Bettis Service Instructions for Models G01 through G10 Double Acting Pneumatic Actuators with M11 Hydraulic Override Manuals & Guides

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Service Instructions

124843E Rev. C

August 2015

G01 through G10 Double-Acting Pneumatic Actuators with M11 Hydraulic Override

Service Instructions

124843E Rev. C

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 and Fluid Requirements .............................................................. 3

1.7 General Tool Information .............................................................................. 4

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

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

1.10 Actuator Start-Up .......................................................................................... 4

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

Table of Contents

August 2015

Section 2: Actuator Disassembly

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

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

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

2.4 M11 Hydraulic Override Cylinder Disassembly ............................................. 11

Section 3: Actuator Reassembly

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

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

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

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

3.5 M11 Hydraulic Override Cylinder Reassembly .............................................. 23

3.6 Actuator Testing ......................................................................................... 25

Section 4: Field Conversions

4.1 Construction Reversal (Exchange Module Locations) ................................... 27

Section 5: Module Removal and Installation

5.1 Pneumatic Power Module Removal .............................................................28

5.2 Pneumatic Power Module Installation ......................................................... 28

5.3 M11 Hydraulic Overrides Cylinder Removal ................................................. 29

5.4 M11 Hydraulic Override Cylinder Installation ............................................... 30

5.5 Powr Swivl Module Removal ........................................................................ 31

5.6 Powr Swivl Module Installation .................................................................... 31

Table of Contents

August 2015

Section 6: Actuator Support Information

Section 7: Troubleshooting

Section 8: Removal and Decommissioning

Service Instructions

124843E Rev. C

6.1 M11 Hydraulic Override System Fluid Volume ............................................. 33

6.2 Module Weights by Item Number and Actuator Housing Size ...................... 33

6.3 G01 Tool Style and Wrench Size ..................................................................34

6.4 G2 Tool Style and Wrench Size..................................................................... 35

6.5 G3 Tool Style and Wrench Size..................................................................... 35

6.6 G4 Tool Style and Wrench Size..................................................................... 36

6.7 G5 Tool Style and Wrench Size..................................................................... 36

6.8 G7 Tool Style and Wrench Size..................................................................... 37

6.9 G8 Tool Style and Wrench Size..................................................................... 37

6.10 G10 Tool Style and Wrench Size ..................................................................38

7.1 Fault Insertion ............................................................................................. 39

7.2 Operational Test .......................................................................................... 40

8.1 Removal and Decommissioning .................................................................. 41

Section 9: Document Revision

Appendix A: List of Tables

Appendix B: List of Drawings

Table of Contents

Service Instructions

124843E Rev. C August 2015

Section 1: Introduction

1.1 General Service Information

1.1.1 This service procedure is offered as a guide to enable general maintenance to be performed on Bettis™ G01XXX-M11, G2XXX M11, G3XXX M11, G4XXX M11, G5XXX M11, G7XXX M11, G8XXX M11, and G10XXX M11 Double-Acting G-Series Actuators with one Pneumatic Power Module and one M11 or M11 S Hydraulic Override Module.

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

NOTE:

Storage time is counted as part of the service interval.

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

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

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

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

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

1.1.8 Actuator module weights are listed in Section 6 Table 6.2.

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.

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.

Section 1: Introduction

August 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

124843E 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 instructions contained within this Service Instruction are strictly adhered to and executed by well trained, equipped, prepared and competent personnel.

WARNING: READ WARNING MESSAGES CAREFULLY

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

WARNING: FOLLOW PLANT SAFETY PROCEDURES

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

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

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

Introduction

Service Instructions

124843E Rev. C August 2015

Section 1: Introduction

1.4 Bettis Reference Materials

1.4.1 Assembly Drawing for G01-M11 through G10-M11 Double-Acting with one Pneumatic Power Module and one Hydraulic Override Module use part number 115680.

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

1.4.3 M11-S Manual Hydraulic Override System operating instructions part number 121962 with M11-S Assembly Drawing part number 121090.

NOTE:

If you require a specic assembly drawing (IE: GXX-M3 OR HYD) please contact Emerson Actuation Technologies Bettis by phone or email at info.actuationtechnologies@emerson.com

1.5 Service Support Items

1.5.1 Bettis module service kits.

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

NOTE:

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

Table 1. G-Series Actuator Models

Actuator Model Bettis Part Number Actuator Model Bettis Part Number

G01 None required G5/G7 117369 G2 123616 G8/G10 117368 G3/G4 117370

1.5.3 Commercial leak testing solution.

1.5.4 Non-hardening thread sealant.

1.6 Lubrication and Fluid Requirements

NOTE:

Lubricants and hydraulic uids other than those listed in step 1.6.1 and 1.6.2 should not be

used without prior written approval of Bettis Product Engineering.

Introduction

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

1.6.2 FLUID REQUIREMENTS: M11 Manual Hydraulic Override System - All temperature service (-20°F to +350°F)/(-28.9°C to 176.6°C) use Dexron II or Shell Tellus T-32 Automatic Transmission Fluid. Low temperature service (-50°F to 150°F)/(-45.5°C to 65.6°C) use Univis J13 or HVI 13 Hydraulic Fluid.

Section 1: Introduction

August 2015

1.7 General Tool Information

1.7.1 Tools: All tools/Hexagons are American Standard inch. Large adjustable wrench, two (2) large screwdrivers, Allen wrench set, set of open/box end wrenches, rubber or leather mallet, torque wrench (up to 1200 foot pounds / 1627 N-m), breaker bar, small drift punch and a drive socket set. For recommended tool and wrench sizes refer to Section 6, Tables 6.3 through 6.10.

1.8 Actuator Storage

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

1.9 Actuator Installation

Service Instructions

124843E Rev. C

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

1.9.2 Actuators that are shipped from the factory with the travel stops adjusted for approximately ninety degree rotation. Generally, it is necessary to make slight travel stop adjustments once the actuator is installed onto the valve. Refer to the

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

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

NOTE:

The actual "stopping" should be done by the actuator. If the valve does not have internal stops, adjust the actuator to the full open position. Using this as a reference point, rotate the valve closed and adjust to the valve manufacturer's specications for total rotation.

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

NOTE:

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

1.10 Actuator Start-Up

1.10.1 Prestart-up checks

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

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

Introduction

Service Instructions

124843E Rev. C August 2015

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

3. Indicated position conrms valve position.

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

1.10.2 Check Connections

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

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

3. Electrical connection terminals are secured.

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

1.10.3 When actuator is rst placed 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 to exercise the seals so as to achieve a service ready condition.

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

1. Power supply line length

2. Power supply line size

3. Power supply line pressure

4. Control valve and tting orice size

5. Torque requirements of the valve

6. Size of the actuator

7. Setting of speed controls

8. Hydraulic manual override (where available)

1.10.5 Due to the interaction of these variables, it is difcult to specify a "normal" operating time. Faster operating time may be obtained by using one or more of the following:

1. Larger supply lines

2. Larger control valve

3. Higher supply pressure *

4. Quick exhaust valves

— * Not to exceed maximum operating pressure of actuator or

control components

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

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

Section 1: Introduction

1.11 Actuator Operation

1.11.1 Controlled Operation: Controlled operation is accomplished by pressurizing and/or depressurizing the appropriate cylinder inlet(s) of a double-acting. Do not exceed pressures indicated on actuator nameplate.

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

Introduction

Section 2: Actuator Disassembly

August 2015

Section 2: Actuator Disassembly

2.1 General Disassembly

WARNING: DANGEROUS GAS AND/OR LIQUIDS

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

2.1.1 Section 2 - Actuator Disassembly is written to either completely disassemble the entire actuator or can be used to disassemble individual modules as needed (pneumatic power module or drive module, M11 override module or hydraulic override cylinder).

2.1.2 The pneumatic power module and the hydraulic override cylinder can be disassembled while still attached to the drive module or they can be removed from the drive module and disassembled separate to the actuator (refer to Section 5 Module Removal And Installation).

Service Instructions

124843E Rev. C

NOTE:

Use a means of capturing the hydraulic uid that will be lost during the removal or disassembly of

the hydraulic override power module. Use a bucket, tub, and large container, etc.

2.1.3 To ensure correct reassembly; that is, with pneumatic power module or M11 hydraulic cylinder assembly on same end of drive module as was, mark or tag right (or left) and mark mating surfaces.

2.2 Pneumatic Power Module Disassembly

NOTE:

Review Section 2 steps 2.1.1 through 2.1.3 General Disassembly before proceeding with pneumatic power module disassembly.

WARNING: DISCONNECT OPERATING PRESSURE

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

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 Refer to assembly drawing sheet 1 Detail "E". Remove two socket cap screws (3-

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

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

Actuator Disassembly

Service Instructions

124843E Rev. C August 2015

Section 2: Actuator Disassembly

CAUTION: DO NOT DAMAGE O-RING GROOVE

Do not damage O-ring groove when removing end cap.

2.2.4 The t between cylinder (3-70) and outer end cap (3-80) is very tight. Break end cap free by tapping with a breaker bar on lip provided on the end cap. Remove outer end cap (3-80) from cylinder (3-70).

NOTE:

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

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

CAUTION: DO NOT USE PIPE WRENCH

Do not use pipe wrench to remove tie bars.

2.2.6 TIE BAR REMOVAL:

NOTE:

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

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

2.2.6.1.1 Unscrew tie bars (3-20) from inner end cap (3-10). Pull the tie bars

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

2.2.6.1.3 Remove tie bars (3-20) by pulling the tie bars out and through

NOTE:

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

NOTE:

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

out of the inner end cap far enough to expose the O-ring seals (4-80).

piston (3-30).

Actuator Disassembly

2.2.6.2 Remove G4 through G10 tie bars (3-20) as follows: Unscrew and remove

tie bars (3-20) from inner end cap (3-10) and piston (3-30).

Section 2: Actuator Disassembly

August 2015

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

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

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

NOTE:

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

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

(3-40).

NOTE:

Steps 2.2.8 is used only on early G2 and G3 models equipped with outboard and inboard tie bar nuts.

Service Instructions

124843E Rev. C

2.2.8 Remove early model G2 and G3 pistons as follows:

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

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

NOTE:

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

2.2.8.2 Slide piston (3-30) toward the inner end cap (3-10) until the out board

split ring halves is exposed enough for removal. Remove outboard split ring halves from piston rod (3-40).

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

(3-40).

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

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

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

NOTE:

On early model G2 and G3 actuators remove two hex nuts (3-90) from housing (1-10). These two nuts will be loose after tie bars (3-20) are removed in step 2.2.6.1 and will be located in the area where the piston rod passes through the housing (1-10).

NOTE:

The piston rod (3-40) removal as outlined in step 2.2.12 is only required when the piston rod is being replaced or when the drive module is to be disassembled.

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

Actuator Disassembly

Service Instructions

124843E Rev. C August 2015

Section 2: Actuator Disassembly

2.3 Drive Module Disassembly

NOTE:

Review Section 2 steps 2.1.1 through 2.1.3 General Disassembly before proceeding with drive module disassembly.

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

2.3.2 Mark stop screws (1-180) left and right.

NOTE:

The setting of stop screws (1-180) should be checked and setting recorded before stop screws are loosened or removed. Stop screws will be removed later in this procedure. For steps 2.3.3 through 2.3.10 refer to assembly drawing sheet 2 Section A-A and Detail “J”.

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

NOTE:

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

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

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

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

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

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

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

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

NOTE:

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

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

2.3.12 Using hex cap screws (1-110), install into holes vacated by hex cap screws (1-120). Use these hex cap screws to jack the housing cover up for removal. Alternately rotate the hex cap screws clockwise until housing cover (1-20) is clear of housing (1-10).

Actuator Disassembly

Section 2: Actuator Disassembly

August 2015

NOTE:

G01, G2, G3 and G4 model housing cover 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 sheet 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) and two yoke/guide block bushings (2-30), by lifting the 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

124843E Rev. C

NOTE:

G01 model actuators skip steps 2.2.23 through 2.2.25 and continue disassembly at step 2.2.26.

2.3.23 Refer to assembly drawing sheet 2 Detail "B". Use Bettis tool part numbers 117368 (G8/G10), 117369 (G5/G7), 117370 (G3/G4), or 123616 (G2) and remove retention retainer nut assemblies (1-60) and (9-60) from guide block (1-30).

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

NOTE:

Spherical washers (1-40) and (9-40) will be removed from guide block (1-30) when the extension rod assemblies are removed.

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

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

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

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

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

Actuator Disassembly

Service Instructions

124843E Rev. C August 2015

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

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

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

2.3.29 The following items do not need to be removed from their assembled locations unless being replaced by new items: Two yoke bearings (2-40 and yoke pin thrust bearing 2-10).

Section 2: Actuator Disassembly

2.4 M11 Hydraulic Override Cylinder Disassembly

NOTE:

Review Section 2 steps 2.1.1 through 2.1.3 General Disassembly before proceeding with M11 Hydraulic Override Cylinder Disassembly.

WARNING: DISCONNECT OPERATING PRESSURE

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

2.4.1 Place the M11 pump control knob (20-320) in the auto position.

NOTE:

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

10). Using a means of capturing the hydraulic uid that will be lost during the following

steps. Use a bucket, tub, and large container, etc.

2.4.2 Remove all the piping from the M11 override cylinder outer end cap (7-80) and inner end cap (7-10).

2.4.3 Mark and record location of the ports on outer end cap (7-80) and inner end cap (7-10).

2.4.4 Remove NPT pipe plug or optional SAE O-ring plug (7-120) from outer end cap (7-80).

2.4.5 Remove hex nuts (7-90), with lockwashers (7-95), from tie bars (7-20).

2.4.6 Remove outer end cap (7-80) from cylinder (7-70), and tie bars (7-20).

2.4.7 Unscrew and remove tie bars (7-20) from inner end cap (7-10).

2.4.8 Remove cylinder (7-70) from inner end cap (7-10), piston (7-30) and piston rod (7-40).

2.4.9 Refer to assembly drawing sheet 2 Detail "G". Remove two split ring halves (7-50) and one retainer ring (7-60) from piston rod (7-40).

2.4.10 Remove piston (7-30) from piston rod (7-40).

2.4.11 Remove O-ring seal (8-70) from piston rod (7-40).

2.4.12 Refer to assembly drawing sheet 2 Detail "G". Remove two split rings (7-50) and one retainer ring (7-60) from piston rod (7-40).

2.4.13 Remove hex cap screws (7-115) with lockwashers (7-110) from inner end cap (7-10).

2.4.14 Remove hex nuts (7-105) from hex cap screws (7-100).

Actuator Disassembly

Section 2: Actuator Disassembly

August 2015

2.4.15 Remove hex cap screws (7-100) with lockwashers (7-110) from inner end cap (7-

10) and housing (1-10).

2.4.16 Remove inner end cap (7-10) off of piston rod (7-40).

NOTE:

The piston rod (7-40) removal as outlined in step 2.4.17 is only required when the piston rod is being replaced or when the drive module is to be disassembled.

2.4.17 Remove piston rod (7-40) from the drive module.

Service Instructions

124843E Rev. C

Actuator Disassembly

Service Instructions

124843E Rev. C August 2015

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.

CAUTION: INSPECT PARTS BEFORE USE

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

new parts.

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

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

NOTE:

The parts and seals used in the actuator will be assembled using lubricant as identied in

Section 1 step 1.6.1 through 1.6.2.

3.2 Drive Module Reassembly

NOTE:

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

NOTE:

Drive module is to be assembled using the lubricant identied in Section 1 step 1.6.1.

Actuator Reassembly

Section 3: Actuator Reassembly

August 2015

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

NOTE:

The guide bar bearing must be pressed into guide block guide bar bore with the seam located ±5 degrees of the top or bottom centerline as shown in Section A-A.

NOTE:

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

3.2.14.

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

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

Service Instructions

124843E Rev. C

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).

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 assembly (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.

3.2.8 Lubricate two spherical washers (9-40) and one extension rod assembly (9-50).

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

NOTE:

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

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

Actuator Reassembly

Service Instructions

124843E Rev. C August 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.

Section 3: Actuator Reassembly

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

NOTE:

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

3.2.15 If the two yoke pin 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 bearings (2-30), between arms of yoke (1-70).

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

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

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

Actuator Reassembly

Section 3: Actuator Reassembly

August 2015

NOTE:

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

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

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

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

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

NOTE:

Refer to Section 2 step 2.3.7 for correct installation position.

Service Instructions

124843E Rev. C

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

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

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

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

NOTE:

On G7 through G10 model actuators apply thread adhesive, Loctite 242, to threads of hex cap screws (1-110). Reference assembly drawing note number 8.

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

NOTE:

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

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

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

3.2.31 Torque tighten hex cap screws (1-110) until a nal lubricated torque, as listed in the following table, has been achieved.

Actuator Reassembly

Service Instructions

Section 3: Actuator Reassembly

124843E Rev. C August 2015

Table 2. Housing Cover Screw Quantity and Torque

Model Qty

G01 4 40 54 G5 8 100 136 G2 6 40 54 G7 8 100 136 G3 8 40 54 G8 12 100 136 G4 8 40 54 G10 16 100 136

TORQUE (±5%)

Lbf-ft. N-m Lbf-ft. N-m

Model Qty

TORQUE (±5%)

NOTE:

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

3.2.32 On G5 through G10 models;

3.2.32.1 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.

3.2.32.2 Install and tighten hex cap screws (1-120) with lockwashers (1-115).

3.2.33 Install thrust bearing (2-110) onto position indicator (1-140).

3.2.34 Install O-ring seal (2-100) onto position indicator (1-140).

3.2.35 Install upper bearing (2-120) into yoke cover (1-150).

3.2.36 Install rod wiper (2-80) into yoke cover (1-150).

3.2.37 Install O-ring seal (2-70) into yoke cover (1-150).

3.2.38 Install yoke cover (1-150) onto housing cover (1-20) and over position indicator assembly (1-140).

Actuator Reassembly

NOTE:

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

3.2.39 Place lockwashers (1-170) onto hex cap screws (1-160).

3.2.40 Install and tighten hex cap screws (1-160) with lockwashers through yoke cover (1-150) and into housing cover (1-20).

3.2.41 Vent check assembly installation as follows:

3.2.41.1 G01, G2 and G3 housing (1-10) using pipe sealant install one vent check

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

3.2.41.2 G01, G2 and G3 housing cover (1-20) using pipe sealant install one vent

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

3.2.41.3 G4 through G10 housing (1-10) using pipe sealant install two vent check

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

Section 3: Actuator Reassembly

August 2015

3.2.42 NOTE: Refer to Section 2 step 2.3.3 for correct position indicator placement. Install position indicator (1-220) over the exposed shaft of position indicator assembly (1-140).

3.2.43 Install stop screw nuts (1-190) onto stop screws (1-180).

3.2.44 Install O-ring (2-90) onto stop screws (1-180).

3.2.45 Install two stop screws (1-180) into two stop screw holes on the front of housing (1-10).

3.2.46 Adjust both stop screws (1-180) back to settings recorded earlier in Section 2 at step

2.3.2.

3.2.47 Tighten both stop screw nuts (1-190) securely.

Service Instructions

3.3 Pneumatic Power Module Reassembly

NOTES:

1. For early model G2 and G3 actuators with double nuts on the power module use section

3.4 for reassembly.

2. Refer to Section 2 step 2.1.3 for the correct installation location for piston rod (3-40).

3. THE ACTUATOR MUST BE IN THE APPROPRIATE OVERTRAVEL POSITION. Confirm over-

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

124843E Rev. C

3.3.1 Lubricate piston rod (3-40) and insert through the side of housing (1-10).

3.3.1.1 G2 through G10 screw piston rod (3-40) onto extension rod assembly

(1-50).

3.3.1.2 G01 screw piston rod (3-40) onto guide block (1-30).

3.3.2 Torque tighten piston rod (3-40) to the lubricated torque as listed in the following table.

Table 3. Piston Rod Torque Information

Housing

Model

G01 50 122 G5 240 325

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

3.3.3 Refer to assembly drawing page 2 of 2 Detail "C". Install one rod wiper (4-10) into inner end cap (3-10).

3.3.4 Install one rod bushing (4-20) into inner end cap (3-10).

3.3.5 Coat one Polypak seal (4-30) with lubricant and install, lip rst, into inner end cap (3-10).

TORQUE (±5%)

Lbf-ft. N-m Lbf-ft. N-m

Housing

Model

TORQUE (±5%)

CAUTION: POLYPAK SEAL FACING PISTON SIDE

Install the Polypak seal with energizer ring facing outboard side (away from housing).

Actuator Reassembly

Service Instructions

124843E Rev. C August 2015

3.3.6 Install one o-ring seal (4-90) into seal groove located on the inboard face of inner end cap (3-10).

3.3.7 Install inner end cap (3-10) on to housing (1-10).

NOTE:

The pressure inlet port should be positioned in the same position as recorded in section 2.2 step 2.2.1.

3.3.8 Place lockwashers (3-110) onto hex cap screws (3-100).

3.3.9 Install hex cap screws (3-100), with lockwashers, through housing (1-10) and into inner end cap (3-10).

3.3.10 Refer to assembly drawing page 2 of 2 Detail "D". Install one O-ring seal (4-70) into the seal groove in piston rod (3-40).

3.3.11 Apply lubricant to two sets of rod T-seal components (4-50).

NOTE:

The T-seal is composed of one rubber seal and two split skive-cut back-up rings.

Section 3: Actuator Reassembly

3.3.11.1 Install two sets of rod T-seals (4-50) into the internal diameter seal

grooves of piston (3-30).

3.3.11.2 Install a back-up ring on each side of the T-seal.

3.3.11.3 When installing the back-up rings, do not align the skive-cuts.

3.3.11.4 If the back-up rings are too long and the rings overlap beyond the skive-

cuts, then the rings must be trimmed with a razor sharp instrument.

3.3.12 Install two split ring halves (3-50) into the inner most groove in piston rod (3-40) and retain by installing the recessed area of piston (3-30) onto the piston rod and over the two split ring halves (3-50).

3.3.13 Install two split ring halves (3-50) into the piston rod, in front of the piston installed in the previous step, and retain with retainer ring (3-60).

3.3.14 Install one O-ring seal (4-40) onto the outer diameter seal groove of inner end cap (3-10).

3.3.15 Coat one D-ring seal (4-60) with lubricant and install into the piston external seal groove.

NOTE:

The at side of the D-ring seal go down into the seal groove.

3.3.16 Coat two tie bars (3-20) with lubricant and install by carefully pushing tie bars through piston (3-30) and rod T-seal (4-50).

3.3.17 Screw tie bars (3-20) into inner end cap (3-10) and tighten until the threads bottom out.

3.3.18 Refer to assembly drawing page 2 of 2 Detail "E". Coat two O-ring seals (4-80) with lubricant and install into outer end cap (3-80).

Actuator Reassembly

Section 3: Actuator Reassembly

August 2015

3.3.19 Apply lubricant to one O-ring seal (4-40) and install into the outer diameter O-ring groove of outer end cap (3-80).

3.3.20 Apply lubricant to the bore of cylinder (3-70).

CAUTION: CAREFULLY INSTALL CYLINDER

If needed, when installing the cylinder, hammer on the end of the cylinder only with a non metallic object.

3.3.21 Install lubricated cylinder (3-70) over piston (3-30) and onto inner end cap (3-10). When installing the cylinder over the piston seal tilt cylinder 15° to 30° degrees to piston rod.

3.3.22 Install outer end cap (3-80) over tie bars (3-20) and into cylinder (3-70).

NOTE:

The pressure inlet port should be positioned in the same position as recorded in Section 2 step 2.2.1.

Service Instructions

124843E Rev. C

3.3.23 Install tie bar nuts (3-90) onto tie bars (3-20). Torque tighten tie bar nuts,

alternately in 100 foot pound / N-m increments, until a nal lubricated torque, as

listed in the following table, has been achieved.

Table 4. Tie Bar Nuts

Housing

Model

G01 120 163 G5 400 542

G2 120 163 G7 500 678 G3 150 203 G8 500 678 G4 150 203 G10 1200 1627

3.3.24 Install lockwashers (3-140) onto socket cap screws (3-130).

3.3.25 Install and tighten socket cap screws (3-130), with lockwashers (3-140), into outer end cap (3-80).

3.3.26 If removed, using pipe dope, install pipe plug (3-120) into outer end cap (3-80).

TORQUE (±5%)

Lbf-ft. N-m Lbf-ft. N-m

Housing

Model

TORQUE (±5%)

Actuator Reassembly

Service Instructions

124843E Rev. C August 2015

Section 3: Actuator Reassembly

3.4 G2 and G3 Early Model Pneumatic Power Module Reassembly

NOTES:

1. Early G2 and G3 pneumatic power modules where equipped with tie bars that had nuts on both ends of the tie bars (3-20) – double nuts.

2. Refer to Section 2 step 2.1.4 for the correct installation location for piston rod (3-40).

3. THE ACTUATOR MUST BE IN THE APPROPRIATE OVERTRAVEL POSITION. Confirm over- travel position by observing the guide block (1-30) is against the inner wall of housing (1-10).

3.4.1 Refer to assembly drawing page 2 of 2 Detail "C". Install one rod wiper (4-10) into

inner end cap (3-10).

3.4.2 Install one rod bushing (4-20) into inner end cap (3-10).

3.4.3 Coat one Polypak seal (4-30) with lubricant and install, lip rst, into inner end cap (3-10).

CAUTION: INSTALL POLYPAK SEAL CORRECTLY

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

3.4.4 Install piston rod (3-40) through inner end cap (3-10).

NOTE:

The piston rod end with retainer grooves to be on the outboard side of inner end cap (3-10).

NOTE:

Piston will be torque tighten when installed into the drive module refer to Section 5 step 5.2.5.

3.4.5 Apply lubricant to two sets of rod T-seal components (4-50).

NOTE:

The T-seal is composed of one rubber seal and two split skive-cut back-up rings.

Actuator Reassembly

3.4.5.1 Install two sets of rod T-seals (4-50) into the internal diameter seal grooves of piston (3-30).

3.4.5.2 Install a back-up ring on each side of the T-seal.

3.4.5.3 When installing the back-up rings, do not align the skive-cuts.

3.4.5.4 If the back-up rings are too long and the rings overlap beyond the skive-

Section 3: Actuator Reassembly

August 2015

cuts, then the rings must be trimmed with a razor sharp instrument.

3.4.6 Coat one D-ring seal (4-60) with lubricant and install into the piston external seal groove.

NOTE:

The at side of the D-ring seal goes down into the seal groove.

3.4.7 Install piston (3-30) onto piston rod (3-40).

NOTE:

The cast rib side of the piston is to be facing away from the outboard side of inner end cap (3-10) or position piston (3-30) on the piston rod so that the retainer grooves are on the out board side of the piston.

3.4.8 Refer to assembly drawing page 2 of 2 Detail "D". Install O-ring seal (4-70) into the seal groove in the outboard end of piston rod (3-40).

3.4.9 Install two split ring halves (3-50) into the outer most groove in piston rod (3-40) and retain by installing the recessed area of piston (3-30) over the two split halves (3-50).

3.4.10 Install two split ring halves (3-50) into the piston rod, in back of the piston and retain with retainer ring (3-60).

3.4.11 Coat two tie bars (3-20) with lubricant and install by carefully pushing tie bars through piston (3-30) and rod T-seal (4-50).

3.4.12 Install two tie bar O-ring seals (4-80) onto the inboard end of tie bars (3-20) and into the O-ring grooves provided.

3.4.13 Insert the tie bars through inner end cap (3-10) and screw hex nuts (3-90) onto inboard end of the tie bars.

Service Instructions

124843E Rev. C

NOTE:

Screw the tie bars through the hex nuts (3-90) until one complete thread is exposed.

3.4.14 Refer to assembly drawing page 2 of 2 Detail "E". Install two tie bar O-ring seals (4-80) onto the outboard end of tie bars (3-20) and into the O-ring grooves provided.

3.4.15 Apply lubricant to one O-ring seal (4-40) and install into the outer diameter O-ring groove of outer end cap (3-80).

3.4.16 Apply lubricant to the bore of cylinder (3-70).

CAUTION: CAREFULLY INSTALL CYLINDER

If needed, when installing the cylinder, hammer on the end of the cylinder only with a non-metallic object.

3.4.17 Install lubricated cylinder (3-70) over piston (3-30) and onto inner end cap (3-10). When installing the cylinder over the piston seal tilt cylinder 15° to 30° degrees to piston rod.

Actuator Reassembly

Service Instructions

124843E Rev. C August 2015

3.4.18 Install outer end cap (3-80) over tie bars (3-20) and into cylinder (3-70).

NOTE:

The pressure inlet port should be positioned in the same position as recorded in section 2.2 step 2.2.1.

3.4.19 Install tie bar nuts (3-90) onto tie bars (3-20). Torque tighten tie bar nuts (3-90) as follows:

3.4.19.1 G2 model actuators torque to 120 Lbf-ft. / 163 N-m (±5 % Percent)

lubricated.

3.4.19.2 G3 model actuators torque to 150 Lbf-ft. / 203 N-m (±5% Percent)

lubricated.

3.4.20 Install lockwashers (3-140) onto socket cap screws (3-130).

3.4.21 Install and tighten socket cap screws (3-130), with lockwashers (3-140), into outer end cap (3-80).

3.4.22 Install pneumatic power module per Section 5 steps 5.2.

Section 3: Actuator Reassembly

3.5 M11 Hydraulic Override Cylinder Reassembly

NOTE:

Review Section 3.1 General Reassembly before proceeding with the M11 hydraulic override cylinder reassembly.

NOTE:

In Section 3.5 where the step indicates to "lubricate, coat or apply uid", use hydraulic uid, as identied in Section 1 step 1.6.2, for lubricating the part being installed.

3.5.1 Lubricate piston rod (7-40) with uid.

3.5.2 Install O-ring seal (8-70) into the seal groove in piston rod (7-40).

3.5.3 Install two split ring halves (7-50) into the inner most groove in piston rod (7-40) and retain with one retainer ring (7-60).

3.5.4 Install piston (7-30) onto piston rod (7-40) and up against split rings install in step 3.5.3.

3.5.5 Install two split ring halves (7-50) into the outer most groove in piston rod (7-40) and retain with one retainer ring (7-60).

3.5.6 Apply uid to the bore of cylinder (7-70).

3.5.7 Coat one piston bearing (8-45) with uid and install into the piston external seal groove.

3.5.8 Install piston (7-30), with piston rod (7-40), into cylinder (7-70) leave the inner most piston seal groove outside of the cylinder.

3.5.9 Coat one piston seal (8-60) with uid and install into the piston external seal groove.

Actuator Reassembly

Section 3: Actuator Reassembly

August 2015

CAUTION: INSTALL PISTON SEAL CORRECTLY

Install the piston seal with energizer ring facing outside edge of piston (7-30).

3.5.10 Push the piston through the cylinder (7-70) until the outboard piston seal groove is exposed.

NOTE:

To move the piston (7-30) through the bore of cylinder (7-70) may require mechanical assistance.

3.5.11 Coat one piston seal (8-60) with uid and install into the piston external seal groove.

3.5.12 Refer to assembly drawing sheet 2 Detail "C". Coat Polypak seal (8-30) with

hydraulic uid and install; lip rst, into inner end cap (7-10).

CAUTION: INSTALL POLYPAK SEAL CORRECTLY

Service Instructions

124843E Rev. C

Install the Polypak seal with energizer ring facing piston side of inner end cap (7-10).

3.5.13 Install rod bushing (8-20) into inner end cap (7-10).

3.5.14 Install rod wiper (8-10) into inner end cap (7-10).

3.5.15 Install one O-ring seal (8-90) into inboard face of inner end cap (7-10).

3.5.16 Install inner end cap (7-10) onto piston rod (7-40).

3.5.17 Install two tie bars (7-20) into inner end cap (7-10).

NOTE:

The tie bars should be installed across from each other. Refer to the CAUTION after step 3.5.20.

3.5.18 Install one O-ring seal (8-40) into inboard face of outer end cap (7-80).

3.5.19 Install outer end cap (7-80) into open end of cylinder (7-70).

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 2.4.3.

3.5.20 Install the remaining tie bars (7-20) through outer end cap (7-80) and into inner end cap (7-10). Refer to the following CAUTION:

CAUTION: INSTALL TIE BARS CORRECTLY

Assemble tie bars (7-20) into inner end cap (7-10) a minimum engagement of one tie bar thread diameter. Insure that three to four threads are equally exposed beyond the tie bar nuts (7-90) at the outer end cap (7-80).

Actuator Reassembly

Service Instructions

124843E Rev. C August 2015

3.5.21 Install lockwashers (7-95) onto tie bars (7-20) and up against outer end cap (7-80).

3.5.22 Install hex nuts (7-90) onto tie bars (7-20) and up against lockwashers (7-95).

3.5.23 Torque tighten hex nuts (7-90) until a nal lubricated torque, as listed in the following table, has been achieved.

Table 5. Tie Bar Nuts (3-90)

Section 3: Actuator Reassembly

Housing

Model

G01 70 95 G5 385 522

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

3.5.24 Torque tighten piston rod (3-40) per the chart in Section 5.4 step 5.4.5.

3.5.25 Install the M11 Hydraulic Override Cylinder per Section 5 step 5.4.

TORQUE (±5%)

Lbf-ft. N-m Lbf-ft. N-m

3.6 Actuator Testing

3.6.1 Leakage Test - All areas where leakage to atmosphere may occur are to be checked, using a commercial leak testing solution.

CAUTION: DO NOT EXCEED MAXIMUM PRESSURE

Pressure applied to the actuator is not to exceed the maximum operating pressure rating listed on the actuator name tag. Test the actuator using a properly adjusted self relieving regulator, with gauge.

3.6.2 Cycle the actuator ve times at the nominal operating pressure (NOP) as listed on the actuator name tag or the customer's normal actuator supply pressure. If excessive leakage across the pistons is noted, generally a bubble which breaks

three seconds or less after starting to form, cycle the actuator ve times as this will

allow the seals to seek their proper service condition.

Housing

Model

TORQUE (±5%)

Actuator Reassembly

NOTE:

If excessive leakage across the piston remains, the actuator must be disassembled and the cause of leakage must be determined and corrected.

3.6.3 Apply NOP pressure to the pressure port in inner end cap (3-10) and allow the actuator to stabilize.

3.6.4 Apply a commercial leak testing solution to the following areas:

3.6.4.1 Joint between inner end cap (3-10) and cylinder (3-70). This checks

cylinder to inner end cap O-ring seal.

3.6.4.2 The port hole in the outer end cap (3-80). This checks the piston seal to

cylinder (3-70), O-ring seal (4-70), and rod seal (4-50).

Section 3: Actuator Reassembly

August 2015

3.6.4.3 The vent check port hole in housing. This checks Polypak seal (4-30) that

seals piston rod (3-40) to inner end cap (3-10).

3.6.4.4 Remove pressure from the pressure inlet port.

3.6.5 If an actuator was disassembled and repaired, the above leakage test must be performed again.

3.6.6 Shell Pressure Test – Optional pressure test could be performed on PED certied 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 actuators 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, Emerson should be contacted for guidance.

Service Instructions

124843E Rev. C

Actuator Reassembly

Service Instructions

124843E Rev. C August 2015

Section 4: Field Conversions

4.1 Construction Reversal (Exchange Module Locations)

4.1.1 Remove pneumatic power module per Section 5.1.

4.1.2 Remove M11 hydraulic override cylinder per Section 5.3.

4.1.3 Using Section 5.1 reinstall the pneumatic power module onto the opposite end of

housing (1-10) as it was previously located.

4.1.4 Using Section 5.3 reinstall the M11 hydraulic override cylinder onto the opposite

end of housing (1-10), as it was previously located.

Field Conversions

Section 5: Module Removal and Installation

August 2015

Service Instructions

124843E Rev. C

Section 5: Module Removal and Installation

5.1 Pneumatic Power Module Removal

CAUTION: USE HEAVY DUTY SUPPORT EQUIPMENT

Due to the weight and size of power module, heavy duty support equipment will be required when removing power module from the actuator housing. Refer to Section 6 for pneumatic power module weights.

5.1.1 Remove pipe plug (3-120) from outer end cap (3-80).

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

5.1.3 Using a male square drive extension, go through outer end cap (3-80) and unscrew

piston rod (3-40) from the drive module housing (1-10).

NOTE:

When removing power module from housing (1-10) be careful not to lose O-ring seal (4-90).

5.1.4 Remove power module from actuator housing (1-10).

5.2 Pneumatic Power Module Installation

NOTE:

Reinstall the power module onto the opposite side of housing (1-10) as it was previously located.

5.2.1 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).

NOTE:

G2 and G3 models conrm that the two inboard hex nuts (3-90) ats are aligned to t into

the slot located in the end of housing (1-10).

5.2.2 Using lifting equipment move the power module up to housing (1-10) and install

as follows: Use step 5.2.3 for G01 and step 5.2.4 for G2 through G10 actuator models.

5.2.3 G01 MODEL ACTUATORS:

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

5.2.3.2 Using a male square drive extension, go through outer end cap (3-80) and screw piston rod (3-40) into guide block (1-30).

Module Removal and Installation

Service Instructions

124843E Rev. C August 2015

Section 5: Module Removal and Installation

WARNING: DO NOT CROSS-THREAD PISTON ROD

When screwing piston rod into guide block (3-30) make certain that the piston rod and guide block threads do not cross-thread.

5.2.4 G2 THROUGH G10 MODEL ACTUATORS:

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

5.2.4.2 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).

WARNING: DO NOT CROSS-THREAD PISTON ROD

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

5.2.5 Torque tighten piston rod (3-40) as follows:

5.2.5.1 G01 model actuators torque to 50 Lbf-ft. / 68 N-m (±5 % Percent) lubricated.

5.2.5.2 G2 and G3 model actuators torque to 90 Lbf-ft. / 122 N-m (±5% Percent) lubricated.

5.2.5.3 G4 through G10 model actuators torque to 240 FT lb / 325 N-m (±5% Percent) lubricated.

5.2.6 Install lock washers (3-110) onto hex cap screws (3-100).

5.2.7 Install and tighten hex cap screws (3-100), with lockwashers, through housing (1-

10) and into inner end cap (3-10).

5.2.8 Using pipe dope, install pipe plug (3-120) into outer end cap (3-80).

5.3 M11 Hydraulic Overrides Cylinder Removal

NOTE:

Review section 2.1 General Disassembly before proceeding with the M11 Hydraulic Override Cylinder disassembly.

5.3.1 Remove O-ring plug (7-120) from outer end cap (7-80).

5.3.2 Using a male square drive extension, go through outer end cap (7-80); unscrew piston rod (7-40) from the drive module housing (1-10).

WARNING: USE PROPER LIFTING EQUIPMENT

Use suitable lifting equipment to support the cylinder assembly.

5.3.3 Remove hex cap screws (7-115), with lockwashers (7-110), from inner end cap (7-10).

5.3.4 Remove hex nuts (7-105) from hex cap screws (7-100).

5.3.5 Remove M11 hydraulic override cylinder from actuator housing (1-10).

Module Removal and Installation

Section 5: Module Removal and Installation

August 2015

Service Instructions

124843E Rev. C

5.4 M11 Hydraulic Override Cylinder Installation

NOTE:

Review Section 3.1 General Reassembly before proceeding with M11 Hydraulic Override Cylinder 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 (7-10).

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 actuator models.

5.4.3 G01 MODEL ACTUATORS:

5.4.3.1 Align piston rod (7-40) with threads in the guide block (1-30).

5.4.3.2 Using a male square drive extension, go through outer end cap (7-80)

and screw piston rod (7-40) into guide block (1-30).

WARNING: DO NOT CROSS-THREAD PISTON ROD

When screwing piston rod into guide block (1-30) make certain that the piston rod and guide block threads do not cross-thread.

5.4.4 G2 THROUGH G10 MODEL ACTUATORS:

5.4.4.1 Align piston rod (7-40) with extension rod assembly (9-50).

5.4.4.2 Using a male square drive extension, go through outer end cap (7-80)

and screw piston rod (7-40) into extension rod assembly (9-50).

WARNING: DO NOT CROSS-THREAD PISTON ROD

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

5.4.5 Torque tighten piston rod (7-40) as follows:

5.4.5.1 G01 model actuators torque to 50 Lbf-ft. / 68 N-m (±5 % Percent)

lubricated.

5.4.5.2 G2 and G3 model actuators torque to 90 Lbf-ft. / 122 N-m (±5 % Percent)

lubricated.

5.4.5.3 G4 through G10 model actuators torque to 240 Lbf-ft. / 325 N-m

(±5 % Percent) lubricated.

5.4.6 Install lock washers (7-110) onto hex cap screws (7-115).

5.4.7 Install and tighten hex cap screws (7-115), with lockwashers, through housing (1-

10) and into inner end cap (7-10).

5.4.8 Refer to assembly drawing sheet 2 Detail "F". Install lock washers (7-110) onto hex cap screws (7-100).

5.4.9 Install hex cap screws (7-100), with lockwashers (7-110), through inner end cap (7-10) and housing (1-10).

Module Removal and Installation

Service Instructions

124843E Rev. C August 2015

5.4.10 Install and tighten hex nuts (7-105) onto hex cap screws (7-100).

5.4.11 Using pipe dope, install standard NPT pipe plug (7-120) into outer end cap (7-80). If the actuator uses SAE threads install SAE O-ring plug (7-120) into outer end cap (7-80).

Section 5: Module Removal and Installation

5.5 Powr Swivl Module Removal

NOTE:

Refer to assembly drawing sheet 2 Detail "B". X- can be 1- or 9- items as required.

5.5.1 Push the guide block to the side of housing (1-10) that will expose the extension rod assembly.

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 Use Bettis tool part number as listed in chart in Section 1 step 1.2.1 to remove retainer nut assembly (X-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 (X-50) from guide block (1-30).

NOTE:

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

5.5.4 Remove the remaining spherical washer (X-40) from guide block (1-30).

5.6 Powr Swivl Module Installation

NOTE:

Refer to assembly drawing sheet 2 Detail "B". X- can be 1- or 9- items as required.

WARNING: CHECK OVERTRAVEL POSITION

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

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

Module Removal and Installation

Section 5: Module Removal and Installation

August 2015

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 (X-40), and one extension rod assembly (X-50).

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

NOTE:

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

30).

5.6.4 Install second spherical washer (X-40) over threaded end of extension rod assembly (X-

50).

Service Instructions

124843E Rev. C

NOTE:

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

5.6.5 Install extension rod assembly (X-50) into right of guide block (1-30) and up

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

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

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

Module Removal and Installation

Service Instructions

Section 6: Actuator Support Information

124843E Rev. C August 2015

Section 6: Actuator Support Information

6.1 M11 Hydraulic Override System Fluid Volume

Table 6. M11 Hydraulic Override System Fluid Volume

ACTUATOR SIZE G01 G2 G3 G4 G5 G7 G8 G10

APPROX VOLUME FLUID

FOR M11 SYSTEM

6.2 Module Weights by Item Number and Actuator Housing Size

Table 7. Module Weight by Item Number and Actuator Housing Size

Quarts 1.0 1.2 1.6 3.1 6.2 10.2 16.6 34.5 Liters 0.95 1.1 1.5 3.0 5.8 9.7 15.7 32.6

ITEM NO.

G01

WT.

WT.G3WT.G4WT.

Lbs. 83 110 162 280 545 1025 1495 2550 Kg 38 50 73 127 247 465 678 1157 Lbs. 69 N/A N/A N/A N/A N/A N/A N/A Kg 31 N/A N/A N/A N/A N/A N/A N/A Lbs. 68 80 N/A N/A N/A N/A N/A N/A Kg 30.5 36 N/A N/A N/A N/A N/A N/A Lbs. 75 73.5 88 N/A N/A N/A N/A N/A Kg 34 33 40 N/A N/A N/A N/A N/A Lbs. 86 86 104 130 N/A N/A N/A N/A Kg 39 39 47 59 N/A N/A N/A N/A Lbs. 96 96 114 145 N/A N/A N/A N/A Kg 44 44 51 66 N/A N/A N/A N/A Lbs. N/A 135 145 168 295 N/A N/A N/A Kg N/A 61 66 76 134 N/A N/A N/A Lbs. N/A N/A 235 260 305 585 N/A N/A Kg N/A N/A 107 118 138 265 N/A N/A Lbs. N/A N/A N/A 340 410 735 911 N/A Kg N/A N/A N/A 154 186 334 413 N/A Lbs. N/A N/A N/A 505 590 810 1225 1120 Kg N/A N/A N/A 229 268 367 556 508 Lbs. N/A N/A N/A N/A 977 1100 1260 1440 Kg N/A N/A N/A N/A 443 499 572 653 Lbs. N/A N/A N/A N/A 1243 1400 1525 1755 Kg N/A N/A N/A N/A 564 653 692 796 Lbs. N/A N/A N/A N/A N/A N/A 1975 2205 Kg N/A N/A N/A N/A N/A N/A 896 1000 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

G5 WT.

G7 WT.

G8 WT.

G10 WT.

MODULE DESCRIPTION

Drive Module

8” Dia. Power

9” Dia. Power

10” Dia. Power

12” Dia. Power

14” Dia. Power

16” Dia. Power

20” Dia. Power

24” Dia. Power

28” Dia. Power

32” Dia. Power

36” Dia. Power

40” Dia. Power

44” Dia. Power

Table 7 (continued).....

Actuator Support Information

Section 6: Actuator Support Information

August 2015

ITEM NO.

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. 27 N/A N/A N/A N/A N/A N/A N/A Kg 12.2 N/A N/A N/A N/A N/A N/A N/A Lbs. N/A 31 N/A N/A N/A N/A N/A N/A Kg N/A 14.1 N/A N/A N/A N/A N/A N/A Lbs. N/A N/A 48 N/A N/A N/A N/A N/A Kg N/A N/A 21.7 N/A N/A N/A N/A N/A Lbs. N/A N/A N/A 84 N/A N/A N/A N/A Kg N/A N/A N/A 38 N/A N/A N/A N/A Lbs. N/A N/A N/A N/A 173 N/A N/A N/A Kg N/A N/A N/A N/A 78 N/A N/A N/A Lbs. N/A N/A N/A N/A N/A 303 N/A N/A Kg N/A N/A N/A N/A N/A 137 N/A N/A Lbs. N/A N/A N/A N/A N/A N/A 485 N/A Kg N/A N/A N/A N/A N/A N/A 220 N/A

Lbs. N/A N/A N/A N/A N/A N/A N/A 808

Kg N/A N/A N/A N/A N/A N/A N/A 367 Lbs. 32 32 32 32 35 35 45 50 Kg 14.5 14.5 14.5 14.5 15.9 15.9 20.4 22.7

G01

WT.

WT.G3WT.G4WT.

G5 WT.

G7 WT.

G8 WT.

Service Instructions

124843E Rev. C

G10

MODULE

WT.

DESCRIPTION

48” Dia. Power

52” Dia. Power

2.2” Dia. H Power Module

2.5” Dia. H Power Module

3.0” Dia. H Power Module

4.0” Dia. H Power Module

5.0” Dia. H Power Module

6.0” Dia. H Power Module

7.0” Dia. H Power Module

9.0” Dia. H Power Module

M11 Pump / Reservoir

6.3 G01 Tool Style and Wrench Size

Table 8. G01 Tool Style and Wrench Size

ITEM NO.

1-110 9/16” 6 Hex Cap Screws Socket 1-160 9/16” 4 Hex Cap 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

3-20 3/8” 2 Tie Bar (ats) Open End or Adjustable

3-40 3/8” Sq. 1 Piston Rod Male Drive Extension

3-90 1-1/8” 2 Standard Hex Nuts Socket

3-100 9/16” 4 Hex Cap Screws Socket 3-120 5/8” Sq. 1 Pipe Plug Open End or Adjustable 3-130 3/16” 2 Socket Cap Screws Allen 7-40 3/8” Sq. 1 Piston Rod Male Drive

7-90 9/16” 4 Standard Hex Nuts Socket

7-100 9/16” 4 Hex Cap Screws Socket

7-105 9/16” 4 Standard Hex Nuts Socket 7-115 9/16” 4 Hex Cap Screws Socket 7-120 9/16” Sq. 1 NPT Pipe Plug Open End or Adjustable 13 3/4” 2 Vent Check Assembly Open End

WRENCH SIZE

ITEM QTY

LOCATION OR DESCRIPTION

RECOMMENDED TOOL STYLE

Actuator Support Information

Service Instructions

Section 6: Actuator Support Information

124843E Rev. C August 2015

6.4 G2 Tool Style and Wrench Size

Table 9. G2 Tool Style and Wrench Size

ITEM NO.

1-110 9/16” 6 Hex Cap Screws Socket 1-160 9/16” 4 Hex Cap 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 3-20 3/8” 2 Tie Bar (ats) Open End or Adjustable 3-40 3/8” Sq. 1 Piston Rod Male Drive 3-90 1-1/8” 4 Standard Hex Nuts Socket 3-100 9/16” 4 Hex Cap Screws Socket 3-120 5/8” Sq. 1 Pipe Plug Open End or Adjustable 3-130 3/16” 2 Socket Cap Screws Allen 7-40 3/8” Sq. 1 Piston Rod Male Drive 7-90 3/4” 4 Standard Hex Nuts Socket 7-100 9/16” 4 Hex Cap Screws Socket 7-105 9/16” 4 Standard Hex Nuts Socket 7-115 9/16” 4 Hex Cap Screws Socket 7-120 9/16” Sq. 1 NPT Pipe Plug Open End or Adjustable 13 3/4” 2 Vent Check Assembly Open End

WRENCH SIZE

ITEM QTY

LOCATION OR DESCRIPTION

6.5 G3 Tool Style and Wrench Size

RECOMMENDED TOOL STYLE

Table 10. G3 Tool Style and Wrench Size

ITEM NO.

1-110 9/16” 8 Hex Cap Screws Socket 1-160 9/16” 4 Hex Cap 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 3-20 1/2” 2 Tie Bar (ats) Open End or Adjustable 3-40 3/8” Sq. 1 Piston Rod Male Drive 3-90 1-5/16” 4 Standard Hex Nuts Socket 3-100 9/16” 6 Hex Cap Screws Socket 3-120 5/8” Sq. 1 Pipe Plug Open End or Adjustable 3-130 3/16” 2 Socket Cap Screws Allen 7-40 3/8” Sq. 1 Piston Rod Male Drive 7-90 3/4” 6 Standard Hex Nuts Socket 7-100 9/16” 4 Hex Cap Screws Socket 7-105 9/16” 4 Standard Hex Nuts Socket 7-115 9/16” 4 Hex Cap Screws Socket 7-120 9/16” Sq. 1 NPT Pipe Plug Open End or Adjustable 13 3/4” 2 Vent Check Assembly Open End

WRENCH SIZE

ITEM QTY

LOCATION OR DESCRIPTION

RECOMMENDED TOOL STYLE

Actuator Support Information

Section 6: Actuator Support Information

August 2015

6.6 G4 Tool Style and Wrench Size

Table 11. G4 Tool Style and Wrench Size

Service Instructions

124843E Rev. C

ITEM NO.

1-110 9/16” 8 Hex Cap Screws Socket 1-160 9/16” 4 Hex Cap 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 3-20 5/8” 2 Tie Bar (ats) Open End or Adjustable 3-40 1/2” Sq. 1 Piston Rod Male Drive 3-90 1-5/8” 2 Standard Hex Nuts Socket 3-100 3/4” 6 Hex Cap Screws Socket 3-120 5/8” Sq. 1 Pipe Plug Open End or Adjustable 3-130 3/16” 2 Socket Cap Screws Allen 7-40 1/2” Sq. 1 Piston Rod Male Drive 7-90 15/16” 6 Standard Hex Nuts Socket 7-100 3/4” 4 Hex Cap Screws Socket 7-105 3/4” 4 Standard Hex Nuts Socket 7-115 3/4” 4 Hex Cap Screws Socket 7-120 5/8” Sq. 1 NPT Pipe Plug Open End or Adjustable 13 3/4” 2 Vent Check Assembly Open End

WRENCH SIZE

ITEM QTY

LOCATION OR DESCRIPTION

6.7 G5 Tool Style and Wrench Size

RECOMMENDED TOOL STYLE

Table 12. G5 Tool Style and Wrench Size

ITEM NO.

1-110 3/4” 8 Hex Cap Screws Socket 1-120 3/4” 4 Hex Cap Screws Socket 1-160 9/16” 6 Hex Cap Screws Socket 1-180 7/8” Sq. 2 Stop Screws Open End or Adjustable 1-190 2-3/8” 2 Heavy Hex Jam Nuts Open End or Adjustable 3-20 1/2” Sq. 2 Tie Bar (ats) Open End or Adjustable 3-40 1/2” Sq. 1 Piston Rod Male Drive 3-90 2” 2 Standard Hex Nuts Socket 3-100 3/4” 8 Hex Cap Screws Socket 3-120 1-1/8” Sq. 1 Pipe Plug Open End or Adjustable 3-130 3/16” 2 Socket Cap Screws Allen 7-40 1/2” Sq. 1 Piston Rod Male Drive 7-90 15/16” 6 Hex Nuts Socket 7-100 3/4” 4 Hex Cap Screws Socket 7-105 3/4” 4 Standard Hex Nuts Socket 7-115 3/4” 4 Hex Cap Screws Socket 7-120 5/8” Sq. 1 NPT Pipe Plug Open End or Adjustable 13 3/4” 2 Vent Check Assembly Open End

WRENCH SIZE

ITEM QTY

LOCATION OR DESCRIPTION

RECOMMENDED TOOL STYLE

Actuator Support Information

Service Instructions

Section 6: Actuator Support Information

124843E Rev. C August 2015

6.8 G7 Tool Style and Wrench Size

Table 13. G7 Tool Style and Wrench Size

ITEM NO.

1-110 3/4” 8 Hex Cap Screws Socket 1-120 3/4” 4 Hex Cap Screws Socket 1-160 9/16” 8 Hex Cap Screws Socket 1-180 1” 2 Stop Screws Open End or Adjustable 3-20 3/4” Sq. 2 Tie Bar (female square) Open End or Adjustable 3-40 3/4” Sq. 1 Piston Rod Male Drive 3-90 2-3/8” 2 Standard Hex Nuts Socket 3-100 15/16” 8 Hex Cap Screws Socket 3-120 1-1/8” Sq. 1 Pipe Plug Open End or Adjustable 3-130 3/16” 2 Socket Cap Screws Allen 7-40 3/4” Sq. 1 Piston Rod Male Drive 7-90 1-1/2” 6 Hex Nuts Socket 7-100 15/16” 8 Hex Cap Screws Socket 7-105 15/16” 8 Standard Hex Nuts Socket 7-115 15/16” 8 Hex Cap Screws Socket 7-120 15/16” 1 NPT Pipe Plug Open End or Adjustable 13 3/4” 2 Vent Check Assembly Open End

WRENCH SIZE

ITEM QTY

LOCATION OR DESCRIPTION

6.9 G8 Tool Style and Wrench Size

RECOMMENDED TOOL STYLE

Table 14. G8 Tool Style and Wrench Size

ITEM NO.

1-110 3/4” 12 Hex Cap Screws Socket 1-120 3/4” 4 Hex Cap Screws Socket 1-160 9/16” 8 Hex Cap Screws Socket 1-180 1-1/4” 2 Stop Screws Open End or Adjustable 3-20 3/4” Sq. 2 Tie Bar (female square) Open End or Adjustable 3-40 3/4” Sq. 1 Piston Rod Male Drive 3-90 2-3/4” 2 Heavy Hex Nuts Socket 3-100 1-1/8” 8 Hex Cap Screws Socket 3-120 1-5/16” Sq. 1 Pipe Plug Open End or Adjustable 3-130 3/16” 2 Socket Cap Screws Allen 7-40 3/4” Sq. 1 Piston Rod Male Drive 7-90 1-1/2” 8 Hex Nuts Socket 7-100 1-1/8” 8 Hex Cap Screws Socket 7-105 1-1/8” 8 Standard Hex Nuts Socket 7-115 1-1/8” 8 Hex Cap Screws Socket 7-120 15/16” 1 NPT Pipe Plug Open End or Adjustable 13 3/4” 2 Vent Check Assembly Open End

WRENCH SIZE

ITEM QTY

LOCATION OR DESCRIPTION

RECOMMENDED TOOL STYLE

Actuator Support Information

Section 6: Actuator Support Information

August 2015

6.10 G10 Tool Style and Wrench Size

Table 15. G10 Tool Style and Wrench Size

Service Instructions

124843E Rev. C

ITEM NO.

1-110 3/4” 16 Hex Cap Screws Socket 1-120 3/4” 4 Hex Cap Screws Socket 1-160 9/16” 8 Hex Cap Screws Socket 1-180 1-1/2” 2 Stop Screws Open End or Adjustable 3-20 3/4” Sq. 2 Tie Bar (female square) Open End or Adjustable 3-40 3/4” Sq. 1 Piston Rod Male Drive 3-90 3-1/2” 2 Heavy Hex Nuts Socket 3-100 1-5/16” 8 Hex Cap Screws Socket 3-120 1-5/16” Sq. 1 Pipe Plug Open End or Adjustable 3-130 3/16” 2 Socket Cap Screws Allen 7-40 3/4” Sq. 1 Piston Rod Male Drive 7-90 3-1/2” 8 Hex Nuts Socket 7-100 1-1/8” 8 Hex Cap Screws Socket 7-105 1-1/8” 8 Standard Hex Nuts Socket 7-115 1-1/8” 8 Hex Cap Screws Socket 7-120 15/16” 1 NPT Pipe Plug Open End or Adjustable 13 3/4” 2 Vent Check Assembly Open End

WRENCH SIZE

ITEM QTY

LOCATION OR DESCRIPTION

RECOMMENDED TOOL STYLE

Actuator Support Information

Service Instructions

Section 7: Troubleshooting

124843E Rev. C August 2015

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 16. Fault Location Table

SYMPTOM

Erratic movement

Short stroke

Apparent lack of torque

POTENTIAL CAUSES REMEDY

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 Consult the valve manufacturer's documentation

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

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

Examine the pipe work for blockages, crushed pipe or leakage. Clear or replace as necessary

Examine the controls, refurbish or renew as necessary. Refer to component manufacturer's documentation

Dismantle the cylinder assembly, remove the defective piston seal. Fit new seal and reassemble

Dismantle the cylinder assembly, remove the defective rod seal. Fit new seal and reassemble

Dismantle the housing assembly, remove the defective seal. Fit new seal and reassemble

Troubleshooting

Section 7: Troubleshooting

August 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 the open/close cycles functioned correctly (e.g. check locally, or automatically via Logic solver, the correct movement of the actuator/valve).

Upon successful completion of the above described Full Stroke Test procedure, the

“Test Coverage” can be considered 99%.

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

7.2.2.1 Procedure

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

7.2.2.1.2 Verify the partial stroke test functioned correctly (e.g. check

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

AVG

cycles 15% of the stroke.

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

Service Instructions

124843E Rev. C

(average

AVG

value

AVG

NOTE:

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

Troubleshooting

Service Instructions

124843E Rev. C August 2015

Section 8: Removal and Decommissioning

8.1 Removal and Decommissioning

WARNING: FOLLOW PROPER PROCEDURE

Always follow safe work practices remove and disassemble 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 (ex. 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 controls 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 actuator is ready to be removed from valve. For complete actuator tear down refer to Section 2 of the manual.

Removal and Decommissioning

Section 9: Document Revision

August 2015

Section 9: Document Revision

Table 17. Revision Overview

ECN DAT E REV BY * DATE

Released Jan. 2002 A B.Cornelius Jan. 2002

19110 July 2006 B UPDATED C. Ross July 2006

VAWCO2750 Aug. 2015 C UPDATED C. Rico Aug. 2015

* Signatures on le Bettis, Houston, Texas

Service Instructions

124843E Rev. C

Document Revision

Service Instructions

124843E Rev. C August 2015

Appendix

Appendix A: List of Tables

Table 1. G-Series Models .................................................................................................... 3

Table 2. Housing Cover Screw Quantity and Torque ......................................................... 17

Table 3. Piston Rod Torque Information ............................................................................ 18

Table 4. Tie Bar Nuts ........................................................................................................ 20

Table 5. Tie Bar Nuts (3-90) .............................................................................................. 25

Table 6. M11 Hydraulic Override System Fluid Volume .................................................... 33

Table 7. Module Weight by Item Number and Actuator Housing Size ................................ 33

Table 8. G01 Tool Style and Wrench Size ............................................................................. 34

Table 9. G2 Tool Style and Wrench Size .............................................................................35

Table 10. G3 Tool Style and Wrench Size ............................................................................. 35

Table 11. G4 Tool Style and Wrench Size ............................................................................. 36

Table 12. G5 Tool Style and Wrench Size ............................................................................ 36

Table 13. G7 Tool Style and Wrench Size ............................................................................. 37

Table 14. G8 Tool Style and Wrench Size ............................................................................ 37

Table 15. G10 Tool Style and Wrench Size ............................................................................ 37

Table 16. Fault Location Table ............................................................................................. 39

Table 17. Revision Overview ............................................................................................... 42

Appendix

August 2015

Service Instructions

Appendix B: List of Drawings

B.1 Part No. 115680, GXXXX-H Pneumatic

Assembly Drawing, Sheet 1 of 2

124843E Rev. C

Appendix

Service Instructions

124843E Rev. C August 2015

Appendix

B.2 Part No. 115680, GXXXX-H Pneumatic

Assembly Drawing, Sheet 2 of 2

Appendix

August 2015

Service Instructions

124843E Rev. C

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

Sheet 1 of 5

Appendix

Service Instructions

124843E Rev. C August 2015

Appendix

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

Sheet 2 of 5

Appendix

August 2015

Service Instructions

124843E Rev. C

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

Sheet 3 of 5

Appendix

Service Instructions

124843E Rev. C August 2015

Appendix

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

Sheet 4 of 5

Appendix

August 2015

Service Instructions

124843E Rev. C

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

Sheet 5 of 5

Appendix

Service Instructions

124843E Rev. C August 2015

Appendix

B.8 Part No. 121090, M11D-S Assembly Drawing,

Sheet 1 of 3

Appendix

August 2015

Service Instructions

124843E Rev. C

B.9 Part No. 121090, M11D-S Assembly Drawing,

Sheet 2 of 3

Appendix

Service Instructions

124843E Rev. C August 2015

Appendix

B.10 Part No. 121090, M11D-S Assembly Drawing,

Sheet 3 of 3

Appendix

August 2015

Service Instructions

B.11 Part No. 121107, M11S Remote Mount

Assembly Drawing, Sheet 1 of 2

124843E Rev. C

Appendix

Service Instructions

124843E Rev. C August 2015

Appendix

B.12 Part No. 121107, M11S Remote Mount

Assembly Drawing, Sheet 2 of 2

Appendix

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Bettis Service Instructions for Models G01 through G10 Double Acting Pneumatic Actuators with M11 Hydraulic Override Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual