Flowserve Heavy Duty Hydraulic Overrides User Manual

11444 Deerfield Road
Cincinnati, Ohio 45242
[phone]
FAX [phone]

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
[phone]
FAX [phone]

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.

B00151-0 Page 2 of 4

11444 Deerfield Road
Cincinnati, Ohio 45242
[phone]
FAX [phone]

Heavy Duty Hydraulic Override

Nuclear Qualified Actuator

Checking Oil Level

1. Actuator should be in full CW position for DA ac­tuator or failed position for SR actuator.

2. Remove cap from oil reservoir and check oil
level.

3. Oil level should be 2-3 inches from top of reser­voir. If required, add hydraulic fluid to reservoir to
reach this level.

Pump/Oil Specifications

Temperature: 0°F to 300°F
Oil Type: Fire resistant, Nuclear Approved hydraulic

fluid, such as Exxon Firexx HS68. Consult
factory for seal compatibility and temperature
ranges of other fluids.

Oil Volume:

Actuator SR/DA Volume (gal)

RN2 SR 1/2

DA 1/2

RN3 SR 1/2

DA 3/4

RN4 SR 1

DA 1 1/2

Pump Pressure: DA 1500 psi

SR 3500 psi

Number of strokes to override:

Actuator SR/DA # Pumps

RN2 SR 17

DA 9

RN3 SR 45

DA 25

RN4 SR 132

DA 74

Bolt Torques

Piston Bolt (3) (SAE Grade 8 Bolt)*

Actuator Size Bolt Size Torque Range

RN2 3/4"-10 UNC 271-320 ft.lb.
RN3 1 1/4"-7 UNC 537-591 ft.lb.
RN4 1 1/4"-7 UNC 1014-1116 ft.lb.

* Not present in SR overrides

Tie Rod (7) (A311 Stressproof Rod)

Actuator Size Bolt Size Torque Range

RN2 5/8"-11 UNC 117-130 ft.lb.
RN3 3/4"-10 UNC 207-229 ft.lb.
RN4 1"-8 UNC 249-270 ft.lb.

Adapter Nut (12) and Stud (ASTM A193 Gr. B7)*

Actuator Size Bolt Size Torque Range

RN2 1/2"-13 UNC 64-71 ft.lb.
RN3 3/4"-10 UNC 226-249 ft.lb.
RN4 1"-8 UNC 546-603 ft.lb.

*Not present in SR Overrides

B00151-0 Page 3 of 4

11444 Deerfield Road
Cincinnati, Ohio 45242
[phone]
FAX [phone]

Heavy Duty Hydraulic Override

Nuclear Qualified Actuator

Parts and Materials

Note: Other components are shown in Heavy Duty
Nuclear Qualified Actuator bulletin, B00143.

DA Hydraulic Override

SR Hydraulic Override

Item Description Material Qty

1 Cylinder Steel/Chrome Pl. 1
2 Piston(DA)/Ram(SR) Steel

3 Piston Bolt Steel
4 Piston Bolt Lockwasher Steel
5 Piston Face Seal Viton
6 Piston Seal Viton/Nylon
7 Tie Rod Steel 4

8 Tie Rod Locknut Steel/Nylon 4

9 Endcap Steel 1
10 Cylinder Seals Viton 2
11 Adapter Steel

12 Adapter Nuts Steel
13 Adapter Stud Locknuts Steel
14 High Pressure Rod Seal Flouromyte/Viton 1*

15 Rod Bearing Bronze
16 Snap Ring Steel
17 Low Pressure Rod Seal Viton

11444 Deerfield Road
Cincinnati, Ohio 45242
[phone]
Fax [phone]

Service Center

4214 Bluebonnet Drive
Stafford, Texas 77477
[phone]
Fax [phone]

Seal Kits

Viton/Flouromyte- RN(Actuator Base Model)-SKV
i.e.: Buna Seal kit for RN316SR80HV is:

†

1

†

1

†

1

†

1*
1*

Replacement hand pumps, manual directional control

†

valves, and manual ball valves are also available.
Consult factory.

*

†

1

†

4

†

4

*Recommended Spare Parts

‡

1
1

1*

†

Not present in SR Actuator Override

‡

‡

Not present in DA Actuator Override

‡

Service Center

7445 Whitepine Road
Richmond Virginia 23237
[phone]
Fax [phone]

RN316SRHSKV

Automax Controls, Inc.

120 Vinyl Court
Woodbridge,Ontario L4L 4A3
[phone]
Fax [phone]

B00151-0 Page 4 of 4