the appropriate instruction manual for any maintenance or adjustments that need to be made on the positioner     2  Breakthe stem connection by removing hex nuts  key 57   lock washers  key 10   and studs  key 58  from the stem  connector  key 18      3  Remove the bonnet to actuator bolting securing the actuator to the valve bonnet     4  Thread two lifting eyes into the free ports on the upper head  key 1  180 degrees apart  Reference tables 4 and 5 for  approximate weights of the actuator to select an appropriate lifting eye  Attach appropriate rigging gear to both  lifting eyes and lift the actuator away from the valve bonnet and stem     5  Place the actuator upside down with the upper head  key 1  flat against the ground  Cloth or wood should be used  to prevent against paint damage     6  Referto the Actuator Mounting section of this manual for instructions on mounting and installing the actuator onto  a valve    Instruction Manual 685 Piston Actuator  D103626X012 September 2014    Seal and O ring Replacement   The follo
9. ation    685 piston actuators utilize a pneumatically controlled piston that moves inside of a cylinder to generate thrust  A seal  contained on the circumference of the piston provides a seal between the piston and the cylinder  preventing supply  pressure leakage     From an equilibrium state  the actuator operates by reacting to a force unbalance that is created by increasing supply  pressure on one side of the piston  and decreasing it on the other  This moves the piston up or down  and results ina  repositioning of the attached control valve  Travel can be adjusted using travel limits within a valve positioner  which  limit the travel range of the actuator  The optional handwheel manual override does not have the ability to act as a    hard travel stop     An optional handwheel manual override is capable of extending or retracting the actuator manually and can be  engaged at any position from full open to full close  This override utilizes a worm gear assembly that is attached to the  stem connector and not attached to the cylinder or piston rod  This enables the manual override to reposition the  control valve even if the actuator cylinder or piston is removed for maintenance     Table 2  Standard Constructions      SIZE DIAMETER AREA CONNECTOR SIZE DIAMETER   Minimum   Maximum    mm        for Area     m   35   1        zos   oms                _    4   3   3          35   Wrews           0 7    3        3   9   z         vom          m        38   4   3   192   z    v
10. being installed without a positioner  the cylinder loading pressures should be supplied through a  4 way solenoid valve or a switching valve  The top and bottom sides of the piston are pressurized through the upper  and lower heads  i e  top and bottom of the cylinder      The supply pressure medium should be clean  dry filtered air  If the supply source is capable of exceeding the  maximum actuator operating pressure or positioner supply pressure  appropriate steps must be taken during  installation to protect the positioner and all connected equipment against over pressurization     The control valve should be located where it will be accessible for servicing  Room should be left above and below the  control valve to permit removal of the actuator and valve plug     Three Way Valve Applications Note    In three way valve applications where the actuator fully strokes at a frequency of once per minute or faster  and the  stroking speed is rapid  less than 0 5 seconds per stroke   there is a possibility that the stem can fracture at the plug if  the actuator cylinder pressure is greater than 5 5 bar  80 psig   This can cause loss of control of process fluid and  further damage to the actuator  Consideration should be given to the use of high strength  fatique resistant stem  materials in these applications     Actuator Mountinq    The following procedure describes how to mount a 685 actuator on a push down to close valve so that the piston rod  to valve plug stem connection al
11. ed  The bypass allows the pressure to  equalize on either side of the piston  so that the manual actuator can be used to position the control valve  Flow  through the bypass tubing is controlled by an angle needle valve  which is operated manually  This valve should be  closed when air pressure is being used to operate the actuator     Key numbers referenced in the following steps are shown in figure 2  Refer to table 7 for handwheel specifications     1  Open the bypass valve     2  Rotate the handwheel  key 45  to position the override engage pin  key 38  with the hole in the stem connector   key 10   Turn the engage pin control knob  key 33  clockwise to insert the override engage pin into the stem  connector until it stops     Note    Depending on construction   the handwheel may have operation information stamped into the part  Always refer to steps 3 and 4  for operation information specific to push down to close and push down to open valves     3  For a push down to close valve  Rotate the handwheel  key 45  clockwise to close the valve and counterclockwise  to open the valve     4  Fora push down to open valve  Rotate the handwheel  key 45  counterclockwise to close the valve and clockwise  to open the valve     5  To disengage the manual handwheel  rotate the handwheel  key 45  to relieve any load placed on the override  engage pin  key 38   turn the engage pin control knob  key 33  counter clockwise until it stops     Table 7  Handwheel Specifications    OUTPUT THRU
12. eer for any additional measures that must be taken to protect against process  media     If installing into an existing application  also refer to the WARNING at the beginning of the Maintenance section in this  instruction manual     Dropping the actuator and any attached accessories and or valve may cause personal injury and or equipment damage  For  all mounting procedures use an adequately sized chain  sling  hoist  or crane to handle the actuator and any attached  accessories and or valve  Use caution during lifting and handling to prevent slippage  swinging  faulty equipment  connections  or sudden shock loads        CAUTION    Special care must be taken when installing an actuator in a horizontal service orientation  To avoid cantilever loads on the  valve stem and yoke  it is the customer   s responsibility to ensure proper support for a horizontal actuator     When an actuator and control valve are shipped together as a control valve assembly  the actuator is normally  mounted on the valve  Follow the valve instructions when installing the valve in the pipeline  If the actuator is shipped  separately or if it is necessary to mount the actuator on the valve  perform the actuator mounting procedures in this  instruction manual  Refer to the individual product instruction manuals for the installation or mounting of a FIELDVUE  DVC6200 digital valve controller or 3610 positioner     685 Piston Actuator Instruction Manual  September 2014 D103626X012    If the actuator is 
13. in 51 mm  2 inch  increments between 305  mm  12 inch  and 660 mm  26 inch   See table 2    S31603  316L stainless steel     Weights  See tables 4 and 5    Operative Temperature Limits  Standard   40 to 93  C   40 to 200  F     Low Temperature   54 to 93  C   65 to 200  F  3   High Temperature   29 to 204  C   20 to 400  F          Yoke Boss and Valve Stem Diameter    B 127 mm  5H inch  yoke boss with 32 mm  1 1 4  inch  stem    178 mm  7 inch  yoke boss with 51 mm   2 inch  stem    Lifting Point Load Ratings  See table 6    1  The pressure temperature limits in this bulletin and any other applicable standard or code should not be exceeded   2  Consult factory for larger travels or cylinder diameters  The Fisher 585C family of actuators are available for smaller travels or cylinder diameters   3  Consult factory for applications requiring low or high temperature requirements     Specifications    Specifications for 685 piston actuators are given in table 1  Refer to the nameplate affixed to the actuator yoke for  specifications specific to individual constructions     Instruction Manual 685 Piston Actuator  D103626X012 September 2014    Educational Services    For information on available courses for Fisher 685 piston actuators  as well as a variety of other products  contact     Emerson Process Management   Educational Services   Registration   Phone  1 641 754 3771 or 1 800 338 8158  E mail  education emerson com  http   www emersonprocess com education    Principle of Oper
14. lows full travel and proper shutoff  Key numbers referenced in the following steps are  shown in figures 2 and 3     If you purchase a 685 actuator for field installation on a control valve  mount the actuator on the valve and secure it to  the bonnet with the eight bonnet to actuator bolts  The stem connection should then be made up to clamp the  actuator stem and valve plug stem together to provide proper valve travel     CAUTION    If the valve stem is allowed to remain in the up position  towards the actuator  during mounting  it can interfere with the  actuator mounting  possibly damage valve stem threads  or bend the valve stem  Be sure the valve stem is pushed down   into the valve body   away from the actuator while mounting     To avoid damaging the seating surfaces  do not rotate the valve plug while it is seated  Also avoid damage to the valve plug  stem by careful use of tools during travel adjustment     1  Thread two lifting eyes into the free ports on the upper head  key 1  180 degrees apart  Reference tables 4 and 5 for  approximate weights of the actuator to select an appropriate lifting eye  Attach appropriate rigging gear to the  lifting eyes    2  Slowly lower the actuator down onto the valve  Once the actuator is in place  insert the bonnet to actuator bolts  and tighten the hex nuts    3  Turn the two stem locknuts  if present  all the way onto the valve stem thread     4  Starting with the cylinder fully retracted  manually  or with air pressure  extend
15. move tie rod hex nuts and lock washers  key 10      9  Remove the yoke  key 21  and the lower head  key 9  assembly from the cylinder  key 4  and place onto a flat  surface with the O ring side facing up  Using straps  secure this assembly to a solid structure to prevent it from  falling over     10  Extract bearing assembly  keys 12  13  14  and 15  from lower head  key 9  by removing the bearing retaining ring   key 16      11  Remove the piston wiper seal  key 15   O ring  key 13   and quad seal  key 12  from the bearing  key 14    12  Clean bearing  key 14  with a light degreaser  if needed     13  Lightly grease the new O ring  key 13  and quad seal  key 12   then install onto bearing  key 14   Without grease   install a new piston wiper seal  key 15  onto the bearing     14  Reinstall bearing assembly  keys 12  13  14  and 15  into lower head  key 9  and secure in place with the bearing  retaining ring  key 16      15  Remove the O ring  key 2  from the lower head  key 9  and clean the groove with a light degreaser   16  Lightly grease the new O ring  key 2  and install on lower head  key 9     17  Remove tie bolts  key 3  from upper head  key 1     18  Lift piston assembly  keys 5  6  7  17  and 19  out from cylinder  key 4  and place on a flat surface   19  Remove the wear ring  key 6  and quad seal  key 7  from the piston  key 5      20  Thread locking compound is applied to the threads of the piston rod  key 17  by the manufacturer during initial  assembly  As a res
16. om           0        39          4   23   z    vs   3   m    2   3     4   325   35    uev   3    0        x    9          mw   z    ev   3    9    35               395                171    25   60    Inches  inch  for Area      m   m   a   m   mkn   so   8          D E I   N11    4 91  1 4 or 2 5H or 7  4 91 254  1 4 or 2 5H or 7    9 62 I 5H or 7       1  Consult your Emerson Process Management sales office for additional sizes     685 Piston Actuator Instruction Manual  September 2014 D103626X012    Table 3  Thrust    THRUST AT SUPPLY PRESSURE  N          1   ACTUATOR SIZE TROKE  p iis 4 1 barg  60 psig  5 5 barg  80 psig  6 9 barg  100 psig  oia  m    30183  6786  40245  9048  50306  11310    75459 16965     16965   41083  9236  54777  12315  68472  15394  102707  23091   Push    85457 00109   168083  38073                  29540  6641  39387  8855  49234  11069  73851  16603   39773  8942  53030  11922  66288  14903  99432  22354   Pull    16  18  20  22  24  26    130873 29423  66602  14974  88803  19965  166506  37434  24  26    81956  18425  109275  24567 136593  30709  204890  46063  99563  22384  132751  29845 165938  37306  248907  55959  24 118166  26566  157555  35422 196944  44277  295416  66415       39      139127  31279  185503  41705 231878  52131  347817  78196    1  Consult your Emerson Process Management sales office for supply pressures below 40 psig   2  Maximum available thrust        Table 4  Approximate Weights for Constructions without Handwheels 
17. r 685 with Manual Handwheel        Qe AS               A L        T S   o     NS          9 SA TWO    UNS LLL LLL LLL ALS __                        Te  DO  NOR OO  7 2  R                  6  e   2 144229                    e          36           D   EI   t   1 8  47  N                       LEFT SIDE VIEW FRONT VIEW 5     Saas PEDEM Ln IL    Sgen SS      E        5             Hm                      9 027     RIGHT SIDE VIEW    09              DOG    Aw TT _ WOO  N              N                         22727777747777777777777777747777777777777772272727777727222277727         1565    685 Piston Actuator Instruction Manual  September 2014 D103626X012    Figure 3  Fisher 685 without Manual Handwheel                    4      3   OA     9   N    mou              ORT ANAS     Ol               X v io  022           TEP ad Non VON  109  13        2 1   iU  O AA     ex E  m       16   17     p    21     E1566    Instruction Manual  D103626X012    685 Piston Actuator  September 2014    685 Piston Actuator Instruction Manual  September 2014 D103626X012    Neither Emerson  Emerson Process Management  nor any of their affiliated entities assumes responsibility for the selection  use or maintenance  of any product  Responsibility for proper selection  use  and maintenance of any product remains solely with the purchaser and end user     Fisher  easy e  and FIELDVUE are marks owned by one of the companies in the Emerson Process Management business unit of Emerson Electric Co  Emerson  P
18. refully read  understand  and follow all the contents of this manual  including all safety cautions and warnings  If  you have any questions about these instructions  contact your Emerson Process Management sales office before  proceeding     Description    The Fisher 685 is a double acting piston actuator that provides accurate  high thrust output for short to long travel  applications  This actuator is designed for use with a variety of medium to large Fisher sliding stem control valves  including the easy e     FB  TBX  HP  EH  and 461     LIT    EMERSON    www Fisher com Process Management    685 Piston Actuator  September 2014    Table 1  Specifications    Operating                  1   Minimum  2 7 bar  40psig   Maximum Allowable  10 3 bar  150 psig     Consult your Emerson Process Management sales  office for supply pressures under 2 7 bar  40 psi     Travel 2     25 mm  1 inch  through 610 mm  24 inch   See table 2    Instruction Manual  D103626X012    Pressure Connections  Standard  3 4 NPT  Optional  1 and 1 1 4 NPT    Instrument Mounting    Mounting kits are available for use with the FIELDVUE  DVC6200 series positioner    Construction Materials    PART MATERIAL  Thrust Capabilities ASTM A36  steel   See table 3 ASTM A36  steel     Cylinder 305 to 559 mm  12 to 22 inch  Cylinder   1026 DOM  steel  with chrome plated  bore  610 to 660 mm  24 to 26 inch  Cylinder   ASTM A516 Grade 70  steel  with  fluoropolymer coated bore    Piston Diameter and Area 2     Available 
19. rocess Management  Emerson  and the Emerson logo are trademarks and service marks of Emerson Electric Co  All other marks are the property of their  respective owners     The contents of this publication are presented for informational purposes only  and while every effort has been made to ensure their accuracy  they are not  to be construed as warranties or quarantees  express or implied  regarding the products or services described herein or their use or applicability  All sales are  governed by our terms and conditions  which are available upon request  We reserve the right to modify or improve the designs or specifications of such  products at any time without notice     Emerson Process Management   Marshalltown  lowa 50158 USA   Sorocaba  18087 Brazil   Chatham  Kent ME4 4QZ UK      Dubai  United Arab Emirates    Singapore 128461 Singapore      wwwfishercom CEM ERSON     Process   en L     2013  2014 Fisher Controls International LLC  All rights reserved  dad cds              a eggs M rc EE    
20. ult  disassembly will require heating to loosen the thread locking compound  To remove the  piston rod O ring  key 19   heat the piston assembly using a torch and unthread the piston rod  key 17  from the  piston  key 5      21  After the piston rod  key 17  has completely cooled  remove the piston rod O ring  key 19   Clean the piston rod  O ring groove with a light degreaser  Lightly grease a new piston rod O ring and install onto the piston rod     22  Reinstall piston rod  key 17  onto piston  key 5  using thread locking compound   23  Clean piston seal grooves  Install new lightly greased quad seal  key 7  onto piston  key 5      685 Piston Actuator Instruction Manual  September 2014 D103626X012    24  Without grease  trim to length and then install a new wear ring  key 6      25  Lift cylinder  key 4  vertically and place on a flat surface  Take extra precaution to avoid scratching or gouging the  inner diameter of the cylinder     26  Remove O ring  key 2  from the upper head  key 1  and clean the seal groove  Install lightly greased new O ring  into upper head seal groove     27  Install cylinder  key 4  onto upper head  key 1  making sure the O ring  key 2  does not move out of its groove     28  Carefully install the piston assembly  keys 5  6  7  17  and 19  into cylinder  key 4  making sure all seals and O rings  stay in place on the outside diameter of the piston  key 5      29  Install tie bolts  key 3  into upper head  key 1      30  Carefully install the yoke 
21. wing procedure is for the replacement of the internal piston seals  bearing seals  and O rings    1  Complete Actuator Removal procedures above    If the actuator has a handwheel manual override proceed to step 2  otherwise proceed directly to step 8    2  Re position the actuator so it is right side up with the yoke  key 21  flat against the ground  Cloth or wood should  be used to prevent against paint damage     3  Measure the gap between the piston rod  key 17  and the engage disengage block  key 43      up to 1 8 inch   and  make note  as this will be used during reassembly     4  Remove the set screw  key 36  from the engage disengage block  key 43      5  Remove the hex head cap screws  key 20  and lock washers  key 10  that secure the yoke  key 21  to the lower head   key 9      6  Using the same lifting eyes as in the Actuator Removal section  attach appropriate rigging gear and remove the  cylinder assembly from the yoke  key 21   The rigging gear should allow the cylinder to be rotated freely  Rotate the  cylinder assembly to unscrew the engage disengage block  key 43  from the piston rod  key 17   After the  engage disengage block is removed  secure the cylinder assembly to the yoke using the hex head cap screws  key  20  and lock washers  key 10      7  Placethe actuator upside down with the upper head  key 1  flat against the ground  Cloth or wood should be used  to prevent against paint damage     8  Loosen tie bolt hex nuts  key 11  in a crisscross pattern  Re
    
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