Flowserve Hydraulic Heavy Duty Actuators User Manual

Automax Valve Automation Systems

Installation, Operation and Maintenance Instructions

Flowserve Corporation 1350 N. Mountain Springs Parkway 1978 Foreman Dr.
Flow Control Division Springville, Utah 84663-3004 Cookeville, TN 38501
www.flowserve.com Phone: [phone] Phone: [phone]

Hydraulic Heavy Duty

Installation

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 a set.

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

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

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

5. To prolong actuator life, use a petroleum based
hydraulic oil, such as Mobil DTE 24. Consult factory
for seal compatibility with other fluids. For normal
temperature ranges (50°-110°F), use an oil with
viscosity of 150 SSU at 100°F.

6. Oil should be filtered with a minimum of 40µ filter,
depending on other system components and
environment.

Travel Stop Adjustments

All actuated valving requires accurate travel-stop
adjustments at both ends of stroke to obtain optimum
performance and valve seat life. Accumulation of tolerances
in adaption of actuators to valves is such that there must be
a range of adjustments for both ends of stroke to achieve
expected performance.

The Heavy Duty series actuators have travel stop
adjustments in both clockwise and counterclockwise
directions. The 12 degree overtravel feature provides
adjustments from -6 to +96 degrees.

Field Conversion from FCW to FCCW

(For Spring Return Actuators)

1. Dismount actuator from valve.

2. Apply hydraulic pressure to actuator and loosen Stop
Bolt Jam nut (17). Back off clockwise Stop Bolt (16)
to remove spring preload.

3. Remove hydraulic pressure from actuator.

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

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

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

7. The Torque Shaft (20) may now be tapped out of
Housing (1) using a soft faced hammer. Use care not
to drop shaft or Bearing (12) when they come out.

8. Rotate Torque Shaft (20) end for end and reinstall
into Yoke (4), using care to line up shaft with Bearing
(12) on opposite end. Push shaft through until shaft
bottoms out. Hand pressure only should be needed to
reinstall shaft.

9. Reinstall Bearing (12) into housing, ensuring that it
is flush with top of housing.

10. Reinstall Bearing Retainer Plate (13) and Screws (14)
ensuring that Gasket (37) is in place.

11. Tighten Spring Cartridge Nuts (41) evenly until all
four are evenly tightened. See bolt torque chart below.

12. Apply hydraulic pressure to actuator and reset Stop
Bolt (16). Never adjust stop bolt against spring force.

13. Reinstall any accessories or position indicator onto
Torque Shaft (20).

14. Check actuator for proper operation.

FCD AXAIM00010-00 (AUTO-10) 08/04

©

2004, Flowserve Corporation, Printed in USA

Page 1 of 4

Automax Valve Automation Systems

Installation, Operation and Maintenance Instructions

Flowserve Corporation 1350 N. Mountain Springs Parkway 1978 Foreman Dr.
Flow Control Division Springville, Utah 84663-3004 Cookeville, TN 38501
www.flowserve.com Phone: [phone] Phone: [phone]

MAINTENANCE INSTRUCTIONS

Disassembly Procedures

1. Disconnect all hydraulic and electrical supplies
from actuator.

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

Spring Group

Note: Personal Injury may result if Step 2 is

attempted before Step 1 is completed.

1. Apply hydraulic pressure to the cylinder to
release spring pressure from Stop Bolt (16).
Remove both Stop Bolts (16) and remove hydraulic
pressure. This will relieve majority of spring load.

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

Note:Support Spring Cartridge (11) during removal

so as not to damage Piston Rod (3).

Pressure Group

Note: Rod pusher pressure group will not have a

piston. Step 3 is not applicable.

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

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

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

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

Note: A double acting actuator will have a rod

pusher pressure group on the opposite side of
the main pressure group (in place of spring
cartridge). Follow disassembly procedure as
above, skipping step 3.

Housing (Body Group)

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

Note: Prior to disassembly of remainder of Body

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

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

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

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

R3 and R4 actuators: Remove both freeze plugs

located in Housing near Bearing Retainer (13).
Through these openings, both Yoke Pin Retainer
Rings (7) can be removed. Yoke Pin Rollers (6)
can be slipped off Yoke Pin (5). Push Yoke Pin (5)
through Piston Rod (3) and out opening in other
side of Housing (1).

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

4. Remove Torque Shaft (20) by tapping with a soft­faced hammer. Use care not to drop shaft or
Bearing (12) as they come out. After removal of
Torque Shaft (20) repeat step 3 on accessory side.

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 and grease all components with a multipurpose
“polymer” fortified grease such as DuBois Chemical
MPG-2. (Different greases may be required for low or
high temperatures; consult factory).

3. Reverse the disassembly procedures to reassemble.
Use the proper torque from the torque chart on the Tie
Rod Locknuts (28), the Adapter Bolts (43), the Spring
Cartridge Nuts (41), and the Piston Bolt (25). These
threads should be lubricated with Locktite
Threadlocker 242 or equivalent prior to assembly.

4. See attached drawing which depicts all required
spare parts.

5. Test the actuator for smooth operation and hydraulic
leakage at service pressure before re-installing.

FCD AXAIM00010-00 (AUTO-10) 08/04

©

2004, Flowserve Corporation, Printed in USA

Page 2 of 4