Installation, Operation and Maintenance ManualLSM-01102001 Rev. AJanuary 2001Shafer Linear Actuator

Installation, Operation and Maintenance ManualLSM-01102001 Rev. ATable of ContentsJanuary 2001Table of ContentsSection 1: Instructions1.1Valve Operation 11.1.1 The Steps for Proper Valve Preparation 11.1.2 Operator Preparation 21.1.3 Installation Procedure 21.1.4 Operation Position Adjustment 31.1.5 Customer Connections 5Section 2: Construction2.12.2Hydraulic Fluid Specifications 62.1.1 For Warm Weather: 20 F to 120 F 62.1.2 For Cold Weather: -40 F to 100 F 6Construction 7Section 3: Basic Operation3.1Operation 83.1.1 Sequence 1 83.1.2 Sequence 2 93.1.3 Sequence 3 10Section 4: Latches and Snubbers4.14.24.3The Hydraulic Latch 114.1.1 Purpose 114.1.2 Operation 114.1.3 Adjustment of the Latches 11Maintenance of the Latch 12The Hydraulic Snubber 12Section 5: Purging5.15.2Purging & Draining 14Purging Procedure 14Section 6: Draining6.1Draining Procedure 16Section 7: Proper Operating Oil LevelsSection 8: Disassembly8.18.2Table of ContentsDisassembly 19Disassembly Procedure 20I

Table of ContentsInstallation, Operation and Maintenance ManualJanuary 2001LSM-01102001 Rev. ASection 9: Reconditioning and Reassembly9.19.2Reconditioning 21Reassembly 22Section 10: Troubleshooting10.1 Checklist 23IITable of Contents

Installation, Operation and Maintenance ManualSection 1: Installation InstructionsLSM-01102001 Rev. AJanuary 2001Section: 1 Instructions1.1Valve OperationCAUTION:When a rising stem linear valve is under pressure, the pressure exerts an upward thrust onthe area of the valve stem. This upward thrust is counteracted by the yoke nut, thrustbearings, and manual gear housing. When these items are removed, there is nothing topre vent the valve stem from being forced upward, possibly causing valve damage orpersonal injury.It is for this reason, that if the valve is under pressure it must be placed in the full openposition 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 thevalve should the gate fall closed by its own weight.1.1.1The Steps for Proper Valve Preparation1.If the valve is pressurized, stroke it to the full open position. If the valve is notpressurized, 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.Installation Instructionsa.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 flange at "Y".f.Remove the stem nut and thrust bearings from the valve stem.g.Re-assemble the bearing housing to the yoke tube flange.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 extensionwill be supplied with an operator stem extension the same length as theyoke tube extension for proper mating.1

Section 1: Installation InstructionsInstallation, Operation and Maintenance ManualJanuary 2001LSM-01102001 Rev. A6.1.1.2Thoroughly clean and generously grease the valve stem and mounting flange.Operator Preparation1.All certified drawings, accessory parts, bolts, etc. are packaged inside of thecontrol box or attached to the operator or shipping crate.2.All operators are designed specifically for horizontal or vertical stem mounting, butnever for universal mounting.3.The operator must be suspended in the proper posi tion from a swivel-hookattached to the lifting device. The operator weight is equal to the valve size times100 pounds. For example: 18" valve x 100 pounds 1800 pounds.CAUTION:Do not use chains to suspend the operator.1.1.34.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 ona closed valve (non pressurized), use the manual hand pump to stroke the operatorclosed while observing the position indicator markings on top of the operator.Installation Procedure1.After the valve and operator have been properly pre pared, suspend the operatordirectly over the valve stem. The operator must be centered as near perfect aspossible and parallel with the valve stem.2.The female operator piston stem has approximately one inch of penetration beforethe 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 valvestem until the mount ing flanges meet.NOTE:Care should be taken not to push (on open valves) or pull (on closed valves) the valve stemor operator piston from their original positions.2Installation Instructions

Installation, Operation and Maintenance ManualSection 1: Installation InstructionsLSM-01102001 Rev. AJanuary 2001Figure 1Stem ProtectorManual GearHousingThrustBearingYoke Tube ExtensionTorque Tube (Remove)XBearing HousingYYoke Tube FlangeStem Stop Nut orDown Stop (Remove)Stem Nut (Remove)Thrust Bearings(Remove)TYPICAL VALVEPumpLatchSnubberGas Hydraulic TankExhaustExhaustShipping PlugsMtg. Brkt.1.1.4Operation Position Adjustment1.When the operator and valve flanges meet, it is possible that the control box doesnot 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 themounting flange holes are in alignment. This action will result in a gap be tweenthe operator and valve mounting flanges.3.If the operator was mounted on a closed valve, at this time hand pump theoperator fully open. Then using the lifting device, pull the operator and valve gate upuntil the gate is against its full open stops. If the gap between the flanges is greaterthan the distance of one complete turn of stem threads, turn the operator downuntil the flanges again meet, and then reposition the control as per step no. 2.Installation Instructions3

Section 1: Installation InstructionsInstallation, Operation and Maintenance ManualJanuary 2001LSM-01102001 Rev. A4.Loosely install the mounting bolts to maintain this desired position.5.To close the gap between the flanges, observe the following directions:For operators with a two-piece telescoping mounting bracket see A, for operatorswith 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 flange of thetelescoping bracket.——This action will allow the lower piece of the mounting flange to slide downand make con tact with the valve mounting flange.——Tighten the operator mounting bolts in a standard criss-cross patternapplying the same torque to each to prevent any misalignment.——Run the upper adjusting nuts (2) to within 1 /8" of the top of the middleflange.——Tighten the lower adjusting nuts ( 1) to the bot tom of the middle flangepulling the bracket to gether 1/8" until the upper (2) and lower ( 1)adjusting nuts are tightly sandwiching the middle flange.B.For one-piece non-adjustable mounting brackets:——Remove the indicator guide pin and roller assembly from the top of theposition indicator stem.——Remove the indicator guide tube retaining bolts and slide the guide tubeup and off of the posi tion indicator stem.——The top portion of the indicator is provided with a wrench hex. Graspthe is hex and turn the piston further onto the valve stem until the gap isclosed.NOTE:While turning the piston, gently hand pump the operator towards the closed position toeliminate any hydraulic pressure below the piston.6.4——Tighten the operator mounting bolts in a stan dard criss-cross patternapplying the same amount of torque to each to prevent misalign ment.——Replace the indicator guide tube, retaining bolts, and roller and guide pinassembly.Using the manual hand pump, stroke the valve fully open and closed. Measure andcompare the travel of the position indicator with the specified valve travel (whichis listed on the Certified Drawings) to insure that the valve is reaching its full end ofstroke posi tion with out overtravel.Installation Instructions

Installation, Operation and Maintenance ManualLSM-01102001 Rev. A1.1.5Section 1: Installation InstructionsJanuary 2001Customer Connections1.All electrical and control tubing connections are pointed out on the certifieddrawings and schematic drawings found in the job folder.NOTE:The exhaust ports must never be restricted through piping smaller than the pipe threadsize of the port on the junction block. On some of the larger gas-powered linear operatorsthere are two exhaust ports. These must never be manifolded together.Figure 2Operator Mtg. BracketValve Mtg. Flange21Operator Mtg. BracketATWO-PIECETELESCOPINGBRACKETInstallation InstructionsBONE-PIECENON ADJUSTABLEBRACKET5

Section 2: ConstructionInstallation, Operation and Maintenance ManualJanuary 2001LSM-01102001 Rev. ASection: 2 Construction2.1Hydraulic Fluid SpecificationsThe following tables show recommended hydraulic fluids for all Shafer Operators.2.1.1For Warm Weather: 20 F to 120 FAPI Gravity 31.1Viscosity at 210 F45.2 SSUViscosity at 100 F115. SSUViscosity at 0 F1600. SSUPour Point -50 FViscosity Index 150Flash Point 335 FFire Point 350 FBase PaParrafinInhibitors Rust-FoamOxidationColor 1Neutralization No. .072.1.2For Cold Weather: -40 F to 100 FAPI Gravity 32.8Viscosity at 210 F42.9 SSUViscosity at 110 F74. SSUViscosity at 0 F360 SSUPour Point -75 FViscosity lndex 225Flash Point 215 FFire Point 250 FBase PetroleumInhibitors Rust-FoamOxidationColor 16.5 (red)Neutralization No. .036Construction

Installation, Operation and Maintenance ManualSection 2: ConstructionLSM-01102001 Rev. A2.2January 2001Construction Simple, basic design with no power-absorbing gearing. Hydraulic piston principleprovides fast, smooth oper ation-without shock. Made from high quality steel plate, ground to precision tolerances. Composition seals and fiber wipers assure leakproof operation at high pressure. Low friction bearing surfaces are provided by a bronze coating on the pistondiameter and bronze bush ings in the heads. Piston is threaded to valve stem. Mounting bracket machined to fit 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 fluid used may affect opera tor movement and restrict handpump suction. For these reasons the above fluid specifications are re commended.(3) Do not use motor oils purchased at gasoline stations. Most motor oils contain sulfurwhich is corrosive, and other additives which will produce a varnish like coating onthe mirror-Iike interior of the operator.Construction7

Section 3: Basic OperationInstallation, Operation and Maintenance ManualJanuary 2001LSM-01102001 Rev. ASection: 3 Basic Operation3.1OperationThe operator may be powered by line pressure, stored gas pressure, or by a centralhydraulic system. Designed specifically for gate valve installations, Shafer Linear Operatorsfeature a special double latch for locking the valve into any desired position.3.1.1Sequence 1For this explanation the operator is shown fitted with gas hydraulic tanks and will bepowered by pipeline pressure. The operator is shown in the full open position with nopressure in the operator or tanks.Figure 3Valve Fully OpenVALVE FULLY OPENVALVE CLOSING8Basic Operation

Installation, Operation and Maintenance ManualLSM-01102001 Rev. A3.1.2Section 3: Basic OperationJanuary 2001Sequence 2Line pressure is admitted to the closing gas hydraulic tank, The pressurized hydraulic fluidflows out of the tank and under the poppet of the closing latch. The poppet is forced off ofits seat and allows the pressurized hydraulic fluid to flow to the top of the operator piston.A separate hydraulic line is ported to the opening latch. The pressurized hydraulic fluidenters under the piston of the opening latch which pulls the opening poppet off of its seat.As the pressurized hydraulic fluid forces the operator to the closed position, the fluid underthe operator pis ton is pushed out of the operator, through the opening latch, and into theVALVE FULLY OPENopening gas hydraulic tank.Figure 4Valve ClosingVALVE CLOSINGVALVE FULLY CLOSEDBasic Operation9

Section 3: Basic OperationInstallation, Operation and Maintenance ManualJanuary 20013.1.3LSM-01102001 Rev. ASequence 3When the operator reaches the fully closed position, the control will neutralize and allow allremaining line pressure to vent to atmosphere, thus neutralizing tank and operatorpressure.When the pressure is neutralized, the latches, being spring actuated, will automaticallyclose and lock the hydraulic fluid both above and below the operator pis ton. Because thehydraulic fluid is non-compressable,the operator will maintain the closed position.VALVE CLOSINGFigure 5Valve Fully ClosedVALVE FULLY CLOSED10Basic Operation

Installation, Operation and Maintenance ManualSection 4: Latches and SnubbersLSM-01102001 Rev. AJanuary 2001Section: 4 Latches and Snubbers4.1The Hydraulic Latch4.1.1PurposeAs previously stated the hydraulic latch is a means to lock hydraulic fluid both above andbelow 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 thevalve and operator open.4.1.2OperationThe latches can be unseated in three ways:Reference Figure using pipeline pressure to power the operator, the hydraulic fluid from thepressurized tank is ported to the bottom of the latch at I. The pressurized hy draulicfluid acting on the seating area of the poppet A forces the poppet off its seatallowing the hydraulic fluid to enter the operator from port II.2.Port III. is connected to port IV of the opposite latch. The pressurized fluid actingas a pilot on the latch pis ton pulls the opposite latch off of its seat allowing the fluidin the operator to flow to the non-pressur ized receiving tank.3.The latches act as relief valves should thermo-expan sion occur. The hydraulic fluidlocked between the operator and the latch when subjected to heat will increase inpressure. The pressure will continue to rise until the force created by this pressureacting on the difference in area between A and B, the area of the poppet stem, issufficient to overcome the force of the spring compression. The poppet will thenbe unseated allowing one or two drops of hydraulic fluid to relieve to the gashydraulic tank. When the pressure is relieved, the spring force will reseat thepoppet.Adjustment of the LatchesIt must be remembered then, that the spring compres sion must be sufficient 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 & Snubbers1.The minimum working power pressure from unseat ing the poppet when usingpower gas to stroke the operator.2.The pressure from thermo expansion from relieving, which could cause damage tothe operator.11

Section 4: Latches & SnubbersInstallation, Operation and Maintenance ManualJanuary 20014.2LSM-01102001 Rev. AMaintenance of the LatchNOTE:The spring cavity in the tops of the latches must be examined for condensation accumulationalways before freezing weather. If sufficient water freezes at this point, the latch will notfunction which will pre vent the operator from functioning in the automatic sequence.Reference Figure 6.4.31.The operator must always be in the open position before the latches can bedisassembled.2.Remove the adjusting screw cover 5.3.Measure and note the distance from the top of the latch head to the top of theadjusting 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 thepre-measured depth from step no. 3.The Hydraulic SnubberWedge type gate valves are supplied with a hydraulic snubber in the upper and lower headsof the operator. The purpose of the snubber is to reduce the speed of the operator andvalve mass so as to prevent the wedge from being jammed into the valve seats at the endof stroke. In the last 1 /2 inch of travel, the piston contacts the in ternal portion of the springloaded snubber. As the piston continues towards the