Valtek Auxiliary Handwheels

and Limit Stops

WARNING: Standard industry safety practices must
Table of Contents be adhered to when working on this, or any other,
Page process control product. Specifically, personal
1 General information protective and lifting devices must be used as
2 Installation warranted.
2 Side-mounted handwheels, size 25 and 50 Valtek control valves are often equipped with auxiliary
(linear actuators) handwheels of the continuously connected or push-only
3 Side-mounted handwheels, size 100 and 200 type, allowing for manual operation of the valve in case
(linear actuators) of air failure. Continuously connected handwheels can
6 Top-mounted, continuously connected hand- also be used as a limit stop to limit valve travel in either
wheels, Size 100 and 200 (linear actuators) the open or closed position. Push-only handwheels are
7 Top-mounted, push-only handwheels (linear designed to close the valve or limit opening. Limit stops
actuators) limit the actuator stroke in one direction or the other.
9 Declutchable handwheels (rotary actuators)
INSTALLATION
11 Push-only limit stops (linear actuators)
11 Pull-only limit stops (linear actuators) Valtek control valves, equipped with auxiliary hand-
wheels and limit stops, are installed as outlined in the
maintenance bulletin for each type of valve. Refer to the
GENERAL INFORMATION sales catalog or certified dimensional drawing for esti-
The following instructions are designed to assist in mated overhead clearance requirements. To allow for
installing, operating, performing maintenance and dis- manual operation and maintenance, adequate access
assembling handwheels and limit stops mounted on to the handwheel or limit stop must be provided.
Valtek spring cylinder actuators. Product users and
maintenance personnel should thoroughly review this SIDE-MOUNTED, CONTINUOUSLY
bulletin in conjunction with the Valtek Installation, Op- CONNECTED HANDWHEELS,
eration, Maintenance Instructions for Cylinder Actua- SIZE 25 AND 50 (Linear Actuators)
tors (IOM 2), prior to working on the handwheels and
limit stops. Operation
If air failure should occur, or if manual control of the
To avoid possible injury to personnel or damage valve is desired, the side-mounted, continuously con-
to valve parts, WARNING and CAUTION notes nected handwheel can be operated as follows:
must be strictly adhered to. Modifying this prod-
1. Set the three-way bypass valve (located on the
uct, substituting non-factory parts, or using main-
supply line to the positioner) to 'manual' to vent the
tenance procedures other than outlined could
air pressure from the actuator.
drastically affect performance, be hazardous to
personnel and equipment, and may void existing NOTE: Three-way valves are installed in the supply
warranties. line only when there is no lock-up system or volume
tank. On volume tank or lock-in-place systems, the

Rev. 6/93 Valtek No. 49015 © 1998 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 5-1
 4. Remove the internal retaining ring with a pair of
bypass valve is located between the top and bottom
internal snap-ring pliers.
cylinder ports.
5. Remove the handwheel screw shaft from the hand-
2. To open the valve, turn the handwheel counter-
wheel nut by turning shaft clockwise (the screw has
clockwise to retract the plug. left-hand threads). After the shaft is free from the
3. To close the valve, turn the handwheel clockwise to nut, pull the shaft and bearings straight out and
extend the plug. remove nut and crank levers from the housing.
4. To return the valve to automatic control, return the 6. After removing the support spacer, slide the two
handwheel nut to 'neutral' as shown by the hand- bearings and support washer (sandwiched between
wheel position indicator and set the three-way the bearings) off the handwheel screw shaft.
bypass valve to 'auto.'
5. Adjusting the handwheel nut to a position other than Reassembly
neutral provides a limit stop function, either limiting To reassemble the side-mounted handwheel on size 25
opening or closing. and 50 linear actuators:

Maintenance 1. Inspect all parts, especially the bearings, for dam-

age or wear; clean all parts and lubricate each
For proper operation of the handwheel, maintain a coat bearing.
of multi-purpose lubricant on the bearings at all times.
To do this: 2. Replace the bearings on the shaft in the following
order: bearing, support washer, bearing, support
1. Locate the two zerk fittings on the handwheel spacer.
housing. One fitting lubricates both bearings
simultaneously. NOTE: The bearings must be oriented with the
largest inside races (thrust supporting) facing each
NOTE: The screw and nut threads are permanently
other, with a support washer between them (refer to
Iubricated with a solid film lubricant, requiring no Figure 1).
additional Iubrication.
CAUTION: If the bearing orientation is incorrect,
2. Check all pivot points for wear and replace worn or
the bearings will be damaged.
damaged parts as necessary. Lubricate all pivot
points. 3. Position the handwheel nut between the two lever
cranks and reinstall the handwheel nut into the
3. Keep screw, nut and bearings free from dirt at all
housing. Make sure the position indicator pin on the
times. If dirt or grease builds up so that handwheel
nut is inserted in the position indicator slot.
operation is impaired, disassemble handwheel and
clean thoroughly. 4. Lubricate the small tip on the handwheel shaft and
mating hole in the housing. Reinsert the handwheel
Disassembly shaft into the housing and begin turning the screw
To disassemble the side-mounted handwheel assem- counter-clockwise into the handwheel nut. Con-
bly on size 25 and 50 linear actuators, refer to Figure 1. tinue to turn until the bearings are seated in the
housing and the nut is in the neutral position.
NOTE: Because of the handwheel’s modular design,
the handwheel assembly can be removed from the 5. Install the internal retaining ring to hold the bearings
actuator without affecting the valve’s operation (unless in the housing.
the handwheel is being used as a limit stop). 6. Replace the handwheel on the shaft, making sure
CAUTION: Prior to removing the handwheel unit, the Woodruff key is properly inserted in key slot.
ensure that the handwheel is not functioning as a 7. Fasten the handwheel securely in position with the
limit stop before removing the housing bolts. Fail- lock nut.
ure to do so could cause serious personal injury. If NOTE: If there is excessive movement ( 1/ 8-inch or
the actuator remains in service during handwheel more) when pulling on the handwheel screw, the
disassembly, keep hands and clothes away from bearings are positioned backwards and must be
moving parts to avoid injury. reversed (refer to Step 2) before bearing damage
1. Remove four housing bolts and lift handwheel as- occurs.
sembly off the yoke. 8. Lubricate and reinsert pivot pin and fasten with
2. Loosen the crank levers by removing two sets of retaining ring. Bolt the two sides of the crank levers
spacers, bolts and nuts fastening the levers to- together, using two sets of spacers, bolts and nuts.
gether. Remove one retaining ring from the pivot pin 9. Reattach the handwheel assembly to the yoke
and push the pin out. using four housing bolts. Make sure the slotted
3. Remove the lock nut, handwheel and Woodruff key ends of the lever cranks mate with the actuator
from the handwheel screw shaft. stem pin.

5-2 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 Handwheel
(Item No. 393-18)

Locking Bar Bearings

(Item No. 393-8)
(Item No. 393-17)
Internal Retaining
Ring Pin Support Washer
(Item No. 393-9) (Item No. 393-10)
(Item No. 393-1)

Support Spacer Housing

(Item No. 393-6) (Item No. 393-14)

Handwheel Housing Bolt

Screw Shaft (Item No. 333)
(Item No. 393-13)

Lock Nut Handwheel Nut

(Item No. 393-4) (Item No. 393-16)

Key Spacer (Item No. 393-7)

(Item No. 393-5) Nut (Item No. 393-3)
Bolt (Item No. 393-2)

Actuator Stem
Not Shown: (Item No. 211)
Grease Fittings
(Item No. 393-15) Pivot Pin Actuator Pin
(Item No. 393-19) (Item No. 372)
Indicator Plate
(Item No. 393-12) External Retaining Ring Crank Lever
(Item No. 393-20) (Item No. 393-11)
Indicator Plate Screws
(Item No. 401)

Figure 1: Size 25 and 50, Side-mounted, Continuously connected Handwheel

NOTE: Item numbers shown above correspond directly to valve’s bill of material. Refer to the bill of material for specific part numbers.

CAUTION: Avoid reattaching the handwheel as- necessary; however, periodically examine the hand-
sembly to the yoke while the actuator remains in wheel assembly:
service. If the actuator remains in service during 1. Check bearing wear by pulling on the handwheel. If
handwheel reassembIy, ensure that the movement more than 1/8 -inch in any one direction is
handwheel is in the neutral position and that present disassemble and inspect bearings.
hands and clothes are kept away from moving 2. Keep the handwheel mechanism free from dirt. If
parts to avoid injury. dirt begins to impair handwheel operation, disas-
SIDE-MOUNTED, CONTINUOUSLY semble and clean thoroughly.
CONNECTED HANDWHEELS, SIZE 100 Disassembly
AND 200 (Linear Actuators only) To disassemble the side-mounted handwheel on size
Operation 100 and 200 linear actuators, refer to Figure 2:
See 'Operation' under Size 25 and 50 Side-mounted 1. Depressurize the process line and actuator to at-
Handwheels section. mospheric pressure. Remove the actuator from
valve (see valve’s maintenance bulletin for instruc-
Maintenance tions). Disassemble cylinder by following steps 1-6
Because the screw threads are permanently lubricated under 'Disassembling Actuator' instructions found
with a solid film lubricant, periodical lubrication is not in IOM 2 (Cylinder Actuators).

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 5-3
 WARNING: Failure to repressurize process line 2. Insert upper actuator stem O-ring and replace
and actuator to atmospheric pressure could O-ring retaining washer and retaining ring.
result in serious personaI injury.
3. If the pinion shaft bearings have been removed,
2. Slide the stem clamp and bellows off the actuator press in two new bearings with a dowel of the same
stem. diameter, using a suitable press.
3. Remove the bolt holding the handwheel to the 4. To install the bevel gear and bearings, place the
pinion shaft. Slide handwheel off pinion shaft. handwheel housing upside down. Lubricate the
upper ball thrust bearing and place it in the housing,
4. Remove the housing set screw at the base of the
squarely on the machined shoulder.
handwheel housing and the retaining ring Iock
screw which releases the compression on the 5. Lubricate the bevel gear thoroughly on the teeth
handwheel housing retaining ring. and the outer surface where it makes contact with
the housing. Lubricate the inside of the square drive
5. Using two screwdrivers, remove the handwheel
tube. Position the bevel gear assembly into the
housing retaining ring.
housing.
6. Pull the handwheel assembly off the yoke, taking
6. Lubricate the pinion gear, shaft and thrust bearings.
care not to gall the actuator stem O-ring as it is
Reposition the pinion gear and thrust bearings.
pulled from yoke.
Slide the pinion shaft through the outside of the
7. With the cylinder and piston removed (Step 1), pull housing until it mates with the pinion gear. Rotate
actuator stem straight out of the housing. the shaft until the hole in the pinion gear aligns with
8. Remove the bearing spacer, lower bearing and the shaft. Insert pin and replace pin retaining ring.
handwheel nut from the actuator stem. 7. Screw the handwheel nut midway onto the actuator
9. To remove the pinion gear and shaft, remove the stem and insert the stem through the center of the
pin retaining ring, rotate the pinion shaft so the pin bevel gear. Be careful not to score the polished
will not hit the indicator gear bearing, and push the surfaces of the actuator stem.
pin out. Slide the pinion shaft out of the pinion gear 8. Position the wave spring on the shoulder of the
and housing. bevel gear. Lubricate the lower ball thrust bearing
10. Remove the bevel gear, wave spring and the upper and place it on the wave spring. Make sure the
thrust bearing. bearing fits into the step in the bevel gear with the
wave spring sandwiched in between. Replace the
11. If the pinion shaft bearings are worn or damaged, bearing spacer with the bearing fitting inside the
push them out with a suitable press and a dowel the spacer’s lip.
same size as the bearing’s outside diameter.
9. After replacing the lower actuator stem O-ring in the
12. Remove the upper actuator stem O-ring. (It is not yoke, insert the yoke into the housing, taking care
necessary to remove the O-ring retaining ring and not to gall the actuator stem on the stem bushings
O-ring retaining washer). or damage the O-ring.
13. The indicator cover plate is attached to the housing 10. Using two screwdrivers, replace the housing retain-
with an adhesive gasket. Gently pry it off. ing ring.
14. With a screwdriver, remove the two carriage screws 11. Rotate the housing to the desired orientation and
holding the position indicator assembly to the hous- screw-in the retaining ring Iockscrew and reinstall
ing. Remove assembly from housing. the housing setscrew until the retaining ring and
15. Normally the position indicator assembly does not housing are locked securely in place.
require disassembly. If disassembly is required, 12. Reinstall the handwheel and handwheel bolt onto
remove the inside stem retaining ring located on the the pinion shaft. Fasten securely with nut.
lower end on the indicator stem. Screw the stem out
of the indicator nut. 13. Reassemble the position indicator assembly by
inserting the indicator stem onto the carriage. Screw
the indicator nut into the stem. Replace the stem
Reassembly retaining ring. Turn the stem until the indicator nut
To reassemble the side-mounted handwheel on Size is centered between the two neutral marks stamped
100 and 200 Iinear actuators: on the carriage.
1. Replace and lubricate all O-rings with a silicone 14. Turn the handwheel counter-clockwise until the
lubricant (Dow Corning® 55M or equivalent). Clean actuator stem begins to retract. Turn the handwheel
all internal parts thoroughly before beginning clockwise for two complete turns, so that the hand-
assembly. wheel nut is in the neutral position.

5-4 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 Upper Ball Thrust Bearing
Housing O-ring
Cylinder Retaining Ring
Carriage Screw
Retaining Ring
Indicator Carriage
O-ring Retaining Washer
Indicator Cover Plate
Upper Actuator Stem
O-ring Indicator
Stem
Stem Bushing
Handwheel Housing
Indicator Nut
Square Drive Tube
Stem Retaining Ring
Handwheel Nut
Indicator Gear
Bevel Gear
Thrust Bearing
Wave Spring
Pinion Shaft Bearing
Lower Ball
Handwheel
Thrust Bearing
Bolt
Housing Setscrew
Pinion Shaft
Handwheel Housing
Retaining Ring Nut
Bearing Spacer Pin Retaining Ring
Stem Bushing
Actuator Stem Retaining Ring Lockscrew
Bellows Pinion Gear
Stem Clamp Lower Actuator Stem O-ring

Figure 2: Size 100 and 200, Side-mounted, Continuously connected Handwheel

NOTE: Refer to factory for valve’s bill of material item numbers.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 5-5
 NOTE: For correct neutral indication, it is important
Cap
to have the handwheel assembly in the neutral (Item No. 381)
position and the indicator nut between the neutral Stem Lock Nut
Gear Operator
marks before installing the indicator assembly in (Item No. 393) (Item No. 350)
the housing.
Cap Liner
15. With two carriage screws, reinstall the position (Item No. 374)
indicator assembly, making sure the indicator gear
Cap Extension
properly meshes with the pinion gear. Turn the (Item No. 387)
handwheel to the full open or closed position and
check for correct orientation; readjust if necessary. Stem Key Handwheel Screw
(Item No. 388)
With the new adhesive gasket, reattach indicator (Item No. 373)

cover plate. Gear Operator Bolts

(Item No. 334)
16. Replace the housing O-ring.
Bolt Gasket
17. Reattach the bellows and stem clamp to the yoke (Item No. 379) Pedestal Bolts
(Item No. 333)
and actuator stem. Pedestal
18. Reassemble the cylinder according to instructions (Item No. 389) Pedestal Gasket
(Item No. 378)
found in IOM 2. Spacer
(Item No. 383)
Spring Button
TOP-MOUNTED, CONTINUOUSLY Bushing (Item No. 227)
(Item No. 390)
CONNECTED HANDWHEELS Handwheel O-ring
Size 100 and 200 (Linear Actuators) Handwheel Stem (Item No. 276)
(Item No. 380)

Operation Stem Pin

Spring (Item No. 372)
(Item No. 229)
If air failure occurs, or if manual control of the valve is
Piston Piston Stem O-ring
desired, the top-mounted, continuously connected hand- (Item No. 272)
(Item No. 225)
wheel can be operated as follows:
Actuator Spacer Actuator Stem
1. Set the three-way bypass valve (located on the (Item No. 228) (Item No. 211)
supply line to the positioner) to 'manual' to vent the
air pressure from the actuator.
Figure 3: Top-mounted, Continuously
NOTE: three-way valves are installed in the supply
connected Handwheel
line only when there is no lock-up system or volume
NOTE: Item numbers shown above correspond directly to the valve’s
tank. On volume tank or lock-in-place systems, the bill of material. Refer to the bill of material for specific part numbers.
bypass valve is Iocated between the top and bottom
cylinder ports.
2. To open the valve, turn the handwheel counter- Disassembly
clockwise to retract the plug. Refer to Figure 3:
3. To close the valve, turn the handwheel clockwise to WARNING: Repressurize line and actuator to atmo-
extend the plug. spheric pressure before disassembling the hand-
4. To return the valve to automatic control, return the wheel or removing the actuator from the valve. Also,
handwheel nut to 'neutral' as shown by the hand- make sure the handwheel screw is in the neutral
wheel position indicator and set the three-way position before disassembly. Failure to do so can
bypass valve to 'auto.' The neutral position is indi- cause serious personal injury to occur.
cated when the top of the screw aligns with the red
line on the cap liner. NOTE: These instructions are for air-to-open only.
Instructions for the air-to-close design is the same with
5. Adjusting the handwheel nut to a position other than
one exception: Pedestal bolts are not used to compress
neutral provides a limit stop function, either limiting
the spring for air-to-close action; therefore, no spring
opening or closing.
tension is released.
Maintenance 1. The handwheel may be disassembled while mounted
Since the top-mounted, continuously connected hand- on the valve, or the actuator can be removed and
wheel is totally enclosed, there is generally no need for disassembled separately. If a change in the failure
periodic maintenance; however, disassembly may be action is required, the entire actuator subassembly
necessary if the mechanism fails. When reassembling must be removed before proceeding (See 'Disas-
the handwheel, be sure to thoroughly clean and lubri- sembling Actuator' in Maintenance Bulletin 1). The
cate the handwheel screw and drive nut with a multi- recommended procedure is to remove the actuator
purpose lubricant. subassembly from the valve.

5-6 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 2. Remove the handwheel cap and the handwheel cap 3. Place the gasket on the cylinder. Place the pedestal
extension. on top of the cylinder. Pedestal should align with
spring button or spring button spacer if used.
3. Loosen stem clamp and slide it off actuator stem.
NOTE: Check bolting alignment for proper hand-
4. Use a wrench on the actuator stem flats to secure
wheel orientation.
the position of the stem so it cannot rotate. Remove
the stem locknut. 4. Replace aluminum flat washers.
CAUTION: Damage to the seating surfaces of NOTE: To prevent air leaks, lightly coat the wash-
the plug and seat can result if the plug is allowed ers with a standard pipe sealant.
to rotate during removal of the stem locknut. 5. Reassemble pedestal bolts. Begin tightening the
5. Unbolt gear operator from pedestal. bolting in a manner that will keep the pedestal
square with the cylinder.
NOTE: Bolts are located on the pedestal under-
neath the gear operator. They are not the bolts WARNING: Failure to keep the pedestal square
located at the top portion of the gear operator itself. with the cylinder may result in damage to the
pedestal O-ring and bushing.
6. Lift off the gear operator, drive nut assembly and
handwheel screw. 6. Tighten the first bolt approximately one-quarter turn,
then tighten the bolt directly opposite one-quarter
7. Unbolt pedestal from the cylinder actuator. This will
turn. Continue tightening until sufficient gasket com-
relieve spring tension in the actuator (air-to-open
pression is applied to seal cylinder and pedestal
only).
tightly. This is necessary to prevent air leakage.
WARNING: Cylinder is spring loaded. Do not
7. Before applying air to the cylinder, make sure the
attempt to remove the handwheel pedestal bolts
cylinder retaining ring is installed properly. Feed air
without following Step 8 exactly. Failure to do
to bottom of cylinder to raise handwheel stem (air-
so can cause serious injury.
to-open only).
8. Remove the six pedestal bolts gradually to relieve
spring tension. This can be done by loosening the 8. Insert round end key into slot in handwheel stem.
first bolt approximately one-quarter turn, then loos- Remove air. Handwheel stem will retract (air-to-
ening the bolt directly opposite one-quarter turn open only).
until all bolts have been loosened and the spring 9. Place gear operator on flat surface with top of the
tension is relieved. operator facing down. Insert key in gear operator
NOTE: The bolts are long enough to relieve all drive nut. Install one set of roller thrust bearings in
spring tension prior to removing the pedestal. gear operator.
9. Remove the pedestal. 10. Align the key to the bevel gear key way and install
drive nut. Install second set of roller thrust bearings.
10. Lift out the spring button and spacer if provided (air-
to-open only). 11. Lubricate handwheel screw, and then screw (screw
is left-hand threaded) into the drive nut until screw
11. Remove cylinder retaining ring.
bottoms out.
12. Disassemble cylinder from yoke. CAUTION: Before completing the next step, be
13. Remove spring and spring button. sure not to allow assembled portion of the
14. Lift out piston, actuator stem and handwheel stem handwheel to drop out of the gear operator.
assembly. Failure to do so will cause the drive nut key to
drop out of place. Steps 9 and 10 will then have
CAUTION: Unless the piston stem O-ring (seal-
to be repeated.
ing the two cylinder air chambers) is leaking, do
not remove the handwheel stem from the actua- 12. Install pedestal gasket.
tor stem. It may be difficult to realign the stem 13. Take the gear operator and handwheel screw as-
pin hole while reassembling the handwheel stem. sembly and insert it on handwheel stem while
15. Remove piston, yoke, and pedestal O-rings. aligning stem key with slot in handwheel screw.
Make sure gear operator is flush with pedestal top.
Reassembly 14. Once the gear operator is flush with the pedestal,
Refer to Figure 3: replace bolts and tighten. Tighten the first bolt one-
1. Make sure all internal parts are thoroughly cleaned quarter turn, then tighten the bolt directly opposite
and lubricated before beginning assembly. Use one-quarter turn. Continue tightening all bolting
new O-rings and gaskets. (O-rings should be lubri- until gear operator and pedestal are firmly seated.
cated with a silicone lubricant such as Dow Corning 15. Install lock nut on handwheel stem, and screw on
55M or equivalent). handwheel cap extension.
2. Reassemble the cylinder actuator using the appro- 16. Insert gaskets and cap liner (sight glass) into hand-
priate actuator maintenance bulletin. wheel cap.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 5-7
17. Screw on handwheel cap until no movement can be Handwheel Stem Nut
(Item No. 348)
felt in the cap liner.
18. Tighten handwheel cap assembly.
CAUTION: Excessive tightening is not required.
This is not a pressure retaining seal. Bolt Gasket Handwheel
(Item No. 379) (Item No. 393)
Reversing Spring Action
Flange Handwheel Key
After following the disassembly of the actuator as (Item No. 389) (Item No. 370)
outlined, the spring action can be reversed as follows:
Handwheel Flange Gasket
1. Remove cylinder retaining ring, cylinder and spring. Stem O-ring (Item No. 378)
(Item No. 276)
2. Drive out the stem pin locking the handwheel stem Flange Bolt
to the actuator stem. Bushing (Item No. 333)
(Item No. 390)
3. Screw the handwheel stem off the actuator stem.
Make sure a wrench is used to prevent the actuator Handwheel
stem from rotating. Stem
(Item No. 380)
CAUTION: Damage to the seating surfaces of
the plug and seat can result if the plug is allowed
to rotate during removal of the handwheel stem.
4. Reinstall the actuator spacer on the opposite side of
the piston. Replace the piston stem O-ring during Figure 4: Top-mounted,
this step.
Push-only Handwheel
5. Screw the handwheel stem back into the actuator
NOTE: Item numbers shown above correspond directly to the
stem. Realign stem pin hole and reinsert stem pin. valve’s bill of material. Refer to the bill of material for specific part
6. Reassemble actuator with spring under the piston numbers.
for air-to-open (spring-to-retract). The spring should
be installed over the piston for air-to-close (spring-
to-extend). Make sure the actuator spacer is on the maintain a coat of multi-purpose lubricant on the screw
same side of the piston as the spring. at all times. To do this:
7. Reassemble by following the instructions in the 1. Turn the handwheel counter-clockwise until the
'Reassembly' section. handwheel runs out of threads and stops, exposing
NOTE: The spring button and spring button guide the full length of the screw.
are not used in the air-to-open configuration and 2. Clean and lubricate the exposed threads.
should be removed and set aside. When changing
to the air-to-close configuration, a spring button and Disassembly
spring button guide must be obtained from Flowserve Refer to Figure 4:
or from existing supply.
1. The handwheel assembly can be disassembled
TOP-MOUNTED, PUSH-ONLY while mounted on the valve, or the actuator can be
HANDWHEELS (Rotary Actuators Only) removed and disassembled separately (see the
valve’s maintenance bulletins for instructions).
Operation
WARNING: Repressurize line and actuator to
The push-only handwheel can be used to close the
atmospheric pressure before removing the ac-
valve or as a limit stop to limit valve opening:
tuator from the valve, or serious personal injury
1. If provided, set the three-way bypass valve on could result.
'manual' to vent air pressure to the actuator.
2. Rotate the handwheel counter-clockwise until the
2. Turn handwheel in a clockwise direction to extend handwheel runs out of threads and stops (neutral
the actuator stem and to lower the valve plug. position). This releases some of the spring com-
3. To return the valve to automatic control, turn the pression.
handwheel counter-clockwise until the handwheel WARNING: Cylinder is spring loaded. Do not
runs out of threads and stops (neutral position), and attempt to remove flange bolts without follow-
set the three-way valve on 'auto.' ing Steps 3 and 4 exactly or serious injury can
4. To limit the opening of the valve, move the hand- occur.
wheel from neutral to the desired limiting position.
3. Remove four of the six handwheel flange bolts,
Maintenance leaving two opposing bolts.
For proper operation of the handwheel, it is important to 4. Remove two remaining handwheel flange bolts

5-8 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 slowly and simultaneously, relieving the remaining Worm
(Item No. 397-10)
spring compression. The bolts are long enough to
relieve all spring compression prior to removing the Stem Pin
flange (as long as the handwheel is in the full (Item No. 397-14)
counter-clockwise position).
Thrust Roller
(Item No. 397-12)
WARNING: Make sure handwheel is in full
counter-clockwise position. Otherwise, serious Thrust Race Handwheel Gear
(Item No. 397-3)
injury may result when removing the flange (Item No. 397-13)
bolts. Stem Bushing
(Item No. 397-7)
Handwheel Stem
5. Lift the handwheel/flange assembly from the actua- (Item No. 397-2)
tor. Remove the flange gasket. Handwheel Key
(Item No. 397-17)
External
6. The actuator may now be disassembled according Retaining Ring
(Item No. 397-16)vva
to the valve’s or actuator’s maintenance bulletin. Handwheel
(Item No. 397-1)
7. If it is necessary to replace the handwheel stem O- Large External
ring, remove handwheel nut and handwheel. Retaining Ring
Handwheel Locknut (Item No. 397-20-3)
8. Screw the handwheel stem off flange and replace (Item No. 397-18)
O-ring. There is no need to replace the bushing. Clutch Handle Screw
Clutch Indicator (Item No. 397-1) (Item No. 397-20-5)
(Item No. 397-20-7)
Reassembly Cover Plate Bolt
Cover Plate (Item No. 397-8)
Refer to Figure 4: (Item No. 397-5)
Compression
1. Make sure all internal parts are thoroughly cleaned Clutch Shaft Spring
and lubricated before beginning reassembly. Use (Item No. 397-20-1) (Item No. 397-20-2)

new O-rings and gaskets (O-rings should be lubri- Small External Clutch Key
cated with a silicone lubricant, such as Dow Corning Retaining Ring (Item No. 397-6)
55 M). (Item No. 397-20-4)
Housing
2. Insert new handwheel stem O-ring. Reassemble Coupling (Item No. 397-9)
(Item No. 397-4)
handwheel assembly (if disassembled) by screw- Flanged
ing the handwheel stem into the flange. Replace the Transfer Case Shaft Bushing
handwheel, handwheel key and lock nut. (Item No. 204) (Item No. 50) (Item No. 397-15)

3. Reassemble the actuator using the valve’s or

actuator’s maintenance bulletin. Figure 5: Declutchable Handwheel
NOTE: Item numbers shown above correspond directly to the valve’s
4. Install a new flange gasket.
bill of material. Refer to the bill of material for specific part numbers.
5. Position the handwheel/flange assembly on the
actuator.
6. Using new bolt gaskets, install two opposing flange 4. To open, turn the handwheel counter-clockwise.
bolts and tighten evenly to compress spring. 5. To close, turn the handwheel clockwise.
7. Remount and tighten four remaining flange bolts. 6. To declutch the handwheel, rotate the handwheel
until there is little or no load on it. Pull the clutch
DECLUTCHABLE HANDWHEELS handle out and index it 90° until it seats in the clutch
(Rotary Actuators Only) indicator’s shallow slot.
NOTE: It will be difficult to pull out the clutch
Operation handle if the handwheel mechanism is transmit-
The declutchable handwheel used on rotary actuators ting torque.
can be operated as follows:
1. Set the three-way bypass valve to 'manual' to vent Maintenance
the air pressure from the actuator. Because the handwheel gearbox is packed with grease,
2. Engage the handwheel mechanism by rotating the periodic maintenance is not required; however, periodi-
clutch handle 90° and allowing it to be fully seated cally examine the handwheel:
in the clutch indicator’s deep slot. 1. Check for bearing and gear wear by pulling on the
3. Rotate the handwheel until the spring loaded clutch handwheel. If it gives more than 1/8 -inch in any one
key engages the handwheel gear. At this point the direction, disassemble and inspect the bearings
handwheel mechanism is fully engaged. and gears.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 5-9
 2. Keep the handwheel mechanism free from dirt. If 1. Clean all parts thoroughly before reassembling the
dirt begins to impair handwheel operation, disas- declutchable handwheel.
semble and clean thoroughly. 2. To reassemble the clutch assembly (if disas-
sembled), slide the clutch key onto the small end of
Disassembly the clutch shaft and secure with the small external
To disassemble the declutchable handwheel on rotary retaining ring. Install the compression spring over
actuators, refer to Figure 5: the shaft. Position the clutch indicator on the out-
1. It is not necessary to remove the valve from line to side of the cover plate. Slide the large end of the
disassemble handwheel, although it is important to clutch shaft through the clutch indicator from the
repressurize the line to atmospheric pressure. inside of the cover. Install the clutch handle and
WARNING: Failure to repressurize the line and large external retaining ring.
actuator to atmospheric pressure could result 3. Using a press, install new stem bushings (if removed).
in serious personal injury. 4. Using a press, install a new flanged bushing (if
2. Remove the four cover-plate bolts and slide the removed). Lubricate and reinstall the coupling. Note
handwheel assembly off the transfer case and that the coupling rotates inside the flanged bushing.
shaft. 5. Thoroughly lubricate the worm and handwheel gear.
3. Remove the two sockethead screws holding the Holding the worm engaged in the gear (as shown in
Figure 5), slide the handwheel gear onto the
clutch indicator to the coupling and remove the
coupling.
cover plate from the assembly.
6. Install a thrust bearing at each end of worm, making
4. If disassembly of clutch assembly is necessary,
sure roller is sandwiched between the two races.
remove large external retaining ring (use snap-ring
pliers) located on the clutch shaft by the clutch 7. Slide the handwheel stem through the stem bear-
ings and worm gear. Align pin holes in the worm
handle. Slide the clutch handle and clutch indicator
gear and stem, and drive pin into place.
off the shaft. Remove clutch shaft from the cover
plate and slide compression spring off of the shaft. 8. If the handwheel was removed from the stem, insert
Remove the small external retaining ring and the the handwheel key into its slot in the handwheel
stem. Slide the handwheel on and secure it with the
clutch key from the shaft.
handwheel locknut.
5. If it is necessary to remove the handwheel from the
9. Pack the entire inside volume of the handwheel
handwheel stem, remove the handwheel lock nut
housing with a multi-purpose grease.
and slide the handwheel and handwheel key off the
handwheel stem. 10. Rotate the coupling until its slot aligns with the slot
in the handwheel gear. Replace the cover plate,
NOTE: All stems use either an external retaining making sure the clutch key slides into the slots.
ring or a shoulder on the stem to hold the handwheel Rotate the clutch handle until it fits into the bottom
in place. The retaining ring does not require removal of the deep slot in the indicator and allows the clutch
except for replacement. key to engage the gear and coupling. If the key does
6. Drive the stem pin through the stem and worm gear not engage, rotate the handwheel back and forth
until it nearly touches the housing wall. Rotate the until it does. Rotate the clutch indicator until the two
stem 180° and pull out the pin with a pair of vice screw holes line up and the pointer points to the
grips or similar tool. stroke indicator scale. Fasten in place with the two
screws.
7. Slide the stem out of the assembly. Simultaneously
slide the handwheel gear off the coupling and CAUTION: Since the gear has limited rotation,
the splines on the shaft and coupling must be
remove the worm. Remove the two sets of thrust
correctly oriented. Incorrect alignment will re-
rollers and races. The two stem bearings should be
sult in limited handwheel rotation.
visually inspected for damage or wear. If removal of
the stem bushings is necessary, push them out 11. To correctly orient the splined shaft and coupling,
using a dowel of the same diameter and a suitable check to see if the valve is open or closed. If closed,
rotate the handwheel clockwise with the clutch
press.
engaged until the gear hits the stop. Next, slide the
8. Pull the coupling out of the housing. Inspect the handwheel assembly onto the splined shaft, mak-
flanged bushing for wear. If necessary, remove with ing sure the line on the end of the shaft lines up
an appropriate press and dowel. exactly with the closest line on the coupling. Rein-
stall the four cover plate bolts.
Reassembly 12. If the handwheel does not stroke the valve fully, the
To reassemble the declutchable handwheel on rotary splined shaft and coupling are not aligned correctly.
actuators, refer to Figure 5: Repeat Step 11.

5-10 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
 Jam Nut 6. Tighten the limit stop jam nut firmly against the
(Item No. 350)
locking stop hub.
Limit Stop Bolt
(Item No. 380)
Disassembly
Refer to Figure 6:
Limit Stop Hub
(Item No. 391)
WARNING: Repressurize line and actuator to atmo-
spheric pressure before disassembling the hand-
Hub Gasket wheel or removing the actuator from the valve, or
(Item No. 248)
serious personal injury could result.
1. The limit stop may be disassembled while mounted
on the valve, or the actuator can be removed and
disassembled separately (see the valve’s mainte-
nance bulletins for instructions).
O-ring 2. Vent air pressure on both sides of the piston.
(Item No. 376)
Loosen the limit stop jam nut and screw the limit
stop bolt counter-clockwise until it can be removed
from the limit stop hub. Remove the O-ring and jam
Spring Button
(Item No. 227)
nut from the limit stop bolt.
3. Screw the limit stop hub off the cylinder. Larger
sizes are designed with an internal flanged hub. If
Cylinder this is the case, remove the flange bolts. Remove
(Item No. 202) the gasket from the limit stop hub.
4. Actuator may now be disassembled according to
Maintenance Bulletin 2.
Reassembly
Refer to Figure 6 and proceed as follows:
1. Make sure all internal parts are thoroughly cleaned
Figure 6: Push-only Limit stop
and lubricated before beginning reassembly. Use
NOTE: Item numbers shown above correspond directly to the valve’s only new O-rings and gaskets (O-rings should be
bill of material. Refer to the bill of material for specific part numbers.
lubricated with a silicone lubricant, such as Dow
Corning 55 M). Reassemble the actuator according
PUSH-ONLY LIMIT STOPS to Maintenance Bulletin 2.
(Linear Actuators Only) 2. Install a new O-ring on the limit stop bolt and a new
gasket on the limit stop hub.
Operation
3. Screw the limit stop hub into the cylinder or on larger
The push-only limit stop is used to limit valve opening. sizes, reinstall hub and flange bolts.
To set the limit stop: 4. Make sure the end of the hub seats properly with the
1. Loosen the limit stop jam nut (see Figure 6). spring button. Tighten the limit stop hub (or flange
bolts) only enough to make an adequate air seal
2. To lengthen the stroke, screw the limit stop bolt
with the gasket.
counter-clockwise from the locking stop hub until
the desired position is reached. To shorten the 5. After installing the jam nut on the limit stop bolt,
stroke, screw the limit stop bolt clockwise into the screw the limit stop bolt into the limit stop hub until
locking stop hub until the desired position is reached. the desired position is reached.
6. Tighten the jam nut against the limit stop hub.
3. Tighten the limit stop jam nut firmly against the
locking stop hub.
PULL-ONLY LIMIT STOPS
Maintenance (Linear Actuators Only)
For proper maintenance of the limit stop, it is important Operation
to maintain a coat of multi-purpose Iubricant on the limit WARNING: The limit stop bolt and jam nuts are
stop bolt threads at all times. To do this: moving parts. Keep hands, hair or clothing clear
1. Vent air pressure on both sides of piston. during operation or serious injury can result.
2. Loosen the limit stop jam nut. The pull-only limit stop is used to limit valve closing. To
3. Extend the limit stop bolt until the entire length of the set the limit stop:
threaded portion is exposed. 1. Loosen the limit stop jam nuts (see Figure 7).
4. Clean and lubricate the threads. 2. Apply air under the piston until the limit position is
5. Return the limit stop bolt to desired position. reached.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 5-11
 3. Readjust the jam nuts until they are seated next to Jam Nut WARNING:
(Item No. 350) MOVING PARTS!
the limit stop flange. Tighten jam nuts securely KEEP HANDS CLEAR
against each other. Bolt Gasket
(Item No. 379)
Maintenance Flange Bolts
For proper maintenance, maintain a coat of multi- Flange (Item No. 333)
Gasket
purpose lubricant on the limit stop bolt threads at all (Item No. 378) Limit Stop
times. To do this: Flange
1. Apply air under the piston until the actuator is fully (Item No. 389)
retracted, exposing the bolt threads.
Limit Stop Bolt
2. Remove the limit stop jam nuts. (Item No. 380)
3. Clean and lubricate the threads.
4. Return limit stop jam nuts to the desired position. Limit Stop
Flange O-ring
5. Securely tighten the jam nuts against each other. (Item No. 276)

Disassembly Bushing
(Item No. 390)
Refer to figure 7:
WARNING: Repressurize the line and actuator to Cylinder
O (Item No. 202)
atmospheric pressure before disassembling the
limit stop or removing the actuator from the valve, Pin
or serious personal injury could result. (Item No. 372)

1. The limit stop may be disassembled while mounted C

Piston Stem
on the valve, or the actuator can be removed and O-ring
disassembled separately (see the valve’s mainte- (Item NO. 272)
nance bulletin for instructions).
2. Vent air on both sides of the piston.
3. Loosen and remove the limit stop jam nuts.
WARNING: Cylinder is spring loaded. Do not
attempt to remove the flange bolts without fol- Figure 7: Pull-only Limit Stop
lowing Steps 4 and 5 exactly or serious injury NOTE: Item numbers shown above correspond directly to the valve’s
bill of material. Refer to the bill of material or specific part numbers.
could occur.
4. Remove all but two opposing flange bolts and bolt
gaskets.
5. Remove the two remaining bolts slowly and simul- only new O-rings and gaskets (O-rings should be
taneously, relieving the remaining spring compres- lubricated with a silicone lubricant such as Dow
sion. The bolts are of sufficient length to relieve all Corning 55 M).
spring compression prior to releasing the flange. 2. Reassemble the actuator according to Maintenance
6. Lift the limit stop flange off the cylinder, taking care Bulletin 2. If the limit stop bolt is being replaced,
not to damage the limit stop bolt threads and replace the piston stem O-ring and screw the limit
bushing. Remove flange gasket from top of cylin- stop bolt and the actuator stem together. Realign
der. the pin hole and drive the stem pin firmly in place.
7. Remove the limit stop flange O-ring. Reassemble the cylinder and retaining ring accord-
ing to Maintenance Bulletin 2.
8. The actuator may now be disassembled according
3. Replace the limit stop flange O-ring. Install the
to Maintenance Bulletin 2.
flange and a new flange gasket on the cylinder.
9. Unless the limit stop bolt is to be replaced, do not
4. Using new bolt gaskets, install two opposing bolts-
remove the pin from the actuator stem, since re-
and tighten evenly to compress the spring.
aligning the pin hole in both pieces is difficult.
However, if it is necessary to replace the piston 5. Reassemble the four remaining bolts and bolt gas-
stem O-ring, drive the stem pin out and screw the kets. Tighten sufficiently to form a proper seal with
limit stop bolt off the actuator stem. the flange gasket and bolt gasket.
6. Apply air under the piston until the desired limit
Reassembly position is reached.
Refer to Figure 7: 7. Reinstall the limit stop jam nuts until they are seated
1. Make sure all internal parts are thoroughly cleaned against the limit stop flange. Tighten both jam nuts
and lubricated before beginning reassembly. Use firmly against each other.

5-12 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611