Flowserve Limitorque L120 Series, Limitorque L120-10, Limitorque L120-40 User Instructions

USER INSTRUCTIONS

Limitorque

For L120-10 through L120-40

FCD LMENIM1201-05-A4 – 03/18

®

Actuation Systems L120 Series

Installation

Operation

Maintenance

Experience In Motion

Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

Contents

1 Introduction 4

1.1 Purpose 4

1.2 User Safety 4

2 Product Inspection - Storage - Identification 5

2.1 Inspection and Recording 5

2.2 Short-Term Storage (less than 1 year) 5

2.3 Product Identification 7

3 Actuator Weights 8
4 Installation Instructions 9

4.1 Safety Precautions 9

4.2 Safety Practices 10

4.3 Initial Actuator Preparation 10

4.3.1 Mounting Base 10

4.3.2 Stem Acceptance 10

4.4 Torque Switch 11

4.4.1 Setting Torque Switch 11

4.4.2 Balancing Torque Switch 12

4.5 Geared Limit Switch 12

4.5.1 Setting Limit Switch 12

4.5.2 Setting Procedure (Refer to Figure 4.2) 13

4.5.3 Combination of Contacts (Refer to Figure 4.2) 14

4.6 Position Indication 14

4.6.1 Local position indication 14

4.6.2 Remote Position Indication 15

4.7 Optional Side-Mounted Handwheel 16

5 Operation 19

5.1 Electrical Start-up 19

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

5.2 Manual Operation 20

5.3 Motor Operation 25

5.4 Torque and Travel Limiting 25

6 Maintenance 26

6.1 Lubrication 26

6.1.1 Lubrication Inspection 26

6.1.2 Factory Lubricant 27

6.2 Minimum Lubricant Qualities Required 27

6.3 Disassembly and Reassembly 28

6.4 Disassembly of the L120-10, 20, and 40 28

6.5 Drive Sleeve and Housing Cover Disassembly 29

6.6 Torque Nut Disassembly (Drive 1 Option) 29

6.7 Thrust Base Disassembly (Drive 2 Option) 30

6.8 Stem Nut Replacement – Thrust Base Applications 30

6.9 Reassembly 31

6.9.1 Declutch Assembly (L120-10) 32

6.9.2 Declutch Assembly (L120-20/40) (Refer to Figure 6.3) 32

6.9.3 Install the Motor (Refer to Figure 5.2) 33

6.9.4 Lubrication Procedure 33

6.9.5 Install Geared Limit Switch, Torque Switch and Finish Assembly 33

7 How to Order Parts 34
8 EC Declaration of Conformity 35

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

Introduction

Flowserve Limitorque actuators are available with a wide range of standard and optional features. Be
aware of these features and their role in the setup and operation of the actuator.

1.1 Purpose

This Installation and Maintenance Manual explains how to install and maintain the L120-10, L120-20,
and L120-40 actuators. Information on installation, disassembly, reassembly, lubrication, and parts is
provided.

1.2 User Safety

Safety notices in this manual detail precautions the user must take to reduce the risk of personal injury
and damage to the equipment. The user must read and be familiar with these instructions before
attempting installation, operation, or maintenance. Work to be performed on the actuator should be
carried out by a qualified tradesman familiar with the operation and maintenance of electric actuators.
Failure to observe these precautions could result in serious bodily injury or death, damage to the equip­ment, voiding of the warranty, or operational difficulty.

Safety notices are presented in this manual in three forms:

c WARNING: Refers to personal safety. Alerts the user to potential danger. Failure to follow warning

notices could result in personal injury or death.

a CAUTION: Directs the user’s attention to general precautions that, if not followed, could result in

personal injury and/or equipment damage.

4

NOTE: Highlights information critical to the user’s understanding of the actuator’s installation and
operation.

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

Product Inspection - Storage -

2

c WARNING: Read this Installation and Maintenance Manual carefully and completely before

attempting to install the actuator. Be aware of the electrical hazards.

Identification

2.1 Inspection and Recording

Upon receipt of the actuator, inspect the condition of the equipment and record nameplate
information:

1. Carefully remove actuator from shipping carton or skid. Thoroughly examine the
equipment for any physical damage that may have occurred during shipment. If
damaged, immediately report the damage to the transport company.

2. Record the actuator nameplate information for future reference; i.e. ordering parts,
obtaining further information.

2.2 Short Term Storage Procedures (less than 1 year)

NOTE: The following are our recommended storage procedures to retain maximum product integrity
during short-term storage. Failure to comply with recommended procedures will void the warranty. For
longer-term storage, contact Limitorque for procedures and recommendations.

Actuators are not weatherproof until properly installed on the valve or prepared for storage.

Store actuators in a clean, dry, protected warehouse away from excessive vibration and rapid tempera­ture changes. If the actuators must be stored outside, they must be stored off the ground, high enough
to prevent them from being immersed in water or buried by snow.

1. Position the actuator in storage with motor and switch compartment horizontal.

2. Connect the internal heaters (if supplied) or place desiccant in the switch compartment.

3. Replace all plastic caps or plugs with pipe plugs and ensure that all covers are tight.

4. If the actuator is mounted on a valve and the stem protrudes from the unit, a suitable stem cover
must be provided.

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

Figure 2.1 – L120-10 through 40

Handwheel

Limit Switch/
Controls
Compartment

Motor

Housing

Actuator
Nameplate
(hidden)

Declutch
Lever

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

2.3 Product Identification

The actuator unit nameplate is located on the back of the unit, opposite the limit switch compartment.
The nameplate contains the following information:

• Limitorque name

• Point of Manufacture

• Unit Size

• Order Number

• Serial Number

• Customer Tagging

• CE Stamp

The motor nameplate is located on the motor. The nameplate contains the following information:

• ID Number

• Start Torque

• Run Torque

• Enclosure Type

• RPM

• Volts

• Full Load Amps

• Locked Rotor Amps

• Insulation Class

• Duty

• Horsepower

• Service Factor

• Phase

• Cycles

• Motor Code

• Ambient Temperature

• Connection Diagram

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

Actuator Weights

The approximate L120 actuator weights are provided below:

Table 3.1 – Actuator weights

Actuator

L120-10

L120-20

L120-40

Note: Approximate weights are based on standard explosion-proof construction, with the largest
three-phase motor available for the model size.

Control Types

Size

NCU 100 45 112 51 107 49 119 54

BIC 115 52 127 58 122 55 134 61

CLAMSHELL 140 64 152 69 147 67 159 72

NCU 140 64 158 72 153 69 171 78

BIC 155 70 173 78 168 76 186 84

CLAMSHELL 180 82 198 90 193 88 211 96

NCU 190 86 216 98 212 96 238 108

BIC 205 93 231 105 227 103 253 115

CLAMSHELL 230 105 256 116 252 114 278 126

Drive 1 Weight (lb./kg) Drive 2 Weight (lb./kg)

Top HW Side HW Top HW Side HW

lb. kg lb. kg lb. kg lb. kg

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

Installation Instructions

4.1 Safety Precautions

c WARNING: Read this Installation and Maintenance Manual carefully and completely before attempting to install,

operate, or troubleshoot the Limitorque actuator.

c WARNING: Be aware of electrical hazards. Turn off incoming power before working on the actuator and before

opening the switch compartment.

c WARNING: Potential HIGH PRESSURE vessel — be aware of high-pressure hazards associated with

the attached valve or other actuated device when installing or performing maintenance on the actuator.
For maintenance and/or disassembly of the actuator while installed on the valve, or removal of the actuator from
the valve or actuated device, ensure that the actuator is not under thrust or torque load. If the valve must be left
in service and under load, the valve stem must be locked in such a way as to prevent any movement of the valve
stem.

c WARNING: Do not attempt to remove the spring cartridge cap, housing cover, or thrust base from the actuator

while the valve or actuated device is under load.

c WARNING: Do not manually operate the actuator with devices other than the installed handwheel and declutch

lever. Using force beyond the ratings of the actuator and/or using additive force devices such as cheater bars,
wheel wrenches, pipe wrenches, or other devices on the actuator handwheel or declutch lever may cause
serious personal injury and/or damage to the actuator and valve.

c WARNING: Do not exceed any design limitations or make modifications to this equipment without first

consulting Limitorque.

c WARNING: Actuators equipped with electrical devices (motors, controls) requiring field wiring must be wired

and checked for proper operation by a qualified tradesman.

c WARNING: Use of the product must be suspended any time it fails to operate properly

a CAUTION: Do not use oversized motor overload heaters. Instead, look for the cause of the overload.

a CAUTION: Do not operate the valve under motor operation without first setting or checking the limit switch

setting and motor direction.

a CAUTION: Do not force the declutch lever into the motor operation position. The lever returns to this position

automatically when the motor is energized.

a CAUTION: Do not depress the declutch lever during motor operation to stop valve travel.

a CAUTION: Do not use replacement parts that are not genuine Flowserve Limitorque parts, as serious personal

injury and/or damage to the actuator and valve may result.

a CAUTION: Eye bolts may be used to lift the actuator for installation on the valve or actuated device. Do not lift

actuator/valve or actuator/gearbox combinations using eye bolts in the L120 actuator.

a CAUTION: Do not lift the actuator by the handwheel.

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

4.2 Safety Practices

The following checks should be performed to maintain safe operation of the L120 actuator.

• Mount motors on a horizontal plane, if possible.

• Keep the controls compartment clean and dry.

• Keep the valve stem clean and lubricated.

• Set up periodic operating schedule for infrequently used valves.

• Carefully check for correct motor rotation direction. If the motor is driving the valve in the wrong
direction, interchange any two leads on three-phase motors or switch the armature leads on DC and

single-phase motors.

• Use a protective stem cover. Check valve stem travel and clearance before mounting covers on rising
stem valves.

• Verify all actuator wiring is in accordance with the applicable wiring diagram, national and local codes,
and Table 4.1.

Table 4.1 – Required Rating for External Wiring

Up to: Use wire rated at least:

40°C 60°C

60°C 75°C

10

4.3 Initial Actuator Preparation

Replace all molded plastic conduit and top protectors (installed for shipping purposes only) with pipe
plugs when installation wiring is complete.

4.3.1 Mounting Base

The mounting hole sizes and quantities are as detailed in Table 4.2.

Table 4.2 – Mounting Base Dimensions

Actuator Size

L120-10 4

L120-20 4

L120-40 4

4.3.2 Stem Acceptance

The maximum stem acceptance is provided in Table 4.3.

Table 4.3 – Maximum Stem Acceptance

Actuator size

L120-10 1.25 32 1.00 25 ¼x3/32 8x6

L120-20 2.25 57 1.875 47 ½x3/16 14x9

L120-40 2.625 66 2.125 52 ½x3/16 16x10

Mounting Holes Tap size

Quantity MSS ISO

3

⁄8-16x0.88 M10x1.5x22.4

5

⁄8-11x1.25 M16x2x32

5

⁄8-11x1.25 M16x2x32

Drive 2 Drive 1

Tapped Bore Key

inch mm inch mm inch mm

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

Balancing

300 Volt Torque Switch

Microswitch-Style Torque Switch

4.4 Torque Switch

The torque switch is designed to protect the actuator in open and close directions.

a CAUTION: Disconnect all incoming power before opening limit switch compartment or working on

the torque switch.

• Do not use abrasive cloth to clean the contacts on the torque switch.

• Do not torque seat 90° operation valves nor run them against the stops. This may cause damage
to the valve.

NOTE: If the actuator has “torqued out,” release torque buildup by operating the actuator manually.

4.4.1 Setting Torque Switch

The torque switch was set at the factory according to customer-supplied information regarding neces­sary torque or thrust output that was provided at the time of the order. However, if the setting needs to
be adjusted, perform the following procedure:

Item letters correspond to Figure 4.1.

1. Place the L120 actuator in manual mode.

2. Release the load on the wormshaft spring pack.

3. For open and close directions, loosen Screw (A) and move Pointer (B) to desired position. A higher
number indicates a high torque and/or thrust output.

4. Tighten Screw (A).

5. Operate the valve electrically to seat valve and to ensure tight shutoff.

6. Rebalance torque switch if required.

a CAUTION: A torque switch limiter plate is provided on most actuators.

• Removal or modification of the torque switch limiter plate will void the actuator warranty.

• Do not exceed the setting indicated by this plate without contacting the Limitorque service

department.

• Installing or adjusting the torque switch with the actuator in a loaded condition will result in a loss

of torque protection.

Figure 4.1 – Microswitch-Style Torque Switch and 300 Volt Torque Switch

B

Maximum Stop
Setting Plate

Index Marks

A

Maximum Stop
Setting Plate

OPEN

-10-20

-10-20

CLOSE

Mounting

B

Screw

A

Balancing
Screws

Index Marks

B

A

A

B

Mounting
Screw

Screws

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

4.4.2 Balancing Torque Switch

Item letters correspond to Figure 4.1.

1. Place the actuator in manual mode.

2. Remove the load from the wormshaft spring pack.

3. Note the open and close torque switch settings prior to reinstalling the torque switch.

4. Loosen Screws (A) and position both Pointers (B) at the #1 setting, tighten Screw (A). In this
position the index marks should be aligned.

5. Loosen balancing screws and install the torque switch. The base of the torque switch should be
flush against the compartment and the hole for the mounting screw should be aligned.

6. Install the mounting screw.

7. Tighten the balancing screws.

a CAUTION: The balancing screws should not be touched except during the balancing procedure.

The switch is now balanced and ready for the pointers to be returned to their original settings.

4.5 Geared Limit Switch

a CAUTION: The geared limit switch is not preset at the factory and must be adjusted after the

actuator has been mounted on associated equipment.

• Disconnect all incoming power to the actuator prior to opening the limit switch compartment and

adjusting the switch.

• Consult the relevant wiring diagram for limit switch contact development. All L120 units are

supplied with 16-contact limit switches - four switches on each of the four rotors. Two rotors are
used for end of travel indication. The remaining two rotors may be adjusted for any intermediate
point of travel.

• Do not use abrasive cloth to clean the contacts on the limit switch.

• Do not attempt to repair gearing in the limit switch. Replace entire gear frame assembly if

necessary.

4.5.1 Setting Limit Switch

Set the limit switch as follows. All item letters and piece numbers refer to Figure 4.2.

NOTE: See chart below for maximum number of drive sleeve turns for each unit size. The Intermediate
Shaft (B), shown in Figure 4.2, may take a considerable number of turns before rotor trip occurs.

Table 4.4 – Maximum Number of Drive Sleeve Turns for Standard Four-Gear and Optional Five-Gear
Limit Switches

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Actuator Size Four-Gear Five-Gear

L120-10 630 6300

L120-20 740 7400

L120-40 640 6400

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

c WARNING: Potential Explosion Hazard. Do not use a variable speed electric drill for setting the limit

switch in an explosive environment.

a CAUTION: When setting the limit switch rotor segments (cams) using a variable speed electric drill,

do not run drill at speeds higher than 200 RPM. Operating the drill at high speeds can damage the
gearing within the limit switch.

Figure 4.2 – Limit Switch

7

8

1

6

Piece Quantity Description

5

11 Gear Frame Assembly
22 Eight-Switch Contact Block Assy.

B

A

9

3
2

312Rotor Segment (short)
44 Rotor Shaft
54 Machine Screw
64 Flat Washer
74 Lock Washer

4

88 Hex Nut
94 Rotor Segments (long)

4.5.2 Setting Procedure (Refer to Figure 4.2)

1. Open the Compartment Cover (piece #200 of Figure 5.2).

2. Put the actuator into manual operation. Use the handwheel to operate the valve in the “open” direc­tion. While operating the valve, note the direction of the Intermediate Shaft (B) corresponding to the
rotor or rotors to be set.

3. When the valve is fully open, close it one turn of the handwheel to allow for coast of moving parts
or refer to the valve manufacturer setting requirements.

4. Push in the Setting Rod (A) and turn one-quarter turn. The rod will latch in this depressed position.

5. Refer to the applicable wiring diagram for contact development. The limit switch contact is closed
when the rotor is engaged with the plunger. If the rotor to be set has not turned 90 degrees to
operate the plunger, turn the intermediate shaft in the same direction as noted in Step 2 until the
rotor clearly trips the switches. This rotor is now set correctly.

6. Before moving the valve, depress and turn the Setting Rod (A) one-quarter turn to the spring
released position. Insert a screwdriver into the intermediate shafts to ensure that they will not move.

a CAUTION: Do not operate the valve when Setting Rod (A) is in a fully depressed position. Loss of

contact setting will occur and the setting rod will be damaged.

7. Operate the valve by handwheel to fully “close” position; reverse direction by one turn of the hand­wheel to allow for coast of moving parts or refer to the valve manufacturer setting requirements.

8. Set the other rotors by following Steps 4 through 6.

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

Figure 4.3 – Setting the open and closed contacts

Closed

position

Open

position

4.5.3 Combination of Contacts (Refer to Figure 4.2)

The rotor segments can be separated and rotated through 90 degrees to give various combinations of
normally open or normally closed contacts to each rotor.

1. Remove Nuts (piece 8) and Fillister Head Machine Screws (piece 5, for a total of two fasteners on
each side of the switch).

2. Remove complete contact assembly from the back plate.

3. Rearrange cams on the camshaft to produce the required combination of contacts.

4. Replace contact assembly on back-plate (ensuring that the registers fit correctly) and secure with
the machine screw and nuts.

14

5. Set limits according to the procedure above.

4.6 Position Indication

4.6.1 Local position indication

The local dial position indicator is factory-selected to show valve position. The position indicator can
only be adjusted when mounted on the valve.

To set the local position indicator:

1. Disconnect all incoming power and remove Switch Compartment Cover (piece 200 of Figure 5.2).

2. Place the valve in the fully “close” position.

3. Loosen the round head machine screw which holds the pointer in place, move the pointer to the “O”

position, and retighten the screw.

The indicator is now set.

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

Typical Connection for a 1000 ohm Potentiometer

NOTE: The end-of-travel rotors of the geared limit switch activate “Flip-flop” type indicators. This type of
indicator will require no further setting after the geared limit switch has been adjusted.

4.6.2 Remote Position Indication

The L120 actuator with a position transmitter installed, transmits a 4-20 mA output signal to a remote
position indicator. The transmitter responds to input of a 1K (ohms) potentiometer and can
be powered by 18 VAC or 24 VDC.

NOTE: The pinion has been left disengaged to prevent damaging of rheostat prior to setting the valve.
Set rheostat by turning pinion until the desired reading is obtained. Loosen the hex nut on the back of
the rheostat and slide the rheostat in the direction of the idler pinion until pinions are engaged. Do not
force engagement of the pinions. Retighten hex nut on back of the rheostat. Do not engage pinion until
unit and valve have been set.

To Calibrate Position Transmitter

1. Position the actuator to mid-travel: valve at 50% position.

2. Disconnect the potentiometer wiring harness from the transmitter board and measure the resis­tance from each end connection to the center connection on the potentiometer.

3. Set the potentiometer to the correct resistance reading. Loosen the set screw that retains the spur
gear on the potentiometer shaft and rotate the shaft until a reading of 500 ohms is achieved.

4. Tighten the set screw and reconnect the wiring harness.

5. Run the actuator fully CLOSED.

6. Calibrate ZERO position by adjusting the zero potentiometer until a 4 mA output signal is read at
terminal +VE and -VE.

7. Run the actuator fully OPEN.

8. Calibrate SPAN position by adjusting the span potentiometer until a 20 mA output signal is read at
terminals +VE and -VE.

9. Repeat steps 5 to 8 and fine-tune as necessary.

Figure 4.4 – 1000 ohm Potentiometer

Gearing

1000 ohms

Receiver

+

DC Power

­Supply

-

+

Customer Equipment

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

157-2

178 &

157-4

4.7 Optional Side-Mounted Handwheel

For actuator sizes L120-10, 20, and 40, the handwheel can be mounted on the side as shown in the
following figures.

Figure 4.5 – L120-10 parts list, attachment ratio 4.2:1

157-3

&

157-6

157-5

158-1

158-3

160

171

182-2

182-1

182-3

161

179

181

177

180

154

169

152

Note: Apply Loctite 601/609

164

158-4

to ID of Bearing Cap

Piece Quantity Description

61Housing Cover Shim
42-11 1 O-Ring / Handwheel Mounting
44 1 Quad Ring
45 1 Pipe Plug
1501Bevel Housing
1511Bevel Housing Adapter
1521Bearing Cap
1531Bevel Gear
1541Bevel Pinion Shaft
157-1 4 Hex Head Cap Screw
157-2 4 Lockwasher
157-3 2 Socket Head Cap Screw
157-4 1 Roll Pin
157-5 2 Socket Head Cap Screw
157-6 2 Lockwasher
158-1 1 Quad Ring
158-2 1 O-Ring
158-3 1 O-Ring
158-4 1 Quad-Ring
160 2 Ball Bearing
161 1 Seal Insert
164 1 Spacer
169 1 Retaining Ring
171 1 Grease Fitting
177 1 Handwheel
178 1 Hex Head Cap Screw
179 1 Lockwasher
180 1 Key
181 1 Retaining Washer
182-1 1 Handwheel Spinner
182-2 1 Socket Head Cap Screw
182-3 1 Hex Jam Nut

16

45

157-1

&

150

158-2

151

153

44

6

42-11

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

6

44

Figure 4.6 – L120-20 with side-mounted handwheel and parts list, attachment ratio 5.7:1

179

182-2

182-1

182-3

&

178

181

180

177

157-5

157-3

157-4

157-1

&

157-2

&

158-1

154

158-3

171

157-6

161

152

169

160

Note: Apply Loctite 601/609

to ID of Bearing Cap

158-2

158-4

Piece Quantity Description

6 1 Housing Cover Shim
42-11 1 O-Ring / Handwheel Mounting
44 1 Quad Ring
45 1 Pipe Plug
150 1 Bevel Housing
151 1 Bevel Housing Adapter
152 1 Bearing Cap
153 1 Bevel Gear
154 1 Bevel Pinion Shaft
157-1 4 Hex Head Cap Screw
157-2 4 Lockwasher
157-3 4 Hex Head Cap Screw
157-4 4 Lockwasher
157-5 1 Roll Pin
157-6 2 Socket Head Cap Screw
158-1 1 Quad-Ring
158-2 1 O-Ring
158-3 1 O-Ring
158-4 1 Quad Ring
160 1 Ball Bearing
161 1 Seal Insert

169 1 Retaining Ring
171 1 Grease Fitting
177 1 Handwheel
178 1 Hex Head Cap Screw
179 1 Lockwasher
180 1 Key
181 1 Retaining Washer
182-1 1 Handwheel Spinner
182-2 1 Socket Head Cap Screw
182-3 1 Hex Jam Nut

45

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

179

Note: Apply Loctite
601/609 to ID of
Bearing Cap

157-5

42-11

Figure 4.7 – L120-40 with side-mounted handwheel and parts list, attachment ratio 12:1

158-4

45

157-1

157-2

150

171

158-5

&

157-6

158-2

182-2

182-1

182-3

158-1

164

157-7

153

155

163

171

161

&

178

181

160

Section Through Pinion

154

152

158-3

151

44

156

6

180

169

177

167

Handwheel

157-3

&

157-4

159

164

Piece Quantity Description

61 Housing Cover Shim
42-11 1 O-ring / Handwheel Mounting
44 1 Quad Ring
45 1 Pipe Plug
150 1 Bevel Housing Cover
151 1 Bevel Housing
152 1 Spur Gear Cover
153 1 Bevel Gear
154 1 Bevel Pinion
155 1 Input Pinion Shaft
156 1 Bevel Gear Adapter
157-1 4 Hex Head Cap Screw
157-2 4 Lockwasher
157-3 4 Hex Head Cap Screw
157-4 4 Lockwasher
157-5 8 Socket Head Cap Screw
157-6 2 Dowel Pin
157-7 1 Socket Head Cap Screw
158-1 1 Quad Ring
158-2 1 O-ring
158-3 1 Gasket
158-4 1 Quad Ring
158-5 1 O-ring
159 1 Spur Gear
160 1 Ball Bearing
161 1 Seal Insert
163 1 Ball Bearing
164 2 Ball Bearing
167 1 Key
169 1 Retaining Ring
171 1 Grease Fitting
177 1 Handwheel
178 1 Hex Head Cap Screw
179 1 Lockwasher
180 1 Key
181 1 Retaining Washer
182-1 1 Handwheel Spinner
182-2 1 Socket Head Cap Screw
182-3 1 Hex Jam Nut

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

Operation

c WARNING: Do not manually operate the actuator with devices other than installed Handwheel and

Declutch Lever. Using force beyond the ratings of the unit and/or using additive force devices such
as cheater bars, wheel wrenches, pipe wrenches or other devices on the actuator Handwheel or
Declutch Lever may cause serious personal injury and/or damage to the actuator or valve.

a CAUTION: Do not motor-operate the valve without first setting or checking the limit switch setting

and motor direction.

• Do not force the declutch lever into hand operation. If the clutch does not easily engage, rotate
handwheel slowly while operating the declutch lever.

• Do not alternately start/stop the motor to open or close a valve which is too tight for normal
operation.

5.1 Electrical Start-up

1. Verify that the actuator has been correctly lubricated. This is particularly important if the actuator
has been in long-term storage.

2. Verify that the geared limit switch has been correctly set (see Section 4.5.1, Setting Limit Switch).

3. If the valve stem is not visible, remove the stem cover or handwheel cover plate to observe output
direction of the drive sleeve.

4. Engage manual operation and hand crank the valve well away from end of travel positions.

5. Turn on power supply and push button to “open.”

6. Check output rotation:

• If phase rotation is correct, the valve should begin to open.

• If valve begins to CLOSE, STOP immediately. Incorrect phase rotation will lead to serious damage

if the valve seats.

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

7. Correct the phase rotation one of two ways:

• Switch any two of the three power leads for three-phase power, or

• Reverse the armature leads for single-phase or DC power.

The actuator should operate correctly and will be stopped at the end of travel positions by torque or limit
switch functions.

Table 5.1 – Required Rating for External Wiring

Up to Use wire rated at least

40°C 60°C

60°C 75°C

Figure 5.1 is a representation of a typical application and may not be applicable to your specific actuator.
Please refer to the wiring diagram supplied with your actuator to confirm the actual
equipment supplied.

5.2 Manual Operation

Piece numbers refer to Figure 5.2.

Counterclockwise rotation of the Declutch Lever (piece 9) causes the declutch actuator to lift the clutch
sleeve out of engagement with the worm gear. Drive lugs on top of the clutch sleeve engage matching
lugs in the Handwheel Adapter (piece 26) and then latches engage the clutch sleeve in this position. The
actuator is now in the handwheel driving option. Energizing the motor at this point will cause the latches
to drop out and the spring-loaded clutch sleeve reengages with the lugs on the worm gear. The actuator
is once more in motor operation.

NOTE 1: The shift from manual operation to motor operation is automatic and does not require external
positioning of the declutch shaft.

NOTE 2: If the declutch mechanism does not engage, rotate handwheel approximately 30-45° and
attempt manual engagement. There is a chance that the lugs on the Clutch Sleeve (piece 19) and
Handwheel Adapter (piece 26) are not correctly aligned.

20

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

SPARE

16

& (8C) FOR TORQUE-SEATING VALVES.

TH.OL-THERMAL OVERLOAD CONTACTS

Figure 5.1 (one of two) – L120-10 through 40 typical wiring diagram

10

GND

13

L1

12

L2

11

L3

ALTERNATE
TRANSFORMER TYPES

500

A

480

B
E

460

TAPS

D

415

E

380

BLACK

BLACK

BLACK

BLACK

BLACK

BLACK

GREEN/WHITE

1

600
575
550

7

(7)(7C)

3

(3)(3C)

21/22

STOP

PB2

FUSE

CD

SS

RED

GREEN

ELEC HTR

MTR HTR

REMOTE

BROWN

AB

115 V

RED

RES

RES

PURPLE

PB1

OPEN

PB3

CLOSE

18 V

YEL

YEL

WHITE

R

WHITE

G

WHITE

H2

BLUE

YELLOW

BLUE

O

YELLOW

C

BROWN

ORANGE

GRAY

PINK

32

230 V
H1 AND H3
TO L1
H2 AND H4

­TO L2

-

H1

OFF

LOCAL

RED

RED

BROWN

RED

GRAY

E

18 V

BLU

WHITE

FUSE

CPT

BLU

19/20

BLUE

(4)

JUMPER
SEE NOTE #5

(8)(8C)

1

2

3

4

5

6

GREEN/WHITE

GREEN/WHITE

4 18

BLUE

RED

(4C)

8

YELLOW

RED

OPEN

CLOSE

STOP

COMMO N

REMOTE IND

REMOTE IND

O

O

O

C

C

C

(5)

(18)

17

(17) (17C)

(1)

P2

5

(18C)

1

(5C)

(1C)

TH.OL

T1

T2

T3

P1

BLUE
BLACK

YELLOW
BLACK

(OPTIONAL)

BLACK

POT

MOTOR

BLUE

WHITE

C

YELLOW

WHITE

O

RED

BROWN

18

1716

P1

O

P1

C

Valve shown in full open position

ROTOR

1
2

OPEN

3
4

5
6

CLOSE

7
8

9
10

INT. 1

11
12

13
14

INT. 2

15

LIMIT SWITCH CONTACT DEVELOPMENT

VALVE POSITION

CONTACT

FULLY
OPEN

A B

A B

FULLY

CLOSED

17

FUNCTION

BYPASS CIR

SPARE

IND LIGHT

OPEN LIMIT

BY-PASS CIR

SPARE

IND LIGHT

CLOSE LIMIT

SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE

18

Notes

1.

2.

3. SEE CERTIFICATION SHEET FOR VOLTAGE SUPPLIED.
TRANSFORMER UNUSED WIRES TO BE SEPARATELY
COVERED WITH INSULATING HEAT SHRINK TUBING.

4. ROTORS INT.1 & INT.2 CAN BE SET AT VALVE
POSITION FULL OPEN, FULL CLOSED OR ANY
POSITION IN BETWEEN AS INDICATED BY
POINTS A AND B.

5. ADD JUMPER ON LS#8 BETWEEN TERMINALS (8)

CLOSING TORQUE SWITCH INTERRUPTS
CONTROL CIRCUIT IF MECHANICAL OVERLOAD
OCCURS DURING CLOSING CYCLE

OPENING TORQUE SWITCH INTERRUPTS
CONTROL CIRCUIT IF MECHANICAL OVERLOAD
OCCURS DURING OPENING CYCLE

OPEN CONTACT
CLOSE CONTACT

Legend
O-OPEN CONTACT

C-CLOSE CONTACT

OPENING COI L

O

CLOSING COIL

C
CPT-CONTROL POWER TRANSFORMER
+-MECHANICAL INTERLOCK

RED INDICATING LIGHT

R

GREEN INDICATING LIGHT

G
SS-SELECTOR SWITCH

(LOCAL-OFF-REMOTE )
PB1-OPEN PUSHBUTTON
PB2-STOP PUSHBUTTON

PB3-CLOSE PUSHBUTTON
ELEC HTR-COMPARTMENT HEATER
MTR HTR-MOTOR HEATER
POT-POTENTIOMETER (OPTIONAL, SEE
CERTIFICATION SHEET IF SUPPLIED)

RES-LAMP RESISTORS˛

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21

Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

Electrical Compartment

Figure 5.1 (two of two) – L120-10 through 40 typical wiring diagram

GRN/WHT

ELEC

HTR

BLK

FUSE

BLK

FOR SIGNAL
CONVERTER USE
WHEN SUPPLIED

WHT

BLK

WHT

BLK

LIMIT SWITCHES

INT.2 ROTOR INT.1 ROTOR

REMOTE OPEN

REMOTE CLOSE

REMOTE STOP

REMOTE COMMON

SELECTOR SWITCH IN
REMOTE INDICATION

FOR SIGNAL

CONVERTER USE

(WHEN SUPPLIED)

INCOMING POWER GROUND

L3 INCOMING POWER

L2 INCOMING POWER

L1 INCOMING POWER

(13C)

(13)

(14C)

(14)

(15C)

(15)

(16C)

REVERSING STARTER

L1F

L2F

(NOTE#3)

PRIMARY

CPT

SECONDARY

18 V

YEL

YEL

2

1

BLU

BLU

BLK/WHT
RED/WHT

1

2

3

4

5

6

7

8

9

10

11

12

13

10 VA

18 V

10 VA

BLU

BLU

BLU

YEL

BRN

ORG

GRY

PNK

BLK/WHT

RED/WHT

GRN/WHT

L3

L2

L1

115 V

75 VA

WHT

RED

1

2

1

2

(9C)

13

14

15

16

(16)

9

(9)

(10C)

10

(10)

(11C)

11

(11)

(12C)

12

(12)

SPARE

P1

O

YEL

BLU/BLK

BLU/RED

RED

BLK

YEL/RED

LIMIT SWITCHES

(5C)

(5)

(6C)

(6)

(7C)

(7)

(8C)

YEL

(8)

CLOSE ROTOR OPEN ROTO R

GRN/WHT

L1 T1

BLU/WHT

BLK

5

6

7

8

WHT

WHT

L2 T2

TORQUE
SWITCH

BLK

BRN

RED

BLK

BLK

L2

L1

L3 T3

YEL/WHT

BLU

(2C)

FUSES

(1C)

1

(1)

2

(2)

(3C)

3

(3)

(4C)

4

(4)

(OPTIONAL)

14

15

16

17

18

19

20

21

22

CHASSIS

P1

C

PUR

(18C)

(17C)

POT

BLK

BRN

SPARE

SPARE

POT (CCW)

POT (SWEEPER)

POT (CW)

P2

H2

H1

GROUND

L2F

L1F

L3 T1

BLU

BLK

18

CLOSE

17

YEL/BLK

YEL/RED

GRN

BLK

BLU/RED

BLUE

RED

OPEN

(18)

(17)

L1 T3

L2 T2

PUR

YEL

BLU/RED

BLU/BLK

YEL/RED

YEL/BLK

MOTOR

T1

TH.OL

T2

MTR HTR

T3

P1

H1

H2

P2

MOTOR GROUND LUG

SW323 PUSHBUTTON STATION

WHT

BLK

BLU YEL

GRN

1

RED

2

WHT

3

LIGHTS

BLK

1

BLU

2

PUR

3

YEL

4

BUTTONS

BRN

1

GRY

2

PNK

3

ORG

4

AUX. TERM.

WIRE COLOR LEGEND

RED

R

PB1

OPEN

LOCAL

BRN

RES

RES

: BLU

BLUE

: YEL

YELLOW

: PUR

PURPLE

: BLK

BLACK

: ORG

ORANGE

: BRN

BROWN

: WHT

WHITE

: RED

RED

: GRN

GREEN

: PNK

PINK

: GRY

GRAY
COLOR/STRIPED

STOP

BRN

PB2

RED

OFF

RED

WHT

REMOTE

BRN

GRY

PB3

CLOSE

GRN

G

ORG

PUR

PNK

22

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

24

Piece Quantity Description

Figure 5.2 (one of two) – L120-10 through 40 drive sleeve and housing cover parts breakdown

29

50

26

44

25

19

20

21

22

16

23

43

27

28

42/11

17

18

Piece Quantity Description

16 1 Ball Bearing
17 1 Ball Bearing
18 1 Drive Sleeve Bevel Gear
19 1 Handwheel Clutch Sleeve
20 1Worm Gear Lug Ring
21 1Worm Gear
22 1 Spirolox Retainer
23 1 Key
24 1 Declutch Spring
25 1 Drive Sleeve
26 1 Handwheel Adapter

27 1 Housing Cover
28 1 Retaining Ring
29 1 Handwheel
33 1* Handwheel Cover Plate
34 1* Handwheel Cover Plate Gasket
42/11 1 O-ring / Handwheel Mounting
43 1 Quad Ring
44 1 Quad Ring
50 A/R Hardware
* Not shown

23

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

** Not Shown

Figure 5.2 (two of two) – L120-10 through 40 parts breakdown

50

39

31

42/7*

38

40

2

50

30

46

42/3

50

305

50

200

50

50

300

50

47

3

42/9

4

42/11

19

21

1

42/5

7

37

35

36

9

15

312

310

11

42/6

9

10

25

5

50

24

Piece Quantity Description

11 Housing
21 Motor Adapter
31 Electrical Compartment
41 Seal Retainer
51 Worm Shaft End Cap
6 1** HSG. Cover Shim Set
71 Declutch Shaft Assembly
91 Declutch Lever
10 1 Roll Pin
11 1 Declutch Cap
15 1Worm Shaft Assembly
19 1 Clutch Sleeve
21 1Worm Gear
25 1 Drive Sleeve
30 1 Nipple Flange
31 1 Motor
32 4** Dowels

35 1Worm Shaft Gear
36 1 Key
37 1 Flexloc Nut

Piece Quantity Description

38 1 Motor Pinion
39 1 Key
40 1 Stop Nut
41 1** Washer
42 1 Seals Kit

42/3 1 Gasket – Mtr Adapter
42/5 1 O-ring – Declutch Assembly
42/6 1 O-ring – Declutch Lever
42/7 1 O-ring Mtr

42/7* 1 Gasket Mtr

42/9 1 Seal – Drive Sleeve

42/11 1 O-Ring – Handwheel Mounting
46 1 O-ring / Motor Nipple
47 1 O-ring / Cover
50 1 Hardware Kit
200 1 Compartment Cover
300 1Torque Switch
305 1 Geared Limit Switch
310 1 Unit Nameplate
312 1 Rimpull Nameplate

* L120-40 Only

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

5.3 Motor Operation

The actuator is always available for motor operation whenever the motor is energized

a CAUTION: Do not force the declutch lever into motor operation. Lever will automatically return to

motor operation when the motor is energized.

Reset the travel limit switches prior to motor operation if the actuator has been dismantled or removed
from the valve.

Piece numbers refer to Figure 5.2.

In motor operation, the Motor Gear Set (piece 35 and 38) drives the Wormshaft (piece 15) and Worm
Gear (piece 21) which in turn rotates the Clutch Sleeve (piece 19) by means of driving the lugs. The
clutch sleeve and worm gear may be assembled to produce either a “no lost motion” or “hammerblow”
effect. The Drive Sleeve (piece 25) is keyed to the clutch sleeve and hence rotates, producing the
required output rotary motion.

5.4 Torque and Travel Limiting

The geared limit switch is driven by a bevel gear connected to the upper drive lugs of the clutch sleeve.
The limit switch is directly connected to the output of the actuator. Once properly set, the limit switch
remains in step with the valve position regardless of electric or manual operation of the Limitorque
actuator.

The worm and wormshaft are supported by two rotating spring packs. As torque is generated by the
actuator, the worm moves axially against one of the spring packs. Each pack is precalibrated and hence
a finite compression represents a finite torque output. Movement of the worm operates the torque
switch, which interrupts the power to the motor. The torque switch is adjustable and can be set to
operate at predetermined torque levels.

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25

6

Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

Maintenance

6.1 Lubrication

The L120 series actuators have a sealed gear case, factory-lubricated with grease. The thrust base,
when supplied, is factory-lubricated with the same grease as the gear case if the stem nut is factory­machined for the customer's driven shaft. If a blank stem nut is installed in the thrust base, a tag is
provided on the actuator advising that the base is not lubricated. The gear case can be mounted in
any position. However, mounting of the motor or the switch compartment in the down position is
not recommended. These mounting positions may result in the motor or switch compartment being
saturated with lubricant if the seal fails.

No seal can remain absolutely tight at all times. Therefore, it is not unusual to find a very small amount
of weeping around shaft seals—especially during long periods of idleness such as storage. Using
grease minimizes this condition as much as possible. If a small amount is weeping at start-up, remove
it with a clean cloth. Once the equipment is operating on a regular basis, the weeping should stop.

6.1.1 Lubrication Inspection

Inspect Limitorque L120 series actuators for correct lubrication prior to operating - particularly
following a long storage period.

Each application has its own effect on the actuator and the frequency of these inspections should be
based on the application and the operating experience. The following lubrication inspection schedule is
recommended until operating experience indicates otherwise.

26

For the Gear Case, inspect lubrication every 18 months or 500 cycles, whichever occurs first.

During an inspection consider the following:

• Quantity – Ensure there is enough lubricant so that the Worm and the Worm Gear are totally
immersed in grease regardless of the position.

Note: The lubricant level can be verified by orienting the actuator with the control compartment facing

up. Remove the Geared Limit Switch. The level of lubricant should be within ½ inch of the bottom
of the opening in the gear housing.

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

• Quality – Inspect lubricant for dirt, water or other foreign matter. If any one of these is found:

1. Flush the actuator with a commercial degreaser/cleaner that is not corrosive and does not affect
the seal materials.

2. Repack the actuator with fresh lubricant allowing room for grease thermal expansion.

• Consistency – Ensure the lubricant is fluid approximating a standard NLGI-0 grade consistency or
less.

6.1.2 Factory Lubricant

Gear Case: The L120 series actuator gear case is factory-lubricated with an EP-0 lithium grease, suitable
for temperatures from -20°F (-29°C) to +250°F (+121°C).

Table 6.1 – Specified Approximate Lubricant Weights

Actuator Size lb. kg

L120-10 2.75 1.3

L120-20 4.25 1.9

L120-40 5.75 2.6

Geared Limit Switch: Permanently lubricated with Beacon 325. Limitorque does not recommend disas­sembly of the gearbox.

6.2 Minimum Lubricant Qualities Required

The standard lubricants used by Limitorque have been proven to be extremely reliable over years of
service. Limitorque does not recommend a particular lubricant substitute for the standard lubricants;
however, Limitorque does require the following lubricant qualities as a minimum.

a CAUTION: Do not mix lubricants of a different base chemical. Mixing lubricant bases may cause

lubricant properties to be ineffective.

The Lubricant must:

• contain an “EP” additive.

• be suitable for the temperature range intended.

• be water and heat-resistant and non-separating.

• not create more than 8% swell in Buna N or Viton.

• not contain any grit, abrasive, or fillers.

• comply with a slump-prefer NLGI-0 grade.

• not be corrosive to steel gears, ball, or roller bearings.

• have a dropping point above 316°F (158°C) for temperature ranges of -20°F (-29°C) to +250°F
(+121°C).

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27

Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

6.3 Disassembly and Reassembly

a CAUTION: Turn off all power services before attempting to perform service on the actuator.

• Remove the actuator from the valve for complex work. Minor work, such as replacing geared limit
switch, torque switch, or motor, may be readily performed while the actuator is still on the valve.

• Potential High-Pressure Vessel. Before removing or disassembling your actuator, ensure that the
valve or other actuated device is isolated and is not under pressure.

NOTE: If the actuator is fitted with a Thrust Base (piece 100 of Figure 6.2), it is possible to remove the
actuator housing while leaving the base on the valve to accept valve thrust. However, it is preferred that
the valve be isolated from service and, if it is a rising stem, that the valve be fully open.

6.4 Disassembly of the L120-10, 20, and 40

Unless otherwise noted, piece numbers refer to the Illustrated Parts Breakdown of Figure 5.2.

1. Turn off power to the actuator.

2. Remove electrical Compartment Cover (piece 200).

3. Disconnect all electrical leads from the Torque Switch (piece 300) and Geared Limit Switch
(piece 305). Ensure that all leads and terminals are clearly marked to facilitate reassembly.

4. Remove two screws holding limit switch and one holding torque switch. Remove both items.

5. Remove four bolts holding Motor (piece 31) and three bolts holding conduit Nipple Flange
(piece 30). Remove motor, drawing motor leads through switch compartment.

6. Remove Motor Pinion (piece 38) by removing Stop Nut (piece 40).

7. Remove Worm Shaft Gear (piece 35), Flexloc Nut (piece 37), and Worm Shaft End Cap (piece 5)
and draw complete wormshaft assembly from housing.

NOTE: The wormshaft has been assembled at the factory to obtain the correct preload on the spring
packs. Do not attempt to disassemble further. If the worm shaft is worn or damaged, it is suggested
that the complete wormshaft subassembly be replaced. The actuator must be in motor operation to
remove the wormshaft assembly. When the wormshaft is partially out, the disc springs will hit the
worm gear. Pull the declutch lever forward slightly without fully engaging the declutch mechanism
and the wormshaft will come out.

8. Remove Declutch Cap (piece 11).

9. For unit size L120-10, completely withdraw the Declutch Assembly (piece 7 of Figure 6.3) from
the housing. For unit sizes L120-20 and 40, remove Declutch Input Pinion (piece 12 of Figure 6.3)
followed by the Declutch Assembly (piece 7 of Figure 6.3).

28

10. Remove Handwheel (piece 29) and Housing Cover (piece 27) and lift complete drive sleeve subas­sembly from housing.

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

6.5 Drive Sleeve and Housing Cover Disassembly

Piece numbers refer to Figure 5.2.

1. Remove Upper Ball Bearing (piece 17), Bevel Gear (piece 18), Declutch Spring (piece 24), Clutch
Sleeve (piece 19), and Key (piece 23).

2. Remove Lower Ball Bearing (piece 16).

3. Spirolox Retainer (piece 22) may now be removed by inserting small flat blade
screwdriver under the end of the ring and prying the first layer from the groove.
Continue around the ring until it is free from the groove.

4. Remove the Worm Gear (piece 21) and the Lug Ring (piece 20).

5. Handwheel Adapter (piece 26) and Seal (piece 42) can be removed from Housing Cover (piece 27)
by removing Retaining Ring (piece 28).

6.6 Torque Nut Disassembly (Drive 1 Option)

For applications requiring torque only, the L120 series actuator can be supplied without the thrust
base option. The torque nut is driven by the drive sleeve lugs and held in place by the torque bushing
connector.

Figure 6.1 – L120-10 through 40 standard and extended drive sleeve assembly

99

97

25

95

183

Standard

25

96

98

183

Piece Quantity Description

25 1 Drive Sleeve
95 1 Torque Nut
96 1 Torque Bushing Connector
97 1 Torque Bushing Washer
98 1 Retaining Ring
99 1 Elastic Stop Nut

95

183 1 Retaining Ring

Unless otherwise stated, piece numbers refer to Figure 6.1.

Standard Drive Sleeve

To remove the Torque Nut (piece 95), remove Retaining Ring (piece 183) and drop the torque nut out
the bottom of the Drive Sleeve (piece 25 of Figure 5.2).

29

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Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

Hex Head Cap Screw

112 1 Relief Fitting

two different part numbers for piece #107 and 107A.

Optional Drive Sleeve

1. Remove the Handwheel (piece 29 of Figure 5.2), Handwheel Cover Plate (piece 33 of Figure 5.2)
and Gasket (piece 34) to provide access to the Elastic Stop Nut (piece 99).

2. Remove the Elastic Stop Nut (piece 99) from the Rod (piece 1). The Torque Nut (piece 95) can now
be removed from the bottom of the Drive Sleeve (piece 25 of Figure 5.2).

3. The Torque Bushing Connector (piece 96) can be removed from the torque nut by removing the
Retaining Ring (piece 98).

6.7 Thrust Base Disassembly (Drive 2 Option)

Piece numbers refer to Figure 6.2.

1. If the Thrust Base (piece 100) option is present, remove the Seal Retainer (piece 102) followed by
Stem Nut (piece 101).

2. Remove the four Hex Head Cap Screws (piece 110) and the Lift Thrust Base from the housing.

107A

109, 112

Figure 6.2– L120-10 through 40 thrust base

103

105

105

107

NOTE: For the L120-10, use the same part number for
piece #107 and 107A. For the L120-20 and L120-40, use

103

104

104

110, 111

106

100

101

102

6.8 Stem Nut Replacement –

108

Piece Quantity Description

100 1 Base Housing
101 1 Stem Nut
102 1 Seal Retainer
103 2 Needle Bearing
104 2 Thrust Washer
105 2 Thrust Washer
106 1 O-ring Seal
107 1 Quad Ring Seal
107A 1 Quad Ring Seal
108 1 Gasket
109 1 Grease Fitting
110 4

111 4 Lock Washer

30

This section is only applicable to thrust base applications. Occasionally the operator stem nut may need
replacing if used in a threaded stem application on rising stem valves.

c WARNING: Possible Hazardous Voltage. Turn power OFF before disassembling or removing the

actuator from the mounting base. This will prevent accidental start-up during service to the unit.

c WARNING: Potential High-Pressure Vessel. Before removing or disassembling the actuator, ensure

that the valve or other actuated device is isolated and not under pressure.

Thrust Base Applications

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

a CAUTION: The L120-10 through 40 thrust base contains lubrication. Ensure that EP-00 is replaced

when reassembling thrust base.

NOTE: Installation and retention of O-rings and quad rings can be eased by applying a small quantity of
EP grease to the ring during assembly.

To replace the stem nut:

1. Disconnect all incoming power to the actuator.

2. Remove actuator from the valve.

3. Remove Seal Retainer (piece 102 of Figure 6.2) followed by stem nut, bearings, and seals.

4. Check the fit of the new stem nut on the valve stem - ensure that the nut travels freely without
binding.

5. Reassemble the thrust base and remount the actuator on the valve.

6. Remount the actuator on the thrust base.

7. Removing the actuator from the valve will change the limit switch settings. Reset the limit switch in
accordance with Section 4.5.1, Setting Limit Switch.

8. Reconnect power.

9. Test for correct functioning.

6.9 Reassembly

Piece numbers refer to Figures 5.1, 5.2, 6.1, 6.2, and 6.3.

1. Install Lug Ring (piece 20) onto Drive Sleeve (piece 25) followed by the Worm Gear (piece 21).
Ensure that the worm gear lugs engage with recesses on lug ring.

2. Install Spirolox Retainer (separate layers of retainer sufficiently to begin threading the retainer into
the drive sleeve groove. Continue threading until the retainer is firmly located in the groove).

3. Install Key (piece 23) and Clutch Sleeve (piece 19).

4. Add the Declutch Spring (piece 24), Bevel Gear (piece 18), Upper Bearing (piece 17), and Lower
Bearing (piece 16) to complete the assembly.

5. Replace the drive sleeve assembly into main housing, and secure with the Housing Cover
(piece 27). Ensure that all the seals are in place.

6. Insert Wormshaft Assembly (piece 15) into the housing and locate the bearings in the housing
journals. Replace the Wormshaft Cap (piece 5).

7. Install the Wormshaft Gear (piece 35) and Flex Loc Nut (piece 37).

NOTE: It is recommended that a new flex loc nut be used during reassembly.

31

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7

Declutch Stop

*L120-20/40 only

7-2

7-1

7-3

Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

Figure 6.3 – L120-10 through 40 declutch assembly parts breakdown

7-1

7-2

8

42/5

&

7A

11

Declutch Stop

42

9

Declutch
Actuator

LUG

Handwheel

Clutch
Sleeve

10

L120-10

&

7-3

Piece Quantity Description

7* 1 Declutch Shaft Assembly L120-20/40
7A 1 Declutch Shaft Assembly
7-1 1 Declutch Actuator
7-2 & 7-3 1 Declutch Latch (left & right)
81 Declutch Return Spring
91 Declutch Lever
10 1 Roll Pin
11 1 Declutch Cap
12* 1 Declutch Input Pinion
42/5 1 O-ring – Declutch

8

42/5

L120-20/40

11

42

9

12

10

32

6.9.1 Declutch Assembly (L120-10)

8. Install Declutch Cap (piece 11) on the Declutch Shaft (piece 7A). Ensure that the return spring is
located correctly in the endcap.

9. Replace Declutch Lever (piece 9) on the shaft with the lever against the stop.

10. While holding the cap steady, rotate the declutch shaft against the spring tension until the holes in
the shaft and lever align.

11. Replace complete assembly in main housing. Ensure that the lug on the Declutch Actuator
(piece 7-1) fits into the groove on the Handwheel Clutch Sleeve (piece 19 of Figure 5.2).

12. Secure the declutch cap.

NOTE: When the declutch lever is disengaged against the declutch stop (motor operation position),
the Declutch Actuator (piece 7-1) should not be in contact with the groove on the Handwheel Clutch
Sleeve (piece 19 of Figure 5.2).

6.9.2 Declutch Assembly (L120-20/40) (Refer to Figure 6.3)

8. Install Declutch Cap (piece 11) on the Declutch Pinion Shaft (piece 12). Ensure that the return
spring is located correctly in the slots.

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

9. Replace Declutch Lever (piece 9) on the pinion and against the stop.

10. While holding the cap steady, rotate the Pinion Shaft (piece 12) against the spring tension until the
holes in the shaft and lever align.

11. Insert Roll Pin (piece 10).

12. Slide Declutch Shaft (piece 7) into the housing, ensuring that the Declutch Shaft (piece 7) fits
correctly into the groove in the Handwheel Clutch Sleeve (piece 19 of Figure 5.2).

13. Install the declutch cap assembly into the housing, finding the nearest tooth on the internal spur
gear which will allow the cap to be secured without placing tension on the Declutch Actuator (piece
7-1) causing it to rub against the groove in the Handwheel Declutch Sleeve (piece 19 of Figure 5.2).

6.9.3 Install the Motor (Refer to Figure 5.2)

1. Install the Motor Pinion (piece 38) and Elastic Stop Nut (piece 40) onto the motor shaft.

NOTE: The elastic stop nut should not be reused. It is recommended that a new nut be used during
reassembly.

2. Install conduit Nipple Flange (piece 30) and Seal (piece 42) onto the conduit nipple in the flange and
secure the motor. Secure the nipple flange.

6.9.4 Lubrication Procedure

1. Set unit on mounting base.

2. Grease through the grease fitting located on the motor adapter, watch for grease entering the
housing cavity.

3. Grease through the grease fitting in the housing cover until the adapter has been completely
greased and grease can be seen entering the drive sleeve compartment.

4. Reposition the unit “nameplate down”.

5. Finish filling housing cavity through the gear limit switch opening to within ½” from the bottom of
the gear limit switch opening.

6.9.5 Install Geared Limit Switch, Torque Switch

and Finish Assembly

1. Install torque and limit switch into the switch compartment housing.

NOTE: The limit switch must be reset before the actuator is placed back into service. The Torque
Switch may need to be rebalanced. If required see Section 4.4.2, Balancing Torque Switch.

2. Connect all electrical leads in the switch compartment.

3. Replace the compartment cover, handwheel and thrust base, if applicable, to complete the
assembly.

33

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7

Limitorque Actuation Systems L120 Series FCD LMENIM1201-05-A4 – 03/18

How to Order Parts

To order parts or obtain further information about your Limitorque L120 valve actuators, contact your
local Flowserve Limitorque distributor sales office, or:

Flowserve Limitorque
5114 Woodall Road
Lynchburg, VA 24502
Telephone [phone]
Fax [phone]

All inquiries or orders must be accompanied by the following information:

1. Actuator Size

2. Limitorque Order Number

3. Limitorque Serial Number

34

8

Limitorque Actuation Systems L120 Series FCD LMENIM1201-04-A4 – 03/18

EC Declaration of Conformity

Application of Council Directives

2004/108/EC; EMC Directive

2006/42/EC; Machinery Directive

2003/10/EC; Airborne Noise Directive

Standards to which Conformity is Declared

Machinery; EN 60204-1

EMC; Emissions; EN 55022; 2006

Immunity; IEC 61000-4-6;2007, IEC 61000-4-8: 2001

ESD; IEC 61000-4-2: 2001

EFT Bursts; IEC 61000-4-4: 2004

Surge Immunity; IEC 61000-4-5: 2006

Airborne Noise; MIL-STD-740-1, Table 1, EN 60204

Manufacturer’s Name

Flowserve Limitorque

Manufacturer’s Address

5114 Woodall Rd Lynchburg, VA 24502 USA

Importer’s Name

Flowserve Limitorque

Importer’s Address

Flowserve Limitorque

Euro House

Abex Road

Newbury

Berkshire, RG14 5EY

United Kingdom

Type & Description of Equipment

Valve Actuators

Model Number

L120-10,20,40, 85

Note: Tested with Limitorque products only and with standards applicable at

time of tests.

I, the undersigned, hereby declare that the equipment specified above

conforms to the above Directives and Standards.

John Thilking

Senior Engineer – Certifications, ATEX/IEC-Ex Authorized Person

Flowserve Limitorque
5114 Woodall Road

Lynchburg, VA 24502 USA

Date; December 4, 2012

flowserve.com

35

Flowserve Corporation
Flow Control

United States

Flowserve Limitorque
5114 Woodall Road
P.O. Box 11318
Lynchburg, VA 24506-1318
Phone: [phone]
Facsimile: 434-845-9736

Italy

Flowserve Limitorque
Via Rio Vallone 17
20883 Mezzago (MB), Italy
Phone: [phone]
Facsimile: [phone]

Japan

Limitorque – Nippon Gear Co., Ltd.
NOF Bldg. 9th Floor
1-11-11, Kita-Saiwai, Nishi-Ku
Yokohama (220-0004)
Japan
Phone: [phone]
Facsimile: 81-45-320-5962

FCD LMENIM1201-05-A4 03/18 Printed in USA.

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.

© 2015 Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation.

Singapore

Flowserve Limitorque
12, Tuas Avenue 20
Singapore 638824
Phone: [phone]
Facsimile: 65-6862-4940

China

Limitorque Beijing, Pte., Ltd.
RM A1/A2
22/F, East Area, Hanwei Plaza
No. 7 Guanghua Road, Chaoyang
District
Beijing 100004, Peoples Republic of
China
Phone: [phone]
Facsimile: 86-10-6561-2702

India

Flowserve Limitorque
Office A, 7th Floor, Plot No. 32
A&B
Ambit IT Park, Ambit IT Park Road
Ambattur Industrial Estate,
Chennai - 600058
Phone: [phone]
91-44-2432-4801
Facsimile: 91-44-2432-8754

flowserve.com