Bettis Service Instructions Disassembly and Reassembly For G01 Through G10 Series Hydraulic Spring Return Actuators With M11 Hydraulic Override Manuals & Guides

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Service Instructions

127072E Rev. C

October 2015

G01 through G10 Series Hydraulic Actuators

Spring-Return Actuators with M11 Hydraulic Override Disassembly and Reassembly

Service Instructions

127072E 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 Requirements ............................................................................. 3

1.7 Fluid Requirements ....................................................................................... 3

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

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

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

1.11 Actuator Start-up .......................................................................................... 4

1.12 Actuator Operation ....................................................................................... 5

Table of Contents

October 2015

Section 2: Actuator Disassembly

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

2.2 Hydraulic Power Module Disassembly .......................................................... 6

2.3 Drive Module Disassembly ............................................................................ 7

2.4 G01 through G5 M11 Hydraulic Override Cylinder Disassembly ................... 10

2.5 G7 through G10 M11 Hydraulic Override Cylinder Disassembly ................... 10

Section 3: Actuator Reassembly

3.1 General Reassembly .................................................................................... 11

3.2 Drive Module Disassembly ..........................................................................11

3.3 Hydraulic Power Module Reassembly ..........................................................16

3.4 G01 through G5 M11 Hydraulic Override Cylinder Reassembly .................... 18

3.5 G7 through G10 M11 Hydraulic Override Cylinder Reassembly .................... 18

3.6 Actuator Testing ......................................................................................... 20

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 with M11 Module ........................................................................... 21

Section 5: Module Removal and Installation

5.1 M11 Override Cylinder Removal .................................................................. 22

5.2 M11 Override Cylinder Installation .............................................................. 23

5.3 Spring Module Removal ..............................................................................24

5.4 Spring Module Installation .......................................................................... 25

5.5 Hydraulic Power Module Removal .............................................................. 27

5.6 Hydraulic Power Module Installation ..........................................................28

5.7 G2 through G10 Powr Swivl™ Removal ....................................................... 29

5.8 G2 through G10 Powr Swivl Module Installation .......................................... 29

ITable of Contents

Table of Contents

October 2015

Section 6: Actuator Support Information

Section 7: Troubleshooting

Section 8: Removal and Decommissioning

Service Instructions

127072E Rev. C

6.1 Module Volume Table .................................................................................31

6.2 Module Weight Tables ................................................................................. 31

6.3 G01 Tool Table ............................................................................................ 33

6.4 G2 Tool Table .............................................................................................. 33

6.5 G3 Tool Table .............................................................................................. 34

6.6 G4 Tool Table .............................................................................................. 34

6.7 G5 Tool Table .............................................................................................. 35

6.8 G7 Tool Table .............................................................................................. 35

6.9 G8 Tool Table .............................................................................................. 36

6.10 G10 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

Table of Contents

Service Instructions

127072E 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 G01X0X.X-SR-M11, G2X0X.X-SR-M11, G3X0X.X-SR-M11, G4X0X.X-SR-M11, G5X0X.X-SR-M11, G7X0X.X-SR-M11, G8X0X.X-SR-M11 and G10X0X.X-SR-M11 Spring-Return Series Single Hydraulic 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

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 is 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.

Section 1: Introduction

October 2015

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.

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

October 2015

CAUTION

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

NOTE:

Advisory and information comments are 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

127072E Rev. C

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 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 For the assembly drawing of G01 through G5 spring-return one power module

hydraulic series actuators use part number 122588.

1�4�2 For the assembly drawing of G7 through G10 spring-return one power module

hydraulic series actuators use part number VA-ED-000-8765-00.

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

127072E Rev. C

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.

Table 1� Actuator Model and Part Number

Section 1: Introduction

October 2015

MODEL

G01 None required G5/G7 117369

G2 123616 G8 117368

G3/G4 117370

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 of Emerson product engineering.

1�6�1 For use in the housing (drive module) and the spring-return cartridge. 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�7 Fluid Requirements

MODEL

BETTIS PART

NUMBER

Introduction

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

recommended uids only and do 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�7�2 For use in the M11 Manual Hydraulic Override System: Hydraulic uids, other than

those listed in steps 1.7.2.1, should not be used without prior written approval of Bettis Product Engineering.

1�7�2�1 All 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.

Section 1: Introduction

October 2015

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 1200 foot pounds / 1627 N-m), breaker bar, and a drive socket set. For recommended tool and wrench sizes refer to Section 6 Tables 6.3 through 6.10.

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 factory.

1�10 Actuator Installation

Service Instructions

127072E Rev. C

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 to

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.

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.

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

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

Introduction

Service Instructions

127072E Rev. C

1�11�2 Check connections:

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

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

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

*Not to exceed maximum operating pressure of actuator or control components

Section 1: Introduction

October 2015

4. Indicated position conrms valve position

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

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

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. 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

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

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.

Introduction

Section 2: Actuator Disassembly

October 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 (hydraulic power module or drive module).

WARNING: CHECK SPRING MODULE

Service Instructions

127072E Rev. C

Do not remove spring module while the 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 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).

2�1�4 To ensure correct reassembly; that is, with hydraulic 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.

2�2 Hydraulic Power Module Disassembly

NOTE:

Review Section 2 steps 2.1.1 through 2.1.5 general disassembly before proceeding with hydraulic power module disassembly.

WARNING: DISCONNECT OPERATING PRESSURE

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

CAUTION: CONTAIN HYDRAULIC FLIUD

Use some means to contain hydraulic uid as the tubing (piping) is disconnected from the

hydraulic power cylinder (2-10).

Actuator Disassembly

Service Instructions

127072E Rev. C

WARNING: CHECK SPRING COMPRESSION

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

2�2�2 Remove hex nuts (3-90), with lockwashers (3-95) from tie bars (3-20). 2�2�3 Remove outer end cap (3-80) from cylinder (3-70) and tie bars (3-20). 2�2�4 Unscrew and remove tie bars (3-20) from inner end cap (3-10). 2�2�5 Remove cylinder (3-70) from inner end cap (3-10), piston (3-30) and piston rod (3-40). 2�2�6 Refer to assembly drawing page 2 of 2 Detail "D". Remove two split ring halves (3-

2�2�7 Remove piston (3-30) from piston rod (3-40). 2�2�8 Remove O-ring seal (4-70) from piston rod (3-40). 2�2�9 Refer to assembly drawing page 2 of 2 Detail "D". Remove two split rings (3-50) and

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

2�2�13 Remove inner end cap (3-10) off of piston rod (3-40).

Section 2: Actuator Disassembly

cap (3-10).

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

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

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

October 2015

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 power module is to be disassembled or removed from the housing (1-10).

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.

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.

Actuator Disassembly

Section 2: Actuator Disassembly

October 2015

For steps 2.3.3 through 2.3.10 refer to assembly drawing page 2 of 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 steps 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).

Service Instructions

127072E Rev. C

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 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).

Actuator Disassembly

Service Instructions

127072E Rev. C

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

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

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

NOTE:

For 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

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

Section 2: Actuator Disassembly

October 2015

block bushings (2-30) by lifting yoke up and out of the housing (1-10).

and pull straight up and out.

yoke (1-70).

117368 (G8/G10), 117369 (G5/G7), 117370 (G3/G4), 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).

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

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 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 For 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 For G4 through G10 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 (2-20), two yoke bearings (2-40), yoke pin bearing (2-25), yoke pin thrust bearing (2-10) and spring pin (1-100).

Actuator Disassembly

Section 2: Actuator Disassembly

October 2015

Service Instructions

127072E Rev. C

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).

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

127072E Rev. C

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.

October 2015

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 5.4.

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.

Actuator Reassembly

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

block (1-30).

Section 3: Actuator Reassembly

October 2015

NOTE:

The guide bar bearing (2-20) must be pressed 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.

For 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 the outside of guide block (1-30).

3�2�4 Install second spherical washer (1-40) over threaded end of extension rod

assembly (1-50).

Service Instructions

127072E Rev. C

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) is immovable. 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 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

127072E Rev. C

NOTE:

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

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-

NOTE:

Consult Houston, Texas Bettis Service Coordinator for “yoke bearing, yoke pin bearing or

yoke/guide block bushing installation information."

Section 3: Actuator Reassembly

October 2015

rst spherical washer (9-40).

into guide block (1-30).

50) is immovable. 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 pressed 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 preassembled 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

October 2015

NOTE:

The yoke pin can be held in place by installing a screw into the .375 16 UNC 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, and 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

127072E 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), while 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.

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

Service Instructions

127072E Rev. C

3�2�30 Torque tighten hex cap screws (1-110) until a nal lubricated torque, as listed in

Section 3: Actuator Reassembly

the following table, has been achieved.

Table 2� Housing Cover Screw Quantity and Torque

October 2015

Model Qty�

G01 4 40 54 G5 8 100 136

G2 6 40 54 G7 8 100 136 G3 8 40 54 G8 12 100 136 G4 8 40 54 G10 16 100 136

TORQUE (±5%)

Lbf-ft� N-m Lbf-ft� N-m

Model Qty�

TORQUE (±5%)

NOTE:

Complete step 3.2.32 on G5, for G10 model actuators. For G01 through G4 model actuators skip step 3.2.32 and proceed to step 3.2.33.

3�2�31 On G5 through G10 models:

3�2�31�1 Place lockwashers (1-115) onto hex cap screws (1-120).

NOTE:

Hex cap screws (1-120) are only used as "hole" llers and serve to protect threads from environment.

3�2�32 Install and tighten hex cap screws (1-120) with lockwashers (1-115). 3�2�33 Install thrust bearing (2-110) onto position indicator (1-140). 3�2�34 Install O-ring seal (2-100) onto position indicator (1-140). 3�2�35 Install upper bearing (2-120) into yoke cover (1-150). 3�2�36 Install rod wiper (2-80) into yoke cover (1-150). 3�2�37 Install O-ring seal (2-70) into yoke cover (1-150). 3�2�38 Install yoke cover (1-150) onto housing cover (1-20) and over position indicator

assembly (1-140).

Actuator Reassembly

NOTE:

During yoke cover installation be careful not to damage O-ring seal (2-70) and rod wiper (2-80).

3�2�39 Place lockwashers (1-170) onto hex cap screws (1-160). 3�2�40 Install and tighten hex cap screws (1-160) with lockwashers through yoke cover

(1-150) and into housing cover (1-20).

3�2�41 Vent check assembly installation as follows:

3�2�41�1 For G01, G2 and G3 housing (1-10) using pipe sealant install one vent

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

3�2�41�2 For G2 and G3 housing (1-10) using pipe sealant install one vent check

assembly (13) into the top area of housing cover (1-20).

3�2�41�3 For G4 through G10 housing (1-10) using pipe sealant install two vent

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

Section 3: Actuator Reassembly

October 2015

NOTE:

Refer to Section 2 step 2.3.3 for correct position indicator placement. Install position indi-

cator (1-220) over the exposed shaft of position indicator assembly (1-140).

3�2�42 Install stop screw nuts (1-190) onto stop screws (1-180). 3�2�43 Install O-ring (2-90) onto stop screws (1-180). 3�2�44 Install two stop screws (1-180) into two stop screw holes on the front of housing (1-10). 3�2�45 Adjust both stop screws (1-180) back to settings recorded earlier in Section 2 at

step 2.3.2.

3�2�46 Tighten both stop screw nuts (1-190) securely.

Service Instructions

3�3 Hydraulic Power Module Reassembly

NOTE:

Review Section 3.1 General Reassembly before proceeding with hydraulic power module reassembly.

127072E Rev. C

In Section 3.3 where the step indicates to "lubricate, coat or apply uid", use hydraulic uid

for lubricating the part being installed.

3�3�1 Lubricate piston rod (3-40) with uid. 3�3�2 Install O-ring seal (4-70) into the seal groove in piston rod (3-40). 3�3�3 Install two split ring halves (3-50) into the inner most groove in piston rod (3-40)

and retain with one retainer ring (3-60).

3�3�4 Install piston (3-30) onto piston rod (3-40) and up against split rings install as

instructed in step 3.3.3.

3�3�5 Install two split ring halves (3-50) into the outer most groove in piston rod (3-40)

and retain with one retainer ring (3-60).

3�3�6 Apply uid to the bore of cylinder (3-70). 3�3�7 Coat one piston bearing (4-45) with uid and install into the piston external seal groove. 3�3�8 Install piston (3-30), with piston rod (3-40), into cylinder (3-70) and leave the inner

most piston seal groove outside of the cylinder.

3�3�9 Coat one piston seal (4-60) with uid and install into the piston external seal groove.

CAUTION: INSTALL PISTON SEAL CORRECTLY

Install the piston seal with energizer ring facing the outside edge of piston (3-30).

3�3�10 Push the piston through the cylinder (3-70) until the outboard piston seal groove

is exposed.

NOTE:

Moving the piston (3-30) through the bore of cylinder (3-70) may require mechanical assistance.

Actuator Reassembly

Service Instructions

127072E Rev. C

3�3�11 Coat one piston seal (4-60) with uid and install into the piston external seal groove.

CAUTION: INSTALL PISTON SEAL CORRECTLY

Install the piston seal with energizer ring facing the outside edge of piston (3-30).

3�3�12 Refer to assembly drawing page 2 of 2 Detail "C". Coat Polypak seal (4-30) with

CAUTION: INSTALL POLYPAK SEAL CORRECTLY

Install the Polypak seal with energizer ring facing piston side of inner end cap (3-10).

3�3�13 Install rod bushing (4-20) into inner end cap (3-10). 3�3�14 Install rod wiper (4-10) into inner end cap (3-10). 3�3�15 Install one O-ring seal (4-90) into inboard face of inner end cap (3-10). 3�3�16 Install inner end cap (3-10) onto piston rod (3-40). 3�3�17 Install two tie bars (3-20) into inner end cap (3-10).

Section 3: Actuator Reassembly

hydraulic uid and install, lip rst, into inner end cap (3-10).

October 2015

NOTE:

The tie bars should be installed across from each other.

3�3�18 Install one O-ring seal (4-40) into inboard face of outer end cap (3-80). 3�3�19 Install outer end cap (3-80) into open end of cylinder (3-70).

NOTE:

The pressure inlet ports of the inner and outer end caps should be positioned in the same position as recorded in Section 2 step 2.2.1.

3�3�20 Install the remaining tie bars (3-20) through outer end cap (3-80) and into inner

end cap (3-10). Screw all tie bars (3-20) into inner end cap until dimension "A" (as shown on assembly drawing page 1 of 2) is achieved.

3�3�21 Install lockwashers (3-95) onto tie bars (3-20) and up against outer end cap (3-80). 3�3�22 Install hex nuts (3-90) onto tie bars (3-20) and up against lockwashers (3-95). 3�3�23 Torque tighten hex nuts (3-90) until a nal lubricated torque, as listed in the

following table, has been achieved.

Table 3� Tie Bar Nuts (3-90) Torque Table

Model

G01 70 95 G5 385 522

G2 70 95 G7 580 786 G3 70 95 G8 580 786 G4 135 183 G10 1000 1356

TORQUE (±5%)

Lbf-ft� N-m Lbf-ft� N-m

Model

TORQUE (±5%)

Actuator Reassembly

Section 3: Actuator Reassembly

October 2015

3�3�24 If the power module is reassembled off the actuator then refer to Section 5 step

5.4 for hydraulic power module installation instructions.

Service Instructions

127072E Rev. C

3�4 G01 through G5 M11 Hydraulic Override

Cylinder Reassembly

NOTE:

Review Section 3.1 General Reassembly before proceeding with G01 through G5 M11 hydraulic override cylinder reassembly.

3�4�1 Install ram bushing (8-20) into hydraulic ram cover (7-10). 3�4�2 Install Polypak seal (8-30) into hydraulic ram cover (7-10).

NOTE:

The lip of Polypak seal (8-30) should face toward the hydraulic override end cap when installed in the hydraulic ram cover.

3�4�3 Install rod wiper (8-10) into hydraulic ram cover (7-10). 3�4�4 Install hydraulic ram (7-20) into hydraulic ram cover (7-10).

NOTE:

When installing the hydraulic ram (7-20) push it through the hydraulic ram cover until the

ram is at least ush with the outboard ram cover.

3�4�5 Install O-ring seal (8-35) into inner diameter seal groove located at the outboard

end of the threads in the hydraulic override end cap (7-70).

3�4�6 Install hydraulic ram cover (7-10) into the hydraulic override end cap (7-70) by

screwing the ram cover into the end cap until the ram cover bottoms out into the end cap.

NOTE:

For M11 hydraulic override cylinder installations refer to Section 5 step 5.2.

3�5 G7 through G10 M11 Hydraulic Override

Cylinder Reassembly

NOTE:

Review Section 3 step 3.1 General Reassembly before proceeding with G7 through G10 M11 hydraulic override cylinder reassembly.

3�5�1 Install Polypak seal (8-30) into hydraulic cylinder assembly (7-10).

Actuator Reassembly

Service Instructions

127072E Rev. C

NOTE:

The lip of Polypak seal (8-30) will face toward the hydraulic override end cap when installed in the hydraulic cylinder assembly.

3�5�2 Install rod bushing (8-20) into hydraulic cylinder assembly (7-10). 3�5�3 Install rod wiper (8-10) into hydraulic cylinder assembly (7-10). 3�5�4 Install two split ring halves (7-30) into the inner most groove in piston rod (7-20)

3�5�5 Apply hydraulic uid to O-ring seal (8-50) and install it into the seal groove located

3�5�6 Install the piston (7-50) onto the piston rod (7-20) and up against the split rings

3�5�7 Install two split ring halves (7-30) into the outboard groove in piston rod (7-20)

3�5�8 Install Polypak seal (8-60) into outer diameter seal groove of piston (7-50).

Section 3: Actuator Reassembly

and retain by installing retainer ring (7-40) onto the split ring halves.

between the two split ring grooves on the piston rod (7-20).

install as instructed in step 3.5.4.

and retain by installing retainer ring (7-40) onto the split ring halves.

October 2015

NOTE:

The lip of Polypak seal (8-60) should face toward the hydraulic override outer end cap (7-

70) when installed in the hydraulic cylinder assembly.

3�5�9 Install piston bearing (8-40) into outer diameter bearing groove of piston (7-50). 3�5�10 Install O-ring seal (8-80) into inner diameter seal groove located in the piston (7-50). 3�5�11 Use pipe dope on the threads and install pipe plug (7-110) into the vent tube hole

in the inboard end of the hydraulic cylinder assembly (7-10).

3�5�12 Install vent tube (7-60) into the hydraulic cylinder assembly inboard end. 3�5�13 Install the assembled piston rod (7-20) with piston (7-50) into the open end of the

hydraulic cylinder assembly and install the piston over the vent tube (7-60).

3�5�14 Install O-ring seal (8-90) into the vent tube port located in the outer end cap (7-70). 3�5�15 Install O-ring seal (8-70) into the O-ring groove located on the inner diameter of

the hydraulic cylinder assembly ange opening.

3�5�16 Install the outer end cap (7-70) assembled piston rod (7-20) with piston (7-50) onto

the open end of the hydraulic cylinder assembly and over the vent tube (7-60).

3�5�17 Install lockwashers (7-90) onto hex cap screws (7-80). 3�5�18 Install and tighten hex cap screws (7-80), with lockwashers (7-90) through outer

end cap (7-70) and into hydraulic cylinder assembly.

NOTE:

For M11 hydraulic override cylinder installations refer to Section 5 step 5.2.

Actuator Reassembly

Section 3: Actuator Reassembly

October 2015

3�6 Actuator Testing

3�6�1 Leakage Test: All sources of leakage to atmosphere and across piston are to be

checked, using hydraulic pressure.

3�6�2 Cycle the actuator ve times at 10 percent of the operating pressure, as listed on

the cylinder name tag under maximum pressure.

NOTE:

If excessive leakage across the piston remains, the actuator must be disassembled and the

cause of leakage must be determined and corrected.

3�6�3 Apply operating pressure as listed in step 3.6.2 to one side of the piston and allow

the actuator to stabilize.

3�6�4 Repeat the above procedure for the opposite side of the piston. 3�6�5 If an actuator was disassembled and repaired, the above leakage test must be

performed again.

3�6�6 Shell test the actuator as follows: Apply 1.5 times the pressure listed on the

cylinder name tag to both sides of the piston simultaneously for a period of two (2) minutes.

Service Instructions

127072E Rev. C

NOTE:

If any leakage occurs during step 3.6.6 the actuator must be disassembled and the cause of leakage must be determined and corrected.

3�6�7 If an actuator was disassembled and repaired, the above testing must be

performed again.

3�6�8 Shell Pressure Test – Optional pressure test could be performed on the actuator by

applying pressure to both sides of the piston simultaneously for a period of two (2) minutes. If any leakage occurs across a static seal, the unit must be disassembled and the cause of leakage determined and corrected.

WARNING: FIELD TEST WITH GUIDANCE

The actuator's main pressure bearing parts will be tested in controlled conditions by pressuring both sides of the piston to avoid damage and over torquing of the actuator components. If further future testing in the eld is necessary, Emerson should be contacted for guidance.

3�6�9 After the actuator is installed on the valve all accessories should be hooked up and

tested for proper operation and replaced if found defective.

Actuator Reassembly

Service Instructions

127072E Rev. C

Section 4: Field Conversions

October 2015

Section 4: Field Conversions

4�1 Fail Mode Reversal (CW to CCW or CCW to CW)

4�1�1 Remove spring module per Section 5.3. 4�1�2 Remove hydraulic power module per Section 5.5. 4�1�3 Reinstall the spring module onto the opposite end of housing (1-10) as it was

previously located per Section 5.4.

4�1�4 Reinstall the override cylinder assembly into spring module per Section 5.2.

4�2 Convert Double-Acting Actuator to

Spring-Return with M11 Module

4�2�1 Remove blind end cap per steps 4.2.1.1 and 4.2.1.2.

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

end cap (5-10).

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

4�2�2 If hydraulic power module needs to be relocated due to fail mode requirements

(fail counterclockwise) use Section 5.3 for removal and Section 5.4 for installation.

4�2�3 Install Powr Swivl module per Section 5.6. 4�2�4 Install the spring module onto the end of housing (1-10) per Section 5.4. 4�2�5 Install the override cylinder assembly into spring module per Section 5.2.

Field Conversions

Section 5: Module Removal and Installation

October 2015

Service Instructions

127072E Rev. C

Section 5: Module Removal and Installation

5�1 M11 Override Cylinder Removal

5�1�1 Shut off and exhaust the operating media from both sides of the actuator’s power

cylinder.

5�1�2 Place the M11 pump control knob (20-320) in the auto position.

NOTE:

Control knob (20-320) is located in front and at the bottom of the M11 pump manifold (20-10).

Use a means of capturing the hydraulic uid that will be lost during the following steps. Use

a bucket, tub, and large container, etc.

5�1�3 Remove all the piping from the M11 override cylinder end cap (7-70). 5�1�4 M11 hydraulic override cylinder removal: For models G01 through G5 use step

5.1.5 and for G7 through G10 use step 5.1.6.

WARNING: CONFIRM PUMP CONTROL KNOB POSITION

Conrm that the M11 pump control knob is in the auto position prior to completing step

5.1.5. Do not stand directly in front of the M11 override cylinder when completing step

5.1.5. Stand to one side or the other.

5�1�5 G01 through G5 M11 override cylinder removal.

5�1�5�1 Unscrew and remove hex cap screws (7-80) with lockwashers (7-90) from

override cylinder end cap (7-70).

5�1�5�2 Remove override cylinder assembly from spring cartridge assembly (5-10).

5�1�6 G7 through G10 M11 override cylinder removal.

CAUTION: DO NOT REMOVE HEX CAP SCREWS

Do not remove hex cap screws (7-80) from M11 override cylinder at this time. If hex cap screws (7-80) are removed at this time it is possible that hydraulic uid will be dumped

inside the spring cartridge.

5�1�6�1 Unscrew and remove hex cap screws (7-100) with lockwashers (7-90)

from override cylinder end cap (7-70).

Module Removal and Installation

Service Instructions

127072E Rev. C

NOTE:

To identify hex cap screws (7-100) from hex cap screws (7-80), hex cap screws (7-100) will

be located to the left and right of spring-return cartridge top dead center and will then be

counted as every other hex cap screw. To verify correct hex cap screws check the following

table for screw length.

Section 5: Module Removal and Installation

Table 4� Wire Length Requirements

October 2015

MODEL

G/GC/GH/

GHC

G7 2 50.8 2.75 69.85

G8 3 76.2 4.5 114.3

G10 3.5 88.9 5.0 127

5�1�6�2 Remove override cylinder assembly from spring cartridge assembly (5-10).

ITEM 7-80 LENGTH ITEM 7-100 LENGTH

Inches mm Inches mm

5�2 M11 Override Cylinder Installation

5�2�1 Install O-ring seal (6-10) into the O-ring groove in the outboard end of spring

cartridge assembly (5-10).

5�2�2 M11 hydraulic override cylinder installation: For models G01 through G5 use step

5.2.3 and for G7 through G10 use step 5.2.4.

5�2�3 G01 through G5 M11 override cylinder installation

5�2�3�1 Insert M11 hydraulic override cylinder assembly through spring cartridge

outer end.

5�2�3�2 Install lockwashers (7-90) on to hex cap screws (7-80). 5�2�3�3 Install hex cap screws (7-80) with lockwashers (7-90) through hydraulic

override end cap (7-70) and into outer end of spring cartridge (5-10).

5�2�4 G7 through G10 M11 override cylinder installation

5�2�4�1 Insert M11 hydraulic override cylinder assembly into spring cartridge

outer end.

5�2�4�2 Install lockwashers (7-90) on to eight hex cap screws (7-100). 5�2�4�3 Install hex cap screws (7-100) with lockwashers (7-90) through hydraulic

override end cap (7-70) and into outer end of spring cartridge (5-10).

5�2�5 Torque tighten hex cap screws (7-100 and 7-80), alternately until a nal lubricated

torque, as listed in the following table, has been achieved.

Module Removal and Installation

Table 5� M11 Override Cylinder End Cap to SR Cartridge Screw Torque

Model

G01 16 21.68 G5 40 54.2

G2 16 21.68 G7 80 108.4 G3 16 21.68 G8 130 176.15 G4 40 54.2 G10 190 257.45

TORQUE (±5%)

Lbf-ft� N-m Lbf-ft� N-m

Model

TORQUE (±5%)

Section 5: Module Removal and Installation

October 2015

5�2�6 Using pipe dope on threads reinstall all piping between hydraulic override cylinder

assembly and the M11 pump.

5�2�7 Fluid lling instructions for M11 and M11-S hydraulic override systems:

5�2�7�1 To uid ll M11 manual hydraulic override system refer to instructions

part number 126858.

5�2�7�2 To uid ll M11-S manual hydraulic override system refer to instructions

part number 121960.

5�3 Spring Module Removal

WARNING: CHECK SPRING CARTRIDGE POSITION

The spring cartridge must be checked to verify that the spring(s) are in their extended position before the spring cartridge is removed from the actuator.

NOTE:

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.

Service Instructions

127072E Rev. C

Review Section 2.1 General Disassembly before proceeding with spring module disassembly.

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

5�3�1 Shut off and exhaust the operating media from both sides of the actuator’s power

cylinder.

5�3�2 The M11 override cylinder must be removed prior to spring module removal:

Proceed to section 5.1 and complete all steps 5.1.1 through 5.1.6, and then continue with step 5.3.3.

5�3�3 Apply hydraulic pressure to the pressure inlet port of inner end cap (3-10) to

compress the spring enough to move the yoke off the stop screw on the spring module side of the drive module.

5�3�4 Loosen the stop screw nut (1-190) located on the stop screw that is closest to or

next to spring module.

5�3�5 Unscrew stop screw (1-180) that is closest to or next to spring cartridge module

(unscrew or back out until the load is removed from the stop screw).

5�3�6 Remove hydraulic pressure from pressure inlet port of inner end cap (3-10).

CAUTION: USE PROPER LIFTING EQUIPMENT

Due to the weight and size of spring cartridge assembly (5-10), heavy duty support equipment will be required when removing spring cartridge assembly from the actuator housing. Refer to Section 6 for spring cartridge module weights.

Module Removal and Installation

Service Instructions

127072E Rev. C

5�3�7 The spring cartridge "pre load" must be removed before spring cartridge (5-10)

CAUTION: OBSERVE CORRECT OPERATING PRESSURE

The maximum pressure to be applied in step 5.3.8 is 25 PSIG.

5�3�8 Apply hydraulic pressure, not to exceed the maximum as indicated in the above

NOTE:

If hydraulic pressure is not available to apply to the pressure inlet port of outer end cap (3-

80), remove hex plug (3-120). Using a long rod, go through the outer end cap vacant pipe

plug port hole and push on the piston rod so as to move the spring cartridge tension rod

hex nut out of its cast hex seat.

Section 5: Module Removal and Installation

October 2015

is removed from housing (1-10). Refer to steps 5.3.4 through 5.3.6 for spring cartridge "pre-load" removal.

“CAUTION”, on the pressure inlet port of outer end cap (3-80) to move the spring

cartridge tension rod hex nut out of its cast hex seat.

5�3�9 Unscrew the spring cartridge tension rod from the drive module. The tension rod

can be rotated for removal by going through the open end of spring cartridge

assembly with a square male drive extension.

5�3�10 Remove hex cap screws (5-20) with lockwashers (5-30) from housing (1-10). 5�3�11 Remove spring cartridge assembly (5-10) from actuator housing (1-10).

WARNING: DO NOT CUT SPRING CARTRIDGE

Under no circumstances should the spring cartridge assembly (5-10) be cut apart, as the spring is preloaded and the spring cartridge is a weld assembly.

5�4 Spring Module Installation

CAUTION: USE PROPER LIFTING EQUIPMENT

Due to the weight and size of spring module, heavy duty support equipment will be required when installing spring cartridge module to the actuator housing. For the approximate weight of the spring cartridge refer to Section 6.

WARNING: CHECK OVERTRAVEL POSITION

Actuator must be in the appropriate overtravel position (see detail “A” on warning tag attached to spring module access hole cover or to Bettis drawing part number 123650).

Conrm overtravel position by observing if the guide block (1-30) is against the inner wall

of housing (1-10).

Module Removal and Installation

Section 5: Module Removal and Installation

October 2015

NOTE:

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

5�4�1 On stop screw (1-180), that is located on the same side of the housing as spring

cartridge (5-10), loosen stop screw nut (1-190).

5�4�2 Unscrew or back out stop screw (1-180) to achieve overtravel as illustrated in detail

“A” on warning tag attached to spring module cover plate or to Bettis drawing part number 123650.

5�4�3 Install O-ring seal (6-20) into the O-ring groove in the inboard end of spring

cartridge assembly (5-10).

5�4�4 Using lifting equipment move spring module up to housing (1-10) and align spring

cartridge tension rod with extension rod assembly (9-50).

WARNING: COMPLETE STEP 5.4.5

Complete step 5.4.5 to avoid severe injury to personnel or incur major damage to the actuator.

Service Instructions

127072E Rev. C

5�4�5 Spring cartridge tension rod to rod extension installation as follows:

5�4�5�1 Using a male square drive extension, go through the open end of

spring module (5-10) and rotate the tension rod nut until initial thread engagement is achieved.

NOTE:

Conrm initial thread engagement of rod extension (9-50) to tension rod.

5�4�5�2 After conrming initial thread engagement rotate tension rod into

extension rod assembly (9-50) per the following table.

WARNING: OBSERVE MINIMUM NUMBER OF TURNS

After initial thread engagement the tension rod must be rotated clockwise, the minimum number of turns listed in the following table.

Table 6� Rod Rotation

ACTUATOR MODEL

MINIMUM NO� TURNS

Torque Units

N/A 6 10 10 10 13 14 20 25

G01 G2 G3 G4 G5 G7 G8 G10

WARNING: DO NOT CROSS-THREAD TENSION RODS

When screwing tension rod into extension rod assembly (9-50) ensure that the tension rod and extension rod assembly threads do not cross-thread.

Module Removal and Installation

Service Instructions

127072E Rev. C

5�4�6 Torque tighten the spring cartridge tension rod as listed in the following table.

Section 5: Module Removal and Installation

Table 7� Spring Cartridge Tension Rod Torque Table

October 2015

Housing

Model

G01 50 68 G5 240 325

G2 90 122 G7 240 325 G3 90 122 G8 240 325 G4 240 325 G10 240 325

5�4�7 Install lock washers (5-30) onto hex cap screws (5-20). 5�4�8 Install hex cap screws (5-20) with lockwashers (5-30) through housing (1-10) and

into spring cartridge assembly (5-10) and tighten.

5�4�9 Install O-ring seal (6-10) into the O-ring groove in the outboard end of spring

cartridge assembly (5-10).

5�4�10 Install lockwashers (7-30) onto hex cap screws (7-20). 5�4�11 Install end cap (7-70) onto the outboard end of spring cartridge assembly (5-10). 5�4�12 Install and tighten hex cap screws (7-80) with lockwashers (7-90) through end cap

(7-70) and into spring cartridge assembly (5-10).

5�4�13 Torque tighten hex cap screws (7-100 and 7-80) alternately until a nal lubricated

torque, as listed in the following table, has been achieved.

Table 8� Spring Cartridge Tension Rod Torque Table

Housing

Model

G01 16 21.68 G5 40 54.2

G2 16 21.68 G7 80 108.4 G3 16 21.68 G8 130 176.15 G4 40 54.2 G10 190 257.45

TORQUE (±5%)

Lbf-ft� N-m Lbf-ft� N-m

TORQUE (±5%)

Lbf-ft� N-m Lbf-ft� N-m

Housing

Model

Housing

Model

TORQUE (±5%)

5�4�14 If removed install stop screw nuts (1-190) onto stop screws (1-180). 5�4�15 If removed install O-ring (2-90) onto stop screws (1-180). 5�4�16 If removed install two stop screws (1-180) into two stop screw holes on the front

of housing (1-10).

5�4�17 Adjust both stop screws (1-180) back to settings recorded earlier in Section 5. 5�4�18 Tighten both stop screw nuts (1-190) securely.

5�5 Hydraulic Power Module Removal

WARNING: CONFIRM EXTENDED SPRING POSITION

The spring cartridge must be checked to verify that the spring(s) are in their extended position before the power module is removed from the actuator.

Module Removal and Installation

Section 5: Module Removal and Installation

October 2015

NOTE:

Review Section 2.1 General Disassembly before proceeding with the hydraulic power module disassembly.

Use a means of capturing the hydraulic uid that will be lost during the following steps. Use

a bucket, tub, and large container, etc.

5�5�1 Remove O-ring plug (3-120) from outer end cap (3-80). 5�5�2 Using a male square drive extension, go through outer end cap (3-80) and unscrew

piston rod (3-40) from extension rod assembly (1-50).

WARNING: USE APPROPRIATE LIFTING EQUIPMENT

Use suitable lifting equipment to support the cylinder assembly.

5�5�3 Remove hex cap screws (3-115), with lockwashers (3-110), from inner end cap (3-10). 5�5�4 Remove hex nuts (3-105) from hex cap screws (3-100). 5�5�5 Remove hydraulic power module from actuator housing (1-10).

Service Instructions

127072E Rev. C

5�6 Hydraulic Power Module Installation

NOTE:

Review section 3.1 General Reassembly before proceeding with hydraulic power module installation.

5�6�1 Check to verify if O-ring seal (4-90) is properly seated in its seal groove located on

the housing side of inner end cap (3-10).

5�6�2 Using lifting equipment move the power module up to housing (1-10) and align

piston rod (3-40) with extension rod assembly (1-50).

5�6�3 Using a male square drive extension, go through outer end cap (3-80) and screw

piston rod (3-40) into extension rod assembly (1-50).

WARNING: DO NOT CROSS-THREAD RODS

When screwing piston rod into extension rod assembly (1-50) ensure that the piston rod and extension rod assembly threads do not cross thread.

5�6�4 Torque tighten piston rod (3-40) to 240 foot pounds lubricated. 5�6�5 Install lock washers (3-110) onto hex cap screws (3-115). 5�6�6 Install hex cap screws (3-115), with lockwashers (3-110), through inner end cap

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

5�6�7 Install lock washers (3-110) onto hex cap screws (3-100). 5�6�8 Install hex cap screws (3-100), with lockwashers (3-110), through inner end cap

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

5�6�9 Install and tighten hex nuts (3-105) onto hex cap screws (3-100). 5�6�10 Using pipe dope, install pipe plug (3-120) into outer end cap (3-80).

Module Removal and Installation

Service Instructions

127072E Rev. C

Section 5: Module Removal and Installation

5�7 G2 through G10 Powr Swivl™ Removal

5�7�1 Push the guide block to the side of housing (1-10) that will expose the extension

rod assembly (1-50).

NOTE:

The guide block can be moved by inserting a long non-metallic rod through the hole where the blind end cap was removed and pushing on the guide block.

5�7�2 Refer to assembly drawing page 2 of 2 Detail "B". Use Bettis tool part number as

listed in chart in Section 1 step 1.5.2 to remove retainer nut assembly (1-60) from the guide block (1-30).

CAUTION: CAREFULLY HANDLE SPHERICAL WASHERS

When removing rod extension assembly from guide block be careful not to drop one of the

spherical washers inside the housing.

October 2015

5�7�3 Remove rod extension assembly (1-50) from guide block (1-30).

NOTE:

One spherical washer (1-40) will be removed from guide block (1-30) when extension rod assembly is removed.

5�7�4 Remove the remaining spherical washer (1-40) from guide block (1-30).

5�8 G2 through G10 Powr Swivl Module Installation

WARNING: CONFIRM OVERTRAVEL POSITION

The actuator must be in the appropriate overtravel position. Conrm overtravel position by

observing if the guide block (1-30) is against the inner wall of housing (1-10).

5�8�1 Push the guide block to the required side of the housing (1-10).

NOTE:

The guide block can be moved by inserting a long rod through either end of the housing and pushing on the guide block.

5�8�2 Lubricate two spherical washers (1-40) and one extension rod assembly (1-50). 5�8�3 Install one spherical washer (1-40) into the side of guide block (1-30).

Module Removal and Installation

Section 5: Module Removal and Installation

October 2015

NOTE:

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

5�8�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.

5�8�5 Install extension rod assembly (1-50) into right of guide block (1-30) and up

against the rst spherical washer (1-40).

5�8�6 Install extension retainer nut assembly (1-60) over extension rod assembly (1-50)

and screw into guide block (1-30).

5�8�7 Tighten extension retainer nut assembly (1-60) until extension rod assembly

(1-50) is immovable. Back off the extension retainer nut assembly (1-60) just enough to allow for extension rod assembly (1-50) to move freely.

Service Instructions

127072E Rev. C

Module Removal and Installation

Service Instructions

Section 6: Actuator Support Information

127072E Rev. C

Section 6: Actuator Support Information

6�1 Module Volume Table

Table 9� M11 Hydraulic Override System Fluid Volume Table

ACTUATOR SIZE G01 G2 G3 G4 G5 G7 G8 G10

October 2015

APPROX� VOLUME

FLUID FOR M11

SYSTEM

Quarts 1.6 1.8 2.0 3.6 10.2 9.7 15.9 27.0

Liters 1.5 1.7 1.9 3.4 9.6 9.1 15.1 25.6

6�2 Module Weight Tables

Table 10� Module Weights by Item Number and Actuator Housing Size

ITEM

NO�

Lbs 83 110 162 280 545 1025 1495 2550

Lbs 26 N/A N/A N/A N/A N/A N/A N/A

Lbs 25 30 N/A N/A N/A N/A N/A N/A

Lbs 26 29 43 N/A N/A N/A N/A N/A

Lbs 27 30 45 N/A N/A N/A N/A N/A

Lbs 28 31 48 71 N/A N/A N/A N/A

Lbs 29 35 48 84.5 N/A N/A N/A N/A

Lbs 32 38 52 83 160 N/A N/A N/A

Lbs N/A 42 57 84 170 287 N/A N/A

Lbs N/A N/A 59 86 177.5 301 N/A N/A

Lbs N/A N/A N/A 92 173 317 411 N/A

Lbs N/A N/A N/A 106 184 303 475 729

Lbs N/A N/A N/A N/A 194 331 485 783

Lbs N/A N/A N/A N/A 228 337 459 756

G01 WT�G2WT�G3WT�G4WT�G5WT�G7WT�G8WT�

Kg 38 50 73 127 247 465 678 1157

Kg 12 N/A N/A N/A N/A N/A N/A N/A

Kg 11.4 13.6 N/A N/A N/A N/A N/A N/A

Kg 11.7 13 19.5 N/A N/A N/A N/A N/A

Kg 12.2 13.6 20.4 N/A N/A N/A N/A N/A

Kg 12.7 14.1 21.7 32 N/A N/A N/A N/A

Kg 13 15.8 21.7 38 N/A N/A N/A N/A

Kg 14.5 17.2 23.5 37.6 73 N/A N/A N/A

Kg N/A 19 25.8 38 77 130 N/A N/A

Kg N/A N/A 26.7 39 80.5 136 N/A N/A

Kg N/A N/A N/A 41.7 78 144 186 N/A

Kg N/A N/A N/A 49 83 137 215 331

Kg N/A N/A N/A N/A 88 150 220 255

Kg N/A N/A N/A N/A 103 153 208 343

G10 WT�

DESCRIPTION

Drive Module

1.5” Dia.

Power Module

1.7” Dia.

Power Module

2.0” Dia.

Power Module

2.2” Dia.

Power Module

2.5” Dia.

Power Module

3.0” Dia.

Power Module

3.5” Dia.

Power Module

4.0” Dia.

Power Module

4.5” Dia.

Power Module

5.0” Dia.

Power Module

6.0” Dia.

Power Module

7.0” Dia.

Power Module

8.0” Dia.

Power Module

Table 8 (continued).......

Actuator Support Information

Section 6: Actuator Support Information

October 2015

ITEM

NO�

G01 WT�G2WT�G3WT�G4WT�G5WT�G7WT�G8WT�

Lbs N/A N/A N/A N/A N/A 394 495 808

Kg N/A N/A N/A N/A N/A 179 225 367

Lbs N/A N/A N/A N/A N/A 400 501 862

Kg N/A N/A N/A N/A N/A 181 227 400

Lbs N/A N/A N/A N/A N/A N/A 599 959

Kg N/A N/A N/A N/A N/A N/A 254 435

Lbs N/A N/A N/A N/A N/A N/A N/A 1104

Kg N/A N/A N/A N/A N/A N/A N/A 501

Lbs N/A N/A N/A N/A N/A N/A N/A N/A

Kg N/A N/A N/A N/A N/A N/A N/A N/A

Lbs N/A N/A N/A N/A N/A N/A N/A N/A

Kg N/A N/A N/A N/A N/A N/A N/A N/A

Lbs 160 225 320 564 975 2740 3545 4975

Kg 73 102 145 256 442 1243 1608 2257

Lbs 158 215 310 549 980 2630 2345 4515

Kg 72 98 141 249 445 1193 1064 2048

Lbs 153 215 295 534 925 2410 3085 4095

Kg 153 98 295 534 925 2410 3085 4095

Lbs 144 200 280 474 860 2210 N/A 3735

Kg 65 91 127 215 390 1002 N/A 1694

Lbs N/A 200 N/A N/A N/A N/A N/A N/A

Kg N/A 91 N/A N/A N/A N/A N/A N/A

Lbs N/A 180 N/A N/A N/A N/A N/A N/A

Kg N/A 82 N/A N/A N/A N/A N/A N/A

Lbs 18 34 47 82 100 181 270 530

Kg 8.2 15.3 21.2 36.9 45 81.45 1275 239

Lbs 35 35 35 45 50 35 45 50

Kg 15.9 15.9 15.9 20.4 22.7 15.9 20.4 22.7

Service Instructions

127072E Rev. C

G10 WT�

DESCRIPTION

9.0” Dia.

Power Module

10.0” Dia.

Power Module

12.0” Dia.

Power Module

14.0” Dia.

Power Module

16.0” Dia.

Power Module

18.0” Dia.

Power Module

SR1 Spring

SR2 Spring

SR3 Spring

SR4 Spring

SRA5 Spring

SRA6 Spring

M11 SR Override

Cylinder

M11 SR Pump /

Reservoir

Actuator Support Information

Service Instructions

127072E Rev. C

6�3 G01 Tool Table

Table 11� G01 Tool Style and Wrench Size

ITEM

NO�

1-110 9/16” 4 Cover Screws Socket 1-160 1/2” 4 Yoke Cover Screws Socket 1-180 3/8” Sq. 2 Stop Screws Open End or Adjustable

1-190 15/16” 2 Hex Jam Nuts Open End or Adjustable

3-40 3/8” Sq. 1 Piston Rod Male Drive

3-90 3/4” 4 Standard Hex Nuts Socket 3-100 9/16” 4 Hex Cap Screws Socket 3-105 9/16” 4 Standard Hex Nuts Socket 3-115 9/16” 4 Hex Cap Screws Socket 3-120 9/16” Sq. 1 Pipe Plug, Square Head Open End or Adjustable 3-210 7/16” Sq. 4 Pipe Plug, Square Head Open End or Adjustable

5-20 9/16” 4 Hex Cap Screws Socket

7-80 9/16” 4 Hex Cap Screws Socket 7-110 1/8” Sq. 1 Square Head Pipe Plug Open End or Adjustable 7-120 9/16” Sq. 1 Square Head Pipe Plug Square Head Pipe Plug

13 3/4” 2 Vent Check Assembly Open End

- 3/8” 1 Pull Rod Male Drive

WRENCH

SIZE

ITEM QTY�

Section 6: Actuator Support Information

October 2015

LOCATION OR DESCRIPTION

RECOMMENDED

TOOL STYLE

6�4 G2 Tool Table

Table 12� G2 Tool Style and Wrench Size

ITEM

NO�

1-110 9/16” 6 Cover Screws Socket 1-160 9/16” 4 Yoke Cover Screws Socket 1-180 3/8” Sq. 2 Stop Screws Open End or Adjustable

1-190 1-1/8” 2 Hex Jam Nuts Open End or Adjustable

3-40 3/8” Sq. 1 Piston Rod Male Drive

3-90 3/4” 4 Standard Hex Nuts Socket 3-100 9/16” 4 Hex Cap Screws Socket 3-105 9/16” 4 Standard Hex Nuts Socket 3-115 9/16” 4 Hex Cap Screws Socket 3-120 9/16” Sq. 1 Square Head Pipe Plug Open End or Adjustable 3-210 7/16” Sq. 4 Square Head Pipe Plug Open End or Adjustable

5-20 9/16” 6 Hex Cap Screws Socket

7-80 9/16” 4 Hex Cap Screws Socket 7-110 1/8” Sq. 1 Square Head Pipe Plug Open End or Adjustable 7-120 1/2” Sq. 1 Square Head Pipe Plug Open End or Adjustable

13 3/4” 2 Vent Check Assembly Open End

WRENCH

SIZE

- 3/8” 1 Pull Rod Male Drive

ITEM QTY�

LOCATION OR DESCRIPTION

RECOMMENDED

TOOL STYLE

Actuator Support Information

Section 6: Actuator Support Information

October 2015

6�5 G3 Tool Table

Table 13� G3 Tool Style and Wrench Size

ITEM

NO�

1-110 9/16” 8 Cover Screws Socket 1-160 9/16” 4 Yoke Cover Screws Socket 1-180 1/2” Sq. 2 Stop Screws Open End or Adjustable

1-190 1-5/16” 2 Hex Jam Nuts Open End or Adjustable

3-40 3/8” Sq. 1 Piston Rod Male Drive

3-90 3/4” 6 Standard Hex Nuts Socket 3-100 9/16” 4 Hex Cap Screws Socket 3-105 9/16” 4 Standard Hex Nuts Socket 3-115 9/16” 4 Hex Cap Screws Socket 3-120 9/16” Sq. 1 Square Head Pipe Plug Open End or Adjustable 3-210 7/16” Sq. 4 Square Head Pipe Plug Open End or Adjustable

5-20 9/16” 6 Hex Cap Screws Socket

7-80 9/16” 6 Hex Cap Screws Socket 7-110 1/8” Sq. 1 Square Head Pipe Plug Open End or Adjustable 7-120 1/2” Sq. 1 Square Head Pipe Plug Open End or Adjustable

13 3/4” 2 Vent Check Assembly Open End

WRENCH

SIZE

- 3/8” 1 Pull Rod Male Drive

ITEM QTY�

LOCATION OR DESCRIPTION

Service Instructions

127072E Rev. C

RECOMMENDED

TOOL STYLE

6�6 G4 Tool Table

Table 14� G4 Tool Style and Wrench Size

ITEM

NO�

1-110 9/16” 8 Cover Screws Socket 1-160 9/16” 4 Yoke Cover Screws Socket 1-180 3/4” Sq. 2 Stop Screws Open End or Adjustable

1-190 1-13/16” 2 Hex Jam Nuts Open End or Adjustable

3-40 1/2” Sq. 1 Piston Rod Male Drive

3-90 15/16” 6 Standard Hex Nuts Socket 3-100 3/4” 4 Hex Cap Screws Socket 3-105 3/4” 4 Standard Hex Nuts Socket 3-115 3/4” 4 Hex Cap Screws Socket 3-120 5/8” Sq. 1 Square Head Pipe Plug Open End or Adjustable 3-210 9/16” Sq. 4 Square Head Pipe Plug Open End or Adjustable

5-20 3/4” 6 Hex Cap Screws Socket

7-80 3/4” 6 Hex Cap Screws Socket 7-110 1/8” Sq. 1 Square Head Pipe Plug Open End or Adjustable 7-120 1/2” Sq. 1 Square Head Pipe Plug Open End or Adjustable

13 3/4” 2 Vent Check Assembly Open End

WRENCH

SIZE

- 3/4” 1 Pull Rod Male Drive

ITEM QTY�

LOCATION OR DESCRIPTION

RECOMMENDED

TOOL STYLE

Actuator Support Information

Service Instructions

127072E Rev. C

6�7 G5 Tool Table

Table 15� G5 Tool Style and Wrench Size

Section 6: Actuator Support Information

October 2015

ITEM

NO�

1-110 3/4” 8 Cover Screws Socket 1-120 3/4” 4 Yoke Cover Screws Socket 1-160 9/16” 6 Hex Cap Screws Socket 1-180 3/4” Sq. 2 Stop Screws Open End or Adjustable 1-190 2-3/8” 2 Heavy Hex Jam Nuts Open End or Adjustable

3-40 1/2” Sq. 1 Piston Rod Male Drive

3-90 15/16” 6 Hex Nuts Socket 3-100 3/4” 4 Hex Cap Screws Socket 3-105 3/4” 4 Standard Hex Nuts Socket 3-115 3/4” 4 Hex Cap Screws Socket 3-120 5/8” Sq. 1 Square Head Pipe Plug Open End or Adjustable 3-210 9/16” Sq. 4 Square Head Pipe Plug Open End or Adjustable

5-20 3/4” 8 Hex Cap Screws Socket

7-80 3/4” 8 Hex Cap Screws Socket 7-110 1/8” Sq. 1 Square Head Pipe Plug Open End or Adjustable 7-120 1/2” Sq. 1 Square Head Pipe Plug Open End or Adjustable

13 3/4” 2 Vent Check Assembly Open End

WRENCH

SIZE

- 3/4” 1 Pull Rod Male Drive

ITEM

6�8 G7 Tool Table

QTY�

LOCATION OR

DESCRIPTION

RECOMMENDED

TOOL STYLE

Table 16� G7 Tool Style and Wrench Size

ITEM

NO�

1-110 3/4” 8 Cover Screws Socket 1-120 3/4” 4 Yoke Cover Screws Socket 1-160 9/16” 8 Hex Cap Screws Socket 1-180 1” 2 Stop Screws Open End or Adjustable

3-40 3/4” Sq. 1 Piston Rod Male Drive

3-90 1-1/2” 6 Hex Nuts Socket 3-100 15/16” 8 Hex Cap Screws Socket 3-105 15/16” 8 Standard Hex Nuts Socket 3-115 15/16” 8 Hex Cap Screws Socket 3-120 15/16” 1 Hex Head Pipe Plug Open End or Adjustable 3-210 9/16” Sq. 4 Square Head Pipe Plug Open End or Adjustable

5-20 15/16” 8 Hex Cap Screws Socket

7-80 15/16” 8 Hex Cap Screws Socket 7-100 15/16” 8 Hex Cap Screws Socket 7-110 9/16” 1 Flush Socket Head Pipe Plug Allen 7-130 9/32” Sq. 1 Square Head Pipe Plug Open End or Adjustable

Actuator Support Information

WRENCH

SIZE

13 3/4” 2 Vent Check Assembly Open End

- 3/4” 1 Pull Rod Male Drive

ITEM

QTY�

LOCATION OR

DESCRIPTION

RECOMMENDED

TOOL STYLE

Section 6: Actuator Support Information

October 2015

6�9 G8 Tool Table

Table 17� G8 Tool Style and Wrench Size

Service Instructions

127072E Rev. C

ITEM

NO�

1-110 3/4” 12 Cover Screws Socket 1-120 3/4” 4 Yoke Cover Screws Socket 1-160 9/16” 8 Hex Cap Screws Socket 1-180 1-1/4” 2 Stop Screws Open End or Adjustable

3-40 3/4” Sq. 1 Piston Rod Male Drive

3-90 1-1/2” 8 Hex Nuts Socket

3-100 1-1/8” 8 Hex Cap Screws Socket 3-105 1-1/8” 8 Standard Hex Nuts Socket 3-115 1-1/8” 8 Hex Cap Screws Socket 3-120 15/16” 1 Hex Head Pipe Plug Open End or Adjustable 3-210 9/16” Sq. 4 Square Head Pipe Plug Open End or Adjustable

5-20 1-1/8” 8 Hex Cap Screws Socket

7-80 1-1/8” 8 Hex Cap Screws Socket

7-100 1-1/8” 8 Hex Cap Screws Socket 7-110 9/16” 1 Flush Socket Head Pipe Plug Allen 7-120 9/16” Sq. 2 Square Head Pipe Plug Open End or Adjustable 7-130 9/32” Sq. 1 Square Head Pipe Plug Open End or Adjustable

13 3/4” 2 Vent Check Assembly Open End

WRENCH

SIZE

- 3/4” 1 Pull Rod Male Drive

ITEM QTY�

6�10 G10 Tool Table

LOCATION OR DESCRIPTION

RECOMMENDED

TOOL STYLE

Table 18� G10 Tool Style and Wrench Size

ITEM

NO�

1-110 3/4” 16 Cover Screws Socket 1-120 3/4” 4 Yoke Cover Screws Socket 1-160 9/16” 8 Hex Cap Screws Socket 1-180 1-1/2” 2 Stop Screws Open End or Adjustable

3-40 3/4” Sq. 1 Piston Rod Male Drive

3-90 1-7/8” 8 Hex Nuts Socket

3-100 1-5/16” 8 Hex Cap Screws Socket 3-105 1-5/16” 8 Standard Hex Nuts Socket 3-115 1-5/16” 8 Hex Cap Screws Socket 3-120 15/16” 1 Hex Head Pipe Plug Open End or Adjustable 3-210 9/16” Sq. 4 Square Head Pipe Plug Open End or Adjustable

5-20 1-5/16” 8 Hex Cap Screws Socket

7-80 1-5/16” 8 Hex Cap Screws Socket

7-100 1-5/16” 8 Hex Cap Screws Socket 7-110 9/16” 1 Flush Socket Head Pipe Plug Allen 7-130 9/32” Sq. 1 Square Head Pipe Plug Open End or Adjustable

13 3/4” 2 Vent Check Assembly Open End

WRENCH

SIZE

- 3/4” 1 Pull Rod Male Drive

ITEM QTY�

LOCATION OR DESCRIPTION

RECOMMENDED

TOOL STYLE

Actuator Support Information

Service Instructions

127072E Rev. C

Section 7: Troubleshooting

7�1 Fault Insertion

In the unlikely event of a fault developing, the following Fault Location Table is provided to assist the service engineer to perform troubleshooting. This table is designed to cover as wide a range of Emerson Bettis actuators as possible. Reference to equipment not supplied should be ignored.

Table 19� Fault Location Table

SYMPTOM POTENTIAL CAUSES REMEDY

Section 7: Troubleshooting

October 2015

Erratic movement

Short stroke

Apparent lack of torque

Irregular Supply of Operating Medium

Inadequate Lubrication Dismantle, relubricate and reassemble

Worn Parts

Defective Valve Consult the valve OEM's documentation Incorrectly Set Stops

(Valve and/or Actuator)

Hardened Grease

Debris Left in the Cylinder or Housing During Maintenance

Defective Valve

Inadequate Supply Pressure

Incorrect Speed Control Settings Adjust speed controls to increase ow

Exhaust Port Blocked

Pipe Work Blocked, Crushed or Leaking

Defective Controls

Defective Piston Seal

Defective Rod Seal

Defective Housing Seal

High Valve Torque or Valve Seized

Defective Spring

Check operating medium for consistent supply pressure and correct as necessary

Dismantle. Visually inspect for signicant wear.

Actuator replacement may be required

Check the position of the travel stops and readjust as necessary

Dismantle, remove any hard grease, relubricate and reassemble

Disassemble cylinder assembly to remove debris. Reassemble cylinder assemble as necessary

Consult the valve manufacturer's documentation

Ensure supply pressure is above the minimum operating pressure of the actuator and that output

torque produced at supply pressure exceeds valve

torque demand

Remove and clean the exhaust port silencers and

replace them

Examine the pipe work for blockages, crushed pipe

or leakage and clear or replace as necessary

Examine the controls and refurbish or renew as

necessary and refer to component manufacturer's documentation

Dismantle the cylinder assembly and remove

the defective piston seal and t new seal and

reassemble Dismantle the cylinder assembly and remove the

defective rod seal and t new seal and reassemble

Dismantle the housing assembly, remove the

defective seal and t new seal and reassemble

Consult the valve OEM documentation

Check for noise and/or erratic operation and replace spring if required

Troubleshooting

Section 7: Troubleshooting

October 2015

7�2 Operational Test

7�2�1 Full Stroke Test

The “full stroke test” (“On-line”) must be performed to satisfy the PFD probability of failure on demand) value. The full stroke test frequencies will be

dened by the nal installer to achieve the dened SIL level.

7�2�1�1 Procedure

7�2�1�1�1 Stroke the actuator/valve assembly two complete open/close

cycles with complete closing of the valve.

7�2�1�1�2 Verify if the open/close cycles functioned correctly (e.g.,

check locally, or automatically via Logic solver, the correct movement of the actuator/valve).

Upon successful completion of the above described full stroke test procedure, the “test coverage” can be considered 99%.

7�2�2 Partial Stroke Test (when requested)

The “partial stroke test” (“On-line”) can be performed to improve the PFD and to satisfy PFD partial stroke value is 15% of the stroke and the recommended test interval is about every one to three months.

7�2�2�1 Procedure

7�2�2�1�1 Operate the actuator/valve assembly for No° 1 open/close

7�2�2�1�2 Verify if the partial stroke test functioned correctly (e.g.,

(average probability of failure on demand) value. A typical

AVG

cycles 15% of the stroke.

check locally, or automatically via logic solver, or via the PST system the correct movement of the actuator/valve was 15% of the stroke).

Service Instructions

127072E Rev. C

(average

AVG

value

AVG

NOTE:

The above test is only applicable on systems equipped with a partial stroke feature.

Troubleshooting

Service Instructions

127072E Rev. C

Section 8: Removal and Decommissioning

October 2015

Section 8: Removal and Decommissioning

8�1 Removal and Decommissioning

WARNING: FOLLOW PROPER PROCEDURE

Always follow safe work practices while removing and disassembling the G-Series actuator.

The below basic 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 Emerson/Bettis representative.

CAUTION: ISOLATE AND POWER OFF ACTUATOR

Make sure actuator is isolated before removing from valve. Turn off the power medium and

bleed off all pressure rst, including storage tank (if present). Next, bleed off pilot pressure

and disconnect: pneumatic pressure supply, pilot tubing and electrical wiring (if equipped).

Before starting the disassembly, a large area should be created around the actuator to allow any kind of movement.

Separate the parts comprising the actuator according to their nature (e.g. metallic, plastic

materials, uids, etc.) and send them to differentiated waste collection sites, as provided

for by the laws and provisions in force. 8�1�1 Drain tanks and remove tubing from actuator. Remove accessories (if equipped)

and control from actuator.

8�1�2 Remove all equipment mounted on top of actuator (limit switches, end of stroke

valve, relevant pneumatic/electric connection, etc.).

8�1�3 Remove mounting bolts and check if actuator is ready to be removed from valve.

For complete actuator teardown refer to Section 2 of the manual.

Removal and Decommissioning

Section 9: Document Revision

October 2015

Section 9: Document Revision

Table 20� Revision Overview

ECN DATE REVISION S TATUS BY * DATE

Released December 2001 A B. Cornelius December 2001

19110 July 2006 B UPDATED C. Ross July 2006

VAWCO2794 October 2015 C UPDATED C. Rico October 2015

*Signatures on le Emerson, Houston, Texas

Service Instructions

127072E Rev. C

Document Revision

Service Instructions

127072E Rev. C

Appendix A: List of Tables

Table 1. Actuator Model and Part Number .......................................................................... 3

Table 2. Housing Cover Screw Quantity and Torque ......................................................... 15

Table 3. Tie Bar Nuts (3-90) Torque Table .......................................................................... 17

Table 4. Wire Length Requirements .................................................................................. 23

Table 5. M11 Override Cylinder End Cap to SR Cartridge Screw Torque ............................ 23

Table 6. Rod Rotation .......................................................................................................26

Table 7. Spring Cartridge Tension Rod Torque Table ......................................................... 27

Table 8. Spring Cartridge Tension Rod Torque Table ......................................................... 27

Table 9. M11 Hydraulic Override System Fluid Volume Table ............................................ 31

Table 10. Module Weights by item Number and Actuator Housing Size .............................. 31

Table 11. G01 Tool Style and Wrench Size ........................................................................... 33

Table 12. G2 Tool Style and Wrench Size ............................................................................. 33

Table 13. G3 Tool Style and Wrench Size ............................................................................. 34

Table 14. G4 Tool Style and Wrench Size ............................................................................. 34

Table 15. G5 Tool Style and Wrench Size ............................................................................. 35

Table 16. G7 Tool Style and Wrench Size ............................................................................. 35

Table 17. G8 Tool Style and Wrench Size ............................................................................. 36

Table 18. G10 Tool Style and Wrench Size ........................................................................... 36

Table 19. Fault Location Table ............................................................................................. 37

Table 20. Revision Overview ............................................................................................... 40

Appendix

October 2015

Appendix

October 2015

Service Instructions

127072E Rev. C

Appendix B: List of Drawings

B�1 Part No� 122588, G1/2/3/4/5-SRX-H Hydraulic

Assembly Drawing, Sheet 1 of 2

Appendix

Service Instructions

127072E Rev. C

Appendix

October 2015

B�2 Part No� 122588, G1/2/3/4/5-SRX-H Hydraulic

Assembly Drawing, Sheet 2 of 2

Appendix

October 2015

Service Instructions

127072E Rev. C

B�3 Part No� 126567, M11 Assembly Drawing,

Sheet 1 of 5

Appendix

Service Instructions

127072E Rev. C

Appendix

October 2015

B�4 Part No� 126567, M11 Assembly Drawing,

Sheet 2 of 5

Appendix

October 2015

Service Instructions

127072E Rev. C

B�5 Part No� 126567, M11 Assembly Drawing,

Sheet 3 of 5

Appendix

Service Instructions

127072E Rev. C

Appendix

October 2015

B�6 Part No� 126567, M11 Assembly Drawing,

Sheet 4 of 5

Appendix

October 2015

Service Instructions

127072E Rev. C

B�7 Part No� 126567, M11 Assembly Drawing,

Sheet 5 of 5

Appendix

Service Instructions

127072E Rev. C

Appendix

October 2015

B�8 Part No� VA-ED-000-8765-00, G7/8/10-SRX-H

Hydraulic Assembly Drawing, Sheet 1 of 2

Appendix

October 2015

Service Instructions

127072E Rev. C

B�9 Part No� VA-ED-000-8765-00, G7/8/10-SRX-H

Hydraulic Assembly Drawing, Sheet 2 of 2

Appendix

Service Instructions

127072E Rev. C

Appendix

October 2015

B�10 Part No� 121107, Remote Mount Assembly

Drawing for M11-S G4/G8 Fire Safe, Sheet 1 of 2

Appendix

October 2015

Service Instructions

127072E Rev. C

B�11 Part No� 121107, Remote Mount Assembly

Drawing for M11-S G4/G8 Fire Safe, Sheet 2 of 2

Appendix

World Area Conﬁ guration Centers (WACC) offer sales support, service, inventory and commissioning to our global customers. Choose the WACC or sales ofﬁ ce nearest you:

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T +36 22 53 09 50

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29017 Fiorenzuola d’Arda (PC)

Italy

T +39 0523 944 411

For complete list of sales and manufacturing sites, please visit

www.emerson.com/actuationtechnologieslocations or contact us at info.actuationtechnologies@emerson.com

www.emerson.com/bettis

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is a mark of one of the Emerson family of companies.

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The contents of this publication are presented for information purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our products at any time without notice.

Bettis Service Instructions Disassembly and Reassembly For G01 Through G10 Series Hydraulic Spring Return Actuators With M11 Hydraulic Override Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual