Bettis Manual: Service Instructions Disassembly and Reassembly For Models G01 Through G13 Series Hydraulic Actuators With Power Module Tie Bar Construction | Bettis Manuals & Guides

Service Instructions

124839E Rev. D

October 2015

G01 through G13 Series Hydraulic Actuators

With Power Module Tie Bar Construction
Disassembly and Reassembly

Service Instructions

124839E Rev. D

Table of Contents

Section 1: Introduction

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

1.2 Denitions .................................................................................................... 2

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

1.4 Bettis Reference Materials ............................................................................. 3

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

1.6 Lubrication Requirements ............................................................................. 3

1.7 Fluid Requirements ....................................................................................... 4

1.8 General Tool Information .............................................................................. 4

1.9 Actuator Storage ........................................................................................... 4

1.10 Actuator Installation ..................................................................................... 4

1.11 Actuator Start-up .......................................................................................... 5

1.12 Actuator Operation ....................................................................................... 6

Table of Contents

October 2015

Section 2: Actuator Disassembly

2.1 General Disassembly ..................................................................................... 7

2.2 Hydraulic Power Module Disassembly ........................................................... 7

2.3 Drive Module Disassembly ............................................................................ 8

2.4 Blind End Cap Module Disassembly ............................................................. 11

Section 3: Actuator Reassembly

3.1 General Reassembly .................................................................................... 12

3.2 Drive Module Disassembly ..........................................................................12

3.3 Hydraulic Power Module Reassembly ..........................................................17

3.4 Blind End Cap Module Reassembly .............................................................. 19

3.5 Actuator Testing ......................................................................................... 19

Section 4: Field Conversions

4.1 Fail Mode Reversal (CW to CCW or CCW to CW) .......................................... 21

4.2 Convert Double-Acting Actuator to Spring-Return ...................................... 21

4.3 Convert Spring-Return Actuator to Double-Acting ...................................... 21

Section 5: Module Removal and Installation

5.1 Spring Module Removal ..............................................................................22

5.2 Spring Module Installation .......................................................................... 24

5.3 Hydraulic Power Module Removal ............................................................... 28

5.4 Hydraulic Power Module Installation ...........................................................28

5.5 G2 Through G13 POWR SWIVL Module Removal ......................................... 29

5.6 G2 Thru G13 POWR SWIVL Module Installation ........................................... 30

Table of Contents

I

Table of Contents

October 2015

Section 6: Actuator Support Information

Section 7: Troubleshooting

Section 8: Removal and Decommissioning

Service Instructions

124839E Rev. D

6.1 Module Weight Tables ................................................................................. 31

6.2 G01 Tool Table ............................................................................................ 32

6.3 G2 Tool Table .............................................................................................. 33

6.4 G3 Tool Table .............................................................................................. 33

6.5 G4 Tool Table .............................................................................................. 34

6.6 G5 Tool Table .............................................................................................. 34

6.7 G7 Tool Table .............................................................................................. 35

6.8 G8 Tool Table .............................................................................................. 35

6.9 G10 Tool Table ............................................................................................ 36

6.10 G13 Tool Table ............................................................................................ 36

7.1 Fault Insertion ............................................................................................. 37

7.2 Operational Test .......................................................................................... 38

8.1 Removal and Decommissioning .................................................................. 39

Section 9: Document Revision ���������������������������������������������40

Appendix A: List of Tables ���������������������������������������������������41

Appendix B: List of Drawings ����������������������������������������������42

II

Table of Contents

Service Instructions

124839E Rev. D

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 G01X0X, G2X0X, G3X0X, G4X0X, G5X0X, G7X0X, G8X0X,
G10X0X and G13X0X double-acting and spring-return Series actuators with one
single hydraulic power module utilizing tie bar construction. This procedure can
also be used on Bettis GXX20X double-acting Series Twin Power Module Hydraulic
actuators.

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.

Section 1: Introduction

October 2015

1�1�3 This procedure is applicable with the understanding that all electrical power and

hydraulic pressure have 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 6.1.
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.

CAUTION: FOLLOW MANUFACTURER'S INSTRUCTIONS

Apply the thread sealant per the manufacturer’s instructions.

1�1�11 Emerson recommends that disassembly of the actuator modules should be done

in a clean area on a work bench.

Introduction

1

Section 1: Introduction

October 2015

1�2 Definitions

WARNING

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

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.

Service Instructions

124839E Rev. D

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

1�3�1 Products supplied by Emerson, in its "as shipped" condition, are intrinsically safe

if the instructions contained within this Service Instruction are strictly adhered to

and executed by well-trained, equipped, prepared and competent personnel.

WARNING: READ WARNING MESSAGES CAREFULLY

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 customers procedures the

differences should be resolved in writing between an authorized customers representative
and an authorized Emerson representative.

2

Introduction

Service Instructions

124839E Rev. D

1�4 Bettis Reference Materials

1�4�1 Assembly Drawing for G01 through G13 Double-Acting One Power Module

Hydraulic Series actuators use part number 116423.

1�4�2 Assembly Drawing for G01 through G13 Double-Acting Twin Power Module

Hydraulic Series actuators use part number 115676.

1�4�3 Assembly Drawing for G01 through G13 Spring-Return One Power Module

Hydraulic Series actuators use part number 115941.

1�5 Service Support Items

1�5�1 Bettis Module Service Kits
1�5�2 For rod extension retainer nut tool, 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;

Section 1: Introduction

October 2015

Table 1� Actuator Model and Part Number

MODEL

G01 None required G5/G7 117369

G2 123616 44 117368

G3/G4 117370 50 122849

1�5�3 Non hardening thread sealant

BETTIS PART

NUMBER

1�6 Lubrication Requirements

NOTE:

Lubricants, other than listed in step 1.6.1, should not be used without prior written ap­proval Emerson 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.

MODEL

BETTIS PART

NUMBER

Introduction

3

Section 1: Introduction

October 2015

1�7 Fluid Requirements

1�7�1 For use in the hydraulic power cylinder. The following listed uids are

recommended uids only and does not limit the use of other hydraulic uids

compatible with supplied seals and coatings.

1.7.1.1 Standard temperature service (-20°F to +350°F)/(-28.9°C to +176.6°C)

use Shell Tellus S2 V Grade 32 automatic transmission uid or an Emerson
approved uid.

1.7.1.2 High temperature service (0°F to +350°F)/(-17°C to +176.6°C) use

Shell Tellus S2 V Grade 32 automatic transmission uid or an Emerson
approved uid.

1.7.1.3 Low temperature service (-50°F to +150°F)/(-45.6°C to 65.6°C) use Mobil

Univis HVI 13 hydraulic uid or an Emerson approved uid.

1�8 General Tool Information

1�8�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 1600 foot pounds/1269 N-m), breaker bar,
and a drive socket set. For recommended tool and wrench sizes refer to Section 6
Tables 6.2 through 6.10.

Service Instructions

124839E Rev. D

1�9 Actuator Storage

For applications where the actuator is not put into immediate service it is recommended
that the actuator be cycled with 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. Also, actuators should not be stored in an

atmosphere harmful to resilient seals. For extended storage, contact the Emerson factory.

1�10 Actuator Installation

1�10�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 guess work out of installation.

1�10�2 Actuators 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 on 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.

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.

4

Introduction

Service Instructions

124839E Rev. D

1�10�3 Good instrument practices are also recommended. Clean/dry regulated hydraulic

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, seals, etc.

1�11 Actuator Start-up

1�11�1 Prestart-up checks

1. Unit has been mounted on valve properly. Gear ange mounting bolts,

stem key, set screw(s) installed and secured

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

3. Indicated position conrms valve position

4. All switching valves in normal operating position as per schematic /
instructions

1�11�2 Check connections:

1. Hydraulic components connected as per schematic enclosed or in service
manual supplied

2. Hydraulic supply connected to identied ports

3. Electrical connections terminals are secure

4. Wiring as per enclosed diagram or service manual supplied

1�11�3 When actuator is rst put into service it should be cycled with regulated

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, exercising the seals, resulting in a service-ready condition.

1�11�4 The actuator speed of operation is determined by a number of factors including:

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

Section 1: Introduction

October 2015

Introduction

5

Section 1: Introduction

October 2015

8. Hydraulic manual override (where available)

1�11�5 Due to the interaction of these variables it is difcult to specify a "normal"

operating time. Faster operating times 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

1�11�6 Slower operating times may be obtained by using ow control valves to meter the

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

1�12 Actuator Operation

1�12�1 Controlled Operation: Controlled operation is accomplished by pressurizing and/or

depressurizing the appropriate cylinder inlet(s) of a double-acting or spring-return
unit by means of an appropriate control valve.

Do not exceed pressures indicated on actuator nameplate�

1�12�2 Manual Operation: All pressure must be vented or equalized on both sides of the

pneumatic piston prior to manual operation.

Service Instructions

124839E Rev. D

6

Introduction

Service Instructions

124839E Rev. D

Section 2: Actuator Disassembly

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
(hydraulic power module or drive module).

2�1�2 When the spring module is to be removed it should be removed from the drive

module prior to the hydraulic power module removal or disassembly.

2�1�3 The hydraulic power module can be disassembled while still attached to the drive

module, or the hydraulic power module can be removed from the drive module
and disassembled separate to the actuator (refer to Section 5 - module removal
and installation).

October 2015

NOTE:

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

2�1�4 To ensure correct reassembly; that is, with hydraulic power module or spring

module on same end of drive module as was marked or tagged right or left and
mark
mating surfaces.

2�1�5 For spring module removal refer to Section 5 step 5.1.

2�2 Hydraulic Power Module Disassembly

NOTE:

1. Review Section 2 steps 2.1.1 through 2.1.5 General Disassembly before proceeding
with hydraulic power module disassembly.

2. If the actuator model is a GXX20X Series (two same-size power modules mounted on
both sides of the drive module) then do the following steps on both power modules
simultaneously or complete one power module and then repeat section 2.2 on the
second power module.

Actuator Disassembly

7

Section 2: Actuator Disassembly

October 2015

WARNING: DISCONNECT OPERATING PRESSURE

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

WARNING: ENSURE SPRING IS DECOMPRESSED

If the actuator is spring-return then the spring cartridge must be checked to verify that the

spring(s) are in their extended position before the hydraulic power module is disassembled

from the drive module (refer to Section 5.1 through step 5.1.6).

2�2�1 Mark and record location of the ports on outer end cap (3-80) and inner end

cap (3-10).

2�2�2 Remove NPT pipe plug or optional SAE O-ring plug (3-120) from outer end cap

(3-80).

2�2�3 Remove hex nuts (3-90) with lockwashers (3-95), from tie bars (3-20).
2�2�4 Remove outer end cap (3-80) from cylinder (3-70) and tie bars (3-20).
2�2�5 Unscrew and remove tie bars (3-20) from inner end cap (3-10).
2�2�6 Remove cylinder (3-70) from inner end cap (3 -10), piston (3-30) and piston rod

(3-40).

2�2�7 Refer to assembly drawing page 2 of 2 Detail "D". Remove two split ring halves

(3-50). and one retainer ring (3-60) from piston rod (3-40).

2�2�8 Remove piston (3-30) from piston rod (3-40).
2�2�9 Remove O-ring seal (4-70) from piston rod (3-40).
2�2�10 Refer to assembly drawing page 2 of 2 Detail "D". Remove two split rings (3-50) and

one retainer ring (3-60) from piston rod (3-40).

2�2�11 Remove hex cap screws (3-115) with lockwashers (3-110) from inner end cap (3-10).
2�2�12 Remove hex nuts (3-105) from hex cap screws (3-100).
2�2�13 Remove hex cap screws (3-100) with lockwashers (3-110) from inner end cap

(3-10) and housing (1-10).

2�2�14 Remove inner end cap (3-10) off of piston rod (3-40).

Service Instructions

124839E Rev. D

NOTE:

The piston rod (3-40) removal as outlined in step 2.2.15 is only required when the piston
rod is being replaced or when the drive module is to be disassembled.

2�2�15 Unscrew and remove piston rod (3-40) from the 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.

2�3�1 If not already removed remove piston rod (3-40) from drive module.

8

Actuator Disassembly

Service Instructions

124839E Rev. D

NOTE:

If the actuator is equipped with submerged stop screws with stop screw covers (1-195)
then proceed to and complete steps 2.3.2.1 and 2.3.2.2 prior to doing step 2.3.2.

2�3�2 Mark stop screws (1-180) left and right. The setting of stop screws (1-180) should

NOTE:

Stop screws will be removed later in this procedure.

NOTE:

For steps 2.3.3 through 2.3.10 refer to assembly drawing page 2 of 2 Section A A and Detail “E”.

Section 2: Actuator Disassembly

October 2015

be checked and setting recorded before stop screws are loosened or removed.

2�3�2�1 Hold stop screw cover (1-195) in place and remove pipe plug (1-260).
2�3�2�2 Hold submerged stop screw (1-180) in place and remove stop screw

cover (1-195).

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 for G4 through
G13 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).
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) or with lockwashers

(1-170), 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.

Actuator Disassembly

2�3�11 Remove hex cap screws (1-120) with lockwashers (1-115) from housing cover (1-20).

9

Section 2: Actuator Disassembly

October 2015

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 screw clockwise until housing cover (1-20) is clear of housing (1-10).

NOTE:

G01, G2, G3 and G4 model housing cover (1-20) will have cast tabs for placing prying tools
to aid in cover removal.

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), extension rod assembly (1-50) and extension rod assembly

(9-50), 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 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).

Service Instructions

124839E Rev. D

10

NOTE:

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

2�3�23 Refer to assembly drawing page 2 of 2 Detail "B". Use Bettis tool part numbers

117368 (G8/G10), 117369 (G5/G7), 117370 (G3/G4), 122849 (G13) or 123616
(G2) and remove retention retainer nut assemblies (1-60) from guide block (1-30).
On spring-return actuators also remove retention retainer nut assemblies (9-60).

2�3�24 Remove rod extension assembly (1-50) from guide block (1-30). On spring-return

actuators also remove rod extension assembly (9-50).

NOTE:

One spherical washer (1-40) will be removed from guide block (1-30) when extension rod
assembly is removed. On spring-return actuators also one spherical washer (9-40) will be
removed from guide block (1-30).

Actuator Disassembly

Service Instructions

124839E Rev. D

2�3�25 Remove the remaining spherical washer (1-40) from guide block (1-30).

On spring-return actuators also remove the remaining spherical washer (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 housing (1-10).
2�3�28 Housing (1-10) vent check assembly removal as follows:

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 G13 housing (1-10) unscrew and remove two vent check

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

2�3�29 The following items do not need to be removed from their assembled locations

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).

Section 2: Actuator Disassembly

2�4 Blind End Cap Module Disassembly

2�4�1 Remove hex cap screws (5-20) with spring lockwashers (5-30), from blind end

cap (5-10).

2�4�2 Remove blind end cap (5-10) from end of housing (1-10).

October 2015

Actuator Disassembly

11

Section 3: Actuator Reassembly

October 2015

Section 3: Actuator Reassembly

3�1 General Reassembly

CAUTION: ONLY USE NEW SEALS

Only new seals, that are still within the seals expectant shelf life, should be installed into
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 and piston rod must be free of deep scratches, pitting, corrosion and

blistering or aking coating.

Service Instructions

124839E Rev. D

CAUTION: REPLACE WORN PARTS

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 housing module will be assembled using lubricant

as identied in Section 1 step 1.6.1. The parts and seals used in the actuator cylinder mod­ule will be assembled using lubricant as identied in Section 1 step 1.7.1.

3�1�5 For Spring Module Installation refer to Section 5 step 5.2.

3�2 Drive Module Disassembly

NOTE:

Review section 3.1 General Reassembly before proceeding with drive module reassembly.

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

12

3�2�1 If guide bar bearings (2-20) is being replaced install new bearings into guide

block (1-30).

Actuator Reassembly