Bettis Manual: Service Instructions Disassembly and Reassembly For Models G01 Through G10 Spring Return Pneumatic Actuators With M11 Hydraulic Override | Bettis Manuals & Guides

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Service Instructions

127073E Rev. C

August 2015

G01 through G10 Spring-Return Pneumatic Actuators with M11 Hydraulic Override

Service Instructions

127073E Rev. C

Table of Contents

Section 1: Introduction

1.1 General Service Information ......................................................................... 1

1.2 Denitions ................................................................................................... 1

1.3 General Safety Information ........................................................................... 2

1.4 Bettis Reference Materials ............................................................................. 2

1.5 Service Support Items .................................................................................. 3

1.6 Lubrication and Fluid Requirements.............................................................. 3

1.7 General Tool Information .............................................................................. 3

1.8 Actuator Storage ........................................................................................... 4

1.9 Actuator Installation ..................................................................................... 4

1.10 Actuator Start-up .......................................................................................... 4

1.11 Actuator Operation ....................................................................................... 5

Table of Contents

August 2015

Section 2: Actuator Disassembly

2.1 General Disassembly .................................................................................... 6

2.2 Pneumatic Power Module Disassembly ......................................................... 6

2.3 Drive Module Disassembly ............................................................................ 9

2.4 G01 Through G5 M11 Hydraulic Override Cylinder Disassembly .................. 11

2.5 G7 Through G10 M11 Hydraulic Override Cylinder Disassembly .................. 12

Section 3: Actuator Reassembly

3.1 General Reassembly .................................................................................... 13

3.2 Drive Module Reassembly ........................................................................... 13

3.3 Pneumatic Power Module Reassembly ........................................................ 18

3.4 G2 and G3 Early Model Pneumatic Power Module Reassembly..................... 21

3.5 G01 through G5 M11 Hydraulic Override Cylinder Reassembly .................... 23

3.6 G7 through G10 M11 Hydraulic Override Cylinder Reassembly .................... 24

3.7 Actuator Testing ......................................................................................... 25

Section 4: Field Conversions

4.1 Fail Mode Reversal (CW to CCW, or CCW to CW) ......................................... 27

4.2 Converting Double-Acting Actuator To Spring-Return With Override

Cylinder Assembly ....................................................................................... 27

Section 5: Module Removal and Installation

5.1 M11 Override Cylinder Removal .................................................................. 28

5.2 M11 Override Cylinder Installation .............................................................. 29

5.3 Spring Module Removal ..............................................................................30

5.4 Spring Module Installation .......................................................................... 32

5.5 Pneumatic Power Module Removal .............................................................34

5.6 Pneumatic Power Module Installation ......................................................... 35

5.7 Powr Swivl Removal .................................................................................... 36

5.8 Powr Swivl Module Installation .................................................................... 37

Table of Contents

August 2015

Section 6: Actuator Support Information

Section 7: Troubleshooting

Section 8: Removal and Decommissioning

Service Instructions

127073E Rev. C

6.1 M11 Hydraulic Override System Fluid Volume ............................................. 38

6.2 Module Weights by Item Number and Actuator Housing Size ...................... 38

6.3 G01 Tool Style and Wrench Size ..................................................................39

6.4 G2 Tool Style and Wrench Size..................................................................... 40

6.5 G3 Tool Style and Wrench Size..................................................................... 40

6.6 G4 Tool Style and Wrench Size..................................................................... 41

6.7 G5 Tool Style and Wrench Size..................................................................... 41

6.8 G7 Tool Style and Wrench Size..................................................................... 42

6.9 G8 Tool Style and Wrench Size..................................................................... 42

6.10 G10 Tool Style and Wrench Size ..................................................................43

7.1 Fault Insertion ............................................................................................. 44

7.2 Operational Test .......................................................................................... 45

8.1 Removal and Decommissioning .................................................................. 46

Section 9: Document Revision ��47

Appendix A: List of Tables ��48

Appendix B: List of Drawings ��49

Table of Contents

Service Instructions

127073E Rev. C

Section 1: Introduction

1�1 General Service Information

1.1.1 This service procedure is offered as a guide to enable general maintenance to be performed on Bettis™ G01XXX-SR, G2XXX SR, G3XXX SR, G4XXX SR, G5XXX SR,

G7XXX SR, G8XXX SR, and G10XXX SR Spring-Return Series Single Pneumatic Power Module Actuators with M11 or M11 S Hydraulic Override Module.

1.1.2 Normal recommended service interval for this actuator series is ve years.

NOTE:

Storage time is counted as part of the service interval.

1.1.3 This procedure is applicable with the understanding that all electrical power and pneumatic pressure has been removed from the actuator.

1.1.4 Remove all piping and mounted accessories that will interfere with the module(s) that are to be worked on.

1.1.5 This procedure should only be implemented by a technically competent technician who should take care to observe good workmanship practices.

1.1.6 Numbers in parentheses, ( ) indicate the bubble number (reference number) used on the Bettis assembly drawing and Actuator Parts List.

1.1.7 This procedure is written using the stop screw side of the housing (1-10) as a reference and this side will be considered the front side of the actuator. The housing cover (1-20) will be the top of the actuator.

1.1.8 Actuator module weights are listed in Section 6 Table 12.

1.1.9 When removing seals from seal grooves, use a commercial seal removing tool or a small screwdriver with sharp corners rounded off.

1.1.10 Use a non-hardening thread sealant on all pipe threads.

Section 1: Introduction

August 2015

CAUTION: FOLLOW MANUFACTURER'S INSTRUCTIONS

Apply the thread sealant per the manufacturer’s instructions.

1.1.11 Bettis recommends that disassembly of the actuator components should be done in a clean area on a workbench.

1�2 Definitions

WARNING

If not observed, user incurs a high risk of severe damage to actuator and/or fatal injury to personnel.

Introduction

Section 1: Introduction

August 2015

CAUTION

If not observed, user may incur damage to actuator and/or injury to personnel.

NOTE:

Advisory and information comments provided to assist maintenance personnel to carry out maintenance procedures.

NOTE:

This product is only intended for use in large-scale xed installations excluded from the

scope of Directive 2011/65/EU on the restriction of the use of certain hazardous substances in electrical and electronic equipment (RoHS 2).

1�3 General Safety Information

Service Instructions

127073E Rev. C

Products supplied by Bettis, in its “as shipped” condition, are intrinsically safe if the instruc-

tions contained within this Service Instruction are strictly adhered to and executed by well

trained, equipped, prepared and competent personnel.

WARNING: READ WARNING SIGNS

For the protection of personnel working on Bettis actuators, this procedure should be reviewed and implemented for safe disassembly and reassembly. Close attention should be noted to the WARNINGS, CAUTIONS and NOTES contained in this procedure.

WARNING: FOLLOW PLANT SAFETY PROCEDURES

This procedure should not supersede or replace any customer’s plant safety or work

procedures. If a conict arises between this procedure and the customer’s procedures the

differences should be resolved in writing between an authorized customer's representative and an authorized Bettis representative.

1�4 Bettis Reference Materials

1.4.1 Assembly Drawing for G2-SR-M11 through G5-SR-M11 model actuators with one Pneumatic Power Module and one Spring Module with M11 Hydraulic Override Module use part number 121410.

1.4.2 Assembly Drawing for G7-SR-M11 through G10-SR-M11 model actuators with one Pneumatic Power Module and one Spring Module with M11 Hydraulic Override Module use part number 121411.

1.4.3 M11 Manual Hydraulic Override System operating instructions part number 126858 with M11 Assembly Drawing part number 126567.

1.4.4 M11-S Manual Hydraulic Override System operating instructions part number 121960 with M11 S Assembly Drawing part number 121107.

Introduction

Service Instructions

127073E Rev. C

1�5 Service Support Items

1.5.1 Bettis module service kits.

1.5.2 For rod extension retainer nut tool part number, refer to the following table.

NOTE:

These tools are required only when extension rod assembly (1-50) or (9-50) is removed or when a new extension rod assembly is installed.

Table 1� G-Series Models

Section 1: Introduction

August 2015

Actuator Model

G01 None required G5/G7 117369

G2 123616 G8/G10 117368

G3/G4 117370

1.5.3 Commercial leak testing solution.

1.5.4 Non-hardening thread sealant.

Bettis Part

Number

Actuator Model

1�6 Lubrication and Fluid Requirements

NOTE:

Lubricants and Fluids, other than listed in step 1.6.1 and 1.6.2 should not be used without prior written approval of Bettis Product Engineering.

1.6.1 All temperature services (-50°F to +350°F)/(-45.5°C to 176.6°C) use Bettis ESL 5 lubricant. ESL 5 lubricant is contained in the Bettis module service kit in tubes or cans and they are marked ESL 4, 5 and 10 lubricant.

1.6.2 M11 Manual Hydraulic Override System Fluid Requirements: Standard and high

temperature service (-20°F to +350°F) use Dexron II or Shell Tellus T-32 Automatic

Transmission Fluid. For low temperature service (-50°F to 150°F) use Univis J13 or HVI 13 Hydraulic Fluid.

Bettis Part

Number

1�7 General Tool Information

1.7.1 Tools: All tools/Hexagons are American Standard inch. Large adjustable wrench, two (2) large screwdrivers, Allen wrench set, set of open/box end wrenches, rubber

or leather mallet, torque wrench (up to 1200 foot pounds / 1627 N-m), breaker bar, small drift punch and a drive socket set. For recommended tool and wrench sizes refer to Section 6, Tables 6.3 through 6.10.

Introduction

Section 1: Introduction

August 2015

1�8 Actuator Storage

For applications where the actuator is not placed into immediate service, it is recommended that the actuator be cycled with regulated clean/dry pneumatic pressure at least once per month. Indoor storage, if available, is recommended for all actuators. Care should be taken to plug all open ports on actuator and controls to keep out foreign particles and moisture. Actuators should not be stored in an atmosphere that is harmful to resilient

seals. Contact factory for extended storage period.

1�9 Actuator Installation

1.9.1 Since there are many valve and actuator combinations, it is not practical to include detailed instructions for each type. Mountings are designed to be as simple as possible to keep the guess work out of the installation.

1.9.2 Actuators that are shipped from the factory with the travel stops adjusted for

approximately ninety degree rotation. Generally, it is necessary to make slight

travel stop adjustments once the actuator is installed onto the valve. Refer to the

valve manufacturer's recommendations for specic requirements. When the valve

has internal stops, the actuator should be adjusted at the same points.

Service Instructions

127073E Rev. C

NOTE:

The actual "stopping" should be done by the actuator. If the valve does not have internal stops, adjust the actuator to the full open position. Using this as a reference point, rotate

the valve closed and adjust to the valve manufacturer's specications for total rotation.

1.9.3 Good instrument practices are also recommended. Clean/dry regulated pneumatic pressure is essential for long service life and satisfactory operation. It should be noted that new pneumatic lines often have scale and other debris in them and these lines should be purged of all foreign material.

NOTE:

Scale and debris can damage control valves, solenoids, and seals.

1�10 Actuator Start-up

1.10.1 Prestart-up checks

1. Inspect to ensure the unit has been mounted onto valve properly. Gear

ange mounting bolts, stem key, set screw(s) are installed and secured.

2. No tubing damaged or accessories dislodged during the shipping or the installation.

3. Indicated position conrms valve position.

4. All switching valves in normal operating position as per SCHEMATIC / INSTRUCTIONS

Introduction

Service Instructions

127073E Rev. C

1.10.2 Check Connections

1.10.3 When actuator is rst placed into service, it should be cycled with regulated

1.10.4 The actuator speed of operation is determined by a number of factors includes:

1.10.5 Due to the interaction of these variables, it is difcult to specify a "normal"

1.10.6 Slower operating time may be obtained by using ow control valves to meter the

Section 1: Introduction

August 2015

1. Pneumatic / hydraulic components connected as per schematic enclosed or in service manual supplied.

2. Pneumatic supply connected to the identied ports.

3. Electrical connection terminals are secured.

4. Wiring as per enclosed diagram or service manual supplied.

pneumatic pressure. This is necessary because the seals have been stationary, causing them to take a "set". Therefore, the actuator should be operated through

several cycles to exercise the seals so as to achieve a service ready condition.

1. Power supply line length

2. Power supply line size

3. Power supply line pressure

4. Control valve and tting orice size

5. Torque requirements of the valve

6. Size of the actuator

7. Setting of speed controls

8. Hydraulic manual override (where available)

operating time. Faster operating time may be obtained by using one or more of the following:

1. Larger supply lines

2. Larger control valve

3. Higher supply pressure *

4. Quick exhaust valves

— * Not to exceed maximum operating pressure of actuator or

control components

exhaust. Excessive exhaust ow metering may cause erratic operation.

1�11 Actuator Operation

1.11.1 Controlled Operation: Controlled operation is accomplished by pressurizing and/or

depressurizing the appropriate cylinder inlet(s) of a double-acting. Do not exceed

pressures indicated on actuator nameplate.

1.11.2 Manual Operation: All pressure must be vented or equalized on both sides of the pneumatic piston prior to manual operation.

Introduction

Section 2: Actuator Disassembly

August 2015

Section 2: Actuator Disassembly

2�1 General Disassembly

WARNING: DANGEROUS GAS AND/OR LIQUIDS

It is possible, that the actuator may contain a dangerous gas and/or liquids. Ensure that all proper measures have been taken to prevent exposure or release of these types of contaminants before commencing any work.

2.1.1 Section 2 - Actuator Disassembly is written to either completely disassemble the entire actuator or can be used to disassemble individual modules as needed (pneumatic power module or drive module).

WARNING: DO NOT REMOVE COMPRESSED MODULE

Service Instructions

127073E Rev. C

Do not remove spring module while spring is compressed.

2.1.2 When the spring module is to be removed it should be removed from the drive module prior to the pneumatic power module removal or disassembly.

2.1.3 The pneumatic power module can be disassembled while still attached to the drive module or the pneumatic power module can be removed from the drive module and disassembled separate to the actuator (refer to Section 5 - Module Removal and Installation).

2.1.4 To ensure correct reassembly; that is, with pneumatic power module or spring module on same end of drive module as was, mark or tag right (or left) and mark mating surfaces.

2.1.5 For spring module removal and installation refer to Section 5 steps 5.3 and 5.4.

NOTE:

Use a means of capturing the hydraulic uid that will be lost during the removal or disassembly of the override power module. Use a bucket, tub, and large container, etc.

2�2 Pneumatic Power Module Disassembly

NOTE:

Review Section 2 steps 2.1.1 through 2.1.5 General Disassembly before proceeding with Pneumatic Power Module Disassembly.

WARNING: REMOVE ALL OPERATING PRESSURE

If not already removed disconnect all operating pressure from actuator power cylinders.

Actuator Disassembly

Service Instructions

127073E Rev. C

WARNING: SPRINGS IN EXTENDED POSITION

The spring cartridge must be checked to verify that the spring(s) are in their extended position before the pneumatic power module is disassembled from the drive module (refer to Section 5.3 steps 5.3.7 through 5.3.9).

2.2.1 Mark and record location of the ports on outer end cap (3-80) and inner end

2.2.2 If actuator is equipped with a power module mounted extended stop (ES) then

2.2.3 Remove breather assembly (12) from outer end cap (3-80).

2.2.4 Refer to assembly drawing sheet 2 Detail "E". Remove two socket cap screws (3-

2.2.5 Remove two tie bar hex nuts (3-90) from outboard side of outer end cap (3-80).

2.2.6 The t between cylinder (3-70) and outer end cap (3-80) is very tight. Break end

Section 2: Actuator Disassembly

August 2015

cap (3-10).

rotate the ES until clear of the piston rod (3-40).

130), with lockwasher (3-140), from outer end cap (3-80).

cap free by tapping with a breaker bar on lip provided on the end cap. Remove outer end cap (3-80) from cylinder (3-70).

CAUTION: DO NOT DAMAGE O-RING GROOVE

Do not damage O-ring groove when removing end cap from cylinder�

NOTE:

When removing cylinder (3-70) off of piston (3-30), tilt the cylinder 15 to 30 degrees with respect to actuator centerline.

2.2.7 Remove cylinder (3-70) from inner end cap (3-10).

CAUTION: DO NOT USE PIPE WRENCH

Do not use pipe wrench to remove tie bars.

2.2.8 TIE BAR REMOVAL:

2.2.8.1 Remove G01, G2 and G3 tie bars (3-20) as follows:

NOTE:

G01, G2 and G3 models have ats on outboard end of tie bars (3-20) for wrench

placement.

Actuator Disassembly

2.2.8.1.1 Unscrew tie bars (3-20) from inner end cap (3-10). Pull the tie bars out of the inner end cap far enough to expose the O-ring seals (4-80).

2.2.8.1.2 Remove O-ring seals (4-80) from the inboard end of tie bars (3-20).

2.2.8.1.3 Remove tie bars (3-20) by pulling the tie bars out and through piston (3-30).

Section 2: Actuator Disassembly

August 2015

2.2.8.2 Remove G4 through G10 tie bars (3-20) as follows:

NOTE:

1. G4 models have ats on outboard end of tie bars (3-20) for wrench placement.

2. G5 through G10 models have a female square on the out board end of tie bars (3-20) for wrench placement.

2.2.8.2.1 Unscrew and remove tie bars (3-20) from inner end cap (3-10)

2.2.9 Remove piston as follows: (On early G2 and G3 models equipped with outboard and inboard tie bar nuts skip this step and go to step 2.2.10).

2.2.9.1 Refer to assembly drawing page 2 of 2 Detail "D". Remove two split ring

halves (3-50) and one retainer ring (3-60) from outboard side of piston (3-30).

NOTE:

Piston (3-30) acts as the retainer for inboard split ring halves (3-50). When removing the piston be careful to not lose inboard split ring halves (3-50).

Service Instructions

127073E Rev. C

and piston (3-30).

2.2.9.2 Remove piston (3-30) and two split ring halves (3-50) from piston rod

(3-40).

NOTE:

Steps 2.2.10 is used only on early G2 and G3 models equipped with outboard and inboard tie bar nuts.

2.2.10 Remove early model G2 and G3 pistons as follows:

2.2.10.1 Refer to assembly drawing page 2 of 2 Detail "D". Remove two split ring

halves (3-50) and one retainer ring (3-60) from inboard side of piston (3-30).

NOTE:

Piston (3-30) acts as the retainer for outboard split ring halves (3-50).

2.2.10.2 Slide piston (3-30) toward the inner end cap (3-10) until the outboard

split ring halves are exposed enough for removal. Remove outboard split

ring halves from piston rod (3-40).

2.2.10.3 Remove piston (3-30) and two split ring halves (3-50) from piston rod

(3-40).

2.2.11 Remove O-ring seal (4-70) from piston rod (3-40).

2.2.12 Remove hex cap screws (3-100) with lockwashers (3-110) from housing (1-10).

2.2.13 Remove inner end cap (3-10) off of piston rod (3-40).

Actuator Disassembly

Service Instructions

127073E Rev. C

NOTE:

On early model G2 and G3 actuators remove two hex nuts (3-90) from housing (1-10).

These two nuts will be loose after tie bars (3-20) are removed in step 2.2.8.1 and will be located in the area where the piston rod passes through the housing (1-10).

NOTE:

The piston rod (3-40) removal as outlined in step 2.2.14 is only required when the piston rod is being replaced or when the drive module is to be disassembled.

2.2.14 Unscrew and remove piston rod (3-40) from drive module.

2�3 Drive Module Disassembly

NOTE:

Review Section 2 steps 2.1.1 through 2.1.5 General Disassembly before proceeding with Drive Module Disassembly.

Section 2: Actuator Disassembly

August 2015

2.3.1 If not already removed remove piston rod (3-40) from drive module.

2.3.2 Mark stop screws (1-180) left and right. The setting of stop screws (1-180) should be checked and setting recorded before stop screws are loosened or removed.

NOTE:

Stop screws will be removed later in this procedure.

NOTE:

For steps 2.3.3 through 2.3.10 refer to assembly drawing sheet 2 Section A-A and Detail “F”.

2.3.3 Before removing position indicator (1-220), record or mark its position. Remove position indicator (1-220).

NOTE:

Step 2.3.4 is used only on G01, G2 and G3 drive modules. Drive modules G4 through G10 will skip step 2.3.4 and continue with step 2.3.5.

2.3.4 Remove one vent check assembly (13) from top of housing cover (1-20).

2.3.5 Unscrew and remove hex cap screws (1-160) with lockwashers (1-170) from yoke cover (1-150).

2.3.6 Remove yoke cover (1-150) from housing cover (1-20).

2.3.7 Mark and record the orientation of the position indicator assembly (1-140) in relation to the top of yoke (1-70).

2.3.8 Remove position indicator assembly (1-140) from top of yoke (1-70).

Actuator Disassembly

Section 2: Actuator Disassembly

August 2015

2.3.9 Remove spring pin (1-100) from top of yoke (1-70).

2.3.10 Remove hex cap screws (1-110), with lockwashers (1-115) from housing cover (1-20).

NOTE:

Steps 2.3.11 and 2.3.12 are used only on G7, G8 and G10 drive modules. Drive modules G01, G2, G3, G4 and G5 will skip steps 2.3.11 and 2.3.12 and continue with step 2.3.13.

2.3.11 Remove hex cap screws (1-120), with lockwashers (1-115), from housing cover (1-20).

2.3.12 Using hex cap screws (1-110), install into holes vacated by hex cap screws (1-120).

Use these hex cap screws to jack the housing cover up for removal. Alternately, rotate the hex cap screws clockwise until housing cover (1-20) is clear

of housing (1-10).

NOTE:

G01, G2, G3 and G4 model housing cover will have cast tabs for placing prying tools to aid in cover removal.

Service Instructions

127073E Rev. C

2.3.13 Remove housing cover (1-20) from housing (1-10).

NOTE:

Groove pins (1-130) will remain in housing cover (1-20) when housing cover is removed from housing (1-10). Groove pins (1-130) should not be removed from housing cover (1-20) unless they are damaged and require new replacements.

2.3.14 Refer to assembly drawing page 2 of 2 Detail "B". Remove guide bar (1-90) from housing (1-10).

2.3.15 Remove top yoke pin thrust bearing (2-10) from top of yoke pin (1-80).

2.3.16 Rotate the arms of yoke (1-70) to the center position of housing (1-10).

2.3.17 Remove yoke (1-70) with yoke pin (1-80), guide block (1-30), two yoke/guide block bushings (2-30) by lifting yoke up and out of the housing (1-10).

2.3.18 Remove bottom yoke pin thrust bearing (2-10) from inside bottom of housing (1-10).

2.3.19 Remove yoke pin (1-80) by inserting 3/8"-16 UNC screw into top of the yoke pin and pull straight up and out.

2.3.20 Remove guide block (1-30) from between the arms of yoke (1-70).

2.3.21 Remove yoke/guide block bushing (2-30) from the top of guide block (1-30).

2.3.22 Remove yoke/guide block bushing (2-30) from the top of the lower yoke arm of yoke (1-70).

NOTE:

G01 model actuators skip steps 2.3.23 through 2.3.25 and continue disassembly at step 2.3.26.

Actuator Disassembly

Service Instructions

127073E Rev. C

2.3.23 Refer to assembly drawing page 2 of 2 Detail "B". Use Bettis tool part numbers

2.3.24 Remove rod extension assemblies (1-50) and (9-50) from guide block (1-30).

NOTE:

Spherical washers (1-40) and (9-40) will be removed from guide block (1-30) when the

extension rod assemblies are removed.

2.3.25 Remove the remaining spherical washers (1-40) and (9-40) from guide block (1-30).

2.3.26 Unscrew and remove two stop screw nuts (1-190) from stop screws (1-180).

2.3.27 Unscrew and remove two stop screws (1-180) from front of housing (1-10).

2.3.28 Housing (1-10) vent check assembly removal as follows:

2.3.29 The following items do not need to be removed from their assembled locations

Section 2: Actuator Disassembly

August 2015

117368 (G8/G10), 117369 (G5/G7), 117370 (G3/G4) or 123616 (G2) and remove retention retainer nut assemblies (1-60) and (9-60) from guide block (1-30).

2.3.28.1 G01, G2 and G3 housing (1-10) unscrew and remove one vent check

assembly (13) from the front of housing (1-10).

2.3.28.2 G4 through G10 housing (1-10) unscrew and remove two vent check

assemblies (13) from the front of housing (1-10).

unless being replaced by new items: Two guide bar bearings, two yoke bearings (2-40), yoke pin bearing), yoke pin thrust bearing (2-10) and spring pin (1-100).

2�4 G01 Through G5 M11 Hydraulic Override

Cylinder Disassembly

NOTE:

For M11 hydraulic override cylinder removal from spring cartridge refer to Section 5 step 5.1.

2.4.1 Unscrew hydraulic ram cover (7-10) from hydraulic override end cap (7-70).

2.4.2 Remove hydraulic ram (7-20) from hydraulic ram cover (7-10).

Actuator Disassembly

Section 2: Actuator Disassembly

August 2015

Service Instructions

127073E Rev. C

2�5 G7 Through G10 M11 Hydraulic Override

Cylinder Disassembly

NOTE:

For M11 hydraulic override cylinder removal from spring cartridge refer to Section 5 step 5.1.

2.5.1 Unscrew and remove hex cap screws (7-80) with lockwashers (7-90) from outer end cap (7-70).

2.5.2 Remove outer end cap (7-70) from hydraulic cylinder assembly (7-10).

2.5.3 Remove piston rod (7-20) from hydraulic cylinder assembly (7-10).

2.5.4 Refer to assembly drawing sheet 1 Detail "G". Remove two split ring halves (7-30) and one retainer ring (7-40) from one side of piston (7-50).

2.5.5 Refer to assembly drawing sheet 1 Detail "G". Remove two split ring halves (7-30) and one retainer ring (7-40) from the other side of piston (7-50).

2.5.6 Remove piston (7-50) from piston rod (7-20).

2.5.7 Remove vent tube (7-60) from the hydraulic cylinder assembly.

2.5.8 Pipe plug (7-110) does not require removal for routine service.

2.5.9 Pipe plug (7-120) does not require removal for routine service.

Actuator Disassembly

Service Instructions

127073E Rev. C

Section 3: Actuator Reassembly

3�1 General Reassembly

CAUTION: CHECK SHELF LIFE OF SEALS

Only new seals, which are still within the seal’s expectant shelf life, should be installed into

the actuator being refurbished.

3.1.1 Remove and discard all old seals and gaskets.

3.1.2 All parts should be cleaned to remove all dirt and other foreign material prior to inspection.

3.1.3 All parts should be thoroughly inspected for excessive wear, stress cracking, galling and pitting. Attention should be directed to threads, sealing surfaces and areas that will be subjected to sliding or rotating motion. Sealing surfaces of the cylinder, tie bars and piston rod must be free of deep scratches, pitting, corrosion

and blistering or aking coating.

August 2015

CAUTION: INSPECT PARTS BEFORE USE

Actuator parts that reect any of the above listed characteristics should be replaced with

new parts.

3.1.4 Before installation coat all moving parts with a complete lm of lubricant.

Coat all seals with a complete lm of lubricant, before installing into seal grooves.

NOTE:

The parts and seals used in the actuator will be assembled using lubricant as identied in Section 1 step 1.6.1.

3.1.5 For spring module installation refer to Section 5 step 5.4.

3�2 Drive Module Reassembly

NOTE:

Review section 3.1 General Reassembly before proceeding with Drive Module Reassembly.

NOTE:

Refer to assembly drawing page 2 of 2 Detail "B" for section drawing of guide block.

Actuator Reassembly

3.2.1 If guide bar bearings are being replaced install new bearings into guide block (1-30).

Section 3: Actuator Reassembly

August 2015

NOTE:

The guide bar bearing must be press t into guide block guide bar bore with the seam

located 45 ±5 degrees of the top or bottom centerline as shown in section A-A.

NOTE:

G01 model actuators skip steps 3.2.2 through 3.2.13 and continue reassembly at step

3.2.14.

3.2.2 Lubricate guide block (1-30), two spherical washers (1-40), and one extension rod assembly (1-50).

3.2.3 Install one spherical washer (1-40) into the side of guide block (1-30).

NOTE:

The spherical side of washer (1-40) will be facing to the outside of guide block (1-30).

Service Instructions

127073E Rev. C

3.2.4 Install second spherical washer (1-40) over threaded end of extension rod assembly (1-50).

NOTE:

The spherical side of the washer will go on the extension rod assembly facing the head of the extension rod assembly.

3.2.5 Install extension rod assembly (1-50) into guide block (1-30) and up against the rst spherical washer (1-40).

3.2.6 Install extension retainer nut (1-60) over extension rod assembly (1-50) and screw into guide block (1-30).

3.2.7 Tighten extension retainer nut assembly (1-60) until extension rod assembly (1-50).

cannot move. Back off the extension retainer nut assembly (1-60) just enough to allow for extension rod assembly (1-50) to move freely.

NOTE:

Steps 3.2.8 through 3.2.13 are to be completed when the actuator is equipped with a spring module. If the actuator is double-acting then skip steps 3.2.8 through 3.2.13 and continue actuator reassembly starting with step 3.2.14.

3.2.8 Lubricate guide block (1-30), two spherical washers (9-40) and one extension rod assembly (9-50).

3.2.9 Install one spherical washer (9-40) into the side of guide block (1-30).

NOTE:

The spherical side of washer (9-40) will be facing to the outside of guide block (1-30).

3.2.10 Install second spherical washer (9-40) over threaded end of extension rod assembly (9-50).

Actuator Reassembly

Service Instructions

127073E Rev. C

3.2.11 Install extension rod assembly (9-50) into guide block (1-30) and up against the

3.2.12 Install extension retainer nut (9-60) over extension rod assembly (9-50) and screw

3.2.13 Tighten extension retainer nut assembly (9-60) until extension rod assembly (9-50)

NOTE:

Consult Houston, Texas Bettis Service Coordinator for “yoke bearing, yoke pin bearing or yoke/guide block bushing installation information".

Section 3: Actuator Reassembly

August 2015

NOTE:

The spherical side of the washer will go on the extension rod assembly facing the head of the extension rod assembly.

rst spherical washer (9-40).

into guide block (1-30).

cannot move. Back off the extension retainer nut assembly (9-60) just enough to allow for extension rod assembly (9-50) to move freely.

3.2.14 If the two yoke bearings (2-40) are being replaced, install new bearing into housing cover (1-20) and housing (1-10).

NOTE:

The yoke bearing (2-40) must be press t into housing (1-10) and housing cover (1-20).

Install the yoke bearings with the bearing seam located 45 ±5 degrees from the yoke arm slot when yoke (1-70) is rotated to its full clockwise position.

3.2.15 If the two yoke pin thrust bearings (2-10) are being replaced install new bearing into housing cover (1-20) and housing (1-10).

3.2.16 Lubricate two yoke/guide block bushings (2-30) and install onto top and bottom sides of guide block (1-30).

NOTE:

The guide block (1-30) should be already pre-assembled with extension rod assembly and associated parts assembled in the guide block.

3.2.17 Install guide block (1-30), with yoke/guide block bushings (2-30), between arms of yoke (1-70).

3.2.18 Install O-ring seal (2-50) into inner diameter O-ring groove in the bottom of housing (1-10).

3.2.19 Coat the bearing surfaces of the yoke (1-70) with lubricant and install into housing (1-10).

3.2.20 Align hole in guide block (1-30) with the matching holes in the two yoke/guide block bushings (2-30) and the slots in the arms of yoke (1-70).

Actuator Reassembly

Section 3: Actuator Reassembly

August 2015

NOTE:

The yoke pin can be held in place by installing a screw into the .375-16UNC tapped hole in the upper end of yoke pin (1-80).

3.2.21 Install yoke pin (1-80) by inserting into the upper yoke arm, upper yoke/guide block bushing, guide block, lower yoke/guide block bushing, lower yoke arm and resting on lower yoke pin thrust bearing (2-10).

3.2.22 Install guide bar (1-90) into either side of housing (1-10) by inserting through the housing, through guide block and then insert the guide bar into the other side of housing (1-10).

3.2.23 Refer to assembly drawing page 2 of 2 Section A-A. Install spring pin (1-100) into the top of yoke (1-70).

3.2.24 Install position indicator assembly (1-140) onto the top of yoke (1-70) and over spring pin (1-100).

NOTE:

Refer to Section 2 step 2.3.7 for correct installation position.

Service Instructions

127073E Rev. C

3.2.25 Install O-ring (2-50) into housing cover (1-20).

3.2.26 Install housing cover O-ring (2-60) into housing cover (1-20).

3.2.27 Install the housing cover (1-20), being careful not to damage O-ring seals (2-50) and (2-60).

3.2.28 Place lockwashers (1-115) onto hex cap screws (1-110).

NOTE:

On G7 through G10 model actuators apply thread adhesive, Loctite 242, to threads of hex

cap screws (1-110). Reference assembly drawing note number 9.

3.2.29 Install hex cap screws (1-110) with lockwashers (1-115) through housing cover (1-20) and into housing (1-10).

NOTE:

Leave hex cap screws (1-110) nger tight - do not tighten.

3.2.30 NOTE: Do this step only if groove pins (1-130) have been pulled or if the pins are being replaced. Drive groove pins (1-130) through housing cover (1-20) and into housing

(1-10). The groove pins should be ush with the cover.

Actuator Reassembly

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Bettis Manual: Service Instructions Disassembly and Reassembly For Models G01 Through G10 Spring Return Pneumatic Actuators With M11 Hydraulic Override | Bettis Manuals & Guides

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