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

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Service Instructions

124839E Rev. D

October 2015

G01 through G13 Series Hydraulic Actuators

With Power Module Tie Bar Construction Disassembly and Reassembly

Service Instructions

124839E Rev. D

Table of Contents

Section 1: Introduction

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

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

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

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

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

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

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

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

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

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

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

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

Table of Contents

October 2015

Section 2: Actuator Disassembly

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

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

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

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

Section 3: Actuator Reassembly

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

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

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

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

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

Section 4: Field Conversions

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

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

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

Section 5: Module Removal and Installation

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

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

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

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

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

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

Table of Contents

October 2015

Section 6: Actuator Support Information

Section 7: Troubleshooting

Section 8: Removal and Decommissioning

Service Instructions

124839E Rev. D

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

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

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

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

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

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

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

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

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

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

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

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

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

Section 9: Document Revision ��40

Appendix A: List of Tables ��41

Appendix B: List of Drawings ��42

Table of Contents

Service Instructions

124839E Rev. D

Section 1: Introduction

1�1 General Service Information

1�1�1 This service procedure is offered as a guide to enable general maintenance to be

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

1�1�2 Normal recommended service interval for this actuator series is ve years.

NOTE:

Storage time is counted as part of the service interval.

Section 1: Introduction

October 2015

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

hydraulic pressure have been removed from the actuator.

1�1�4 Remove all piping and mounted accessories that will interfere with the module(s)

that are to be worked on.

1�1�5 This procedure should only be implemented by a technically competent technician

who should take care to observe good workmanship practices.

1�1�6 Numbers in parentheses ( ) indicate the bubble number (reference number) used

on the Bettis Assembly Drawing and actuator parts list.

1�1�7 This procedure is written using the stop screw side of the housing (1-10) as a

reference and this side will be considered the front side of the actuator. The housing cover (1-20) will be the top of the actuator.

1�1�8 Actuator module weights are listed in Section 6 Table 6.1. 1�1�9 When removing seals from seal grooves, use a commercial seal removing tool or a

small screwdriver with sharp corners rounded off.

1�1�10 Use a non-hardening thread sealant on all pipe threads.

CAUTION: FOLLOW MANUFACTURER'S INSTRUCTIONS

Apply the thread sealant per the manufacturer’s instructions.

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

in a clean area on a work bench.

Introduction

Section 1: Introduction

October 2015

1�2 Definitions

WARNING

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

CAUTION

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

NOTE:

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

Service Instructions

124839E Rev. D

NOTE:

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

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

1�3 General Safety Information

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

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

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

WARNING: READ WARNING MESSAGES CAREFULLY

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

WARNING: FOLLOW PLANT SAFETY PROCEDURES

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

procedures. If a conict arises between this procedure and the customers procedures the

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

Introduction

Service Instructions

124839E Rev. D

1�4 Bettis Reference Materials

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

Hydraulic Series actuators use part number 116423.

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

Hydraulic Series actuators use part number 115676.

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

Hydraulic Series actuators use part number 115941.

1�5 Service Support Items

1�5�1 Bettis Module Service Kits 1�5�2 For rod extension retainer nut tool, refer to the following table.

NOTE:

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

Section 1: Introduction

October 2015

Table 1� Actuator Model and Part Number

MODEL

G01 None required G5/G7 117369

G2 123616 44 117368

G3/G4 117370 50 122849

1�5�3 Non hardening thread sealant

BETTIS PART

NUMBER

1�6 Lubrication Requirements

NOTE:

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

1�6�1 All temperature services (-50°F to +350°F)/(-45.5°C to 176.6°C) use Bettis ESL-5

lubricant. ESL-5 lubricant is contained in the Bettis Module Service Kit in tubes or cans and they are marked ESL -4, 5 and 10 lubricant.

MODEL

BETTIS PART

NUMBER

Introduction

Section 1: Introduction

October 2015

1�7 Fluid Requirements

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

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

compatible with supplied seals and coatings.

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

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

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

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

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

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

1�8 General Tool Information

1�8�1 Tools: All tools/hexagons are American Standard inch. Large adjustable wrench,

two (2) large screwdrivers, Allen wrench set, set of open/box end wrenches, rubber

or leather mallet, torque wrench (up to 1600 foot pounds/1269 N-m), breaker bar, and a drive socket set. For recommended tool and wrench sizes refer to Section 6 Tables 6.2 through 6.10.

Service Instructions

124839E Rev. D

1�9 Actuator Storage

For applications where the actuator is not put into immediate service it is recommended that the actuator be cycled with at least once per month. Indoor storage, if available, is recommended for all actuators. Care should be taken to plug all open ports on actuator and controls to keep out foreign particles and moisture. Also, actuators should not be stored in an

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

1�10 Actuator Installation

1�10�1 Since there are many valve and actuator combinations, it is not practical to include

detailed instructions for each type. Mountings are designed to be as simple as possible to keep guess work out of installation.

1�10�2 Actuators are shipped from the factory with the travel stops adjusted for

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

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

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

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

NOTE:

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

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

Introduction

Service Instructions

124839E Rev. D

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

pressure is essential for long service life and satisfactory operation. It should be noted that new pneumatic lines often have scale and other debris in them and these lines should be purged of all foreign material.

NOTE:

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

1�11 Actuator Start-up

1�11�1 Prestart-up checks

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

stem key, set screw(s) installed and secured

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

3. Indicated position conrms valve position

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

1�11�2 Check connections:

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

2. Hydraulic supply connected to identied ports

3. Electrical connections terminals are secure

4. Wiring as per enclosed diagram or service manual supplied

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

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

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

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

1. Power supply line length

2. Power supply line size

3. Power supply line pressure

4. Control valve and tting orice size

5. Torque requirements of the valve

6. Size of the actuator

7. Setting of speed controls

Section 1: Introduction

October 2015

Introduction

Section 1: Introduction

October 2015

8. Hydraulic manual override (where available)

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

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

1. Larger supply lines

2. Larger control valve

3. Higher supply pressure*

4. Quick exhaust valves

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

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

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

1�12 Actuator Operation

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

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

Do not exceed pressures indicated on actuator nameplate�

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

pneumatic piston prior to manual operation.

Service Instructions

124839E Rev. D

Introduction

Service Instructions

124839E Rev. D

Section 2: Actuator Disassembly

2�1 General Disassembly

WARNING: DANGEROUS GAS AND/OR LIQUIDS

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

2�1�1 Section 2 - Actuator disassembly is written to either completely disassemble

the entire actuator or can be used to disassemble individual modules as needed (hydraulic power module or drive module).

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

module prior to the hydraulic power module removal or disassembly.

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

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

October 2015

NOTE:

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

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

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

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

2�2 Hydraulic Power Module Disassembly

NOTE:

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

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

Actuator Disassembly

Section 2: Actuator Disassembly

October 2015

WARNING: DISCONNECT OPERATING PRESSURE

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

WARNING: ENSURE SPRING IS DECOMPRESSED

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

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

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

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

cap (3-10).

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

(3-80).

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

(3-40).

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

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

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

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

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

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

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

Service Instructions

124839E Rev. D

NOTE:

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

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

2�3 Drive Module Disassembly

NOTE:

Review Section 2 steps 2.1.1 through 2.1.5 General Disassembly before proceeding with drive module disassembly.

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

Actuator Disassembly

Service Instructions

124839E Rev. D

NOTE:

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

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

NOTE:

Stop screws will be removed later in this procedure.

NOTE:

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

Section 2: Actuator Disassembly

October 2015

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

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

cover (1-195).

2�3�3 Before removing position indicator (1-220), record or mark its position.

Remove position indicator (1-220).

NOTE:

Step 2.3.4 is used only on G01, G2 and G3 drive modules. Drive modules for G4 through G13 will skip step 2.3.4 and continue with step 2.3.5.

2�3�4 Remove one vent check assembly (13) from top of housing cover (1-20). 2�3�5 Unscrew and remove hex cap screws (1-160) with lockwashers (1-170) from yoke

cover (1-150).

2�3�6 Remove yoke cover (1-150) from housing cover (1-20). 2�3�7 Mark and record the orientation of the position indicator assembly (1-140) in

relation to the top of yoke (1-70).

2�3�8 Remove position indicator assembly (1-140) from top of yoke (1-70). 2�3�9 Remove spring pin (1-100) from top of yoke (1-70). 2�3�10 Remove hex cap screws (1-110), with lockwashers (1-115) or with lockwashers

(1-170), from housing cover (1-20).

NOTE:

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

Actuator Disassembly

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

Section 2: Actuator Disassembly

October 2015

2�3�12 Using hex cap screws (1-110), install into holes vacated by hex cap screws (1-120).

Use these hex cap screws to jack the housing cover up for removal. Alternately rotate the hex cap screw clockwise until housing cover (1-20) is clear of housing (1-10).

NOTE:

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

2�3�13 Remove housing cover (1-20) from housing (1-10).

NOTE:

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

2�3�14 Refer to assembly drawing page 2 of 2 Detail "B". Remove guide bar (1-90) from

housing (1-10).

2�3�15 Remove top yoke pin thrust bearing (2-10) from top of yoke pin (1-80). 2�3�16 Rotate the arms of yoke (1-70) to the center position of housing (1-10). 2�3�17 Remove yoke (1-70) with yoke pin (1-80), guide block (1-30), two yoke/guide

block bushings (2-30), extension rod assembly (1-50) and extension rod assembly

(9-50), by lifting yoke up and out of the housing (1-10).

2�3�18 Remove bottom yoke pin thrust bearing (2-10) from inside bottom of housing (1-10). 2�3�19 Remove yoke pin (1-80) by inserting 3/8" 16 UNC screw into top of the yoke pin

and pull straight up and out.

2�3�20 Remove guide block (1-30) from between the arms of yoke (1-70). 2�3�21 Remove yoke/guide block bushing (2-30) from top of guide block (1-30). 2�3�22 Remove yoke/guide block bushing (2-30) from the top of the lower yoke arm of

yoke (1-70).

Service Instructions

124839E Rev. D

NOTE:

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

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

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

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

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

NOTE:

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

Actuator Disassembly

Service Instructions

124839E Rev. D

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

On spring-return actuators also remove the remaining spherical washer (9-40) from guide block (1-30).

2�3�26 Unscrew and remove two stop screw nuts (1-190) from stop screws (1-180). 2�3�27 Unscrew and remove two stop screws (1-180) from housing (1-10). 2�3�28 Housing (1-10) vent check assembly removal as follows:

2�3�28�1 G01, G2 and G3 housing (1-10) unscrew and remove one vent check

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

2�3�28�2 G4 through G13 housing (1-10) unscrew and remove two vent check

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

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

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

Section 2: Actuator Disassembly

2�4 Blind End Cap Module Disassembly

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

cap (5-10).

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

October 2015

Actuator Disassembly

Section 3: Actuator Reassembly

October 2015

Section 3: Actuator Reassembly

3�1 General Reassembly

CAUTION: ONLY USE NEW SEALS

Only new seals, that are still within the seals expectant shelf life, should be installed into actuator being refurbished.

3�1�1 Remove and discard all old seals and gaskets. 3�1�2 All parts should be cleaned to remove all dirt and other foreign material prior

to inspection.

3�1�3 All parts should be thoroughly inspected for excessive wear, stress cracking,

galling and pitting. Attention should be directed to threads, sealing surfaces and areas that will be subjected to sliding or rotating motion. Sealing surfaces of the cylinder and piston rod must be free of deep scratches, pitting, corrosion and

blistering or aking coating.

Service Instructions

124839E Rev. D

CAUTION: REPLACE WORN PARTS

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

3�1�4 Before installation coat all moving parts with a complete lm of lubricant. Coat all

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

NOTE:

The parts and seals used in the actuator housing module will be assembled using lubricant

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

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

3�2 Drive Module Disassembly

NOTE:

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

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

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

block (1-30).

Actuator Reassembly

Service Instructions

124839E Rev. D

NOTE:

The guide bar bearing (2-20) must be press t into guide block guide bar bore with the

seam located ±5° 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

assembly (1-50).

Section 3: Actuator Reassembly

October 2015

NOTE:

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

3�2�5 Install extension rod assembly (1-50) into guide block (1-30) and up against the

rst spherical washer (1-40).

3�2�6 Install extension retainer nut (1-60) over extension rod assembly (1-50) and screw

into guide block (1-30).

3�2�7 Tighten extension retainer nut assembly (1-60) until extension rod assembly (1-

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

NOTE:

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

3�2�8 Lubricate guide block (1-30), two spherical washers (9-40) and one extension rod

assembly (9-50).

3�2�9 Install one spherical washer (9-40) into the side of guide block (1-30).

Actuator Reassembly

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).

Section 3: Actuator Reassembly

October 2015

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

rst spherical washer (9-40).

3�2�12 Install extension retainer nut (9-60) over extension rod assembly (9-50) and screw

into guide block (1-30).

3�2�13 Tighten extension retainer nut assembly (9-60) until extension rod assembly

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

NOTE:

Consult Houston Texas Bettis service coordinator for “yoke bearing, yoke pin bearing or

yoke/guide block bushing installation information".

Service Instructions

124839E Rev. D

3�2�14 If the two yoke bearings (2-40) are being replaced, install new bearing into housing

cover (1-20) and housing (1-10).

NOTE:

The yoke bearing (2-40) must be press t into housing (1-10) and housing cover (1-20). Install the yoke bearings with the bearing seam located 45° ±5° from the yoke arm slot when yoke (1-70) is rotated to its full clockwise position.

3�2�15 If the two yoke pin thrust bearings (2-10) are being replaced install new bearing

into housing cover (1-20) and housing (1-10).

3�2�16 Lubricate two yoke/guide block bushings (2-30) and install onto top and bottom

sides of guide block (1-30).

NOTE:

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

3�2�17 Install guide block (1-30), with yoke/guide block bushings (2-30), between arms of

yoke (1-70).

3�2�18 Install O-ring seal (2-50) into inner diameter O-ring groove in the bottom of

housing (1-10).

3�2�19 Coat the bearing surfaces of the yoke (1-70) with lubricant and install into

housing (1-10).

3�2�20 Align hole in guide block (1-30) with the matching holes in the two yoke/guide

block bushings (2-30) and the slots in the arms of yoke (1-70).

Actuator Reassembly

Service Instructions

124839E Rev. D

NOTE:

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

3�2�21 Install yoke pin (1-80) by inserting into the upper yoke arm, upper yoke/guide

3�2�22 Install guide bar (1-90) into either side of housing (1-10) by inserting through the

3�2�23 Refer to assembly drawing page 2 of 2 Section A-A. Install spring pin (1-100) into

3�2�24 Install position indicator assembly (1-140) onto the top of yoke (1-70) and over

NOTE:

Refer to Section 2 step 2.3.7 for correct installation position.

Section 3: Actuator Reassembly

October 2015

block bushing, guide block, lower yoke/guide block bushing, lower yoke arm and resting on lower yoke pin thrust bearing (2-10).

housing, through guide block and then insert the guide bar into the other side of housing (1-10).

the top of yoke (1-70).

spring pin (1-100).

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 G13 model actuators apply thread adhesive, Locktite 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

Section 3: Actuator Reassembly

October 2015

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

the following table, has been achieved.

Table 2� Housing Cover Screw Quantity and Torque

Service Instructions

124839E Rev. D

Model Qty

G01 4 40 54 G7 8 100 136

G2 6 40 54 G8 12 100 136 G3 8 40 54 G10 16 100 136 G4 8 40 54 G13 20 340 461 G5 8 100 136

TORQUE (±5%)

Lbf-ft� N-m Lbf-ft� N-m

Model Qty

TORQUE (±5%)

NOTE:

Complete step 3.2.32 on G5, through G13 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 G13 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 to protect threads from environment.

3�2�31�2 Install and tighten hex cap screws (1-120) with lockwashers (1-115). 3�2�32 Install thrust bearing (2-110) onto position indicator (1-140). 3�2�33 Install O-ring seal (2-100) onto position indicator (1-140). 3�2�34 Install upper bearing (2-120) into yoke cover (1-150). 3�2�35 Install rod wiper (2-80) into yoke cover (1-150). 3�2�36 Install O-ring seal (2-70) into yoke cover (1-150). 3�2�37 Install yoke cover (1-150) onto housing cover (1-20) and over position indicator

assembly (1-140).

NOTE:

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

3�2�38 Place lockwashers (1-170) onto hex cap screws (1-160). 3�2�39 Install and tighten hex cap screws (1-160) with lockwashers through yoke cover

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

3�2�40 Vent check assembly installation as follows:

3�2�40�1 G01, G2 and G3 housing (1-10) using pipe sealant install one vent check

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

Actuator Reassembly

Service Instructions

124839E Rev. D

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�41 Install stop screw nuts (1-190) onto stop screws (1-180). 3�2�42 Install O-ring (2-90) onto stop screws (1-180). 3�2�43 Install two stop screws (1-180) into two stop screw holes on the front of housing

3�2�44 Adjust both stop screws (1-180) back to settings recorded earlier in Section 2 at

3�2�45 Tighten both stop screw nuts (1-190) securely.

Section 3: Actuator Reassembly

October 2015

3�2�40�2 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�40�3 G4 through G13 housing (1-10) using pipe sealant install two vent check

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

(1-10).

step 2.3.2.

3�3 Hydraulic Power Module Reassembly

NOTE:

Review Section 3.1 General Reassembly before proceeding with Hydraulic Power Module Reassembly.

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

indicated 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.

Actuator Reassembly

CAUTION: CORRECTLY INSTALL PISTON SEAL

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

Section 3: Actuator Reassembly

October 2015

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

is exposed.

NOTE:

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

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

CAUTION: CORRECTLY INSTALL PISTON SEAL

Install the piston seal with energizer ring facing 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

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

Service Instructions

124839E Rev. D

CAUTION: CORRECTLY INSTALL POLYPAK SEAL

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).

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.

Actuator Reassembly

Service Instructions

124839E Rev. D

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

Model Quantity Torque (±5%) Model Quantity Torque (± 5%)

G01 4 40 54 G7 8 100 136

G2 6 40 54 G8 12 100 136 G3 8 40 54 G10 16 100 136 G4 8 40 54 G13 20 340 461 G5 8 100 136

3�3�24 Torque tighten piston rod (3-40) per the chart in Section 5.4 step 5.4.4. 3�3�25 If the power module is reassembled off the actuator then refer to Section 5 step

5.4 for hydraulic power module installation instructions.

Section 3: Actuator Reassembly

3�4 Blind End Cap Module Reassembly

3�4�1 Install O-ring seal (6-10) into the O-ring groove in blind end cap (5-10). 3�4�2 Install lockwashers (5-30) onto hex cap screws (5-20). 3�4�3 Install blind end cap (5-10) onto end of housing (1-10). 3�4�4 Install and tighten hex cap screws (5-20) with lockwashers (5-30) through housing

(1-10) and into blind end cap (5-10).

October 2015

3�5 Actuator Testing

3�5�1 Leakage Test: All sources of leakage to atmosphere and across piston are to be

checked, using hydraulic pressure.

3�5�2 Cycle the actuator ve times at 10% 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�5�3 Apply operating pressure as listed in step 3.5.2 to one side of the piston and allow

the actuator to stabilize.

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

performed again.

3�5�6 Shell pressure 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.

NOTE:

If any leakage occurs during step 3.5.6 the actuator must be disassembled and the cause of leakage must be determined and corrected.

Actuator Reassembly

Section 3: Actuator Reassembly

October 2015

3�5�7 If an actuator was disassembled and repaired, the above testing must be

performed again.

3�5�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: PED PRESSURE TESTING

The actuator's main pressure bearing parts will be tested in controlled conditions in accordance with the requirement of PED 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, the factory should be contacted for guidance.

3�5�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.

Service Instructions

124839E Rev. D

Actuator Reassembly

Service Instructions

124839E Rev. D

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 5.1. 4�1�2 Remove hydraulic power module per Section 5.3. 4�1�3 Reinstall the spring module onto the opposite end of housing (1-10) as it was

previously located per Section 5.2.

4�1�4 Reinstall the hydraulic power module onto the opposite end of housing (1-10) as it

was previously located per Section 5.4.

4�2 Convert Double-Acting Actuator to

Spring-Return

4�2�1 Remove blind end cap module per Section 2.4. 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 5.2.

4�3 Convert Spring-Return Actuator to

Double-Acting

4�3�1 Remove the spring cartridge per Section 5.1 4�3�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.

NOTE:

Skip step 4.3.3 when working on G01-SR models and continue to step 4.3.4.

4�3�3 Remove the spring cartridge Powr Swivl module per Section 5.5. 4�3�4 Install the blind end cap module per Section 3.4.

Field Conversions

Section 5: Module Removal and Installation

October 2015

Service Instructions

124839E Rev. D

Section 5: Module Removal and Installation

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.

WARNING: CHECK FOR COMPRESSED SPRINGS

Do not remove spring module while spring is compressed.

WARNING: READ ACTUATOR WARNING TAGS

For actuators equipped with a spring cartridge mounted M3 jackscrew or an extended stop

(ES) read warning tag wired to the spring cartridge cover plate.

5�1 Spring Module Removal

WARNING: CHECK FOR COMPRESSED SPRINGS

Do not remove spring module while spring is compressed.

NOTE:

1. Review Section 2.1 general disassembly before proceeding with spring module disassembly.

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

3. For G2-SRF and G3-SRF use step 5.1.1. For G01-SR, G2-SR, G3-SR through G13 skip step 5.1.1 and start at step 5.1.2.

5�1�1 For G2-SRF and G3-SRF unscrew and remove pipe plug (7 10) from spring cartridge

assembly (5-10). Skip steps 5.1.2 and 5.1.3 and start at step 5.1.4.

WARNING: EXTENDED STOP CONTACTS

If an M3, M3HW jackscrew or extended stop (ES) is mounted in the spring module cover

plate (7-10), the M3, M3HW or ES assembly (7-40) should not contact the end of the spring module tension rod.

5�1�2 Unscrew hex cap screws (7-20) with lockwashers (7-30) from cover plate (7-10) or

if spring module has a ES or M3 SR adapter plate (7-10) remove safety wire from

hex cap screws (7-20) and then remove hex cap screws (7-20).

5�1�3 Remove cover plate (7-10) from spring cartridge assembly (5-10).

Module Removal and Installation

Service Instructions

124839E Rev. D

5�1�4 Apply hydraulic pressure to the pressure inlet port of inner end cap (3-10) to

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

5�1�6 Unscrew stop screw (1-180) that is closest to or next to spring cartridge module

5�1�7 Remove hydraulic pressure from pressure inlet port of inner end cap (3-10).

CAUTION: USE HEAVY DUTY SUPPORT 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.

5�1�8 The spring cartridge "pre load" must be removed before spring cartridge (5-10)

Section 5: Module Removal and Installation

October 2015

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

next to spring module.

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

is removed from housing (1-10). Refer to steps 5.1.4 through 5.1.6 for spring cartridge "pre load" removal.

CAUTION: DO NOT EXCEED MAXIMUM PRESSURE

The maximum pressure to be applied in step 5.1.9 is 25 PSIG.

5�1�9 Apply hydraulic pressure, which should not to exceed the maximum as indicated

in the above “CAUTION” to 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.

NOTE:

If hydraulic pressure is not available to apply to the pressure inlet port of outer end cap (3-80) then remove hex plug (3-120). Using a long rod go through the outer end cap vacant pipe plug port hole and push the piston rod so as to move the spring cartridge tension

rod hex nut out of its cast hex seat.

5�1�10 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�1�11 Remove hex cap screws (5-20) with lockwashers (5-30) from housing (1-10). 5�1�12 Remove spring cartridge assembly (5-10) from actuator housing (1-10).

WARNING: DO NOT CUT SPRING CARTRIDGE ASSY.

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.

Module Removal and Installation

Section 5: Module Removal and Installation

October 2015

5�2 Spring Module Installation

CAUTION: USE HEAVY DUTY SUPPORT 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 CORRECT OVERTRAVEL POSITIONS

ACTUATOR MUST BE IN THE APPROPRIATE OVERTRAVEL POSITION (Refer to detail “A” on warning tag attached to spring module access hole cover or to Bettis drawing part number 130084 for G01 models or part number 123650 for G2 through G13 models). Conrm over-travel position by observing the guide block (1-30) is against the inner wall of housing (1-10).

Service Instructions

124839E Rev. D

NOTE:

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

5�2�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�2�2 Unscrew or back out stop screw (1-180) to achieve over travel as illustrated in

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

5�2�3 Install O-ring seal (6-20) into the O-ring groove in the inboard end of spring

cartridge assembly (5-10).

5�2�4 Using lifting equipment move spring module up to housing (1-10) and align spring

cartridge tension rod with extension rod assembly (9-50) for G2 through G13

models or G01 models align spring cartridge with tapped hole in guide block (1-30).

WARNING: COMPLETE STEP 5.2.5

Complete step 5.2.5 to avoid severe injury to personnel or incur major damage to the actuator.

5�2�5 Spring cartridge tension rod to rod extension installation as follows:

5�2�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.

Module Removal and Installation

Service Instructions

124839E Rev. D

WARNING: OBSERVE MINIMUM NUMBER OF TURNS

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

Table 4� Rod Rotation

ACTUATOR MODEL G/GC/GH/GHC

MINIMUM NO� TURNS

WARNING: CORRECTLY SCREW TENSION ROD

Section 5: Module Removal and Installation

October 2015

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

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

G01 G2 G3 G4 G5 G7 G8 G10 G13

6 10 10 10 13 14 20 25 31

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

5�2�6 Torque tighten the spring cartridge tension rod as listed in the following table.

Table 5� Spring Cartridge Tension Rod Torque Table

HOUSING

MODEL

G/GC/GH/

GHC

G01 50 68 G7 240 325

G2 90 122 G8 240 325 G3 90 122 G10 240 325 G4 240 325 G13 240 325 G5 240 325

5�2�7 Install lock washers (5-30) onto hex cap screws (5-20). 5�2�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�2�9 Install O-ring seal (6-10) into the O-ring groove in the outboard end of spring

cartridge assembly (5-10).

TORQUE

(±5 % Percent)

Lbf-ft� N-m Lbf-ft� N-m

HOUSING

MODEL

G/GC/GH/

GHC

TORQUE

(±5 % Percent)

NOTE:

For G2-SRF and G3-SRF use step 5.2.10. For G01-SR, G2-SR, G3-SR through G13-SR skip step 5.2.10 and start at step 5.2.11.

Module Removal and Installation

Section 5: Module Removal and Installation

October 2015

5�2�10 Using pipe sealant on the threads install pipe plug (7-10) in the vacant hole in out

board end of spring cartridge assembly (5-10). Skip steps 5.2.11 through 5.2.14 and start at step 5.2.15.

5�2�11 Install lockwashers (7-30) onto hex cap screws (7-20). 5�2�12 Install the cover plate (7-10) or install M3 adapter plate (7-10) onto the outboard

end of spring cartridge assembly (5-10).

5�2�13 Install and tighten hex cap screws (7-20) with lockwashers (7-30) through cover

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

5�2�14 Torque tighten hex cap screws (7-20) until a nal lubricated torque, as listed in the

following table, has been achieved.

Table 6� Hex Cap Screws (7-20) Torque Table

Service Instructions

124839E Rev. D

HOUSING

MODEL

G/GC/GH/

GHC

G01 30 41 G7 135 183

G2 30 41 G8 240 325 G3 30 41 G10 285 386 G4 65 88 G13 340 461 G5 65 88

TORQUE

(±5 % Percent)

Lbf-ft� N-m Lbf-ft� N-m

HOUSING

MODEL

G/GC/GH/

GHC

TORQUE

(±5 % Percent)

5�2�15 On M3, M3HW and ES models install Monel wire (6-130) through each hex cap

screw (7-20) per the following steps:

NOTE:

The following steps provides guidelines for wire locking hex cap screws to discourage screw

loosening and removal in applications where screw removal could be hazardous.

5�2�15�1 Make sure hex cap screws are tightened to their specied torque.

5�2�15�2 Using required lengths of 0.31 diameter Monel wire as provided in the

Module ordered. When replacing Monel wire use the following table for wire length requirements.

Table 7� Wire Length Requirements

MODEL

G/GC/GH/

GHC

G01-SR 36 914.4 G5-SR 66 1676.4

G2-SR 44 1117.6 G7-SR 79 2006.6

G3-SR 48 1219.2 G8-SR 88 2235.2 G4-SR 55 1397.0 G10-SR 110 2794.0

LENGTH MODEL

Inch mm Inch mm

G/GC/GH/

GHC

LENGTH

5�2�15�3 Twist the end of both wires together and insert one through the drilled

hole in the hex cap screw head, pass the second wire over the screw head and twist it three (3) times around the rst wire at a location where the rst wire exits the screw head.

Module Removal and Installation

Service Instructions

TOGETHER

124839E Rev. D

Figure 1 Tag Attachment Guide

Section 5: Module Removal and Installation

October 2015

5�2�15�4 Repeat the procedure until the second wire is twist tied to the screw head

through wire of the last screw head.

5�2�15�5 Attach caution tag and twist tie the wires from the last screw head to the

twisted wires of the rst screw head. See following for illustration.

TAG

TWIST FOUR ENDS

5�2�16 If removed install stop screw nuts (1-190) onto stop screws (1-180). 5�2�17 If removed install O-ring (2-90) onto stop screws (1-180). 5�2�18 If removed install two stop screws (1-180) into two stop screw holes on the front

of housing (1-10).

5�2�19 Adjust both stop screws (1-180) back to settings recorded earlier in Section 5. 5�2�20 Tighten both stop screw nuts (1-190) securely.

Module Removal and Installation

Section 5: Module Removal and Installation

October 2015

5�3 Hydraulic Power Module Removal

WARNING: CHECK FOR EXTENDED SPRINGS

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.

NOTE:

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

5�3�1 Remove O-ring plug (3-120) from outer end cap (3-80). 5�3�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).

Service Instructions

124839E Rev. D

WARNING: USE APPROPRIATE LIFTING EQUIPMENT

Use suitable lifting equipment to support the cylinder assembly.

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

5�4 Hydraulic Power Module Installation

NOTE:

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

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

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

5�4�2 Using lifting equipment move the power module up to housing (1-10) and install

as follows: Use step 5.4.3 for G01 and step 5.4.4 for G2 through G10 model actuators.

5�4�3 G01 Model Actuator:

5�4�3�1 Align piston rod (3-40) with threads in the guide block (1-30).

5�4�3�2 Using a male square drive extension, go through outer end cap (3-80)

and screw piston rod (3-40) into guide block (1-30).

WARNING: CORRECTLY SCREW RODS

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

Module Removal and Installation

Service Instructions

124839E Rev. D

5�4�4 G2 through G10 model actuators:

WARNING: DO NOT CROSS-THREAD RODS

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

5�4�5 Torque tighten piston rod (3-40) per the following chart.

5�4�6 Torque tighten piston rod (3-40) per the following chart. 5�4�7 Install hex cap screws (3-115) with lockwashers (3-110), through inner end cap

5�4�8 Install lock washers (3-110) onto hex cap screws (3-100). 5�4�9 Install hex cap screws (3-100) with lockwashers (3-110), through inner end cap

5�4�10 Install and tighten hex nuts (3-105) onto hex cap screws (3-100). 5�4�11 Using pipe dope, install standard NPT pipe plug (3-120) into outer end cap (3-80).

Section 5: Module Removal and Installation

October 2015

5�4�4�1 Align piston rod (3-40) with extension rod assembly (1-50).

5�4�4�2 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).

5�4�5�1 G01 model actuators torque to 50 foot pounds / 68 N-m lubricated

5�4�5�2 G2 and G3 model actuators torque to 90 foot pounds / 122 N-m

lubricated

5�4�5�3 G4 through G13 model actuators torque to 240 foot pounds / 325 N-m

lubricated

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

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

If the actuator uses SAE threads install SAE O-ring plug (3-120) into outer end cap (3-80).

5�5 G2 Through G13 POWR SWIVL Module Removal

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

listed in chart in section 1 step 1.2.1 to remove retainer nut assembly (1-60) from the guide block (1-30).

CAUTION: DO NOT DROP SPHERICAL WASHERS

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

spherical washers inside the housing.

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

Module Removal and Installation

Section 5: Module Removal and Installation

October 2015

NOTE:

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

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

Service Instructions

124839E Rev. D

5�6 G2 Thru G13 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�6�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�6�2 Lubricate two spherical washers (1-40) and one extension rod assembly (1-50). 5�6�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).

5�6�4 Install second spherical washer (1-40) over threaded end of extension rod

assembly (1-50).

NOTE:

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

5�6�5 Install extension rod assembly (1-50) into right of guide block (1-30) and up

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

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

and screw into guide block (1-30).

5�6�7 Tighten extension retainer nut assembly (1-60) until extension rod assembly

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

Module Removal and Installation

Service Instructions

Section 6: Actuator Support Information

124839E Rev. D

Section 6: Actuator Support Information

6�1 Module Weight Tables

Table 8� Module Weights by Item Number and Actuator Housing Size

ITEM

NO�

G01 WT�G2WT�G3WT�G4WT�G5WT�G7WT�G8WT�

Lbs 83 110 162 280 545 1025 1495 2550 4625

Kg 38 50 73 127 247 465 678 1157 2098

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

Kg 12 N/A 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 N/A

Kg 11.4 13.6 N/A 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 N/A

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

Lbs 27 30 45 N/A 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 N/A

Lbs 28 31 48 71 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 N/A

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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 1139

Kg N/A N/A N/A N/A N/A N/A 254 435 517

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 -

G10 WT�

G13 WT�

DESCRIPTION

Drive Module

Power Module

October 2015

1.5” Dia.

1.7” Dia.

2.0” Dia.

2.2” Dia.

2.5” Dia.

3.0” Dia.

3.5” Dia.

4.0” Dia.

4.5” Dia.

5.0” Dia.

6.0” Dia.

7.0” Dia.

8.0” Dia.

9.0” Dia.

10.0” Dia.

12.0” Dia.

14.0” Dia.

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

Actuator Support Information

Section 6: Actuator Support Information

October 2015

Service Instructions

124839E Rev. D

ITEM

NO�

G01 WT�G2WT�G3WT�G4WT�G5WT�G7WT�G8WT�

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 10010

Kg 73 102 145 256 442 1243 1608 2257 4541

Lbs 158 215 310 549 980 2630 2345 4515 9275

Kg 72 98 141 249 445 1193 1064 2048 4207

Lbs N/A 200 N/A 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 N/A

Lbs N/A 180 N/A 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 N/A

Lbs N/A 220 310 N/A N/A N/A N/A N/A N/A

Kg N/A 100 141 N/A N/A N/A N/A N/A N/A

Lbs N/A 210 300 N/A N/A N/A N/A N/A N/A

Kg N/A 95 136 N/A N/A N/A N/A N/A N/A

Lbs N/A 210 285 N/A N/A N/A N/A N/A N/A

Kg N/A 95 129 N/A N/A N/A N/A N/A N/A

Lbs N/A 195 270 N/A N/A N/A N/A N/A N/A

Kg N/A 88 122 N/A N/A N/A N/A N/A N/A

Lbs N/A 205 N/A N/A N/A N/A N/A N/A N/A

Kg N/A 93 N/A N/A N/A N/A N/A N/A N/A

Lbs N/A 185 N/A N/A N/A N/A N/A N/A N/A

Kg N/A 84 N/A N/A N/A N/A N/A N/A N/A

G10 WT�

G13 WT�

DESCRIPTION

16.0” Dia.

Power Module

18.0” Dia.

Power Module

SR1 Spring

Module

SR2 Spring

Module

SRA5 Spring

Module

SRA6 Spring

Module

SRF1 Spring

Module

SRF2 Spring

Module

SRF3 Spring

Module

SRF4 Spring

Module

SRF5 Spring

Module

SRF6 Spring

Module

6�2 G01 Tool Table

Table 9� 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

7-20 9/16” 4 Hex Cap Screw Socket

13 3/4” 2 Vent Check Assembly Open End

- 3/8” 1 Pull Rod Male Drive

WRENCH

SIZE

ITEM QTY�

LOCATION OR DESCRIPTION

RECOMMENDED

TOOL STYLE

Actuator Support Information

Service Instructions

124839E Rev. D

6�3 G2 Tool Table

Table 10� 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

5-20 9/16” 6 Hex Cap Screws Socket

7-20 9/16” 6 Hex Cap Screws Socket

13 3/4” 2 Vent Check Assembly Open End

WRENCH

SIZE

- 3/8” 1 Pull Rod Male Drive

ITEM QTY�

Section 6: Actuator Support Information

LOCATION OR DESCRIPTION

October 2015

RECOMMENDED

TOOL STYLE

6�4 G3 Tool Table

Table 11� 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

7-20 9/16” 6 Hex Cap Screws Socket

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 G4 Tool Table

Table 12� G4 Tool Style and Wrench Size

Service Instructions

124839E Rev. D

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

7-20 3/4” 6 Hex Cap Screws Socket

13 3/4” 2 Vent Check Assembly Open End

WRENCH

SIZE

- 3/4” 1 Pull Rod Male Drive

ITEM QTY�

6�6 G5 Tool Table

Table 13� G5 Tool Style and Wrench Size

LOCATION OR DESCRIPTION

RECOMMENDED

TOOL STYLE

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

7-20 3/4” 8 Hex Cap Screws Socket

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

124839E Rev. D

6�7 G7 Tool Table

Table 14� G7 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” 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

7-20 15/16” 8 Hex Cap Screws Socket

13 3/4” 2 Vent Check Assembly Open End

WRENCH

SIZE

- 3/4” 1 Pull Rod Male Drive

ITEM QTY�

6�8 G8 Tool Table

Table 15� G8 Tool Style and Wrench Size

LOCATION OR DESCRIPTION

RECOMMENDED

TOOL STYLE

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

7-20 1 1/8” 8 Hex Cap Screws Socket

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

Section 6: Actuator Support Information

October 2015

6�9 G10 Tool Table

Table 16� G10 Tool Style and Wrench Size

Service Instructions

124839E Rev. D

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 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 1-5/16” 8 Hex Cap Screws Socket

7-20 1-5/16” 8 Hex Cap Screws Socket

13 3/4” 2 Vent Check Assembly Open End

WRENCH

SIZE

- 3/4” 1 Pull Rod Male Drive

ITEM QTY�

6�10 G13 Tool Table

Table 17� G13 Tool Style and Wrench Size

LOCATION OR DESCRIPTION

RECOMMENDED

TOOL STYLE

ITEM

NO�

1-110 1 1/8” 20 Cover Screws Socket 1-120 1 1/8” 4 Yoke Cover Screws Socket 1-160 9/16” 12 Hex Cap Screws Socket

1-180 2” Sq. 2 Stop Screws Open End or Adjustable

3-40 7/8” Sq. 1 Piston Rod Male Drive

3-90 2-3/16” 8 Hex Nuts Socket 3-100 1 11/16” 8 Hex Cap Screws Socket 3-105 1 11/16” 8 Standard Hex Nuts Socket 3-115 1 11/16” 8 Hex Cap Screws Socket 3-120 15/16” Sq. 1 Square Head Pipe Plug Open End or Adjustable 3-210 13/16” Sq. 4 Square Head Pipe Plug Open End or Adjustable

5-20 1 13/16” 8 Hex Cap Screws Socket

7-20 1 13/16” 8 Hex Cap Screws Socket

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

124839E Rev. D

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 18� 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 Consult the valve OEM documentation

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

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).

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

cycles 15% of the stroke.

7�2�1�1�2 Verify if the partial stroke test functioned correctly

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

AVG

(e.g., check locally, or automatically via logic solver, or via the PST system if the correct movement of the actuator/valve was

15% of the stroke).

Service Instructions

124839E Rev. D

(average

AVG

value

AVG

NOTE:

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

Troubleshooting

Service Instructions

124839E Rev. D

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,

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

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

Separate the parts composing the actuator according to their nature (e.g., metallic, and

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, and 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 19� Revision Overview

ECN DAT E REVISION STAT US BY * DATE

17787 December 2001 B B. Cornelius

19110 July 2006 C UPDATED C. Ross July 2006

VAWCO2794 October 2015 D UPDATED C. Rico October 2015

*Signatures on le Emerson, Houston, Texas

Service Instructions

124839E Rev. D

December

2001

Document Revision

Service Instructions

124839E Rev. D

Appendix A: List of Tables

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

Table 2. Housing Cover Screw Quantity and Torque ......................................................... 16

Table 3. Tie Bar Nuts (3-90) Torque Table .......................................................................... 19

Table 4. Rod Rotation .......................................................................................................25

Table 5. Spring Cartridge Tension Rod Torque Table ......................................................... 25

Table 6. Hex Cap Screws (7-20) Torque Table .................................................................... 26

Table 7. Wire Length Requirements .................................................................................. 26

Table 8. Module Weights by Item Number and Actuator Housing Size .............................. 31

Table 9. G01 Tool Style and Wrench Size ...........................................................................32

Table 10. G2 Tool Style and Wrench Size ............................................................................. 33

Table 11. G3 Tool Style and Wrench Size ............................................................................. 33

Table 12. G4 Tool Style and Wrench Size ............................................................................. 34

Table 13. G5 Tool Style and Wrench Size ............................................................................. 34

Table 14. G7 Tool Style and Wrench Size ............................................................................. 35

Table 15. G8 Tool Style and Wrench Size ............................................................................. 35

Table 16. G10 Tool Style and Wrench Size ........................................................................... 36

Table 17. G13 Tool Style and Wrench Size ........................................................................... 36

Table 18. Fault Location Table ............................................................................................. 37

Table 19. Revision Overview ............................................................................................... 40

Appendix

October 2015

Appendix

October 2015

Service Instructions

124839E Rev. D

Appendix B: List of Drawings

B�1 Part No� 116423, GXXXX�X Hydraulic Assembly

Drawing, Sheet 1 of 2

Appendix

Service Instructions

124839E Rev. D

Appendix

October 2015

B�2 Part No� 116423, GXXXX�X Hydraulic Assembly

Drawing, Sheet 2 of 2

Appendix

October 2015

Service Instructions

B�3 Part No� 115676, GXX2XX�X Hydraulic

Assembly Drawing, Sheet 1 of 2

124839E Rev. D

Appendix

Service Instructions

124839E Rev. D

B�4 Part No� 115676, GXX2XX�X Hydraulic

Assembly Drawing, Sheet 2 of 2

Appendix

October 2015

Appendix

October 2015

Service Instructions

124839E Rev. D

B�5 Part No� 115941, GXXXX�X-SRX Hydraulic

Assembly Drawing, Sheet 1 of 2

Appendix

Service Instructions

124839E Rev. D

October 2015

B�6 Part No� 115941, GXXXX�X-SRX Hydraulic

Assembly Drawing, Sheet 2 of 2

Appendix

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Specifications and Main Features

Frequently Asked Questions

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