Flowserve Heavy Duty Actuator User Manual

Automax Valve Automation Systems

Installation, Operation and Maintenance Instructions

Flowserve Corporation 765 South 100 East Phone: [phone]
Flow Control Division Provo, Utah 84606 Facsimile: 801 489 2228
Automation Business Unit www.flowserve.com E-mail: [e-mail]

Heavy Duty Actuator

Installation Instructions

1. All actuators are factory lubricated for life, but
still should be protected from the elements and stored

indoors until ready for use. The ports of the actuator are
plugged as supplied from the factory. If actuators are
stored for a long period of time prior to installation, the
units should be stroked every 3 months to prevent the
seals from taking set.

2. Prior to assembly, manually open and close valve
to insure freeness of operation. Be sure valve and actuator
rotate in the same direction and are in the same position
(i.e., valve closed, actuator closed).

3. Check the mounting surfaces, the stem adaptor and the
bracket to assure proper fit. Secure the valve in the closed
position with the stem vertical. Bolt the bracket to the valve
and place the stem adaptor on the valve stem. Position the
actuator over the valve and lower to engage the stem
adaptor to the actuator shaft. Continue to lower until the
actuator seats on the bracket mounting surface. In order to
align the bolt holes, it may be necessary to turn or stroke
the actuator a few degrees and/or adjust the actuator travel
stops. Bolt the actuator to the bracket.

4. After consulting the valve manufacturer's recommen­dations, adjust the travel stop bolts of the actuator for
the proper open and closed valve positions. Pneumatically
stroke the actuator several times to assure proper
operation without binding of stem adaptor. If the actuator
is equipped with an Ultraswitch or other accessories adjust
them at this time.

Field Conversion from Fail CW to Fail CCW

(For Spring Return Actuators)

1. Apply supply air to actuator and loosen Stop Bolt Jam
Nut (17) and back off clockwise Stop Bolt (16) to remove
all spring cartridge preload.

2. Remove supply air from actuator.

3. Support Spring Cartridge (11) and loosen all 4 Nuts
(41) evenly till all 4 nuts are loose. The spring cartridge
does not have to be removed.

4. Remove the Position Indicator (44) or any other
accessories that may be on the output shaft.

5. Remove the Bearing Retainer Screws (14) from the
valve mounting side and slide the Retainer Plate (13) off
the shaft.

6. The Torque Shaft (20) may now be tapped out using a
soft faced hammer. Use care not to drop the shaft or the
Bearing (12) when they come out.

7. Rotate Torque Shaft (20) end for end and reinstall
into the Yoke (4) using care to line up the shaft with the
Bearing (12) on the opposite end. Push the shaft thru till
the shaft bottoms out. This should only require hand
pressure to reinstall the shaft.

8. Reinstall the Bearing (12) back into the housing until it
is flush with the top of the housing.

5. To prolong actuator life use only clean, dry plant air.
Lubricated air is not required, however it is recommended
particularly for high cycle applications.

lubricated air with positioners.

Travel Stop Adjustments

All actuated valving requires accurate travel-stop adjust­ments at both ends of the stroke to obtain optimum
performance and valve seat life. The accumulation of
tolerances in the adaption of actuators to valves is such
that there must be a range of adjustments for both ends
of the stroke to achieve the expected performance. The
Heavy Duty series actuators have travel stop adjustments
in both the clockwise and counter-clockwise directions.
The 12 degree overtravel feature provides adjustments
from -6 to +96 degrees.

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© 2001, Flowserve Corporation, Provo, UT

Caution: Do not use

9. Reinstall the Bearing Retainer Plate (13) and Screws
(14) insuring that the Gasket (37) is in place.

10. Tighten the Spring Cartridge Nuts (41) evenly until
they are all 4 evenly tightened. See bolt torque chart.

11. Apply supply air to actuator and reset Stop Bolt (16).
Never try to adjust stop bolt against force of spring.

12. Reinstall any accessories or position indicator on
Torque Shaft (20).

13. Check actuator for proper operation.

14. The result of this operation is that the “valve”
side of the actuator has been reversed.

Automax Valve Automation Systems

Installation, Operation and Maintenance Instructions

Flowserve Corporation 765 South 100 East Phone: [phone]
Flow Control Division Provo, Utah 84606 Facsimile: 801 489 2228
Automation Business Unit www.flowserve.com E-mail: [e-mail]

Maintenance Instructions

Disassembly Procedures

1. Disconnect all air and electrical supplies from actuator.

2. Remove all accessories from actuator and dismount
from valve.

Spring Group (Spring Return Actuators)

1. Apply air pressure to the Pneumatic Cylinder to release
spring pressure from the Stop Bolt (16). Remove both
Stop Bolts (16) and release air pressure. This will
relieve the majority of the spring preload.

NOTE: PERSONAL INJURY may result if Step 2 is at-

tempted before Step 1 is completed.

2. The Spring Cartridge (11) is welded into an integral
component and cannot be disassembled. To remove
from actuator, remove Spring Cartridge Nuts (41) and
Lockwasher (42). At this point, all spring forces are
contained within the welded cartridge and the spring
cartridge can be removed from the center body.

NOTE: Support the Spring Cartridge (11) during removal

so as not to damage the Piston Rod (3).

Rod Cover (Double Acting Actuators)

1. Remove the Rod Cover Bolts (40) and Lockwashers
(42). The Rod Cover (11) can now be removed from
the Housing (1), taking care not to damage the Piston
Rod (3).

Pressure Group

1. Remove the Tie Rod Nuts (28), Tie Rods (27), and the
Endcap (29).

2. Slide the Cylinder (23) over and off the Piston (24),
being careful not to scratch or dent the honed and
chrome plated surface of the cylinder (23).

3. Remove the Piston Bolt (25), Piston Bolt Lockwasher
(26) and remove the Piston (24) and Piston Face Seal
(32).

Housing or Body Group

1. Unscrew the Inspection Cover Screw (9) with
Lockwashers (10) and remove the Cover (8) and the
Cover Gasket (35).

NOTE: Prior to disassembly of remainder of the Body

Group, you should check visually through the inspec­tion opening to determine whether further disassembly
is necessary. If the Yoke (4), the Yoke Pin (5), and the
Yoke Pin Rollers (6) are in good condition, do not
disassemble further.

2. To remove the Piston Rod (3) and Piston Rod Bearing
(2), center the Yoke in the Mid or 45 degree position.

R2 Actuators: To remove the Yoke Pin Retainers (7),

use snap ring pliers with 90 degree tips through the
inspection cover opening. Turn the Piston Rod (3) to
remove the Yoke Pin Rollers (6) and the Yoke Pin (5)
through the inspection cover opening.

R3 and R4 Actuator: Remove both freeze plugs that

are located in the Housing near the Bearing Retainer (13).
Through these openings the Snap Ring, Yoke Pin Retainers
(7) can be removed. The Yoke Pin Rollers (6) can now be
slipped off the Yoke Pin (5), and the Yoke Pin (5) can be
pushed through the Piston Rod (3) and out through the
opening in the other side of housing.

Remove Piston Rod (3) and Piston Rod Bearings (2) at this
time, using care not to scratch the surface of the Piston
Rod.

3. Unscrew the Bearing Retainer Bolts (14) and remove
the Bearing Retainer (13), the Retainer Gasket (37), and
the Torque Shaft Seal (38) from the valve mounting
side of the actuator.

4. The Torque Shaft (20) may be tapped out using a soft
faced hammer. Use care not to drop the shaft or the
Bearing (12) when they come out. After removal of the
Torque Shaft (20) repeat step 3 on accessory side.

4. Remove the Adaptor Bolts (43) and carefully slide the
Adaptor (22) over the Piston Rod (3).

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© 2001, Flowserve Corporation, Provo, UT