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USER INSTRUCTIONS |
LimitorqueTM SR Series |
Installation |
FCD LMENIM3701-00-AQ 11/14 |
Operation |
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Maintenance |
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Experience In Motion
Limitorque SR Series FCD LMENIM3701-00-AQ - 11/14
Contents
1 |
Introduction |
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1.1 |
Purpose |
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1.2 |
User Safety |
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2 |
Inspection, Installation and Mounting Procedures |
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2.1 |
Initial Inspection and Storage Instructions |
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2.2 |
Inspection and Recording |
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2.3 |
Storage Procedure |
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2.4 |
Safety Precautions |
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2.5 |
Safety Practices |
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2.6 |
General Mounting Instructions |
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2.7 |
Stem Cover Mounting Instructions |
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3 |
Lubrication |
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4 |
Product Weights |
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5 |
Disassembly and Reassembly Instructions |
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5.1 |
Disassembly and Reassembly of SR200 through SR600 |
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5.2 |
Disassembly and Reassembly of SR200H through SR600H |
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6 |
How to Order Parts |
22 |
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Limitorque SR Series FCD LMENIM3701-00-AQ - 11/14
Figures
Figure 2.1 |
– SR Exploded View |
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Figure 2.2 |
– SRH Exploded View |
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Figure 5.1 |
– SR200 - SR600 Assembly View |
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Figure 5.2 |
– SR200H - SR600H Assembly View |
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Tables
Table 3.1 |
– Lubricants |
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Table 4.1 |
– SR and SRH Gearbox Weights |
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Table 5.1 |
– SR200 through SR600 Parts List |
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Table 5.2 |
– SR200H through SR600H Parts List |
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flowserve.com
Limitorque SR Series FCD LMENIM3701-00-AQ - 11/14
1 Introduction
1.1 Purpose
The installation and maintenance manual (IOM) explains how to install and maintain the Flowserve Limitorque SR gearbox. Information on installation, disassembly, reassembly, lubrication and product weights 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. Failure to observe these precautions could result in serious bodily injury, damage to the equipment, voiding of the warranty, or operational difficulty.
Safety notices are presented in this manual in three forms:
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WARNING: Refers to personal safety. Alerts the user to potential danger. Failure to follow warning notices could |
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result in personal injury or death. |
aCAUTION: Directs the user’s attention to general precautions that, if not followed, could result in personal injury and/or equipment damage.
NOTE: Highlights information critical to the user’s understanding of the SR gearbox’s installation and operation.
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Limitorque SR Series FCD LMENIM3701-00-AQ - 11/14
2 Inspection, Installation and
Mounting Procedures
Figure 2.1 - SR Exploded View
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c WARNING: Do not manually operate the SR gearbox with devices other than the installed handwheel or wrench nut. Using additive force devices (cheater bars, wheel wrenches, pipe wrenches, or other devices of this nature) on the gearbox handwheel, wrench or wrench nut may cause serious personal injury and/or damage to the gearbox or valve.
flowserve.com
Limitorque SR Series FCD LMENIM3701-00-AQ - 11/14
Figure 2.2 - SRH Exploded View
2.1 Initial Inspection and Storage Instructions
c WARNING: Read this installation and maintenance manual carefully and completely before attempting to store the gearbox. If an electric actuator is attached to the SR gearbox, be aware of the electrical hazards. Consult the electric actuator installation and maintenance manual for guidance.
2.2 Inspection and Recording
Upon receipt of the gearbox, inspect the condition of the equipment, and record nameplate information.
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Carefully remove the gearbox from the shipping carton or skid. Thoroughly examine the equipment for any physical damage that may have |
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occurred during shipment. If damaged, immediately report the damage to the transport company. |
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2. |
A nameplate is attached to each gearbox with the following information: |
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Gearbox size |
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Order number |
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Serial number |
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Customer tagging |
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Record this information for future reference, e.g., ordering parts, or obtaining further information.
Limitorque SR Series FCD LMENIM3701-00-AQ - 11/14
2.3 Storage Procedure
NOTE: The following is the recommended storage procedure to retain maximum product integrity during storage. Failure to comply with recommended procedure will void the warranty.
Storage (less than one year)
Store the gearboxes on wooden skids to protect the machined mounting flange. Place the wooden skids containing the gearboxes in a clean, dry, protected warehouse. If the gearboxes must be stored outside, they must be covered in polyethylene protection with silica gel crystals to absorb moisture. If an electric actuator is attached to the SR gearbox, refer to the storage procedures in its respective manual for appropriate storage procedures. Rotate input shafts every three months to mix the lubricant.
2.4 Safety Precautions
c WARNING: Read this Installation, Operation and Maintenance manual carefully and completely before attempting to install, operate or troubleshoot the Limitorque gearbox.
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 gearbox. Do not remove the gearbox mounting bolts from the valve or actuated device unless the valve or device stem is secured or there is no pressure in the line.
c WARNING: For maintenance and/or disassembly of the gearbox while installed on the valve, ensure that the gearbox is not under thrust or torque load. If the valve must be left in service, the valve stem must be locked in such a way as to prevent any movement of the valve stem.
c WARNING: Do not manually operate the gearbox with devices other than the installed handwheel. Using force beyond the ratings of the gearbox and/or using additive force devices such as cheater bars, wheel wrenches, pipe wrenches, or other devices on the gearbox handwheel may cause serious personal injury and/or damage to the gearbox and valve.
c c
WARNING: Do not exceed any design limitations or make modifications to this equipment without first consulting Flowserve Limitorque.
WARNING: Use of this product must be suspended any time it fails to operate properly.
aCAUTION: If a motor actuator is driving the gearbox, do not operate the valve under motor operation without first checking and setting the limit switch and checking for correct motor rotation.
aCAUTION: Do not use replacement parts that are not genuine Flowserve Limitorque parts, as serious personal injury and/or damage to the gearbox and valve may result.
2.5 Safety Practices
The following checkpoints should be performed to maintain safe operation of the SR gearbox:
•Set up a periodic operating schedule on infrequently used valves.
•Ensure that the limit and/or torque switches on any electric actuator fitted to the SR gearbox are correctly and appropriately adjusted.
2.6 General Mounting Instructions
The mounting instructions for the SR spur gearboxes are outlined below. The SR200 through SR600 gearboxes are designed with a splined top-entry Stem Nut which is retained in the Drive Sleeve by two Lock Nuts.
The SR200H through SR600H gearboxes are designed with a Stem Nut which is retained by two Thrust Roller Bearings within the Thrust Housing |
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and Thrust Base. Partial disassembly of the Thrust Base is required for Stem Nut removal and/or installation. |
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flowserve.com
Limitorque SR Series FCD LMENIM3701-00-AQ - 11/14
2.6.1Installing a Gearbox with a Threaded Stem Nut – SR200 through SR600 and SR200H through SR600H
1.Position the gearbox above the valve stem.
2.Rotate the gearbox handwheel or wrench nut several turns until there is positive engagement between the valve stem and the gearbox Stem Nut.
3.Rotate the handwheel to lower the gearbox onto the valve until contact has been made with the valve fllange.
4.Bolt the gearbox securely to the valve mounting fllange.
2.6.2 Installing a Gearbox with a Blank Stem Nut – SR200 through SR600
Refer to Figure 5.1
1. Remove the Stem Cover Adapter (pc# 28) by loosening the Set Screw (pc# 20).
2. Remove the two threaded Lock Nuts (pc# 7) from the Drive Sleeve (pc# 6), accessed through the top of the Housing (pc# 1). 3. Remove the Stem Nut (pc# 5) from the Drive Sleeve (pc# 6) through the top of the Housing (pc# 1).
4. Machine the Stem Nut (pc# 5) to suit the valve stem.
a CAUTION: Care must be taken to ensure that the clamping devices used during machining do not damage splined surfaces of the Stem Nut. 5. Reinstall the Stem Nut (pc# 5) into the Drive Sleeve (pc# 6), ensuring the splines are properly engaged.
6. Reinstall the two threaded Lock Nuts (pc# 7) into the Drive Sleeve (pc# 6). 7. Install the Stem Cover Adapter (pc# 28) and tighten the Set Screw (pc# 20).
8. Mount the gearbox on the valve as detailed in Section 2.6.1 Installing a Gearbox with a Threaded Stem Nut.
2.6.3 Installing a Gearbox with a Blank Stem Nut – SR200H through SR600H
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Refer to Figure 5.2 |
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Place the gearbox upside down to access the mounting base. |
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Remove the Socket Head Cap Screws (pc# 34) which mount the Thrust Base (pc# 31) to the Thrust Housing (pc# 37). |
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Remove the Thrust Base (pc# 31) and Gasket (pc# 32) from the Thrust Housing (pc# 37). |
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CAUTION: Care must be taken to ensure that the O-ring (pc# 35) located in the Thrust Base (pc# 31) is not damaged during disassembly. |
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Remove the Stem Nut (pc# 5) and lower Thrust Roller Bearing (pc# 33). |
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Remove the upper Thrust Roller Bearing (pc# 33). Place all bearings in a clean, dry area until reassembly. |
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6. |
Machine the Stem Nut (pc# 5) to suit the valve stem. |
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a CAUTION: Care must be taken to ensure that the clamping devices used during machining do not damage the outer surface of the |
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Stem Nut (pc# 5) which seals against the O-ring (pc# 35). |
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7. |
Reinstall the upper Thrust Roller Bearing (pc# 33) into the Thrust Housing (pc# 37). |
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