Flowserve Heavy Duty Hydraulic Overrides User Manual
11444 Deerfield Road
Cincinnati, Ohio 45242
(513) 489-7800
FAX (513) 489-5243
Heavy Duty Hydraulic Override
Nuclear Qualified Actuator
Installation, Operating, and Maintenance Instructions
Heavy Duty Hydraulic Overrides
Hydraulic manual overrides on Automax heavy-duty
actuators provide a compact, rugged method for
manually operating the actuator. The hydraulic
override consists of either a hydraulic piston or ram, a
hand pump, and a control valve. Double acting
actuators require a piston, and spring return actuators
utilize a ram. The piston or ram is an integral part of
the actuator, designed to override the full rated torque
of the actuator.
Installation
Automax standard hydraulic overrides are supplied
as a complete integral component of the heavy duty
actuator. Override units are shipped with required
accessories, tubing, and fluid installed on actuator,
ready to be used. No additional customer installation
is required. Oil level in hydraulic override should be
checked prior to installing actuator into service. See
maintenance instructions for checking oil level. See
Automax Nuclear Qaulified Heavy Duty Actuator
bulletin B00143 for instructions on installing Heavy
Duty actuator into service.
Note: Actuator orientation must be specified when
ordering, to allow for proper orientation of pump and
reservoir. Standard orientation is horizontal, as
shown below, under 'Manual Override Dimensional
Data'.
Special hydraulic override units may be supplied with
remote mounted pump and controls. Installation of
such units is as follows:
1. Run required hydraulic supply tubing from remote
pump and controls to appropriate ports on hydraulic override, per schematic supplied with unit.
2. Fill pump reservoir with a fire-resistant, nuclear
approved hydraulic fluid, such as Exxon Firexx
HS68. Consult factory for seal compatibility.
3. Use hand pump to circulate fluid into hydraulic
lines. Bleed air from lines by loosening cylinder
bleed plug or fitting on the hydraulic override.
Pump reservoir may have to be filled a few of
times to completely fill the hydraulic lines.
4. See maintenance instructions to check oil level.
MANUAL OVERRIDE
DIMENSIONAL DATA
Note: Other actuator dimensions may
be found in Heavy Duty Catalog
Double Acting Hydraulic
Manual Override
Spring Return Hydraulic
Manual Override
SR and DA Hydraulic Manual
Override Overall and Pump
Handle Dimensions
Model A(DA) A(SR) B(DA) B(SR) C(DA) C(SR) D
RN2 18.31 28.95 5.50 4.00 30.53 32.18 36.75
RN3 22.44 33.75 7.13 5.13 31.35 36.24 39.31
RN4 29.13 45.93 9.82 6.75 32.69 39.70 44.34
B00151-0 Page 1 of 4
11444 Deerfield Road
Cincinnati, Ohio 45242
(513) 489-7800
FAX (513) 489-5243
Heavy Duty Hydraulic Override
Nuclear Qualified Actuator
Operation
Operation of hydraulic overrides requires shifting a
manual valve and operating a hand pump. Standard
operation for DA or SR actuators is described below.
Operation of special hydraulic override designs is per
hydraulic schematics supplied with actuator.
Double Acting
Pneumatic Operation:
1. Open ball valve 'B' on hydraulic override.
2. Place directional valve 'C' in mid position.
3. Open dump valves 'A' on pneumatic cylinder.
4. Connect air supply pressure and operate.
Manual Override:
1. Close both dump valves 'A' clockwise to block air
pressure and vent cylinder.
2. Close ball valve 'B' clockwise.
3. Rotate directional valve 'C' handle full clockwise
to manual override actuator counter-clockwise.
4. Rotate directional valve 'C' handle full counterclockwise to manual override actuator clockwise.
5. Operate manual pump 'D' to override actuator.
Spring Return
Pneumatic Operation:
1. Open ball valve 'B' on hydraulic override.
2. Open dump valve 'A' on pneumatic cylinder.
3. Connect air supply pressure and operate.
Manual Override:
1. Close dump valve 'A' clockwise to block air pressure and vent cylinder.
2. Close valve 'B' clockwise.
3. Operate pump to open actuator against spring.
4. Open valve 'B' to allow actuator to spring return.
Maintenance
Disassembly Procedures
1. Disconnect all air and electric supplies from
actuator.
2. Remove all accessories from actuator and dismount actuator from valve.
Note: See Heavy Duty Nuclear Qualified Actuator
Bulletin B00143 for complete instructions on actuator
disassembly.
Hydraulic Pressure Group
1. Drain hydraulic fluid from cylinder.
2. Remove Tie Rod Nuts (8), Tie Rods (7), and the
Endcap (9).
3. Slide Cylinder (1) over Piston (2) or Ram (2). DA
Cylinder is honed and chromed; care should be
taken not to scratch inner cylinder walls.
4. DA: Remove Piston Bolt (3), and Piston Bolt
Lockwasher (4). Remove Piston (2) and Piston
Face Seal (5).
5. DA: Remove Adapter Nuts (12) and Lockwashers
(13), and carefully slide Adapter (11) over Piston
Rod. Remove High Pressure Rod Seal (14).
SR: Remove Hydraulic Adapter (11), High Pressure Rod Seal (14), Rod Bearing (15), and Low
Pressure Rod Seal (16).
Reassembly Procedures
1. Inspect all parts for wear and replace any worn
parts as needed. Normally, all seals and gaskets should be replaced when reassembling an
actuator.
2. Clean all components and lubricate seals with the
hydraulic fluid.
3. Reverse the disassembly procedures to
reassemble. Tie Rod Locknuts (8), Adapter Nuts
(12), and Piston Bolts (3) should be tightened to
torque listed on Bolt Torque chart. All threads
should be lubricated with Locktite Nuclear Grade
Pipe Sealant 580 prior to assembly.
4. Recommended spare parts are shown in Parts
and Materials section below.
5. Test the actuator for smooth operation and absence of hydraulic leakage before re-installing.
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