OPERATION AND MAINTENANCE MANUAL, WECO 300 AND 500

Transcription

Doc No: OMM50001912
Rev: A Page 1 of 39
OPERATION AND MAINTENANCE MANUAL, WECO 300 AND 500
SERIES DOUBLE-ACTING AND SPRING-RETURN TYPE AIR
PNEUMATIC ACTUATORS
Rev
ECN No.
Date
Reviewed By
Approved By
Status
A
5026450
04-APR-2011
Darby, Scott A.
Douglas, Don
RELEASED
Summary:
This document covers the safe operation, maintenance, and repair of the Weco® 300
and 500 series double-acting and spring-return type air pneumatic actuators.
Subject to contractual terms and conditions to the contrary, this document and all the information contained herein are the confidential and exclusive
property of FMC Technologies, and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by FMC.
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Table of Contents
Section
Title
Page
1.0
Warnings ...................................................................................... 3
2.0
Operating Instructions ................................................................ 6
2.1
Required Tools .............................................................................. 6
2.2
Mounting Actuator ......................................................................... 6
2.3
Dismounting Actuator .................................................................. 13
2.4
Operating Instructions ................................................................. 13
3.0
Maintenance Instructions ......................................................... 14
3.1
Routine Maintenance .................................................................. 14
3.2
Required Tools and Lubricants for Assembly &
Disassembly .............................................................................. 15
3.3
Disassembly ................................................................................ 15
3.4
Repair and Parts Replacement ................................................... 17
3.5
Repair Kits ................................................................................... 17
3.6
Double-Acting Models Assembly Procedure ............................... 18
3.7
Spring-Return Models Assembly Procedure................................ 28
4.0
Functional Testing .................................................................... 38
5.0
Storage Instructions.................................................................. 39
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Operating and Maintenance Manual
1.0
Warnings
FMC cannot anticipate all of the situations a user may encounter while installing and
using FMC products. Therefore, the user of FMC products MUST know and follow all
applicable industry specifications on the safe installation and use of these products.
Refer to the FMC product catalogues, product brochures and installation, operating and
maintenance manuals for additional product safety information or contact FMC at 800772-8582.
Failure to follow these safety warnings could result in death, serious
personal injury, and/or severe property damage.
WARNING
1. Never mix or assemble components or parts with different pressure ratings.
Mismatched conditions may fail under pressure resulting in death, serious
personal injury or severe property damage.
2. Never use or substitute non FMC components or parts in FMC products or
assemblies.
3. Never modify or repair FMC products in a manner not specifically directed in
instructions published by FMC Technologies.
4. Never strike, tighten, loosen or attempt repairs on pressurized components or
connections.
5. Never exceed the rated working pressure of the product.
6. Complete and proper make-up of components and connections is required to
attain rated working pressure. Always apply essential care, attention, handling
and inspection to threaded components before, during and after make-up.
7. Never use severely worn, eroded or corroded products. Contact FMC
Technologies for more information on how to identify the limits of erosion and
corrosion.
8. Always follow safe practices when using products in overhead applications.
Products not properly secured could fall.
Never exceed the load rating of lifting devices on products or lifting
equipment.
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9. Always follow safe practices when manually lifting and carrying products.
10. Always select only appropriate product and materials for the intended service.
11. Always follow manufacturer’s instructions and Material Safety Data Sheet
directions when using solvents.
12. Always make certain that personnel and facilities are protected from residual
hazardous fluids before disassembly of any product.
13. Whenever leakage is detected from FMC Technologies products, remove them
from service immediately to prevent death, serious personal injury, and/or
property damage.
SAFETY INSTRUCTIONS: The applications of FMC products are in working
environments and systems which must be properly designed and controlled. Safety
procedures and policies MUST be clearly established by the user and followed. Always
use appropriate protective equipment.
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Double-Acting Type Air Pneumatic Actuator
Spring-Return Type Air Pneumatic Actuator
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2.0
Operating Instructions
Do not connect air supply to actuator until actuator is completely
installed and secured to the equipment.
WARNING
Disconnect air supply from actuator before attempting to disconnect
actuator from the equipment or remove any components.
WARNING
Use Weco® air pneumatic actuators for operating equipment in the full
open and full closed positions only.
NOTE
Weco® 300 and 500 series air pneumatic actuators were designed so that the
mounting surface on the actuators mates with either Weco® butterfly valves or plug
valves. The following instructions provide detail on installing and dismounting the
actuators. It is preferred to mount an actuator with the shaft in the horizontal position
and the air inlet ports facing down to allow any air condensation to be flushed from
the actuator with each actuation cycle. It is also recommended to supply the actuator
with lubricated and filtered dry air to prevent condensation from entering the actuator.
2.1
Required Tools
Adjustable wrenches and open ended wrenches
2.2
Mounting Actuator
1. Locate retainer attached to the actuator housing and
remove the four hex head cap screws and lock washers
from the housing. Remove the retainer from the housing.
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Cap Screws &
Lock Washers
Retainer
2. Position retainer so that the flat side faces the mounting
surface on the equipment and the raised face is pointing
away from the equipment.
For butterfly valves, rest retainer on flange and align holes of retainer with
holes on flange.
Raised Face
Butterfly Valve Stem
Flange
For plug valves, rest retainer on mounting bracket and align holes of retainer
with holes on bracket.
Mounting Bracket
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3. Select best mounting position of the actuator for the
application or placement in the flow line. The actuator can
be mounted in one of the four following graphics:
4. Position actuator so that the side with the retainer removed
now faces the equipment and will receive the raised surface
of the retainer.
For butterfly valves, mount actuator over upper stem of valve so that the
square hole of the actuator shaft receives the square stem of the valve.
Make certain the housing is flush with the retainer and the holes of the
housing are aligned with the holes of both the retainer and the flange.
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Actuator Shaft
Retainer
Cap Screws & Lock Washers
For plug valves, mount actuator onto bracket so that the square hole of the
actuator shaft receives small mounting stem on plug valve. Make certain the
housing is flush with the retainer and the holes of the housing are aligned
with the holes of both the retainer and the mounting holes on the bracket.
Cap Screws &
Lock Washers
5. Install the lock washers onto the cap screws then insert the
cap screws through either the flange or the mounting
bracket and fasten to the actuator. Apply torque to the cap
screws until the lock washers are flat.
6. Remove the components of the actuator mounting kit.
Install small O-ring into groove on the bottom side of the
indicator.
7. Place large O-ring onto face of actuator housing.
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8. Position indicator so that the raised boss and the letters are
facing upward and the side with the small O-ring is facing
down towards the square hole of the actuator shaft.
9. Orient and align the raised boss of the indicator with the
appropriate direction of the equipment.
For butterfly valves, orient raised boss with V-slot on top of the square stem
on the valve. This will require looking into the square hole of the actuator
shaft to locate the V-slot.
Large O-ring
Raised Boss
Butterfly Valve Stem
V-Slot
For plug valves, orient raised boss with the bore of the plug. If the plug valve
is not connected to any equipment or is free from a flow line, simply align the
raised boss with the direction of the bore of the plug inside the valve. If the
plug valve is connected to equipment or installed in a flow line, align raised
boss with the bottom slot on the mounting adapter on top of the plug stem.
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Mounting Stem
Mounting
Bracket
Mounting
Adapter
Raised Boss
Bottom Slot
10. Insert indicator into square hole of actuator shaft. If
necessary, stretch large O-ring so that the indicator rests
on face of actuator housing.
11. Place lock washer on top of square on indicator.
12. Thread the 2 hex nuts onto threaded stud about 1-inch from
end of stud. Install acorn nut onto same end of stud as hex
nuts.
13. Run free end of stud through lock washer into hole of
indicator and thread into tapped hole of stem. Continue
threading stud until it bottoms out in tapped hole.
14. Thread bottom hex nut down until it shoulders against lock
washer.
15. Thread top hex nut down until it shoulders against bottom
hex nut.
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16. Using wrench on each hex nut, torque hex nuts together
with no more than 100 in-lbs of torque to prevent the nuts
from backing off.
17. Make certain acorn nut is secured onto stud. Optional
thread locking compound such as Loctite® can be applied
to internal threads of acorn nut prior to installation.
Hex Nuts
Acorn Nut
Lock Washer
Threaded Stud
Square on
Indicator
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2.3
Dismounting Actuator
1. Using wrench, connect to bottom hex nut on stud on the
actuator mounting kit to unthread stud from stem. Once
free from stem, remove stud from indicator.
2. Remove lock washer from top of indicator.
3. Un-torque hex nuts from each other. Thread top hex nut
towards acorn nut then do the same for the bottom hex nut.
Do not remove hex nuts or acorn nut from stud.
4. Pull indicator out of actuator shaft.
5. Remove large O-ring from housing. Set aside all
components of actuator mounting kit.
6. Remove the 4 cap screws and lock washers that secure the
actuator to the equipment.
7. Pull actuator off equipment.
2.4
Operating Instructions
Once the actuator is connected to the equipment, a check should be made to verify
the actuator operates properly. This can be accomplished by attaching air supply
lines to the actuator. For double-acting models, an air supply line should be
connected to both air inlet ports. For spring-return models, one air supply line should
be connected to the single air inlet port in the cylinder head.
Once air supply has been connected to the actuator, inject 60-80 psi through one air
supply line to activate the piston inside the actuator. While operating the actuator,
listen for the sound of the piston cycle from one position to the other. If actuator does
not operate or sounds as if there is a major leak, shut off air pressure to actuator and
remove actuator from equipment then proceed to investigate per the maintenance
instructions.
The following tables list the air supply line maximum operating pressure:
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Actuator Model
Model Type
FMC Part Number
330
Double-Acting
3235438
332
Spring-Return
3237525
333
Spring-Return
3237368
354
Spring-Return
3237373
355
Spring-Return
3237515
Maximum
Operating Pressure
120 psi
550
Double-Acting
3236771
550A
Double-Acting
3237183
596
Spring-Return
3237865
597A
Spring-Return
3237866
Actuator Model
Model Type
FMC Part Number
350
Double-Acting
3237369
590
Double-Acting
3237886
590A
Double-Acting
3237887
3.0
Maintenance Instructions
3.1
Routine Maintenance
Maximum
Operating Pressure
80 psi
Weco® air pneumatic actuators were designed so that no regular maintenance is
required. However, repairing or replacing some internal components may be required
especially if condensation is not flushed from the inside of the actuator or if leakage is
detected.
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A check should be made to the actuator mounting kit every 1-2 weeks to verify it is
properly connected to the stem of either a butterfly valve or a plug valve. This check
should make certain the hex nuts are locked together on the threaded stud and that
the threaded stud is connected to the stem. Simply feeling the top hex nut to verify if
it is loose from the bottom hex nut all that is needed. If the hex nuts are locked
together against the lock washer, the indicator is secured to the stem.
3.2
Required Tools and Lubricants for Assembly & Disassembly
1. Adjustable or open ended wrenches ranging from 7/16 inch
to 13/16 inch.
2. Socket wrench and assorted size sockets ranging from 3/8
inch to 1-1/4 inch in both regular and deep socket types.
3. Service tool kit P547132 with the 3 sizes of piston hex tools
to operate the different piston sizes.
4. Soft-faced mallet, pliers with wire cutters, small flat head
screw driver or O-ring pick tool.
5. Assembly grease is Climax S-3 EPs with Moly Disulfide.
6. Multi-purpose sealant is Dow Corning 732.
7. Thread locking adhesive is Loctite 271.
8. Thread sealant is Loctite 592.
3.3
Disassembly
Make certain the air supply is disconnected from the actuator before
attempting disassembly. Failure to de-energize the actuator can result in
serious bodily harm.
WARNING
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The internal spring inside spring-return type actuators still contain
unreleased energy from being slightly compressed from their relaxed
fully lengthen state. This energy can cause serious bodily harm if
precautions are not observed. It is recommended to secure the actuator
and the cylinder head from movement to prevent an unexpected released
WARNING in energy from the spring in case internal components are broken.
1.
Remove the hex nuts from the long studs around the actuator cylinder and
the flange of the housing if necessary. Remove the studs from the holes
of the housing and the cylinder head.
2.
Remove the cylinder head off the end of the cylinder. For spring return
models, take caution to gently remove cylinder head for potential of
released energy from spring in case other internal components are
broken.
3.
Remove the cylinder from the housing.
NOTE
Removing cylinder from housing will require the cylinder to be pulled
over the piston seals. If necessary, a soft mallet can be used to tap the
end of the cylinder to slide the cylinder over the piston seals. Take care
not to damage end of the cylinder when tapping with soft mallet.
For spring-return models, piston inside cylinder must be in the fully
lengthened position.
After removing cylinder, double-acting models proceed to step 9 and springreturn models proceed to step 4.
If possible, devise means to restrain spring to prevent further
lengthening of spring while removing piston and related hardware.
NOTE
4.
Using wrench or socket, remove lock nut from end of clevis assembly
inside piston. Remove washer and seal washer from clevis assembly.
5.
Based on hex profile in piston, use appropriate size hex tool and place
one end of tool inside hex profile in piston. Use correct socket size to fit
over free end of hex tool. Using socket wrench connected to socket,
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gently unthread and remove piston from clevis assembly. Take caution of
spring lengthening to full relaxed state while unthreading piston from
clevis.
6.
Remove spring from assembly.
7.
Remove piston spacer from clevis assembly.
8.
For models that have a spring retainer, remove spring retainer.
9.
For models that have an adapter, remove cap screws and lock washers
that secure adapter to housing flange. Afterward, remove adapter from
flange.
10. Remove the cap screws and lock washers from retainer. Remove the
retainer from the housing.
11. Position actuator so that the side with the retainer removed now faces a
flat area with a hole to allow the shaft to be removed from the housing.
12. Using a round bar or other suitable devise, place in counter bore of shaft.
Strike bar with hammer or use a press to remove the shaft from the
housing. Take care not to lose key connected to outside of shaft.
13. For double-acting models, extract piston-clevis-lever assembly from
housing. For spring return models, extract clevis-lever assembly from
housing.
14. Using screw driver, remove the O-rings from the shaft grooves taking care
not to damage the seal grooves.
15. Using screw driver, remove the back-up rings from the sides of the piston
seal. Afterward, remove the piston seal from the piston groove. Take
care not to damage the groove.
16. Using screw driver, extract gaskets from the grooves of the cylinder head
and housing or the adapter if used on certain models. Extract the O-ring
from the groove in the housing for models that use an adapter. Take care
not to damage the grooves.
3.4
Repair and Parts Replacement
After all parts have been disassembled and all seals removed, clean all parts free of
grease, debris, and dirt. Inspect all parts for signs of wear or damage. Replace any
damaged or excessively worn parts. Replace all seals, gaskets, and O-rings with
exception of the O-rings used with the actuator mounting kit.
3.5
Repair Kits
Replacement parts are available in kits used for repairing all models of actuators.
The following table illustrates the parts in each kit:
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Models 330, 332, 333, 550, & 550A
Without an Adapter
Models 350, 354, 355, 590, 590A, 596, &
597A With an Adapter
Piston Seal with Back-Up Rings
Piston Seal with Back-Up Rings
Gaskets
Gaskets
Shaft O-rings
O-ring for Housing Groove
Thread Seal for Clevis
Shaft O-rings
Lock Nut (for 330, 332, & 333 Models)
Thread Seal for Clevis
Grease
Lock Nut (for 354, 355, 596, & 597A
Models)
Thread Sealant
Grease
Multi-purpose sealant (RTV silicone)
Thread Sealant
Multi-purpose sealant (RTV silicone)
The following table lists the part numbers for the repair kits and the corresponding
actuator models.
3.6
Kit Part Number
Actuator Models
3241285
330, 332, & 333
3241286
350, 354, & 355
3241287
550 & 550A
3245010
590, 590A, 596, & 597A
Double-Acting Models Assembly Procedure
1. Apply multi-purpose sealant to gasket groove located on
cylinder head and on the housing. For actuator models that
use an adapter, apply multi-purpose seal to gasket groove.
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2. Insert a gasket into the gasket groove of the cylinder head
and the housing. For actuator models that use an adapter,
insert correct sized O-ring into the gasket groove in the
housing. Wipe any excessive sealant that has extruded out
of groove with a clean cloth or rag. Let sealant cure for at
least one hour before using in assembly.
Gasket
Cylinder
Head
Adapter
O-ring
3. Slide flat washer onto piston bolt until it rests upon head of
bolt. Slide seal washer onto piston bolt until it rests against
flat washer.
Seal Washer
Piston Bolt
Flat Washer
4. Insert threaded end of piston bolt through hole of piston
until seal washer rests against flat bottom surface on
piston.
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Piston
5. Apply thread locking adhesive to threads of piston bolt and
install clevis onto threaded end of piston bolt.
An alternate method is to apply thread locking adhesive to threads of bolt
before inserting through hole of piston.
Clevis
6. For any models that use an adapter, slide clevis side of
piston-clevis assembly through hole in adapter. Make
certain gasket side of adapter is facing towards piston.
Adapter
7. Place roller into curved groove in lever.
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Roller
Lever
8. Position open end of clevis so that each tine is straddled
over the lever. Align holes of clevis with the hole in the
roller.
9. Connect clevis to lever by inserting pin through holes of the
clevis tines and the roller.
Pin
10. Apply grease to the curved groove on the lever, the roller,
and the pin. Apply grease on the sides of the lever, but not
to the large shaft hole or square notch.
11. Place housing on a bench so that the flange is facing up.
Orient the housing so that the threaded hole is pointing
away from the assembler.
12. Apply grease to each pin groove inside housing.
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Pin Groove
13. Install small key into slot on outside of shaft OD. Prior to
installation, position key so that the stepped end of the key
faces the large diameter side of the shaft. Insert flat side of
key down into slot in shaft. Key may require being tapped
with a hammer to complete installation.
Stepped End
14. Lubricate O-rings with grease then install into grooves of
shaft.
15. Apply grease to large diameter and small diameter of shaft.
Only apply grease to top edges of key, do not apply grease
to middle diameter on shaft OD.
16. Lift piston-lever assembly up so that the lever is suspended
on the bottom. Orient the piston-lever assembly so that the
large hole in the lever is positioned away from the
assembler.
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Large Hole
17. Insert piston-lever assembly down into the top of the
housing with pin fitting in grooves of housing. Align hole of
lever with bore holes in housing. For models with an
adapter, position the adapter on the piston-clevis assembly
so that the notches on the inner hole are aligned with the
pin grooves in the housing. Align bolt holes of adapter with
the bolt holes on the housing flange. Secure the adapter to
the housing by installing cap screws with lock washers
through the bolt holes of the flange on the housing into the
holes of the adapter.
Pin
Pin Groove
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Adapter
Cap Screws &
Lock Washers
18. Align key on shaft with notch in lever. Insert small diameter
side of shaft into large diameter bore in housing. Continue
inserting shaft so that small diameter portion of shaft
passes through hole in lever until key is engaged with notch
in lever. Small rotational adjustments of shaft may be
required for key to engage square notch in lever.
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19. Take housing with internal components to manual press,
position small bore side of housing down onto table of
manual press. Large bore side of housing should be facing
up. Using press, drive shaft into lever until shaft is fully
engaged with lever.
20. Remove housing from press and stand upright on bench so
that the piston is facing up. Apply grease to groove on
piston.
21. Install T-seal into groove of piston with flat side down into
the groove. Using scissors or cutters, cut approximately
1/4 inch of material from one end of each back-up ring.
Install one back-up ring on one side of T-seal and install the
other back-up ring on the other side of the T-seal making
sure the splits on each back-up ring are oriented 180degrees apart from each other.
T-Seal with
Back-Up Rings
22. Apply grease to the T-seal and back-up rings.
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23. Apply grease to the ID of the cylinder.
24. Position cylinder so that the chamfered end is facing
towards the piston then wipe chamfered end free of grease.
Install chamfered end over piston and work the cylinder
down until it is installed into the gasket groove.
Internal
Chamfer
25. Wipe opposite end of cylinder free of grease then align air
inlet port on cylinder head with small threaded hole in
housing. Install cylinder head onto cylinder so that end of
cylinder fits in the gasket groove.
Air Inlet Ports
26. Run long studs or cap screws through holes of cylinder
head and holes of housing. Install hex nuts onto ends of
studs or long cap screws and tighten in star type pattern.
Apply no more than 100 inch-lbs of torque to hex nuts so
that they are tight. Do not over tighten until the threads
break.
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Hex Nuts
Cap Screws
or Studs
27. Apply Teflon tape to OD threads on air inlet bushing then
install bushing into small threaded hole in housing.
Air Inlet
Bushing
28. Apply grease to end of large diameter side of shaft.
29. Position retainer so that raised face is pointing towards
shaft and place retainer onto mounting surface on housing.
Align holes of retainer with the mounting holes on the
housing.
30. Insert lock washers onto the (4) cap screws and install the
cap screws through the holes of the retainer into the holes
in the housing. Tighten the cap screws so that the lock
washers are flat.
Cap Screws &
Lock Washers
Retainer
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3.7
Spring-Return Models Assembly Procedure
1. Apply multi-purpose sealant to gasket groove located on
cylinder head and on the housing. For actuator models that
use an adapter, apply multi-purpose seal to gasket groove.
2. Insert a gasket into the gasket groove of the cylinder head
and the housing. For actuator models that use an adapter,
insert correct sized O-ring into the gasket groove in the
housing. Wipe any excessive sealant that has extruded out
of groove with a clean cloth or rag. Let sealant cure for at
least one hour before using in assembly.
O-ring
Adapter
Gasket
Cylinder
Head
3. Apply thread locking adhesive to threads of clevis rod and
install into threaded end of clevis. Let adhesive cure on
threads per manufacturer’s recommendation before further
use in assembly. For clevis sub-assemblies that require a
pin, align hole of clevis rod with holes through clevis and
install pin through holes to secure the clevis to the rod.
Pin
Clevis
Clevis Rod
4. Place roller into curved groove in lever.
5. Position open end of clevis so that each tine is straddled
over the lever. Align holes of clevis with the hole in the
roller.
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Clevis Sub-assembly
6. Connect clevis sub-assembly to lever by inserting pin
through holes of the clevis tines and the roller.
Pin
7. Apply grease to the curved groove on the lever, the roller,
and the pin. Apply grease on the sides of the lever, but not
to the large shaft hole or square notch.
8. Place housing on a bench so that the flange is facing up.
Orient the housing so that the threaded hole is pointing
away from the assembler.
9. Apply grease to each pin groove inside housing.
10. Install small key into slot on outside of shaft OD. Prior to
installation, position key so that the stepped end of the key
faces the large diameter side of the shaft. Insert flat side of
key down into slot in shaft. Key may require being tapped
with a hammer to complete installation.
Step
11. Lubricate O-rings with grease then install into grooves of
shaft.
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12. Apply grease to large diameter and small diameter of shaft.
Only apply grease to top edges of key, do not apply grease
to middle diameter on shaft OD.
13. Lift clevis-lever assembly up so that the lever is suspended
on the bottom. Orient the clevis-lever assembly so that the
large hole in the lever is positioned away from the
assembler.
Pin
Pin Groove
14. Insert clevis-lever assembly down into the top of the
housing. Align hole of lever with bore holes in housing.
15. Position adapter so that the gasket is facing up and the
notches on the inner hole are aligned with the pin grooves
in the housing. Slide adapter down over clevis rod with the
rod sticking out of the hole in the adapter until it rests on
flange of housing. Align bolt holes of adapter with the bolt
holes on the housing flange. Secure the adapter to the
housing by installing cap screws with lock washers through
the bolt holes of the housing flange into the bolt holes of the
adapter.
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Adapter
Cap Screws &
Lock Washers
16. Align key on shaft with notch in lever. Insert small diameter
side of shaft into large diameter bore in housing. Continue
inserting shaft so that small diameter portion of shaft
passes through hole in lever until key is engaged with notch
in lever. Small rotational adjustments of shaft may be
required for key to engage square notch in lever.
17. Take housing with internal components to manual press,
position small bore side of housing down onto table of
manual press. Large bore side of housing should be facing
up. Using press, drive shaft into lever until shaft is fully
engaged with lever.
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18. Remove housing from press and stand upright on bench so
that the piston is facing up. Apply grease to groove on
piston.
19. For actuator models that use a spring retainer, position
spring retainer so that the lettering side is facing down
towards the housing then slide spring retainer down over
clevis rod with the rod sticking out of the hole in the spring
retainer until it rests on flange of housing. Make certain
spring retainer fits evenly on housing flange and does not
cover up any of the gasket groove.
Spring
Retainer
Gasket
20. Apply grease to clevis rod about 2 inches below the threads
on the exposed end of the rod.
21. Slide small diameter side of spacer down over clevis rod
until it rests against the end of the clevis.
Spacer
Small Diameter End
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22. Slide spring down over clevis rod and spacer until it rests
against the adapter or spring retainer. Make certain spring
fits outside of the raised profile on the adapter or spring
retainer.
Spring
Retainer
Adapter
Spring
23. Place assembly into spring compression cage fixture so
that spring if pointing up. Connect necessary hooks to end
of spring making certain hooks will not slide off spring.
Activate controls of cage to start compressing spring.
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24. Apply grease to the back side surface of piston that will
contact the spring.
Apply Grease Here
25. As spring is compressed, install conical end of piston onto
threaded end of clevis rod until it rests against end of
spacer.
26. Install seal washer onto threaded end of clevis rod, being
careful not to damage the rubber seal against the threads.
27. Slide flat washer over clevis rod until it rests against seal
washer.
28. Make certain the threads on the clevis rod are clean of any
grease before applying thread sealant to the threads on the
end of the clevis rod.
29. Install lock nut onto threaded end of clevis rod.
Doc No: OMM50001912
Flat Washer
Lock Nut
Seal Washer
30. Using controls of spring compression cage, gently release
force on spring, allowing spring to apply full force on
washers and lock nut.
31. Remove assembly from spring compression cage and
place assembly in a vice with piston side facing up.
32. Apply grease to groove on piston.
33. Install T-seal into groove of piston with flat side down into
the groove. Using scissors or cutters, cut approximately
1/4 inch of material from one end of each back-up ring.
Install one back-up ring on one side of T-seal and install the
other back-up ring on the other side of the T-seal making
sure the splits on each back-up ring are oriented 180degrees apart from each other.
34. Apply grease to the T-seal and back-up rings.
35. Apply grease to the ID of the cylinder.
36. Position cylinder so that the chamfered end is facing
towards the piston then wipe chamfered end free of grease.
Install chamfered end over piston and work the cylinder
down until it is installed into the gasket groove.
Doc No: OMM50001912
Internal Chamfer
T-Seal with
Back-Up Rings
37. Wipe opposite end of cylinder free of grease then align air
inlet port on cylinder head with small threaded hole in
housing. Install cylinder head onto cylinder so that end of
cylinder fits in the gasket groove.
Air Inlet Port
Air Inlet Port
38. Run long studs or cap screws through holes of cylinder
head and holes of housing. Install hex nuts onto ends of
studs or long cap screws and tighten in star type pattern.
Apply no more than 100 inch-lbs of torque to hex nuts so
that they are tight. Do not over tighten until the threads
break.
Doc No: OMM50001912
Hex Nuts
Studs
Hex Nuts
39. Apply Teflon tape to OD threads on hex plug then install
hex plug into small threaded hole in housing.
Hex Plug
40. Apply thread sealant to the threads of the bushing and
install into threaded hole of hex plug. Apply thread selant
to threads of pressure relief fitting and install into hole of
bushing.
Doc No: OMM50001912
Relief Fitting
Bushing
41. Apply grease to end of large diameter side of shaft.
42. Position retainer so that raised face is pointing towards
shaft and place retainer onto mounting surface on housing.
Align holes of retainer with the mounting holes on the
housing.
43. Insert lock washers onto the (4) cap screws and install the
cap screws through the holes of the retainer into the holes
in the housing. Tighten the cap screws so that the lock
washers are flat.
4.0
Functional Testing
1. Install male quick connects or other suitable air pressure
fittings into threaded air inlet ports. For spring return
models, install only one male quick connect or air fitting into
air inlet port of cylinder head.
2. Inject no more than 80 psi into one of the air inlet ports then
repeat in opposite air inlet port. For spring return models,
just inject air into the air inlet port in the cylinder head to
actuate then remove air from the inlet port to allow the
spring to move the piston. The actuator shall cycle in both
directions smoothly without binding.
3. If actuator fails to cycle, the piston or other internal
components may be hindering movement. Disconnect air
supply from actuator then proceed to investigate cause of
problem. Review the assembly steps above.
Doc No: OMM50001912
5.0
Storage Instructions
When not in use, the actuator and repair kits should be stored in a dry area that
protects it from sun, rain, heat and moisture. The air inlet ports should either have
thread protectors installed or covered in a manner that prevents dirt or dust from
entering into the inside of the actuator.

OPERATION AND MAINTENANCE MANUAL, WECO 300 AND 500

Transcription

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