Flowserve LHS Hydraulic Heavy-Duty Actuator Series User Manual

USER INSTRUCTIONS

LHS Hydraulic Heavy-Duty Actuator Series

Single Acting & Double Acting

LFENIM0003-00-AQ – 07/14

Installation

Operation

Maintenance

Experience In Motion

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

Contents

1. Standard Information 3

1.1 General Usage 3

1.2 Terms Concerning Safety 3

1.3 Protective Clothing 3

1.4 Qualified Personnel 4

1.5 Other General Requirements for In-Plant Installation 4

1.6 Spare Parts 4

1.7 Service/Repair 4

1.8 Actuator Lifting and Handling 4

1.9 Storage 6

1.10 Valve and Actuator Variations 7

1.11 Unpacking 7

2 Installation Instructions 8

2.1 Valve and Actuator Check 8

2.2 Connection With Valve and Mounting Kit 9

2.3 Travel Stop Bolts and Accessories 10

2.4 Grounding System 10

2.5 Hydraulic Supply Pressure 11

2.6 Initial Operation 11

2.7 Fail Open and Fail Close Configuration 12

3 Field Conversion 13

3.1 Actuator Disassembled From the Valve 13

3.2 Actuator Connected to the Valve (and the valve can be stroked) 14

4. Maintenance Instructions 16

4.1 General Disassembly Instructions 16

4.2 Spring Container Maintenance 17

4.3 Hydraulic Cylinder Maintenance 18

4.4 Scotch Yoke Housing Maintenance 19
5 Troubleshooting 20
6 Disposal of Decommissioned Actuators 22
7 Annex 23

Figures

Figure 1: Eyebolts for the Lifting 5
Figure 2: Handling of the Double Acting Actuator 5
Figure 3: Vent Valve Position 5
Figure 4: Single Acting Actuator Lifting System 5
Figure 5: Correct Lifting System 6
Figure 6: Actuator’s Position on Wooden Pallet 6
Figure 7: Standard Nameplate Position 8
Figure 8: Nameplate Sample 8
Figure 9: Grounding Kit Assembled 10
Figure 10: Grounding Kit – Exploded View 10
Figure 11: Grounding Kit 10
Figure 12: Single Acting Actuator Configuration: Fail Close – Fail Clockwise 12
Figure 13: Single Acting Actuator Configuration: Fail Open – Fail Counter Clockwise 12
Figure 14: Double Acting Actuator Configuration – Close Position 12
Figure 15: Double Acting Actuator Configuration – Open Position 12
Figure 16: Single Acting LHS – Fail Close Configuration With Valve 12
Figure 17: Double Acting LHS With Valve 12
Figure 18: Single Acting Actuator 16
Figure 19: Spring Can Exploded View 17
Figure 20: Exploded View of Hydraulic Cylinder 18
Figure 21: Exploded View of Adaptor Kit 19

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Figure 22: Exploded View of Housing 19
Figure 23: LHS Model Selection Table 23
Figure 24: Weight Selection Table – Double Acting Models 23
Figure 25: Weight Selection Table – Single Acting Models 23

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

Standard Information

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1.1 General Usage

The following instructions are designed to assist in unpacking, installing and performing maintenance as required on
Flowserve products. Product users and maintenance personnel should thoroughly review this bulletin prior to installing,
operating or performing any maintenance.

In most cases Flowserve actuators and accessories are designed for specific applications with regard to medium,
pressure and temperature. For this reason they should not be used in other applications without first contacting the
manufacturer.

1.2 Terms Concerning Safety

The safety terms DANGER, WARNING, CAUTION and NOTE are used in these instructions to highlight particular
dangers and/or to provide additional information on aspects that may not be readily apparent.

DANGER: indicates that death, severe personal injury and/or substantial property damage will occur if proper

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precautions are not taken.

a WARNING: indicates that death, severe personal injury and/or substantial property damage can occur if proper

precautions are not taken.

a CAUTION: indicates that minor personal injury and/or property damage can occur if proper precautions are not

taken.

NOTE: indicates and provides additional technical information, which may not be very obvious, even to qualified
personnel.

Compliance with other, not particularly emphasized notes, with regard to transport, assembly, operation and main­tenance and with regard to technical documentation (e.g. in the operating instruction, product documentation or on
the product itself) is essential, in order to avoid faults, which in themselves might directly or indirectly cause severe
personal injury or property damage.

1.3 Protective Clothing

Flowserve products are often used in problematic applications (e.g. extremely high pressures, dangerous, toxic or
corrosive media). When performing service, inspection or repair operations always ensure, that the valve and actuator
are depressurized and that the valve has been cleaned and is free from harmful substances. In such cases pay particular
attention to personal protection (protective clothing, gloves, glasses etc.).

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

1.4 Qualified Personnel

Qualified personnel are people who, on account of their training, experience and instruction and their knowledge of
relevant standards, specifications, accident prevention regulations and operating conditions, have been authorized by
those responsible for the safety of the plant to perform the necessary work and who can recognize and avoid possible
dangers.

1.5 Other General Requirements for In-Plant Installation

• Pipelines must be correctly aligned to ensure that the valve is not fitted under tension.

• Flowserve can provide fire protection system. If not expressly agreed, fire protection must be provided by user.

1.6 Spare Parts

Use only Flowserve original spare parts. Flowserve cannot accept responsibility for any damages that occur from using
spare parts or fastening materials from other manufacturers. If Flowserve products (especially sealing materials) have
been stored for long periods (more than 4 months to two years) check these for corrosion or deterioration before using
these products.

1.7 Service/Repair

To avoid possible injury to personnel or damage to products, safety terms must be strictly adhered to. Modifying
this product, substituting non-factory parts, or using maintenance procedures other than outlined in this instruction
could drastically affect performance and be hazardous to personnel and equipment, and may void existing warranties.
Between actuator and valve there are moving parts. To avoid injury Flowserve provides pinch-point-protection in the
form of cover plates, especially where side-mounted positioners are fitted. These protections are according to Machine
Directive 2006/42/EC recommendations. If these plates are removed for inspection, service or repair special attention is
required. After completing work the cover plates must be refitted.

Apart from the operating instructions and the obligatory accident prevention directives valid in the country of use, all
recognized regulations for safety and good engineering practices must be followed.

a WARNING: Before products are returned to Flowserve for repair or service, Flowserve must be provided with

a certificate which confirms that the product has been decontaminated and is clean. Flowserve will not accept
deliveries if a certificate has not been provided (a form can be obtained from Flowserve).

1.8 Actuator Lifting and Handling

Only Allen wrenches and hexagonal wrenches of the correct size are required for overall maintenance operations. The
lifting equipment consists on commercial chains and slings of adequate dimensions.

In order to prevent any damage to actuator accessories and actuator control panel, before starting the lifting operations,

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check that the lifting tools are away from them and avoid any interference between them.

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

a CAUTION: The actuator lifting and handling should be made by qualified staff and in compliance with the laws and

provisions in force.

a WARNING: The lifting lugs are appropriate for actuator lifting alone and not for the valve and actuator assembly

lifting. Avoid that during the handling, the actuator passes above the staff. The actuator should be handled with
appropriate lifting means. The weight of the actuator is reported on the packing slip and on overall-dimensions
drawings furnished with the documents accompanying the actuator.

For actuator weight, refer to Figures 24 and 25 in Annex section. For the general actuator dimensions, refer to LHS
technical bulletin LFENTB0003, available on www.flowserve.com.

NOTE: For lifting and handling, use the eyebolts on the

housing. The eyebolt on the spring can (for single
acting version) is only for the mounting/dismounting
steps or eventually for balancing the actuator.

Figure 1: Eyebolts for the Lifting

Figure 2: Handling of the Double Acting Actuator

a WARNING: Only for actuator balancing or spring

container mounting/dismounting operation

Figure 3: Vent Valve Position

CENTER OF MASS

Figure 4: Single Acting Actuator Lifting System

EYEBOLTS FOR ACTUATOR LIFTING

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

Figure 5: Correct Lifting System

a WARNING: For actuator lifting and handling use the appropriate lifting eyebolts installed on the scotch-yoke

housing, as shown in Figures 4 and 5.

1.9 Storage

In many cases Flowserve products are manufactured from stainless steel. Products not manufactured from stainless
steel are typically provided with an epoxy resin coating or with other painting systems agreed with the customer.
This means that Flowserve products are well protected from corrosion. Nevertheless, in order to maintain good
working conditions and a good finish until the actuator is installed on the plant, it is necessary to follow a few rules
during the storage period:

• Flowserve products must be stored adequately in a clean, dry environment.

• Ensure that plastic caps are fitted to protect the hydraulic connections and the cable entries, to prevent the ingress

of foreign materials. These caps should not be removed until the product is actually mounted into the system.

• If the storage is outdoor, or if long-term

storage (more than 4 months) is necessary,
the plastic protection plugs have to be
replaced by metal plugs, because the plastic
plugs are not weather-proof function, where­as the metal ones guarantee a weatherproof
protection.

• The actuator must be placed on a wooden

pallet, in order to not damage the coupling
base and avoid that other surfaces rest on
the ground.

Figure 6: Actuator’s Position on Wooden Pallet

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

In case of long-term storage (more than 4 months), additionally perform the following measures:

• Coat the coupling parts (spool piece base, flanges, bushings, joints) with protective oil or grease.

• If possible, blank off the spool piece base flange by a protection disk.

• Provide a tarpaulin cover or some other means of protection, especially if the storage is outdoor.

• It is important to periodically operate the actuator

1.10 Valve and Actuator Variations

These instructions cannot claim to cover all details of all possible product variations, nor can they provide informa­tion for every possible example of installation, operation or maintenance. This means that the instructions normally
include only the directions to be followed by qualified personnel where the product is being used for its defined
purpose. If there are any uncertainties in this respect particularly in the event of missing product-related information,
clarification must be obtained via the appropriate Flowserve sales office.

1.11 Unpacking

• Each delivery includes a packing slip. When unpacking, check all delivered actuators and accessories using this

packing slip.

• Report transport damage to the carrier immediately.

• In case of discrepancies, contact your nearest Flowserve location.

• If necessary, retouch minor damage to the paint coating which may have occurred during transport or storage.

NOTE: When the actuator has ATEX or SIL requirements, ensure that the “LHS Series Safety Manual”
(Functional Safety and SIL Certification) and “LHS Series Safety Extract and Instruction Manual”
(Explosive Atmosphere Equipment and ATEX Certification) accompany this manual and are referred to
for equipment usage.

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

Installation Instructions

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The LHS is a fully modular design scotch-yoke actuator, with mounting base in compliance with ISO 5211 and the
Technical Bulletin (LFENTB0003-00). It may also be customized, if required.

The LHS Hydraulic Scotch Yoke Spring Return Actuators adopt a push-to-compress spring design.

a WARNING: Actuator operation/pressure limitations must be in accordance with Technical Bulletin (LFENTB0003-00)

2.1 Valve and Actuator Check

DANGER: Before installation check the order no., serial no., and/or the tag no. to ensure that the valve/actuator is

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correct for the intended application.

Figure 7: Standard Nameplate Position

Figure 8: Nameplate Sample

Prior to mounting the actuator to the valve, manually open and close the valve (if possible) to ensure it is not stuck. Be
sure valve and Limitorque actuator rotate in the same direction and are in the same position (i.e.: valve closed, actuator
closed). The assembly position of the actuator, with reference to the valve, has to be in accordance with the plant
requirements (actuator axis parallel or perpendicular to the pipeline axis).

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

2.2 Connection With Valve and Mounting Kit

The LHS actuator is usually supplied with the spool piece already assembled. To assemble the actuator onto the
valve, perform the following steps:

2.2.1 Check the mounting surfaces, the stem adaptor and the spool piece to
assure the proper fit. Clean the flange of the valve and spool piece to
remove oils and greases since the torque is transmitted by friction. Also
remove any rust that may have occurred during the storage.

2.2.2 Secure the valve in the closed/open position, if possible, with the stem
vertical. Lubricate the valve stem in order to ease the assembly. Place the
stem adaptor on the valve stem.

2.2.3 Lift the actuator by specific lift points (eyebolts), using a proper lifting
system. Position the actuator over the valve and lower to engage the
stem adaptor to the actuator bore. Continue to lower until the spool piece
sits on valve mounting surface. This coupling has to take place without
force and only with the weight of the actuator. The mounting bolts (or
studs) of the valve should easily fit into the bolt holes of the spool piece
without any binding. If needed, turn or stroke the actuator a few degrees
and/or adjust the actuator travel-stops.

2.2.4 The mounting nuts (or bolts) connecting the base of the spool piece to the
valve flange must be evenly tightened according to specific tables, available
upon request to Flowserve After Sales Department.

NOTE: In some cases, the coupling between valve and actuator can be direct,
without the need of a spool piece. In other cases, Flowserve can provide an
intermediate spool piece or an adapter flange (fitted under the actuator
housing) and a special bushing to be inserted into the yoke bore.

a WARNING: In case of spool piece (or adapter flange) installation by the client, it is mandatory to refer to the

“Mounting Interface Dimensions” paragraph of Technical Bulletin No. LFENTB0003, or to follow more specific
instructions included in the job documentation supplied along with the actuator. These assembling instructions
include details of prescribed stud bolts and their maximum allowable threaded length, in addition to the Loctite
type to be used for a perfect sealing of Scotch yoke housing.

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a CAUTION: The actuator lifting and handling should be made by qualified staff and in compliance with the laws and

provisions in force

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

a WARNING: The lifting lugs are appropriate for actuator lifting alone and not for the valve and actuator assembly

lifting. Avoid that during the handling, the actuator passes above the staff. The actuator should be handled with
appropriate lifting means. The weight of the actuator is reported on the packing slip and on overall-dimensions
drawings furnished with the documents accompanying the actuator.

2.3 Travel Stop Bolts and Accessories

All actuated valves require accurate travel-stop adjustments at both ends of the stroke to obtain optimum performance
and valve seat life. Adjust the travel-stop bolts of the actuator for the proper open and close valve positions, per valve
manufacturer’s recommendations.

The LHS actuators have travel-stop adjustments in both the clockwise and counter-clockwise directions.

The +/- 5-degree adjustment feature provides shaft rotation from 80 to 100 degrees overall.

The adjustment of the travel-stops is performed in accordance with the following steps. Refer to Figures 19, 20, 21 and 22.

Hydraulic cylinder stop (25): Loosen the seal nut (if present) with a proper wrench. Screw or unscrew the stop (25),
using a proper Allen key, while keeping the seal nut stationary. Tighten the seal nut.

Spring container stop (7): Remove the spring container end flange (11) after unscrewing the hex screws (10). Screw or
unscrew the end stop (7) to the desired position, using a proper Allen key. Replace the end flange and tighten the hex screws.

Hydraulically stroke the actuator several times to assure proper operation. The stem adaptor should not bind during
operation. If the actuator is equipped with a switch, positioner or other accessories, adjust them at this time.

2.4 Grounding System

For the actuator earthing, use the grounding kit, shown in Figure 9:

High Nut ISO 4033-M8

Figure 9: Grounding Kit Assembled

Ground Nameplate

High Nut ISO 4033-M8

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Figure 11: Grounding Kit

Grub Screw-ISO 4026-M8x45

Lock Washer, DIN 6798 A, Ø8

High Locking Nut with Nylon Insert-ISO 7040-M8

Figure 10: Grounding Kit – Exploded View

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

2.5 Hydraulic Supply Pressure

To prolong actuator life use below recommended oil or equivalent. Periodically check that the oil is in good condi­tion and clean. The cleanliness level for actuator without control system is minimum NAS 1638 Class 8 – ISO 4406
19/17/14. For actuators with control system the oil cleanliness level required by each control system component is
normally more stringent. Please verify with Flowserve Service or control system component Manufacturer.
Standard operating temperature range -29°C to 100°C (-20°F to 212°F).

Advised Maintenance Materials

Hydraulic Fluid Characteristics

Kinematic Viscosity

(ASTM D445)

40°C cSt

100°C cSt

Viscosity Index

(ISO 2909)

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Density at 15°C [Kg/dm

(ISO 12185)

Cleveland Open Cup °C

(ISO 2592)

Pour Point°C

(ISO 3016)

AGMA N. EP5

]

220

19.4

100

0.899

200

-18

Worked Penetration [dmm] 280

Dropping Point ASTM [°C] 190

Base Oil viscosity a 40°C [mm

ISO L-X-BCHA 2

DIN 51 825 K2K-20

Note: Indications for standard operating temperature.
For different conditions, contact Flowserve.

Grease Characteristics

2

/s] 100

For low temperature -60°C (-76°F) and High temperature 160°C (320°F) applications, consult Flowserve Limitorque
Fluid Power Systems.

2.6 Initial Operation

Before initial operation of the actuator, perform the following checks:

• Check that all electrical supply, control and signal lines are properly connected, by following the dedicated

customer procedures;

• Check that the pressure and quality of the supply fluids are as prescribed;

• Check the absence of leaks in the hydraulic connections. If necessary tighten the pipe fittings.

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

2.7 Fail Open and Fail Close Configuration

The actuator is designed for work in both configurations: fail open and fail close. For conversion from one configura­tion to the other, refer to next paragraph.

Figure 12: Single Acting Actuator Configuration: Fail Close – Fail Clockwise

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Figure 13: Single Acting Actuator Configuration: Fail Open – Fail Counter Clockwise

Figure 14: Double Acting Actuator Configuration – Close Position

Figure 15: Double Acting Actuator Configuration – Open Position

Figure 16: Single Acting LHS – Fail Close
Configuration With Valve

Figure 17: Double Acting LHS With Valve

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

Field Conversion

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Field Conversion from Fail CW to Fail CCW or vice versa (Spring Return)

NOTE:

• The actuator designation needs to be suitably changed on the name plate.

• An additional adapter kit is required for field conversion from Fail CW to CCW and vice versa.

There are two different situations, requiring different sequences of instructions: in the first situation, the actuator is
already disassembled from the valve. The second situation regards the conversion with the actuator assembled on the
valve. The reference drawings are Figures 19, 20, 21 and 22.

3.1 Actuator Disassembled From the Valve

a WARNING: Ensure that the hydraulic connection ports of the cylinder are disconnected. Also make sure that all

hydraulic supplies to the control unit and all power supplies are disconnected. Finally, make sure that the actuator
is in fail safe position, i.e. that it is not locked in a position with the spring compressed by means of locking
devices.

3.1.1 Unscrew and remove the end stop (25) from the hydraulic cylinder. For
removing the stop, refer to paragraph 2.3. If necessary, feed the hydraulic
cylinder port on the head flange (19) at minimum necessary pressure to
facilitate the movement of the scotch-yoke and assure the total retraction
of the piston rod (20). Remove the pressure. In this way the spring is fully
extended. Remove the cover (46) from the housing by unscrewing all of
the locking components: hex screws (45), hex head shoulder bolts (44)
and eyebolts (42) plus upper nuts (43). Leave the studs (41) screwed into
the housing (51).

3.1.2 Remove the spring can, carefully following the instructions given in
paragraph 4.2. Manually rotate the scotch yoke (36) counterclockwise (or
clockwise, depending on the original fail configuration) up to a position of
approximately 45°. Locate the studs (57) that connect the housing to the
hydraulic cylinder. With the scotch-yoke rotated of 45°, it is possible to
easily access these studs. Carefully unscrew the nuts (56) and the studs
(57). Pull out the whole hydraulic cylinder (The stem is fully retracted).

NOTE: Take care during removal, so as not to damage the piston rod or the stud threads.

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

3.1.3 Change the adapter kit. Replace the adapters (54 and 55) designed for fail
close (open) action, with the new ones designed for the opposite action.
NOTE: Take care to choose the adapter kit suitable for the scotch-yoke
type in use (symmetric or canted).
Reassemble the hydraulic cylinder with adapter, using the reverse
procedure as described in point 4.3.
NOTE: You can recognize the cylinder adapter to the spring can adapter
through the three grub screws (53).

3.1.4 Manually rotate the scotch-yoke (36) until the guide block (48) is in contact
with the cylinder adapter (54), in correspondence of the relevant slot.

Reassemble the spring can, as instructed in paragraph 4.2. Reposition
the cover, taking care to replace the cover gasket (47).

Readjust the stops, as instructed in paragraph 2.3.

Periodically operate the actuator to check the functioning in the
new fail configuration.

3.2 Actuator Connected to the Valve

(and the valve can be stroked)

NOTE: If the valve cannot be rotated, due to the requirements of the plant, the actuator must be removed from
the valve following the instructions given in paragraph 2.2. In this case, use the procedure described above. The
actuator should be reinstalled in the same position of the valve.

a WARNING: Ensure that the hydraulic connection ports of the cylinder are disconnected. Also make sure that

all hydraulic supplies to the control unit and all power supplies are disconnected. Finally, make sure that the
actuator is in fail safe position, i.e. that it is not locked in a position with the spring compressed by means of
locking devices.

3.2.1 Apply the minimum necessary pressure to the cylinder hydraulic port on the end flange and move the actu­ator to approximately 45°. If the actuator is provided with a manual override, you can use it to perform this
operation.

3.2.2 Measure the position of the spring can end stop (7), remove it, and then lock the spring in the compressed
position by means of a special tool for this maintenance. The tool is to be installed in the opening where the
spring-end travel-stop has been removed. Remove pressure from the hydraulic cylinder.

a WARNING: At this point the spring is compressed and the spring module contains a large quantity of stored

energy. Failure to properly engage the retaining device or failure to handle the spring carefully could result in
release of the spring with potential damage to equipment or injury to personnel.

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

3.2.3 Unscrew and remove the travel-stop of the hydraulic cylinder (25). For removing the stop, refer to paragraph

2.3. Feed the hydraulic cylinder from the port on the head (19) at minimum necessary pressure up to totally
retract the piston rod (20).

3.2.4 Remove the cover (46) from the scotch-yoke housing by unscrewing all of the locking components: hex
screws (45), hex head shoulder bolts (44) and eyebolts (42) plus upper nuts (43). Leave the studs (41)
screwed into the scotch-yoke housing (51).

3.2.5 Remove the spring can, carefully following the instructions given in paragraph 4.2.

3.2.6 Locate the studs (57) that connect the scotch-yoke housing to the cylinder. With the scotch-yoke (36) rotated
of 45°, it is possible to easily access these studs. Carefully unscrew the nuts (56). Pull out the whole hydrau­lic cylinder. The stem has to be fully retracted.

NOTE: Take care during removal, so as not to damage the piston rod or the stud threads.

3.2.7 Change the adapter kit. Replace the adapters (54 and 55) designed for fail close (open) action, with the new
ones designed for the opposite action. Take care to choose the adapter kit suitable for the scotch-yoke type in
use (symmetric or canted).

3.2.8 Reassemble the spring can, as instructed in paragraph 4.2.

3.2.9 Reassemble the hydraulic cylinder with adapter, following the reverse procedure as described in point 4.3.

3.2.10 Apply the minimum pressure necessary to the hydraulic cylinder port on the end flange (27) until the piston
rod moves the guide block (48) and partially compresses the spring. In this condition it will be possible to
remove the special tool from the spring can.

3.2.11 Remove the pressure, checking that the actuator goes in the correct new fail safe position.

3.2.12 Reposition the cover, taking care to replace the cover gasket (47).

3.2.13 Readjust the travel-stops, as instructed in paragraph 2.3.

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

Maintenance Instructions

4

LHS Series actuators are designed to offer the greatest ease of operations of assembly, disassembly and maintenance.
The maintenance and disassembly do not require special equipment or special or large wrenches. Furthermore the
joints among the moving parts of the actuator are made exclusively through pins and then not using bolts to be
tightened with specific torques.

LHS Series actuators do not need maintenance for long period, even if they are working in severe condition. The
life-time of these actuators is guarantee for 25 years with a regular and programmed maintenance operation every 6
years. However, if the actuator operation happens infrequently, it is recommended to periodically check the actuator,
performing the following steps:

• In the plants, where it is possible, carry out few opening and closing operations, involving all the control unit
components, checking that the actuator operates correctly and within the required stroking times;

• Check that all the signals (hydraulic and electric) arriving at the actuator are correct and that the supply fluid pressure
is within the required range. Check for the absence of leaks in the hydraulic connections. If necessary, tighten the
pipe fittings.

• Check the paint coating. If some areas are damaged due to accidental events, retouch them according to the paint
procedure supplied along with the actuator documentation.

• In case of scheduled preventive maintenance, or following accidental events, refer to the following maintenance
instructions regarding the main actuators components.

4.1 General Disassembly Instructions

The LHS Series actuator is available in two different configurations, single acting and double acting, composed by the
main parts showed in Figure 18.

Housing

Spring Can

4.1.1 Disconnect all air and electrical supplies from actuator;

Hydraulic Cylinder

Stop Bolt

Figure 18: Single Acting Actuator

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4.1.2 If removal of the actuator from valve is necessary, before dismounting the actuator, remove all

accessories from actuator.

4.1.3 The reference drawings for the instructions reported in the following paragraphs are exploded views of single

acting and double acting actuators, included as Figures 19, 20, 21 and 22.

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

4.2 Spring Container Maintenance

The spring container does not require maintenance. The lubricating of internal parts is carried out during the
assembly and is not necessary during the normal life of the actuator. The substitution of the spring container is not
expected over the entire actuator life. However, accidental events may result in damage to this component. In these
cases, proceed as described in the following steps.

The spring container is a single welded module. In case of damage, the whole container must be disassembled
from the actuator and replaced with a new one equal to the original.

The removal of the spring container from the actuator has to be performed through the following steps. The
reference drawing is Figure 19.

a WARNING: Ensure that the hydraulic connection ports of the cylinder are disconnected. Also make sure that

all hydraulic supplies to the control unit and all power supplies are disconnected. Finally, make sure that the
actuator is in fail safe position, i.e. that it is not locked in a position with the spring compressed by means of
locking devices.

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15

16

18

14

13

11

12

10

9

8

7

4.2.1 Unscrew and remove the travel-stop of the hydraulic cylinder (25). For removing the stop, refer to paragraph

2.3. If necessary, feed the hydraulic cylinder from the port on the head flange (19) at minimum necessary
pressure to facilitate the movement of the scotch-yoke and assure the total retraction of the piston rod (20).
Remove the pressure. This way the spring is fully extended.

4.2.2 Remove the cover (46) from the housing by unscrewing all of the locking components: hex screw (45),
hex head shoulder bolts (44) and eyebolts (42) plus upper nuts (43). Leave the studs (41) screwed into the
scotch-yoke housing (51).

4.2.3 Hook and hold in tension the spring container using the specific lifting lug located on the top of the spring
can. Care should be taken to choose a lifting system suitable for the weight of the spring container. Refer to
the weight table shown in Figures 24 and 25.

Locate the studs (57) that connect the scotch yoke housing with the spring container. Carefully unscrew the
nuts (56) and the studs (57). Pull out the whole spring container.

1

2

3

4

5

6

Figure 19: Spring Can Exploded View

NOTE: take care to horizontally support the spring module during removal, so as not to damage the spring rod
or the stud threads.

17

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

4.2.4 Before reassembling the new spring module to body, make sure stud threads are free of any dirt, shavings, or
other debris. Clean threads with rag and solvent if required, and lubricate threads with an anti-seize compound.

Assemble the new spring can, following the reverse procedure as described in points 4.2.4 to 4.2.3.
Readjust the travel-stop (25) of the hydraulic cylinder, as instructed in paragraph 2.3.

4.3 Hydraulic Cylinder Maintenance

The hydraulic cylinder maintenance mainly consists in the replacement of all parts that may degrade in the course of
time, even in the absence of faults. These components are the O-rings and the sliding elements of the piston.
The substitution of cylinder components (or of the whole cylinder) is not expected over the entire actuator life.
However, accidental events may result in damage to these components. In these cases, proceed as described in the
following steps.

There are two possible types of maintenance: standard maintenance which can be performed in the field without the
need to remove the hydraulic cylinder from the actuator, and a more thorough one, following unexpected events,
which often can be performed only after removing the cylinder from the actuator.

Standard in–field Maintenance – perform the following steps:
The reference drawing is Figure 20.

32

34

20

19

21

33

22

23

31

30

24

Figure 20: Exploded View of Hydraulic Cylinder

29

27

28

25

26

a WARNING: ensure that the hydraulic connection ports of the cylinder are disconnected. Also make sure that

all hydraulic supplies to the control unit and all power supplies are disconnected. Finally, make sure that the
actuator is in fail position, i.e. that it is not locked in a position with the spring compressed by means of locking
device.

4.3.1 If necessary, feed the hydraulic cylinder from the port on the head flange (19) at minimum necessary
pressure to facilitate the movement of the scotch yoke and assure the total retraction of the piston rod (20).
In this way the spring is fully extended. Unscrew and remove the travel stop of the hydraulic cylinder. For
removing the stop, refer to the indications given in paragraph 2.3.

18

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

4.3.2 Remove at least two of the tie rods (31) positioned on the upper part of the cylinder by unscrewing the nuts
on the sides of the end flange and of the head flange (or unscrewing the tie rods from the head flange if
threaded into the flange). This operation provides two free holes to be used for lifting the end flange (27).
Screw two male eyebolts in these two holes and connect the end flange to a lifting system. Care should be
taken to choose a lifting system suitable for the weight of the cylinder. Refer to the weight table shown in
Figures 24 and 25. Remove all other tie rods (31), following the same procedure described in point 4.3.2.
Then remove carefully the end flange (27) from the tube (30).

4.3.3 Finally, remove the tube (30). Take care not to scratch or dent the honed and plated inner surface of the tube.
Remove the O-rings (28) from the flange; remove the O-ring of the piston (33) and finally the guide rings
(23) from the piston. Clean all surfaces of piston and flanges in contact with these components with rag
and solvent. Brush the O-ring grooves with a light oil film and install the new O-rings. Spread a thin layer
of grease on the bottom of the guide ring grooves and install the new guide rings (23). Clean the internal
surface of the tube (30) and lubricate with a protective oil film.

4.3.4 Reassemble the parts of the cylinder with the reverse procedure as described in points 4.3.3 to 4.3.2. The
tie rods should be tightened using a torque wrench, alternating between opposite holes, applying a torque
according to according to specific tables, available upon request to Flowserve After Sales Department.
Readjust the stops as instructed in paragraph 2.3.

4.4 Scotch Yoke Housing Maintenance

Standard maintenance of the scotch yoke housing may take place in the field, without the need to disassemble the
spring container or the hydraulic cylinder. Perform the following steps. The reference drawing is Figure 21 and 22.

54

53

56

Figure 21: Exploded View of Adaptor Kit

55

57

41

40

39

38

37

36

35

Figure 22: Exploded View of Housing

42

43

44

45

46

47

48

49

50

51

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19

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

a WARNING: Ensure that the hydraulic connection ports of the cylinder are disconnected. Also make sure that all

hydraulic supplies to the control unit and all power supplies are disconnected. Finally, make sure that the actuator
is in fail position, i.e. that it is not locked in a position with the spring compressed by means of locking devices.

4.4.1 Remove the position indicators or other accessories, if fitted. Remove the cover (46) from the scotch yoke
housing by unscrewing all the locking components: hex screw (45), hex head shoulder bolts (44) and eye­bolts (42) plus upper nuts (43). Leave the studs (41) screwed into the scotch-yoke housing (51).

4.4.2 Remove the worn internal O-ring (39) of the bushing (35) inserted in the cover (46). Clean the O-ring groove
and the sliding area of the bushing and after having brushed these surfaces with a light oil film, install the
new internal O-ring (39).

Apply a generous layer of grease on the sliding surfaces of the accessible moving parts inside the housing.

In particular, grease the guide bar (50) and the surfaces of the slots of the wings of the scotch yoke (36), in
which the slider blocks (37) run.

4.4.3 Reposition the cover, taking care to replace the cover gasket (47).

The design of LHS actuators features ease of on-site maintenance and an increased actuator life cycle. For this rea­son, appropriate procedures and equipment have been prepared, in order to allow the replacement of all parts of the
scotch yoke without the need to disassemble the actuator from the valve. These instructions are part of a dedicated
and separate procedure, available on request.

NOTE: Spring Can and Hydraulic Cylinder must be removed before disassembling the Scotch-Yoke Housing.

NOTE: For the specific type and viscosity of grease to be used, refer to instructions packed with Flowserve

replacement parts.

Troubleshooting

5

To prevent the actuator from not proper functioning or low performance, first ensure that the installation and the
adjustment operations are carried out completely in accordance with this manual.

a WARNING: During the activities of identifying faults, it is very important to observe all the regulations and

instructions about safety. Read all the paragraphs of this manual concerning maintenance before opening for
inspection or starting to repair any actuator components. If in doubt, choose SAFETY FIRST.

20

You can identify the causes of possible malfunctions with the help of the following table (“troubleshooting table”). If a
malfunction cannot be identified and eliminated using the table, Flowserve Service Department should be contacted.

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

Problem Possible Cause Solution

Check that all the hydraulic connections and that all the hydraulic
components have been installed correctly, and are in accordance with the
actuator operating mode.

Check that the actuator is properly connected to the valve and that there
aren’t problems in the mounting kit.

Check that sufficient supply pressure is available at actuator inlet port. If
possible, place a gage in line and monitor the pressure level, in order to
discover unexpected pressure drops.

Check the correct functioning of the control panel. In particular, check all
the hydraulic and electric connections.

Check the correct level of supply voltage for solenoid valves and other
electrical/electronic components.

Check that valve is free to rotate. If necessary disassemble the actuator
from the valve.

Screw cap(s) must be disengaged. Ensure vent ports are free. If not,
clean them of any obstructions and clean the dust excluders, if present.

Ensure that the actuator is properly lubricated, and that there is no solid
ified grease among sliding parts or rotating parts. If actuator lubrication
is inadequate or improper, apply a uniform lubricant layer. Follow the
instructions for cylinder maintenance (para. 4.3). Consult Flowserve for
proper oil and grease to be used.

Check if any moving part is blocked. If so, follow the maintenance
instructions given in the relevant paragraphs of this manual or in special
maintenance operating instructions.

A significant oil leak may prevent the actuator from operating. Ensure
that there aren’t any leaks in the hydraulic cylinder toward the outside.
If possible, detect them using a leak finder spray. Check also that there
are not leaks across the piston. If leaks are present, follow the cylinder
maintenance instructions given in paragraph 4.3.

Check the actuator nameplate and the plant requirements. If there are
mismatches, contact Flowserve Service Department.

Check the proper functioning of the spring can. If problems are found,
contact Flowserve Service Department.

Perform the following test: disassemble the actuator from the valve and
measure the minimum pressure values necessary to move and compress
the spring. Compare the measured values with the ones reported on the
Testing Certificate. If there are significant differences you should contact
Flowserve Service Department.

Disconnect the lockout module.

Adjust the end stop of the hydraulic cylinder can until the valve is leak­tight across the seat. Follow the instructions given in the paragraph about
travel stop bolts (2.3)

As above, check the position of the end stop in opening and closing
direction. If necessary adjust them. Follow the instructions given in
paragraph 2.3.

Screw cap(s) must be disengaged. Ensure vent port are free. If not, clean
them of any obstruction and clean the dust excluders, if present.

In order to do a check it is necessary to perform the following test: disas
semble the actuator from the valve and measure the minimum pressure
values necessary to move and compress the spring (if the actuator is
a single acting model) or the minimum values necessary to move the
actuator yoke and perform a stroke (for double acting models). Compare
the measured values with the ones reported on the Testing Certificate.

The actuator does not

move

The valve does not shut

off properly and there are

leaks

The valve does not fully

perform the stroke, during

opening and closing

Actuator has not been properly
installed.

Supply Pressure Problems.

Problems in the control panel (if
present).

The valve is blocked.

Exhaust port(s) obstructed.

Problem with lubricants.

A moving part is seized up.

Leakage of the hydraulic cylinder.

The actuator model is not the correct
one, or is not suitable for the plant
conditions.

Spring Problems (if actuator is a
single acting model).

A lockout device has been inserted
and forgotten in that position.

The actuator is not correctly adjusted

The actuator is not correctly adjusted

Exhaust port(s) obstructed

Actuator torque lower than required

-

-

If there are significant differences you should contact Flowserve Service
Department.

During the stroke the

actuator exhibits excessive

amounts of backlash.

Some components are excessively
worn.

Identify and replace these components, according to the procedure
described in the relevant paragraphs of this manual, or in special
maintenance operating instructions.

In case of other problems not listed in this table, you should contact Flowserve Service Department.

21

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

Disposal of

Decommissioned

6

Actuators

Actuators that are to be decommissioned permanently due to a plant closure or for another reason must have the
stored energy in the spring neutralized. This can be done in several ways:

• Decommissioning by filling with concrete – following proper removal of the actuator from any hazardous areas,

the spring module may be neutralized by cutting a small opening in the end or side of the spring can and filling
the spring can with liquid concrete and allowing the concrete to dry. This will eliminate any possibility of spring
decompression if it were to be removed from the actuator without following proper procedures.

• Decommissioning by cutting the spring – following proper removal of the actuator from any hazardous areas, the

spring module may be neutralized by cutting a small opening in the side of the spring can and accessing the spring
coils. The spring coils are then cut using a torch to relieve all compression and stored energy. Care should be taken
that the opening in the spring can is sufficiently small to prevent any pieces of the spring from escaping when the
spring is cut.

a WARNING: Failure to neutralize the spring in the actuator or to follow these instructions could lead to injury to

personnel or property damage.

Either method is acceptable to Flowserve although the method outlined in the first point is preferred, as the stored
energy in the spring is not suddenly released when the spring is cut. Hence, this is the safest method.

No actions need be taken on any other portions of the actuator to decommission it.

22

Annex

example model n°

LHS-15X

FC 1-1-090Y

-

LHS-15X-90Y

D1

HYDRAULIC CYLINDER SIZE

-

LHS-15X-90Y

FC 1-1

-

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

7

HOUSING SIZE

15

20

25

30

HOUSING SIZE

35

40

15

20

25

30

35

40

A

B

C

YOKE TYPE

65 B - BUNA

75

80

85

SEAL MATERIAL

90

100

110

HYDRAULIC CYLINDER SIZE

130

160

180

200

220

240

260

280

V - VITON

S - SILICON

Z - SPECIAL

FC - FAIL CLOSE

FO - FAIL OPEN

SINGLE

ACTING

D1 - 1 CYLINDER D.A.

D2 - 2 CYLINDER D.A.

ACTING

DOUBLE

DD - 2 CYLINDERS TANDEM

1-1

1-2

1-3

1-4

1-5

2-1

SPRING CAN SIZE

2-2

2-3

2-4

2-5

3-1

3-2

3-3

3-4

3-5

4-1

4-2

4-3

4-4

4-5

Figure 23: LHS Model Selection Table

example model n°

50 (110)

100 (220)

140 (308)

250 (550)

470 (1034)

990 (2178)

50

55

60

24 (53) 27 (59) -

65

75

80

28 (62) * *

85

30 (67)

90

100

110

120

130

15 20 25

* * -

* * -

* * -

* 29 (64) *

* * 42 (93)

36 (80) 46 (102)

- * *

- 42 (93) 53 (118)

- 50 (110) 63 (139)

- - 72 (160)

weights in kg (lbs)

Weights may be subject to
changes over time. For the

accurate measurement please

contact Flowserve

Figure 24: Weight Selection Table – Double Acting Models

example model n°

25

20

50 (110)

15

20

140 (308)

25

HOUSING SIZE

weights in kg (lbs)

Weights may be subject to
changes over time. For the

accurate measurement please

contact Flowserve

15 20 25

* * -

50

* * -

55

* * -

60

24 (53)

65

* 29 (64)

75

* * 42 (93)

80

28 (62) * *

85

30 (67) 36 (80) 46 (102)

90

100

- 42 (93) 53 (118)

110

- 50 (110) 63 (139)

120

HYDRAULIC CYLINDER SIZE

- - 72 (160)

130

* Under development. Please contact Flowserve for more information

27 (59)

* *-

-

*

1-1

1-2

1-3

1-4

2-1

2-2

2-3

2-4

3-1

3-2

3-3

3-4

4-1

SPRING CAN SIZE

4-2

4-3

4-4

15

* 53 (117) 101 (222)

49 (109) -100 (220)

48 (105) - 147 (323)

76 (167) 112 (245)

84 (184) 114 (251) 153 (337)

82 (180) 130 (287) 143 (315)

69 (151) 162 (356) 182 (400)

76 (168) 179 (393) 143 (315)

74 (163) 169 (372) 153 (337)

132 (291)

- - 137 (302)

137 (301)

121 (265) -

-

- - 154 (338)

- - 170 (373)

- - 184 (404)

- - 187 (411)

- - 184 (404)

23

Figure 25: Weight Selection Table – Single Acting Models

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FCD LFENIM0003-00-AQ 07/14 © 2014 Flowserve Corporation.

Flowserve Limitorque
Fluid Power Systems
Product Sales

Via Rio Vallone 17
20883 Mezzago (MB), Italy
Phone: [phone]
Fax: [phone]
Email: [e-mail]

Flowserve Limitorque
Fluid Power Systems
Manufacturing and Operations

Via Rio Vallone 17
20883 Mezzago (MB), Italy
Phone: [phone]
Fax: [phone]
Email: [e-mail]

Flowserve Limitorque
Fluid Power Systems
Research and Development

Viale dell’Artigianato 24
29122 Piacenza (PC), Italy
Email: [e-mail]

To find your local Flowserve representative

or for more information about Flowserve Corporation, visit
www.flowserve.com.

Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended
function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide
variety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The pur­chaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should
read and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in
connection with the specific application.

While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or as
a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this
product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice.
Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or offices.

© 2014 Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation.

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