(AXAIM00010) KP 8/13/04 3:33 PM Page 1
Flowserve Corporation
Flow Control Division www.flowserve.com
Automax Valve Automation Systems
Installation, Operation and Maintenance Instructions
1350 N. Mountain Springs Parkway
Springville, Utah 84663-3004
Phone: 801 489 2233
1978 Foreman Dr.
Cookeville, TN 38501
Phone: 931 432 4021
Hydraulic Heavy Duty
Installation
1.
All actuators are factory lubricated for life, but still should be protected from the elements and stored indoors until ready for use. The ports of the actuator are plugged as supplied from the factory. If actuators are stored for a long period of time prior to installation, the units should be stroked every 3 months to prevent the seals from taking a set.
The Heavy Duty series actuators have travel stop adjustments in both clockwise and counterclockwise directions. The 12 degree overtravel feature provides adjustments from -6 to +96 degrees.
2.
Prior to assembly, manually open and close valve to insure freeness of operation. Be sure valve and
Automax Actuator rotate in same direction and are in same position, i.e. valve closed, actuator closed.
3.
Check mounting surfaces, stem adapter, and bracket to assure proper fit. Secure valve in closed position with stem vertical. Bolt bracket to valve and place stem adapter on valve stem. Position actuator over valve and lower to engage stem adapter to actuator shaft. Continue to lower until actuator seats on bracket mounting surface. To align bolt holes, it may be necessary to turn or stroke actuator a few degrees and/or adjust actuator travel stops. Bolt actuator to bracket.
4.
After consulting valve manufacturer’s recommendations, adjust travel stop bolts of actuator for proper open and closed valve positions.
Hydraulically stroke actuator several times to assure proper operation without binding of stem adapter.
If actuator is equipped with an Ultraswitch or other accessories, adjust them at this time.
5.
To prolong actuator life, use a petroleum based hydraulic oil, such as Mobil DTE 24. Consult factory for seal compatibility with other fluids. For normal temperature ranges (50
°
-110
°
F), use an oil with viscosity of 150 SSU at 100
°
F.
6.
Oil should be filtered with a minimum of 40
µ
filter, depending on other system components and environment.
Field Conversion from FCW to FCCW
(For Spring Return Actuators)
1.
Dismount actuator from valve.
2.
Apply hydraulic pressure to actuator and loosen Stop
Bolt Jam nut (17). Back off clockwise Stop Bolt (16) to remove spring preload.
3.
Remove hydraulic pressure from actuator.
4.
Support Spring Cartridge (11) and loosen all four
Spring Cartridge Nuts (41) evenly until all nuts are loose. The spring cartridge does not have to be removed.
5.
Remove Position Indicator (44) or any other accessories that may be on output shaft.
6.
Remove Bearing Retainer Screws (14) from valve mounting side, and slide Retainer Plate (13) off shaft.
7.
The Torque Shaft (20) may now be tapped out of
Housing (1) using a soft faced hammer. Use care not to drop shaft or Bearing (12) when they come out.
8.
Rotate Torque Shaft (20) end for end and reinstall into Yoke (4), using care to line up shaft with Bearing
(12) on opposite end. Push shaft through until shaft bottoms out. Hand pressure only should be needed to reinstall shaft.
9.
Reinstall Bearing (12) into housing, ensuring that it is flush with top of housing.
10.
Reinstall Bearing Retainer Plate (13) and Screws (14) ensuring that Gasket (37) is in place.
11.
Tighten Spring Cartridge Nuts (41) evenly until all four are evenly tightened. See bolt torque chart below.
12.
Apply hydraulic pressure to actuator and reset Stop
Bolt (16). Never adjust stop bolt against spring force.
13.
Reinstall any accessories or position indicator onto
Torque Shaft (20).
14.
Check actuator for proper operation.
Travel Stop Adjustments
All actuated valving requires accurate travel-stop adjustments at both ends of stroke to obtain optimum performance and valve seat life. Accumulation of tolerances in adaption of actuators to valves is such that there must be a range of adjustments for both ends of stroke to achieve expected performance.
FCD AXAIM00010-00 (AUTO-10) 08/04
© 2004, Flowserve Corporation, Printed in USA
Page 1 of 4
© TriCom, Inc., 2004, All Rights Reserved.
(AXAIM00010) KP 8/13/04 3:33 PM Page 2
Flowserve Corporation
Flow Control Division www.flowserve.com
MAINTENANCE INSTRUCTIONS
Automax Valve Automation Systems
Installation, Operation and Maintenance Instructions
1350 N. Mountain Springs Parkway
Springville, Utah 84663-3004
Phone: 801 489 2233
Disassembly Procedures
1.
Disconnect all hydraulic and electrical supplies from actuator.
2.
Remove all accessories from actuator and dismount from valve.
Spring Group
Note: Personal Injury may result if Step 2 is attempted before Step 1 is completed.
1.
Apply hydraulic pressure to the cylinder to release spring pressure from Stop Bolt (16).
Remove both Stop Bolts (16) and remove hydraulic pressure. This will relieve majority of spring load.
2.
The Spring Cartridge (11) is welded as an integral component and cannot be disassembled.
To remove from actuator remove Spring Cartridge
Nuts (41) and Lockwashers (42). At this point all spring forces are contained within welded cartridge and spring may be removed from body.
Note:Support Spring Cartridge (11) during removal so as not to damage Piston Rod (3).
Pressure Group
Note: Rod pusher pressure group will not have a piston. Step 3 is not applicable.
1.
Remove Tie Rod Nuts (28), Tie Rods (27), and
Endcap (29).
2.
Slide Cylinder (23) over and off Piston (24), being careful not to scratch or dent honed and chrome plated surface of cylinder (23).
3.
Remove Piston Bolt (25), Piston Bolt
Lockwasher (26), Piston (24), and Piston Face
Seal (32).
4.
Remove Adapter Bolts (43) and carefully slide the Adapter (22) over the Piston Rod (3).
Note: A double acting actuator will have a rod pusher pressure group on the opposite side of the main pressure group (in place of spring cartridge). Follow disassembly procedure as above, skipping step 3.
Housing (Body Group)
1.
Unscrew Inspection Cover Screw (9) with Lockwashers (10) and remove Cover (8) and Cover
Gasket (35).
Note: Prior to disassembly of remainder of Body
Group visually check inspection opening to
determine whether further disassembly is necessary. If Yoke (4), Yoke Pin (5), and Yoke
Rollers (6) are in good condition, do not disassemble further.
FCD AXAIM00010-00 (AUTO-10) 08/04
© 2004, Flowserve Corporation, Printed in USA
1978 Foreman Dr.
Cookeville, TN 38501
Phone: 931 432 4021
2.
To remove Piston Rod (3) and Piston Rod Bearing (2), center Yoke in mid- or 45 degree position.
R2 actuators: To remove the Yoke Pin Retainers (7), use snap ring pliers with 90
°
tips. Access snap rings through inspection cover opening. Turn
Piston Rod (3) to remove Yoke Pin Rollers (6) and
Yoke Pin (5) through inspection cover opening.
R3 and R4 actuators: Remove both freeze plugs located in Housing near Bearing Retainer (13).
Through these openings, both Yoke Pin Retainer
Rings (7) can be removed. Yoke Pin Rollers (6) can be slipped off Yoke Pin (5). Push Yoke Pin (5) through Piston Rod (3) and out opening in other side of Housing (1).
3.
Unscrew Bearing Retainer Bolts (14) and remove
Bearing Retainer (13), Retainer Gasket (37), and
Torque Shaft Seal (38) from valve mounting side of actuator.
4.
Remove Torque Shaft (20) by tapping with a softfaced hammer. Use care not to drop shaft or
Bearing (12) as they come out. After removal of
Torque Shaft (20) repeat step 3 on accessory side.
Reassembly Procedures
1.
Inspect all parts for wear and replace any worn parts as needed. Normally all seals and gaskets should be replaced when reassembling an actuator.
2.
Clean and grease all components with a multipurpose
“polymer” fortified grease such as DuBois Chemical
MPG-2. (Different greases may be required for low or high temperatures; consult factory).
3.
Reverse the disassembly procedures to reassemble.
Use the proper torque from the torque chart on the Tie
Rod Locknuts (28), the Adapter Bolts (43), the Spring
Cartridge Nuts (41), and the Piston Bolt (25). These threads should be lubricated with Locktite
Threadlocker 242 or equivalent prior to assembly.
4.
See attached drawing which depicts all required spare parts.
5.
Test the actuator for smooth operation and hydraulic leakage at service pressure before re-installing.
Page 2 of 4
© TriCom, Inc., 2004, All Rights Reserved.
(AXAIM00010) KP 8/13/04 3:33 PM Page 3
Flowserve Corporation
Flow Control Division www.flowserve.com
Automax Valve Automation Systems
Installation, Operation and Maintenance Instructions
1350 N. Mountain Springs Parkway
Springville, Utah 84663-3004
Phone: 801 489 2233
1978 Foreman Dr.
Cookeville, TN 38501
Phone: 931 432 4021
MODEL A DA SR05 SR07 SR10 SR12 SR15
R2HR 19.50
19.50
29.00
30.00
30.00
32.00
38.00
R2HP 20.50
19.50
30.00
32.00
38.00
40.00
41.00
R3HR 21.00
21.00
34.00
34.00
36.00
39.00
38.00
R3HP 22.00
21.00
34.00
36.00
38.00
41.00
43.00
R3HM 23.00
21.00
36.00
38.00
41.00
44.00
45.00
R3HL 23.00
21.00
39.00
41.00
44.00
45.00
N/A
R4HR 28.50
28.50
N/A 50.00
56.00
59.00
55.00
R4HP 31.00
28.50
50.00
56.00
59.00
55.00
56.00
R4HM 31.00
28.50
56.00
55.00
56.00
57.00
59.00
R4HL 33.00
28.50
59.00
56.00
57.00
59.00
N/A
B
SR17 SR20
38.00
38.00
41.00
N/A
42.00
41.00
44.00
45.00
45.00
N/A
N/A N/A
55.00
56.00
56.00
58.00
59.00
N/A
N/A
N/A
SR22
40.00
N/A
43.00
45.00
N/A
N/A
56.00
59.00
N/A
N/A
SR25 C D E F DA
41.00
5.00
0.00
1/4 7.19
5.00
N/A 5.00
0.50
1/4 7.19
5.00
44.00
5.50
0.00
3/8 8.19
6.75
N/A 6.00
0.00
3/8 8.19
6.75
N/A 6.50
0.00
3/8 8.19
6.75
N/A 7.13
0.00
3/8 8.19
6.75
58.00
6.50
1.00
3/8 10.56
7.19
59.00
7.00
1.00
3/8 10.56
7.19
N/A 7.50
1.00
3/8 10.56
7.19
N/A 8.00
1.00
3/8 10.56
7.19
Notes:
1.
Actuator is shown in full
Clockwise position.
2.
Double Acting: Pressure at Port DA1 will result in CW rotation. Pressure at
Port DA2 will result in CCW rotation.
Spring Return: Pressure at Port DA2 will result in CW rotation. Spring provides
CW rotation upon loss of supply pressure.
∅
G
MODEL SR05 SR07 SR10 SR12 SR15 SR17 SR20 SR22 SR25 H J K L Vol.
R2HR 9.13
9.13
9.13
9.13
9.13
9.13
9.13
9.13
9.13
3.00 3.25 2.78 5.75 11
R2HP 9.13
9.13
9.13
9.13
9.13
9.13
9.13
9.13
9.13
3.00 3.25 2.78 5.75 19
R3HR 13.25 13.25 13.25 13.25 13.25 13.25 13.25 13.25 13.25 3.00 4.13 4.44 6.81 30
R3HP 13.25 13.25 13.25 13.25 13.25 13.25 14.63 14.63
N/A 3.00 4.13 4.44 6.81 42
R3HM 13.25 13.25 13.25 13.25 14.63 14.63
N/A N/A N/A 3.00 4.13 4.44 6.81 58
R3HL 13.25 13.25 14.63 14.63
N/A N/A N/A N/A N/A 3.00 4.13 4.44 6.81 75
R4HR N/A 14.63 14.63 16.63 16.63 16.63 16.63 16.63 16.63 4.50 5.82 6.50 9.75 87
R4HP 14.63 14.63 16.63 16.63 16.63 16.63 16.63 16.63
N/A 4.50 5.82 6.50 9.75 113
R4HM 14.63 16.63 16.63 16.63 16.63 16.63
N/A N/A N/A 4.50 5.82 6.50 9.75 177
R4HL 16.63 16.63 16.63 16.63
N/A N/A N/A N/A N/A 4.50 5.82 6.50 9.75 255
“Vol.” is Swept volume (in 3 )
BOLT TORQUE
Piston Bolt (25) (SAE Grade 8 Bolt)*
Actuator Size
R2HP
Bolt Size
3/4”-10 UNC
Torque Range
271-320 ft.lb.
R3HP,R3HM,R3HL 1 1/4”-7 UNC 537-591 ft.lb.
R4HP,R4HM,R4HL 1 1/4”-7 UNC 1014-1116 ft.lb.
*Not present in rod pusher actuators
Tie Rod (27) (A311 Stressproof Rod)
Actuator Size
R2HR,R2HP
R3HR-R4HL
Bolt Size
5/8”-11 UNC
3/4”-10 UNC
Torque Range
117-130 ft.lb.
207-229 ft.lb.
Adaptor Bolt (43) (SAE Grade 5 Bolt)
Actuator Size
R2HR,R2HP
R3HR-R4HL
Bolt Size
5/8”-11 UNC
3/4”-10 UNC
Torque Range
123-136 ft.lb.
217-240 ft.lb.
Spring Cartridge Stud (ASTM A193 Grade B7)
Actuator Size
R2HP
R3HR-R3HL
R4HR-R4HL
Bolt Size
1/2”-13 UNC
3/4”-10 UNC
1”-8 UNC
Torque Range
64-71 ft.lb.
226-249 ft.lb.
546-603 ft.lb.
FCD AXAIM00010-00 (AUTO-10) 08/04
© 2004, Flowserve Corporation, Printed in USA
Page 3 of 4
© TriCom, Inc., 2004, All Rights Reserved.
(AXAIM00010) KP 8/13/04 3:33 PM Page 4
Flowserve Corporation
Flow Control Division www.flowserve.com
Parts and Materials
Automax Valve Automation Systems
Installation, Operation and Maintenance Instructions
1350 N. Mountain Springs Parkway
Springville, Utah 84663-3004
Phone: 801 489 2233
1978 Foreman Dr.
Cookeville, TN 38501
Phone: 931 432 4021
Note: Spring Cartridge is replaced by rod pusher pressure group on DA actuator.
10
11
12
7
8
9
Item
1
2
3
4
5
6
Description
Housing
Piston Rod Bearing
Piston Rod
Yoke
Yoke Pin
Yoke Pin Roller
Yoke Pin Retaining Ring
Inspection Cover
Inspection Cover Screw
Inspection Cover Lockwasher
Spring Cartridge/Rod Cover Gp
Torque Shaft Bearing
16
17
18
13
14
15
Bearing Retainer Plate
Bearing Retainer Screw
Bearing Retainer Lockwasher
Stop Bolt
Stop Bolt Jam Nut
Stop Bolt Washer
19
20
Yoke Key
Torque Shaft
21* Piston Rod Seal
22
23
Adapter
Cylinder
Material
Ductile Iron
Bronze
Qty.
1
2
Steel/Chrome 1
Ductile Iron
Steel
Steel
1
1
2
Steel
Steel
Steel
Steel
Steel
Steel
6
1
2
2
1
6
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Molythane
Steel 1
Steel/Chrome 1
1
1
1
2
2
2
2
8
8
*Recommended Spare Parts
**Not present in rod pusher pressure group
FCD AXAIM00010-00 (AUTO-10) 08/04
© 2004, Flowserve Corporation, Printed in USA
Item Description
24 Piston
25 Piston Bolt
26 Piston Bolt Lockwasher
27 Tie Rod
28 Tie Rod Locknut
29 Endcap
30* Pressure Cylinder Seal
31* Piston Cylinder Seal
32* Piston Face Seal
33* Adapter Bolt Thread Seal
34* Adapter Gasket-Pressure Side
35* Inspection Cover Gasket
36 Breather Plug
37* Bearing Retainer Gasket
38* Torque Shaft Seal
39* S.C./Rod Cover Gp Gasket
40 Bolt (Rod Cover Gp) DA only
41 S.C./Rod Cover Gp. Nut
42 S.C./Rod Cover Gp. Lockwasher
43 Adapter Bolt-Pressure Side
44 Position Indicator
45 Position Indicator Bolt
46 Position Indicator Lockwasher
Bronze
Fiber
Nitrile
Fiber
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Material
Steel
Steel
Steel
Steel
Steel/Nylon
Steel
Nitrile 2
Molythane 1**
Nitrile 1
Nitrile/Steel
Fiber
Fiber
4
1
1
Qty.
1**
1**
1**
4
4
1
4
4
1
4
4
1
2
2
1
2
2
Seal Kits
Buna/Molythane - R(Actuator Base Model No.)SKB
Viton/Fluoromyte - R(Actuator Base Model No.)SKV ie: Buna Seal Kit for R3HRDA is R3HRSKB
Temperature Ratings
Standard- Buna/Molythane -25
°
F to 180
°
F
High Temperature - Viton/Fluoromyte 0
°
F to 300
°
F
Note: These temperature ranges are for seals only. Hydraulic fluid temperature limitations may apply. Consult hydraulic fluid supplier.
Page 4 of 4
© TriCom, Inc., 2004, All Rights Reserved.
