Genebre Building. Av.

de Joan Carles I, 46-48

08908 L'Hospitalet de Llobregat. Barcelona (Spain)
genebre@genebre.es - www.genebre.es

INSTALLATION, OPERATION AND MAINTENANCE

MANUAL

Manual Gear Operator

GENEBRE Reference: 5975-5976-5977-5978

GENEBRE S.A. LAST UPDATE: 04/04/2013 UPDATE NUMBER: 1

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 Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
genebre@genebre.es - www.genebre.es

Installation, operation and maintenance instructions

1) ASSEMBLY DRAWING ........................................................................................ 3

2) STORAGE ............................................................................................................... 4

3) INSTALLATION INSTRUCTIONS ...................................................................... 4

3.1) PREPARATION ....................................................................................................... 4
3.2) ASSEMBLING TO THE VALVE.................................................................................. 4
3.3) ADJUSTMENT OF THE REGULATION SCREWS ........................................................... 4

4) OPERATION INSTRUCTIONS ............................................................................ 5

4.1) MANUAL OPERATION ............................................................................................ 5
4.2) TORQUES .............................................................................................................. 5

5) MAINTENANCE OPERATIONS .......................................................................... 6

6) ACCESSORIES ....................................................................................................... 6

7) HYGIENE AND SAFETY INSTRUCTIONS ........................................................ 7

GENEBRE S.A. LAST UPDATE: 04/04/2013 UPDATE NUMBER: 1

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 Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
genebre@genebre.es - www.genebre.es

1) Assembly drawing

Parts list:

Nº Name Material Surface Treatment

1 HOUSING CAST IRON PAINTED
2 SEALING RING NBR -------
3 PIN STEEL -------
4 WORM STEEL -------
5 WORM GEAR DUCTILE IRON -------
6 SCREW STEEL ZINC PLATED
7 INDICATOR STEEL ZINC PLATED
8 REGULATION SCREW STEEL BROWNING
9 STUD BOLT STEEL BROWNING
10 SHAFT STEEL ZINC PLATED
11 HOUSING COVER CAST IRON PAINTED
12 SCREW STEEL ZINC PLATED
13 GASKET PAPER WITH GRAPHITE -------
14 O’RING NBR -------
15 HANDWHEEL CAST IRON PAINTED
16 PIN STEEL -------

GENEBRE S.A. LAST UPDATE: 04/04/2013 UPDATE NUMBER: 1

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 Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
genebre@genebre.es - www.genebre.es

2) Storage

During storage it is recommended to keep the Gear Operator in the same position as
delivered, with the included protective wrapping to avoid damages or dirt accumulation. The
wrap must not be removed until the operator is to be installed. As far as possible, store in a
dry and clean environment. If you expect to have the product stored for a long period of time,
apply anti rust oil over machined areas. Repeat every 6 months if necessary.

3) Installation instructions

3.1) Preparation

Remove any wrapping material from the product.

The Gear Operator is delivered in the closed position.
It is recommended to put the Handwheel (part. 15) together with the Shaft (part. 10) before
assembling the Gear Operator to the valve. The included Pin (part. 16) will be used for this
purpose.

3.2) Assembling to the valve

1- Check if the bolt circle on top flange and stem dimensions of the valve coincide with the
bolt circle and square hole of the gear operator, respectively.

2- Make sure that both valve and gear operator are in fully closed position.

3- Mount the gear box with its shaft perpendicular to the valve (or pipeline) by means of the
attached four screws and washers. Apply "cross method" for tightening.

4- The assembly is ready for adjustment (see below).

3.3) Adjustment of the regulation screws

The unit is already adjusted in the factory at 0º and 90º, however it could be necessary a
later adjustment in Open and/or Close position of the valve. The range of adjustment is +/-
10º for both positions.

Before regulating the Screws (part. 8) must remove both Stud Bolt (part. 9) to provide access.

The procedure simply consists on checking that the valve is fully open in Open position and
fully closed in Close position. Adjust the Regulating Screws as much as necessary (between
the range of adjustment).

GENEBRE S.A. LAST UPDATE: 04/04/2013 UPDATE NUMBER: 1

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 Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
genebre@genebre.es - www.genebre.es

REMARKS:

- degrease completely the contact surface between valve and gear box.

- it could be necessary the addition of square adapters for a proper coupling.

- in butterfly valves it is recommended assembling and adjustment with the valve closed.

- however, in ball valves it is recommended assembling and adjustment with the valve open.

- gear box can be installed in any position, however, in outdoors it is recommended to be

installed vertical (with handwheel parallel to the floor) to avoid water inside.

- the working temperature of the gear operator is in environments from -20º to 80º.

4) Operation instructions

4.1) Manual operation

The gear boxes are manually operated by handwheel. Turn clockwise for closing or turn
counter clockwise for opening the valve. The position is shown by the indicator plate on top
of the gear box.

In case the valve can't completely achieve Open or Close positions, first try to find out the
reason of malfunction to prevent further damage. Do not attempt to force the handwheel
beyond the stop limits.

For the valves operated with gear box, the quantity of turns to be done for a complete
operation cycle 90º will be conditioned by the transmission ratio of the gear box. See table
below:

GENEBRE S.A. LAST UPDATE: 04/04/2013 UPDATE NUMBER: 1

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 Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
genebre@genebre.es - www.genebre.es

Article Trans. Ratio Nº gear turns (90º)

5975 24:1 6
5976 30:1 7.5
5977 50:1 12.5
5978 80:1 20

4.2) Torques

The maximum allowable output torque of the gear operator is as listed below:

Output Torque
Article
(N.m)
5975 300
5976 750
5977 1200
5978 2000

It is recommended not to overpass the 90% of the maximum allowable torque for a longer life
of the product.

5) Maintenance operations

Gear operators are designed so that they do not need any lubrication and/or periodical
maintenance during their life cycle. However, periodical checks will be useful to extend the
service life of the product. Verify all locks and threaded ends to check if they are loose or with
rust. Tighten them if necessary.

6) Accessories

Accessories for gear operator such as Limit Switch (Art. 5987) are available, but need special
support and coupling on demand.

GENEBRE S.A. LAST UPDATE: 04/04/2013 UPDATE NUMBER: 1

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 Genebre Building. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
genebre@genebre.es - www.genebre.es

7) Hygiene and Safety Instructions

7.1) Fluids that go through the valve can be corrosive, toxic, flammable or pollutant. When
operating valves, you must follow the security instructions and it is recommended to use
personal protection gadgets:

1) Protect your eyes.

2) Wear gloves and appropriate working clothes.
3) Wear safety footwear.
4) Wear a helmet.
5) Have running water at hand.
6) To operate flammable fluids, make sure you have an extinguisher at hand.

7.2) Before removing a valve from a pipe, check always if the line is completely drained and
depressurized.

7.3) Any valve being used by toxic services department needs to obtain a cleanliness
certificate before being operated.

GENEBRE S.A. LAST UPDATE: 04/04/2013 UPDATE NUMBER: 1

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