Flowserve 10 ACCESS I Worcester Controls - Manual (Page 10)

10 10, 15, 20 ACCESS I and 10-40 Access M 39 Actuators Intrinsically Safe WCAIM2028
ACTUATOR REASSEMBLY
1. Be sure the actuator surfaces are clean and free of grit and
scratches. If the inside walls of the body are scored, or the guide
rod surfaces are scratched, the actuator will leak after rebuilding.
New parts should be obtained from the factory. Light tracking,
barely detectable to touch, is acceptable.
2. All rebuilding kit O-rings and bearings may now be installed.
Lubricate the standard actuator thoroughly with a #1 grease.
Apply a light film of grease to all O-rings. NOTE: “High-
temperature” actuators and O-rings must be lubricated with Dow
Corning #7 or other equivalent high temperature silicone or
graphite base grease. (Note that kits also contain some parts for
earlier revisions of actuators which will not be needed.)
3. Replace the two split-ring style bearings (6A) and one guide rod
O-ring (15B) in each end cap.
Replace the split-ring style bearing (6B) and guide rod O-ring(s)
(15B) into I.D. groove(s) in each piston (3). Install O-rings (15C)
onto pistons.
4. Replace O-ring (15E) and bearing (15H) (10–40 sizes only) on
the bottom of shaft. On the top of the shaft add the two
stainless steel washers (10–35 sizes only) with the thrust
bearing (10) between them.
NOTE: For size 40 model only, a single stainless steel washer is
used and thrust bearing (10) is not used. Locate the top bearing
(15G) and O-ring (15D) into the body. For sizes 10–35 Rev. R6
actuators, top bearing (15G) is flat, the same as and
interchangeable with thrust bearing (10). Replace the shaft
through the larger opening in the bottom of the body.
For sizes 25 through 40 actuators, replace anti-ejection ring (15J)
in its groove on the shaft (2B), if removed.
5. Very carefully align the piston guide rod assemblies inside the
body. Keep the pistons square to the body. (This is very important
in the 30 39 actuator where steel set screws can cause internal
body damage if the piston assemblies “cock” inside the actuator
body.)
IMPORTANT: One piston guide rod assembly has a through-hole
drilled in it. It can be easily located by looking down the ends of
both guide rods. This piston assembly must be reassembled,
with its respective guide rod, opposite the nameplate on the
body, as it was removed.
6. Align the shaft so that the teeth on the shaft will “pick-up” the
piston assembly’s rack teeth when turning the top extension of
the shaft clockwise (CW). (See Figure 6.)
IMPORTANT: Proper 90° rotation can only be ensured if the shaft
teeth begin to mesh with the piston assembly’s teeth at the
“proper tooth” between these meshing gear pairs. (See Figure 6.)
7. To ensure proper meshing of teeth, move the shaft 15 to 20
degrees counter-clockwise (CCW) from its normal position when
the piston assemblies are located at the body ends (See Figure 7).
NOTE: The “normal position” of the shaft on 10-20 sizes is when
the top flats are parallel to the main axis of the actuator body. On
the 25-40 sizes the teeth of the shaft will be on the left side of the
actuator when viewed from the ends of the actuator. (See Figure
6.)
8. With the piston assemblies in the body, gently push each piston
into the body. Turn the top shaft extension clockwise (CW). Do
not allow the pistons to “cock”.
At the proper point of engagement between the shaft and piston
assemblies, both piston assemblies will move toward the center
of the body when turning the top shaft extension of the actuator
clockwise (CW).
9. Once the shaft and pistons are properly engaged, ensure that
smooth movement and full closed operation can occur without
moving the pistons out of the actuator body. This is important!
10. Install O-ring (15A) into and replace the actuator end caps, (5A
and 5B), noting that the “foolproof” pin between the body and end
cap mates properly. For spring-return actuators, see spring
installation section before installing end caps.
NOTE: When installing the end cap O-rings, use a small amount of
a general purpose lubricant, such as petroleum jelly, to hold them
in place for ease of assembly and to avoid having them fall and
get pinched.
11. Replace the stainless steel washer over the top shaft extension.
12. VERY IMPORTANT: Install the NEW shaft clip (15F) into its mating
groove on the top shaft extension. (The removed shaft clip is not
to be reused.)
Place the numbered side up on the shaft clip and be certain the
clip is fully seated in its groove. See Note in Step 7 of Actuator
Disassembly for installation of spiral ring type shaft clip (which
newer rebuilding kits will contain).
If control block (7A) or air connection block (7B) was removed:
Properly insert appropriate gasket (9A, 9B or 9C) between control
block or air connection block and end cap (see figure 4 and
actuator exploded view), and attach block securely to end cap. Do
not apply any grease to gasket, it must be installed dry.
13. Replace position indicator (17) (if any). See Section D.7 in
Installation Section for proper installation and to determine
position indication.
14. Mark Rebuild/Accessory Addition Label, if included in repair kit,
and apply to actuator.
Flow Control
Worcester Controls