Installation, Operation and Maintenance Manual
Shafer Linear Actuator
LSM-01102001 Rev. A
January 2001
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
Table of Contents
Section 1: Instructions
1.1 Valve Operation ............................................................................................. 1
1.1.1 The Steps for Proper Valve Preparation ................................................. 1
1.1.2 Operator Preparation ........................................................................... 2
1.1.3 Installation Procedure .......................................................................... 2
1.1.4 Operation Position Adjustment ............................................................ 3
1.1.5 Customer Connections ......................................................................... 5
Section 2: Construction
2.1 Hydraulic Fluid Specications ......................................................................... 6
2.1.1 For Warm Weather: 20° F to 120° F ....................................................... 6
2.1.2 For Cold Weather: -40° F to 100° F ........................................................ 6
2.2 Construction .................................................................................................. 7
Table of Contents
January 2001
Section 3: Basic Operation
3.1 Operation ...................................................................................................... 8
3.1.1 Sequence 1 .......................................................................................... 8
3.1.2 Sequence 2 .......................................................................................... 9
3.1.3 Sequence 3 ........................................................................................ 10
Section 4: Latches and Snubbers
4.1 The Hydraulic Latch ...................................................................................... 11
4.1.1 Purpose .............................................................................................. 11
4.1.2 Operation........................................................................................... 11
4.1.3 Adjustment of the Latches .................................................................. 11
4.2 Maintenance of the Latch ............................................................................. 12
4.3 The Hydraulic Snubber ................................................................................. 12
Section 5: Purging
5.1 Purging & Draining ....................................................................................... 14
5.2 Purging Procedure ....................................................................................... 14
Section 6: Draining
6.1 Draining Procedure ...................................................................................... 16
Section 7: Proper Operating Oil Levels
Table of Contents
Section 8: Disassembly
8.1 Disassembly ................................................................................................. 19
8.2 Disassembly Procedure ................................................................................ 20
I
Table of Contents
January 2001
Section 9: Reconditioning and Reassembly
Section 10: Troubleshooting
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
9.1 Reconditioning ............................................................................................ 21
9.2 Reassembly .................................................................................................. 22
10.1 Checklist ...................................................................................................... 23
II
Table of Contents
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
Section: 1 Instructions
1.1 Valve Operation
CAUTION:
When a rising stem linear valve is under pressure, the pressure exerts an upward thrust on
the area of the valve stem. This upward thrust is counteracted by the yoke nut, thrust
bearings, and manual gear housing. When these items are removed, there is nothing to
pre vent the valve stem from being forced upward, possibly causing valve damage or
personal injury.
It is for this reason, that if the valve is under pressure it must be placed in the full open
position before attempt ing to install the Shafer Operator. If the valve is not under pressure,
it is advisable to place the valve in the closed position.
This is true especially in the case of larger valves as it will prevent possible dam age to the
valve should the gate fall closed by its own weight.
Section 1: Installation Instructions
January 2001
1.1.1 The Steps for Proper Valve Preparation
1. If the valve is pressurized, stroke it to the full open position. If the valve is not
pressurized, stroke it to the full closed position.
2. Remove the valve stem protective cover, if existant.
3. Remove the stem stop-nut from the end of the valve stem, if existant.
4. Remove the manual gear housing mounting bolts.
5. Turn the gear housing up and off of the valve stem, and remove all thrust bearings.
NOTE:
For Grove Gate Valves with yoke tube exten sions.
a. Remove the mounting bolts and gear housing.
b. Remove the keyed torque tube.
c. Remove the yoke tube extension at point "X".
d. Remove the stem stop nut or downstop.
e. Remove the bearing housing from the yoke tube ange at "Y".
f. Remove the stem nut and thrust bearings from the valve stem.
g. Re-assemble the bearing housing to the yoke tube ange.
h. Re-assemble the yoke tube extension to the top of the bearing housing.
i. Shafer Linear Operators for Grove Gate Valves with yoke tube extension
will be supplied with an operator stem extension the same length as the
yoke tube extension for proper mating.
Installation Instructions
1
Section 1: Installation Instructions
January 2001
6. Thoroughly clean and generously grease the valve stem and mounting ange.
1.1.2 Operator Preparation
1. All certied drawings, accessory parts, bolts, etc. are packaged inside of the
control box or attached to the operator or shipping crate.
2. All operators are designed specically for horizontal or vertical stem mounting, but
never for universal mounting.
3. The operator must be suspended in the proper posi tion from a swivel-hook
attached to the lifting device. The operator weight is equal to the valve size times
100 pounds. For example: 18" valve x 100 pounds = 1800 pounds.
CAUTION:
Do not use chains to suspend the operator.
4. Remove the shipping plugs from the exhaust ports of the control junction block.
5. Check to make sure that the operator and valve are in the same relative position,
l.E. both open or both closed.
6. The operator will be shipped in the open position. If the operator is to be mounted on
a closed valve (non pressurized), use the manual hand pump to stroke the operator
closed while observing the position indicator markings on top of the operator.
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
1.1.3 Installation Procedure
1. After the valve and operator have been properly pre pared, suspend the operator
directly over the valve stem. The operator must be centered as near perfect as
possible and parallel with the valve stem.
2. The female operator piston stem has approximately one inch of penetration before
the internal thread begins to allow for ease in alignment.
3. Make note of whether the valve stem has a right hand or left hand thread.
4. Lower the operator until the stem threads meet. If an automotive winch is used,
disconnect the distribu tor and use only the starter.
5. Carefully continue to lower while rotating the entire operator down over the valve
stem until the mount ing anges meet.
NOTE:
Care should be taken not to push (on open valves) or pull (on closed valves) the valve stem
or operator piston from their original positions.
2
Installation Instructions
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
Figure 1
Stem Protector
Manual Gear
Housing
Thrust
Bearing
TYPICAL VALVE
Section 1: Installation Instructions
Yoke Tube Extension
Bearing Housing
Yoke Tube Flange
January 2001
Torque Tube (Remove)
Stem Stop Nut or
X
Y
Down Stop (Remove)
Stem Nut (Remove)
Thrust Bearings
(Remove)
Pump
Latch
Gas Hydraulic Tank
Exhaust
Shipping Plugs
Mtg. Brkt.
1.1.4 Operation Position Adjustment
1. When the operator and valve anges meet, it is possible that the control box does
not face in the desired direction, and some position adjustment will be necessary.
2. Rotate the operator back until the control faces in the desired direction and the
mounting ange holes are in alignment. This action will result in a gap be tween
the operator and valve mounting anges.
3. If the operator was mounted on a closed valve, at this time hand pump the
operator fully open. Then using the lifting device, pull the operator and valve gate up
until the gate is against its full open stops. If the gap between the anges is greater
than the distance of one complete turn of stem threads, turn the operator down
until the anges again meet, and then reposition the control as per step no. 2.
Snubber
Exhaust
Installation Instructions
3
Section 1: Installation Instructions
January 2001
4. Loosely install the mounting bolts to maintain this desired position.
5. To close the gap between the anges, observe the following directions:
For operators with a two-piece telescoping mounting bracket see A, for operators
with a one-piece non-adjustable bracket see B on Figure 2.
A. For telescoping two-piece bracket:
— Loosen the adjusting nuts (1) on the bottom of the middle ange of the
telescoping bracket.
— This action will allow the lower piece of the mounting ange to slide down
and make con tact with the valve mounting ange.
— Tighten the operator mounting bolts in a standard criss-cross pattern
applying the same torque to each to prevent any misalignment.
— Run the upper adjusting nuts (2) to within 1 /8" of the top of the middle
ange.
— Tighten the lower adjusting nuts ( 1) to the bot tom of the middle ange
pulling the bracket to gether 1/8" until the upper (2) and lower ( 1)
adjusting nuts are tightly sandwiching the middle ange.
B. For one-piece non-adjustable mounting brackets:
— Remove the indicator guide pin and roller assembly from the top of the
position indicator stem.
— Remove the indicator guide tube retaining bolts and slide the guide tube
up and off of the posi tion indicator stem.
— The top portion of the indicator is provided with a wrench hex. Grasp
the is hex and turn the piston further onto the valve stem until the gap is
closed.
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
NOTE:
While turning the piston, gently hand pump the operator towards the closed position to
eliminate any hydraulic pressure below the piston.
— Tighten the operator mounting bolts in a stan dard criss-cross pattern
applying the same amount of torque to each to prevent misalign ment.
— Replace the indicator guide tube, retaining bolts, and roller and guide pin
assembly.
6. Using the manual hand pump, stroke the valve fully open and closed. Measure and
compare the travel of the position indicator with the specied valve travel (which
is listed on the Certied Drawings) to insure that the valve is reaching its full end of
stroke posi tion with out overtravel.
4
Installation Instructions
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
1.1.5 Customer Connections
1. All electrical and control tubing connections are pointed out on the certied
drawings and schematic drawings found in the job folder.
NOTE:
The exhaust ports must never be restricted through piping smaller than the pipe thread
size of the port on the junction block. On some of the larger gas-powered linear operators
there are two exhaust ports. These must never be manifolded together.
Figure 2
Section 1: Installation Instructions
January 2001
2
1
Operator Mtg. Bracket
Operator Mtg. Bracket
Valve Mtg. Flange
Installation Instructions
A
TWO-PIECE
TELESCOPING
BRACKET
B
ONE-PIECE
NON ADJUSTABLE
BRACKET
5
Section 2: Construction
January 2001
Installation, Operation and Maintenance Manual
Section: 2 Construction
2.1 Hydraulic Fluid Specifications
The following tables show recommended hydraulic uids for all Shafer Operators.
2.1.1 For Warm Weather: 20° F to 120° F
API Gravity 31.1
Viscosity at 210° F 45.2 SSU
Viscosity at 100° F 115. SSU
Viscosity at 0° F 1600. SSU
Pour Point -50° F
Viscosity Index 150
LSM-01102001 Rev. A
Flash Point 335° F
Fire Point 350° F
Base Pa Parran
Inhibitors Rust-Foam
Oxidation
Color 1
Neutralization No. .07
2.1.2 For Cold Weather: -40° F to 100° F
API Gravity 32.8
Viscosity at 210° F 42.9 SSU
Viscosity at 110° F 74. SSU
Viscosity at 0° F 360 SSU
Pour Point -75° F
Viscosity lndex 225
Flash Point 215° F
Fire Point 250° F
Base Petroleum
Inhibitors Rust-Foam
Oxidation
Color 16.5 (red)
Neutralization No. .03
6
Construction
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
2.2 Construction
• Simple, basic design with no power-absorbing gearing. Hydraulic piston principle
provides fast, smooth oper ation-without shock.
• Made from high quality steel plate, ground to precision tolerances.
• Composition seals and ber wipers assure leakproof operation at high pressure.
• Low friction bearing surfaces are provided by a bronze coating on the piston
diameter and bronze bush ings in the heads.
• Piston is threaded to valve stem.
• Mounting bracket machined to t valve bonnet or yoke tube.
• Special latch device provided to lock the valve in any position desired.
• Snubbers installed for wedge type gate valves.
NOTE:
(1) Consult factory for temperatures below -40° F.
(2) Viscosity of hydraulic uid used may affect opera tor movement and restrict hand
pump suction. For these reasons the above uid specications are re commended.
(3) Do not use motor oils purchased at gasoline stations. Most motor oils contain sulfur
which is corrosive, and other additives which will produce a varnish like coating on
the mirror-Iike interior of the operator.
Section 2: Construction
January 2001
Construction
7
Section 3: Basic Operation
January 2001
Installation, Operation and Maintenance Manual
Section: 3 Basic Operation
3.1 Operation
The operator may be powered by line pressure, stored gas pressure, or by a central
hydraulic system. Designed specically for gate valve installations, Shafer Linear Operators
feature a special double latch for locking the valve into any desired position.
3.1.1 Sequence 1
For this explanation the operator is shown tted with gas hydraulic tanks and will be
powered by pipeline pressure. The operator is shown in the full open position with no
pressure in the operator or tanks.
Figure 3 Valve Fully Open
LSM-01102001 Rev. A
8
Basic Operation
Installation, Operation and Maintenance Manual
VALVE FULLY OPEN
LSM-01102001 Rev. A
3.1.2 Sequence 2
Line pressure is admitted to the closing gas hydraulic tank, The pressurized hydraulic uid
ows out of the tank and under the poppet of the closing latch. The poppet is forced off of
its seat and allows the pressurized hydraulic uid to ow to the top of the operator piston.
A separate hydraulic line is ported to the opening latch. The pressurized hydraulic uid
enters under the piston of the opening latch which pulls the opening poppet off of its seat.
As the pressurized hydraulic uid forces the operator to the closed position, the uid under
the operator pis ton is pushed out of the operator, through the opening latch, and into the
opening gas hydraulic tank.
Figure 4 Valve Closing
Section 3: Basic Operation
January 2001
Basic Operation
9
VALVE FULLY OPEN
VALVE CLOSING
Section 3: Basic Operation
January 2001
3.1.3 Sequence 3
When the operator reaches the fully closed position, the control will neutralize and allow all
remaining line pressure to vent to atmosphere, thus neutralizing tank and operator
pressure.
When the pressure is neutralized, the latches, being spring actuated, will automatically
close and lock the hydraulic uid both above and below the operator pis ton. Because the
hydraulic uid is non-compressable, the operator will maintain the closed position.
Figure 5 Valve Fully Closed
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
10
Basic Operation
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
Section 4: Latches and Snubbers
Section: 4 Latches and Snubbers
4.1 The Hydraulic Latch
4.1.1 Purpose
As previously stated the hydraulic latch is a means to lock hydraulic uid both above and
below the operator piston which in turn maintains the desired position of the valve.
Without the latches, pipeline pressure acting on the area of the valve stem would force the
valve and operator open.
4.1.2 Operation
The latches can be unseated in three ways:
Reference Figure 6.
January 2001
1. When using pipeline pressure to power the operator, the hydraulic uid from the
pressurized tank is ported to the bottom of the latch at I. The pressurized hy draulic
uid acting on the seating area of the poppet A forces the poppet off its seat
allowing the hydraulic uid to enter the operator from port II.
2. Port III. is connected to port IV of the opposite latch. The pressurized uid acting
as a pilot on the latch pis ton pulls the opposite latch off of its seat allowing the uid
in the operator to ow to the non-pressur ized receiving tank.
3. The latches act as relief valves should thermo-expan sion occur. The hydraulic uid
locked between the operator and the latch when subjected to heat will increase in
pressure. The pressure will continue to rise until the force created by this pressure
acting on the difference in area between A and B, the area of the poppet stem, is
sufcient to overcome the force of the spring compression. The poppet will then
be unseated allowing one or two drops of hydraulic uid to relieve to the gas
hydraulic tank. When the pressure is relieved, the spring force will reseat the
poppet.
4.1.3 Adjustment of the Latches
It must be remembered then, that the spring compres sion must be sufcient enough to:
1. Allow stroking the operator with the hand pump without relieving.
2. Lock the operator in any desired position against the natural upward thrust.
And yet, the spring compression cannot be so great as to prevent:
Latches & Snubbers
1. The minimum working power pressure from unseat ing the poppet when using
power gas to stroke the operator.
2. The pressure from thermo expansion from relieving, which could cause damage to
the operator.
11
Section 4: Latches & Snubbers
January 2001
Installation, Operation and Maintenance Manual
4.2 Maintenance of the Latch
NOTE:
The spring cavity in the tops of the latches must be examined for condensation accumulation
always before freezing weather. If sufcient water freezes at this point, the latch will not
function which will pre vent the operator from functioning in the automatic sequence.
Reference Figure 6.
1. The operator must always be in the open position before the latches can be
disassembled.
2. Remove the adjusting screw cover 5.
3. Measure and note the distance from the top of the latch head to the top of the
adjusting screw 6.
4. Remove the adjusting screw with a large screwdriver.
5. Remove, clean, and grease the spring 8.
6. Remove the body retaining bolts 14, and upper head 1.
7. Remove the upper cylinder 2, and the piston and poppet assembly 4 and 9.
8. Inspect the seating area of the poppet and seat for any scratches or nicks.
(The body seat can be cleaned and polished with crochus and emery cloth).
9. Replace seals and poppet if necessary.
10. Clean and grease all parts.
11. Reassemble in reverse order making sure that the ad justing screw is "run in" to the
pre-measured depth from step no. 3.
LSM-01102001 Rev. A
4.3 The Hydraulic Snubber
Wedge type gate valves are supplied with a hydraulic snubber in the upper and lower heads
of the operator. The purpose of the snubber is to reduce the speed of the operator and
valve mass so as to prevent the wedge from being jammed into the valve seats at the end
of stroke. In the last 1 /2 inch of travel, the piston contacts the in ternal portion of the spring
loaded snubber. As the piston continues towards the head, the snubber is forced into its
seat and continues to restrict the ow of uid out of the operator, thus causing the braking
action. The snubber is also used on ultra high-speed operators to prevent shock by buffering the end of stroke momentum.
12
Latches & Snubbers
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
Figure 6
15
5 14
8
10
IV
10
11
13
12
9
3
III
3
5
4
6
1
6
2
4
7
II
I
Operator Head
1
2
Operator Piston
Section 4: Latches and Snubbers
January 2001
HYDRAULIC LATCH
Bill of Material
Item Qt y. Description
1 1 Head
2 1 Upper Body
3 1 Lower Body
4 1 Piston
5 1 Adjusting Screw Cap
6 1 Adjusting Screw
7 1 Latch Pin
8 1 Spring
9 1 Neoprene Disc.
10 2 O-Ring Linear *11 - 224
11 1 O-Ring Linear *11 - 024
12 1 Truarc Snap Ring No. 5103-62
13 1 Sps. 187 Spring Pin 1-3/16 Lg.
14 6 5/16 - 18 x 3 15 1 1/18" Alemite Relief Fitting No.
HYDRAULIC SNUBBER
Bill of Material
Item Qt y. Description
1 1 Body
2 1 Plunger
3 1 Body Cap
4 1 Spring MP-39
5 1 O-Ring PRP-568-116
6 1 O-Ring PRP-568-215
1/2
Hex. Hd. Cap. Scr.
Latches & Snubbers
13
Section 5: Purging
January 2001
Installation, Operation and Maintenance Manual
Section: 5 Purging
5.1 Purging & Draining
A properly purged and periodically drained operator will retain its mirror-like interior and
extend its seal life by preventing the possibility of corrosion and galling.
For proper operation and maintenance, the operator must be completely lled with
hydraulic uid, both above and below the operator piston.
The following observations would indicate that the op erator is not completely full of
hydraulic uid:
1. Delayed or erratic movement of the operator when using power gas.
2. "Sponginess" when using the hand pump.
3. Valve drift or "creep" from the desired position.
5.2 Purging Procedure
LSM-01102001 Rev. A
To rid the operator of gas and restore it to proper oper ation, follow these steps:
1. Place the operator in the full open position.
CAUTION:
Disarm the control from the operator by rst turning off power gas, Then remove the pivot
pin of the control rocker arm to prevent any remote signals from actuating the control, and
remove the bull plugs from the tops of the gas-hydraulic tanks.
2. Fill the closing gas hydraulic tank to the upper weld ring on welded tanks, or the
upper radius on spun tanks, as per Figure 7.
Figure 7 Valve Fully Open
Bull Plugs
Oil
Full Level
14
Closing Tank
Purging
Installation, Operation and Maintenance Manual
Bull Plugs
Oil
VALVE FULLY OPEN
FIGURE NO.1
LSM-01102001 Rev. A
3. Place the selector lever of the hand pump in the closed position and slowly pump
the operator fully closed.
4. Fill the opening gas hydraulic tank to the upper weld ring on welded tanks, or
upper radius on spun tanks, as per Figure 8.
Figure 8 Valve Fully Closed
Oil
Full Level
Section 5: Purging
January 2001
Opening Tank
5. Place the selector lever of hand pump in the open position and slowly pump the
operator fully open.
6. Return the selector lever of the hand pump to the mid, or automatic, position.
7. The operator has now been properly purged and, after proper oil levels are
established in the gas hy draulic tanks (page 18), the bull plugs can be reinstalled
and the control re-armed.
Purging
15
Section 6: Draining
January 2001
Installation, Operation and Maintenance Manual
Section: 6 Draining
6.1 Draining Procedure
The operator and tanks should be periodically inspected and drained to remove any
accumulation of condensate and foreign matter. The frequency of this maintenance
procedure is dependent of the wetness of the power gas, and certain climatic conditions.
But, always drain the operator before freezing weather sets in.
To properly drain the operator:
CAUTION:
Disarm the control from the operator by rst turning off power gas. Then remove the pivot
pin of the control rocker arm to prevent any remote signals from actuating the control, and
remove the bull plugs from the top of the gas hydraulic tanks.
LSM-01102001 Rev. A
1. Loosen, but do not completely remove, the bull plugs at the bottom of the gas
hydraulic tanks and allow the water and contaminates to drain. When clear
hydraulic uid appears, retighten the bulI plugs, as per Figure 9.
2. Loosen, but do not completely remove, the hydraulic tubing tting at the
bottom of the operator and allow the water and contaminates to drain. When
clean hydraulic uid appears, retighten the tting, as per Figure 9.
Figure 9
Contaminants
16
Draining
Installation, Operation and Maintenance Manual
VALVE FULLY OPEN
FIGURE NO.1
Contaminants
LSM-01102001 Rev. A
3. To drain the upper portion of the operator, it must be in the fully open position.
4. With the operator in the open position, completely remove the hydraulic tting or
snubber, whichever is existent.
5. Insert a exible siphon through the upper port to reach the accumulation of
contaminates laying in the dished out portion of the piston. Pour in clean hydraulic
uid and replace the tting or snubber.
6. After draining the operator and tanks of contaminates, use the above purging
procedure to ll the op erator for normal operation.
Figure 10
Section 6: Draining
January 2001
It is recommended that the hydraulic uid be changed completely every ve years.
This can be accomplished as follows:
CAUTION:
Disarm the control from the operator.
1. With the operator in the open position, drain the closing gas hydraulic tank, and ll
with new hydraulic uid. Then, hand pump the operator to the fully closed position.
2. Drain the opening gas hydraulic, and ll with new hydraulic uid.
3. Re-arm the control for normal operation.
Draining
17
Section 7: Proper Operating Oil Levels
January 2001
Installation, Operation and Maintenance Manual
Section: 7 Proper Operating Oil Levels
Figure 11
LSM-01102001 Rev. A
18
Closing
Tank
VALVE FULLY OPEN VALVE FULLY CLOSED
Opening
Tank
Closing
Tank
Opening
Tank
NOTE:
For best results, the operator should be purged of any trapped gas before proceeding with
the establishment of proper oil levels in the gas hydraulic tanks.
All linear valve operators are equipped with 1-1/4 volume tanks. This means that each tank
will hold 1-1/4 times the amount of oil needed to stroke the particular operator.
The proper operating oil levels are as follows:
1. If the operator is in the open position, the closing or "ready" tank should be lled
to the upper weld ring, and the opening or "receiving" tank should be lled 2 to 4
inches above the lower weld ring.
2. If the operator is in the closed position, the opening or "ready" tank should be lled
2 to 4 inches above the lower weld ring.
3. Any excess oil will spill out of the exhaust port with the next cycling of the operator.
Continued or excessive need to re-establish the proper oil levels is usually a result of one or
more of the following:
• CAUSE I Improper use of the hand pump when pump ing the operator open.
• SOLUTION I The operator in some cases will drift open on its own as soon as the
hand pump se lector lever is moved to the open position.
This situation is not detrimental to the proper oil levels if the selector
lever is completely "snapped in" the open position. However, DO NOT
attempt to control the speed of the up ward drift by "throttling" the
selector lever between the mid and open positions as this action causes
improper transfer of hydraulic uid in the tanks.
• CAUSE II Leakage in the sealing areas of the hand pump.
• SOLUTION II Refer to the "Shafer Manual Hand Pump Installation, Operation and
Maintenance Manual" for proper maintenance.
• CAUSE lll Leakage across the operator piston seals.
• SOLUTION lll Replace the operator seals as per this manual.
Proper Operating Oil Levels
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
Section: 8 Disassembly
Figure 12
Guide Tube
Retainer Washer
Felt Packing
Guide Tube Flange
Bronze Bushing
Head Bolts
Upper Head
Upper Head Seal
Snap Ring
Indicator Roller
Indicator Pin
Indicator Shaft
Mounting Block
Back-Up Ring
D-Ring
Back-Up Ring
Piston
Mounting Bolt
Felt Wiper
O-Ring
Felt Wiper
O-Ring
Snap Ring
Indicator Roller
Indicator Pin
Mounting
Block Screw
Felt Wipers
Cylinder
Lower Head Seal
Felt Wiper
O-Ring
Felt Wiper
Upper Valve Extension
O-Ring
Relief Fitting
Lower Valve Extension
Section 8: Disassembly
January 2001
Lower Head
Lower Head Bolts
Hex. Nut
Stud
Hex. Nuts
Yoke
Mounting Bolts
8.1 Disassembly
NOTE:
Make certain that a complete set of replacement seals is available before attempting
disassembly. The operator must be removed from the valve before disassembly can be
accomplished.
CAUTION:
The valve must be in the fully opened posi tion, if there is pressure in the pipeline, before
the operator can be removed.
Disassembly
19
Section 8: Disassembly
January 2001
Installation, Operation and Maintenance Manual
8.2 Disassembly Procedure
1. After being removed from the valve, support the operator in an upright position
and drain the hydrau lic uid.
2. If limit switches or trigger valves are existent, they must be removed from the
upper head.
3. Remove the guide pin and roller assembly.
4. Remove the guide tube ange retaining bolts, and slide the guide tube off of the
indicator stem.
5. Remove the upper head bolts.
6. Install lifting eye bolts in the upper head and pull the head from the operator.
7. Pull the piston from the cylinder by installing eye bolts in the lift holes provided.
LSM-01102001 Rev. A
20
DIsassembly
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
Section 9: Reconditioning and Reassembly
January 2001
Section: 9 Reconditioning and Reassembly
9.1 Reconditioning
Thoroughly clean all components and inspect the cylinder for scoring, galling, and
corrosion, all of which are indications that the operator has not been properly maintained.
Use ne emery cloth to remove any disgurations or corrosion followed by a nal
polishing with crochus cloth. Remember, the operator's cylinder is a sealing surface, and
must be smooth to seal properly and pre vent damage to the new seals.
Replace all seals, back-up rings, and wipers. The replace ment seals may be ordered
simply by specifying the operator's serial number. Lubricate all surfaces and seals with a
light grease before reassembly. Remember, all seals should be replaced as they are less
expensive than the man-hours involved in reassembling the operator using the old existing
seals, and then discovering a seal to be faulty.
Figure 13
Reconditioning and Reassembly
21
Section 9: Reconditioning and Reassembly
January 2001
9.2 Reassembly
Once the operator has been reconditioned and tted with new, well-lubricated seals,
proceed as follows:
1. Slowly lower the piston into the cylinder. A rubber mallet can be used to position
the piston into the cylinder, as there will be slight resistance caused by the seal
compression. Be careful not to damage the seal or back-up ring in this step.
2. Replace the upper head and tighten the head bolts using the standard criss-cross
torque method.
3. Replace the guide tube and ange assembly, retain ing bolts, and guide pin and
roller assembly.
4. If limit switches or trigger valves were removed, replace them at this point.
5. Rell the operator using the purging procedure as described on Section 5 of this
manual.
6. Re-install the operator to the valve as per Section 1 of this manual.
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
Figure 14
22
Reconditioning and Reassembly
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
Section: 10 Troubleshooting
It a particular problem should arise, it is wise to trouble shoot starting with the various
components of the sys tem, because most always the operator itself will be the last source
of trouble. In other words, it takes more man-hours to pull the head of an operator thought
to contain bad seals than it does to recondition the hydrau lic latch where the problem
really exists. The following are the problems that might arise, their causes, and what steps
to take to correct the situation.
10.1 Checklist
PROBLEM 1 Spongy, erratic, or faster than normal operation.
• PROBABLE CAUSE Lack of hydraulic uid in the operator.
• SOLUTION Purge the operator of all gas and foam and establish proper
oil levels as indicated in this manual in Section 5 and 7.
PROBLEM 2 Operator moves too slowly.
Section 10: Troubleshooting
January 2001
• PROBABLE CAUSE Speed controls, it existent, are pinched too far.
• SOLUTION Open speed controls to allow more ow.
• PROBABLE CAUSE Use of improper hydraulic uid.
• SOLUTION Refer to proper hydraulic uid tables in this manual on
Section 2.
• PROBABLE CAUSE Restriction of exhaust port of control.
• SOLUTION Check to make sure exhaust port is clear, and if exhaust is
manifolded away that tubing size or length does not cause
restriction and back pressure.
• PROBABLE CAUSE Restriction of power gas because of:
— Low gas pressure.
— Ice in system causing blockage.
— Dirt, grease, or contaminates in control strainers.
— Power gas connecting lines from pipeline to control too
small in diameter.
— Shafer control out of adjustment.
• SOLUTION Refer to the Shafer Poppet Block Control Installation,
Operation and Maintenance Manual.
PROBLEM 3 Operator will not move valve.
Tourbleshooting
• PROBABLE CAUSE Low power pressure or valve thrust requirements exceed
operator thrust output.
• SOLUTION Raise power pressure if possible, and re check the valve
thrust requirements. In some cases the manual hand pump
can be used to create more hydraulic pressure.
23
Section 10: Troubleshooting
January 2001
NOTE:
Valve body distortion, whether by pipeline force or thermal force, can cause the valve to
tighten either permanently or at certain times of the day.
• PROBABLE CAUSE Operator and valve are not in the same relationship.
• SOLUTION Check to insure that an open operator has been installed
on an open valve, If not, the operator will have to be
properly re-installed.
• PROBABLE CAUSE Valve is stuck.
• SOLUTION Remove the operator from the valve and use the hand
pump to stroke it. If the operator strokes independently
from the valve, consult the valve manufacturer.
PROBLEM 4 Operator drifts or creeps toward the open position, or if
the operator cannot be stroked when using the
hand pump.
• PROBABLE CAUSE Lack of hydraulic uid.
• SOLUTION Purge the operator of all gas and foam and establish proper
operating oil levels as per this manual in Section 5 and 7.
• PROBABLE CAUSE Malfunction of hand pump.
• SOLUTION Refer to the Shafer Manual Hand Pump Installation,
Operation and Maintenance Manual.
• PROBABLE CAUSE Malfunction of the hydraulic latch caused by leakage.
• SOLUTION Disassemble the latches, recondition all sealing surfaces,
and replace all seals and the neoprene poppet.
Reassemble the latch and re install.
• PROBABLE CAUSE Failure of operator piston seals.
• SOLUTION After all other factors have been elimi nated as the cause of
trouble, it is necessary to recondition the operator as per
this manual.
Installation, Operation and Maintenance Manual
LSM-01102001 Rev. A
24
Tourbleshooting
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