Service Instructions Disassembly and Reassembly For Models G01F Through G13F Series Hydraulic Actuators With Power Module Flange Construction
Bettis Service Instructions Disassembly and Reassembly For Models G01F Through G13F Series Hydraulic Actuators With Power Module Flange Construction Manuals & Guides
Service Instructions
126343E Rev. C
November 2012
G01F Through G13F Series
Hydraulic Actuators with Power Module Flange Construction
Service Instructions
126343E Rev. C
Table of Contents
Section 1: Introduction
1.1 General Service Information .......................................................................... 1
1.2 Denitions .................................................................................................... 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
Section 2: Actuator Disassembly
2.1 General Disassembly ..................................................................................... 5
2.2 Hydraulic Power Module Disassembly ........................................................... 5
2.3 Drive Module Disassembly ............................................................................. 6
2.4 Blind End Cap Module Removal ..................................................................... 9
Table of Contents
November 2012
Section 3: Actuator Reassembly
3.1 General Reassembly .................................................................................... 10
3.2 Drive Module Reassembly ............................................................................ 10
3.3 Hydraulic Power Module Resassembly ......................................................... 15
3.4 Blind End Cap Module Installation ............................................................... 17
3.5 Actuator Testing .......................................................................................... 17
Section 4: Field Conversions
4.1 Fail Mode Reversal (CW TO CCW, OR CCW TO CW) ...................................... 19
4.2 Converting Double Acting Actuator To Spring Return .................................. 19
Section 5: Module Removal and Installation
5.1 Spring Module Removal ............................................................................... 20
5.2 Spring Module Installation ........................................................................... 22
5.3 Hydraulic Power Module Removal ............................................................... 25
5.4 Hydraulic Power Module Installation ........................................................... 26
5.5 Powr Swivl Removal ..................................................................................... 28
5.6 Powr Swivl Module Installation .................................................................... 28
Table of Contents
I
Table of Contents
November 2012
Table of Contents (continued)
Section 6: Actuator Support Information
6.1 Module Weights by Item Number and Actuator Housing Size ...................... 30
6.2 G01F Tool Style and Wrench Size ................................................................. 32
6.3 G2F Tool Style and Wrench Size ................................................................... 32
6.4 G3F Tool Style and Wrench Size ................................................................... 33
6.5 G4F Tool Style and Wrench Size ................................................................... 33
6.6 G5F Tool Style and Wrench Size ................................................................... 34
6.7 G7F Tool Style and Wrench Size ................................................................... 34
6.8 G8F Tool Style and Wrench Size ................................................................... 35
6.9 G10F Tool Style and Wrench Size ................................................................. 35
6.10 G13F Tool Style and Wrench Size ................................................................. 36
Section 7: Document Revision ��������������������������������������������37
Service Instructions
126343E Rev. C
Appendix A: List of Tables ���������������������������������������������������38
Appendix B: List of Drawings
B.1 Part No. 119576, GXXXX.XF Hydraulic Assy Dwg, Sheet 1 of 2 .................... 39
B.2 Part No. 119576, GXXXX.XF Hydraulic Assy Dwg, Sheet 2 of 2 .................... 40
B.3 Part No. 116740, GXXXXF Hydraulic Assy Dwg, Sheet X of X ....................... 41
II
Table of Contents
Service Instructions
126343E 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 G01X0XF, G2X0XF, G3X0XF, G4X0XF, G5X0XF, G7X0XF,
G8X0XF, G10X0XF and G13X0XF Double Acting and Spring Return Series
Actuators with one single Hydraulic Power Module - power module utilizing ange
construction.
1.1.2 Normal recommended service interval for this actuator series is ve years.
NOTE:
Storage time is counted as part of the service interval.
1.1.3 This procedure is applicable with the understanding that all electrical power and
pneumatic pressure has been removed from the actuator.
1.1.4 Remove all piping and mounted accessories that will interfere with the module(s)
that are to be worked on.
1.1.5 This procedure should only be implemented by a technically competent technician
who should take care to observe good workmanship practices.
1.1.6 Numbers in parentheses, ( ) indicate the bubble number (reference number) used
on the Bettis Assembly Drawing and Actuator Parts List.
1.1.7 This procedure is written using the stop screw side of the housing (1-10) as a
reference and this side will be considered the front side of the actuator. The
housing cover (1-20) will be the top of the actuator.
1.1.8 Actuator Module weights are listed in Section 6 Table 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
November 2012
Introduction
CAUTION: FOLLOW MANUFACTURER'S INSTRUCTIONS
Apply the thread sealant per the manufacturer’s instructions.
1.1.11 Bettis recommends that disassembly of the actuator components should be done
in a clean area on a workbench.
1
Section 1: Introduction
November 2012
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
126343E Rev. C
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
Products supplied by Bettis, in its “as shipped” condition, are intrinsically safe if the instruc-
tions contained within this Service Instruction are strictly adhered to and executed by well
trained, equipped, prepared and competent personnel.
WARNING: READ WARNING 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 conict 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.
2
Introduction
Service Instructions
126343E Rev. C
1�4 Bettis Reference Materials
1.4.1 Assembly Drawing for GXXXXF Double Acting Hydraulic Series Actuators use part
number 119576.
1.4.2 Assembly Drawing for GXXXXF Spring Return Hydraulic Series Actuators use part
number 116740.
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� G Series Models
Section 1: Introduction
November 2012
Actuator Model Bettis Part Number Actuator Model Bettis Part Number
G01 None required G5/G7 117369
G2 123616 G8/G10 117368
G3/G4 117370 G13 122849
1.5.3 Non-hardening thread sealant.
1�6 Lubrication Requirements
NOTE:
Lubricants, other than listed in step 1.6.1 should not be used without prior written approval
of Bettis Product Engineering.
1.6.1 LUBRICANT REQUIREMENTS: For use in the housing (drive module) and the SR
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 & 10 lubricant.
Introduction
3
Section 1: Introduction
November 2012
1�7 Fluid Requirements
1.7.1 FLUID REQUIREMENTS: 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 Dexron Automatic Transmission Fluid.
1.7.1.2 High temperature service (0°F to +350°F)/(-17°C to +176.6°C) use Dexron
Automatic Transmission Fluid.
1.7.1.3 Low temperature service (-40°F to +150°F}/(-40°C to +65.6°C) use Exxon
Univis J13 Hydraulic Fluid.
1�8 General Tool Information
1.8.1 Tools: All tools/Hexagons are American Standard inch (Imperial). 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 / 2169
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
126343E Rev. C
4
Introduction
Service Instructions
126343E Rev. C
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 If the actuator has a Spring Module and the Spring Module is to be removed it should
be removed from the Drive Module prior to the Hydraulic Power Module removal or
disassembly. See Section 5 step 5.1.
2.1.3 This procedure is written with the Power Module removed from the Drive module
prior to Power Module disassembly. Remove Power Module per Section 5 step 5.3. The
Hydraulic Power Module can be disassembled while still attached to the Drive Module.
November 2012
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, etc.
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 refer to Section 5 step 5.1.
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 operating pressure from actuator power cylinders.
WARNING: VERIFY SPRING POSITIONS
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).
Actuator Disassembly
5
Section 2: Actuator Disassembly
November 2012
2.2.1 Mark and record location of the ports on inner end cap (3-20).
2.2.2 Remove four pipe plugs (3-80) from cylinder assembly (3-10) and drain hydraulic
uid from cylinder assembly (hydraulic uid may have been drained if all piping to
pressure ports have previously been removed).
2.2.3 Remove 12 point cap screws (1-130), with lockwashers (3-110), from the ange of
cylinder assembly (3-10).
2.2.4 Remove cylinder (3-10) from inner end cap (3-20), piston (3-30) and piston rod
(3-40).
NOTE:
Refer to assembly drawing page 2 of 2 Detail "D" for steps 2.2.5 through 2.2.9.
2.2.5 Remove two split ring halves (3-50) and one retainer ring (3-60) from outboard
side of piston (3-30) and piston rod (3-40).
2.2.6 Remove piston (3-30) from piston rod (3-40).
2.2.7 Remove o-ring seal (4-70) from piston rod (3-40).
2.2.8 Remove two split ring halves (3-50) and one retainer ring (3-60) from piston rod
(3-40).
2.2.9 Remove stop tube (3-70) from piston rod (3-40).
Service Instructions
126343E Rev. C
NOTE:
Not all Power Modules will be equipped with a stop tube (3-70).
2.2.10 Remove hex cap screws (3-100) with lockwashers (3-110) from inner end cap (3-
20) and housing (1-10).
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 the Drive Module.
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
be checked and setting recorded before stop screws are loosened or removed.
6
Actuator Disassembly
Service Instructions
126343E Rev. C
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 “F”.
2.3.3 Before removing position indicator (1-220), record or mark it's position. Remove
NOTE:
Step 2.3.4 is used only on G01, G2 and G3 Drive Modules. Drive Modules G4 through G13
will skip steps 2.3.4 and continue with step 2.3.5.
Section 2: Actuator Disassembly
November 2012
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).
position indicator (1-220).
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 the 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.
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).
Actuator Disassembly
7
Section 2: Actuator Disassembly
November 2012
NOTE:
G01, G2, G3 and G4 model housing cover (1-20) will have three 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) and extension rod assembly (1-50), by lifting yoke up and
out of the housing (1-10). On spring return actuators also remove yoke (1-70) with
extension rod assembly (9-50).
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
126343E Rev. C
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).
8
Actuator Disassembly
Service Instructions
126343E Rev. C
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 (2-20), two yoke
bearings (2-40), yoke pin bearing (2-25), yoke pin thrust bearing (2-10) and spring
pin (1-100).
Section 2: Actuator Disassembly
2�4 Blind End Cap Module Removal
November 2012
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).
Actuator Disassembly
9
Section 3: Actuator Reassembly
November 2012
Section 3: Actuator Reassembly
3�1 General Reassembly
CAUTION: CHECK SHELF LIFE OF SEALS
Only new seals, which are still within the seal’s expectant shelf life, should be installed into
the actuator being refurbished.
3.1.1 Remove and discard all old seals and gaskets.
3.1.2 All parts should be cleaned to remove all dirt and other foreign material prior to
inspection.
3.1.3 All parts should be thoroughly inspected for excessive wear, stress cracking,
galling and pitting. Attention should be directed to threads, sealing surfaces and
areas that will be subjected to sliding or rotating motion. Sealing surfaces of the
cylinder, tie bars and piston rod must be free of deep scratches, pitting, corrosion
and blistering or aking coating.
Service Instructions
126343E Rev. C
CAUTION: INSPECT PARTS BEFORE USE
Actuator parts that reect 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 drive module will be assembled using lubricant as
identied in Section 1 step 1.6.1. The parts and seals used in the actuator cylinder module
will be assembled using lubricant as identied 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 Reassembly
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.
10
3.2.1 If guide bar bearings (2-20) is being replaced install new bearings into guide block (1-30).
Actuator Reassembly
Service Instructions
126343E Rev. C
NOTE:
The guide bar bearing (2-20) must be press t into guide block guide bar bore with the
seam located ±5° degrees of the top or bottom centerline as shown in section A-A. 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
3.2.3 Install one spherical washer (1-40) into the side of guide block (1-30).
NOTE:
The spherical side of washer (1-40) will be facing to the outside of guide block (1-30).
3.2.4 Install second spherical washer (1-40) over threaded end of extension rod
Section 3: Actuator Reassembly
November 2012
assembly (1-50).
assembly (1-50).
NOTE:
The spherical side of the washer will go on the extension rod assembly facing the head of
the extension rod assembly.
3.2.5 Install extension rod assembly (1-50) into guide block (1-30) and up against the
rst spherical washer (1-40).
3.2.6 Install extension retainer nut (1-60) over extension rod assembly (1-50) and screw
into guide block (1-30).
3.2.7 Tighten extension retainer nut assembly (1-60) until extension rod assembly (1-
50) can not move. Back off the extension retainer nut assembly (1-60) just enough
to allow for extension rod assembly (1-50) to move freely.
NOTE:
Steps 3.2.8 through 3.2.13 are to be completed when the actuator is equipped with a
Spring Module. If the actuator is Double Acting then skip steps 3.2.8 through 3.2.13 and
continue actuator reassembly starting with step 3.2.14.
3.2.8 Lubricate guide block (1-30), two spherical washers (9-40) and one extension rod
assembly (9-50).
3.2.9 Install one spherical washer (9-40) into the side of guide block (1-30).
Actuator Reassembly
NOTE:
The spherical side of washer (9-40) will be facing to the outside of guide block (1-30).
3.2.10 Install second spherical washer (9-40) over threaded end of extension rod
assembly (9-50).
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