Emerson Bettis G2XXX M11 series Operating instructions

Service Instructions
124843E Rev. C
August 2015
G01 through G10 Double-Acting Pneumatic
Actuators with M11 Hydraulic Override

I
Service Instructions
124843E Rev. C
Table of Contents
August 2015
Table of Contents
Table of Contents
Section 1: Introduction
1.1 General Service Information ...................................................................... 1
1.2 Definitions ................................................................................................. 2
1.3 General Safety Information ........................................................................ 2
1.4 Bettis Reference Materials .......................................................................... 2
1.5 Service Support Items ............................................................................... 3
1.6 Lubrication and Fluid Requirements............................................................ 3
1.7 General Tool Information ............................................................................ 3
1.8 Actuator Storage......................................................................................... 4
1.9 Actuator Installation ................................................................................... 4
1.10 Actuator Start-Up........................................................................................ 4
1.11 Actuator Operation..................................................................................... 5
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

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Service Instructions
124843E Rev. C
Table of Contents
August 2015
Table of Contents
Section 6: Actuator Support Information
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
Section 7: Troubleshooting
7.1 Fault Insertion........................................................................................... 39
7.2 Operational Test ....................................................................................... 40
Section 8: Removal and Decommissioning
8.1 Removal and Decommissioning................................................................ 41
Section 9: Document Revision ��������������������������������������������42
Appendix A: List of Tables ���������������������������������������������������43
Appendix B: List of Drawings ���������������������������������������������44

Service Instructions
124843E Rev. C August 2015
1
Section 1: Introduction
Introduction
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 five 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.
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.

Service Instructions
124843E Rev. C
August 2015
2
Section 1: Introduction
Introduction
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.
NOTE:
This product is only intended for use in large-scale fixed 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 conflict 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.

Service Instructions
124843E Rev. C August 2015
3
Section 1: Introduction
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 specific assembly drawing (IE: GXX-M3 OR HYD) please contact Emerson
Actuation Technologies Bettis by phone or email at [email protected]
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 fluids 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.
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.

Service Instructions
124843E Rev. C
August 2015
4
Section 1: Introduction
Introduction
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 recom-
mended 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
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 specific 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 specifications 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
flange mounting bolts, stem key, setscrew(s) are installed and secured.

Service Instructions
124843E Rev. C August 2015
5
Section 1: Introduction
Introduction
2. No tubing damaged or accessories dislodged during the shipping or
the installation.
3. Indicated position confirms 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 identified ports.
3. Electrical connection terminals are secured.
4. Wiring as per enclosed diagram or service manual supplied.
1.10.3 When actuator is first 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 fitting orifice 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 difficult 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 flow control valves to meter
the exhaust. Excessive exhaust flow metering may cause erratic operation.
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.

Service Instructions
124843E Rev. C
August 2015
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Section 2: Actuator Disassembly
Actuator Disassembly
Section 2: Actuator Disassembly
2�1 General Disassembly
WARNING: DANGEROUS GAS AND/OR LIQUIDS
It is possible, that the actuator may contain a dangerous gas and/or liquids. Ensure that
all proper measures have been taken to prevent exposure or release of these types of
contaminants before commencing any work.
2.1.1 Section 2 - Actuator Disassembly is written to either completely disassemble
the entire actuator or can be used to disassemble individual modules as needed
(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).
NOTE:
Use a means of capturing the hydraulic fluid 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).

Service Instructions
124843E Rev. C August 2015
7
Section 2: Actuator Disassembly
Actuator Disassembly
CAUTION: DO NOT DAMAGE O-RING GROOVE
Do not damage O-ring groove when removing end cap.
2.2.4 The fit 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 flats 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 out of the inner end cap far enough to expose the O-ring
seals (4-80).
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 piston (3-30).
NOTE:
G4 models have flats 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.
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).

Service Instructions
124843E Rev. C
August 2015
8
Section 2: Actuator Disassembly
Actuator Disassembly
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 re-
moving 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.
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.

Service Instructions
124843E Rev. C August 2015
9
Section 2: Actuator Disassembly
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).

Service Instructions
124843E Rev. C
August 2015
10
Section 2: Actuator Disassembly
Actuator Disassembly
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).
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).

Service Instructions
124843E Rev. C August 2015
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Section 2: Actuator Disassembly
Actuator Disassembly
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 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).
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 fluid that will be lost during the follow-
ing 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).

Service Instructions
124843E Rev. C
August 2015
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Section 2: Actuator Disassembly
Actuator Disassembly
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).
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 August 2015
13
Section 3: Actuator Reassembly
Actuator Reassembly
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 flaking coating.
CAUTION: INSPECT PARTS BEFORE USE
Actuator parts that reflect any of the above listed characteristics should be replaced
with new parts.
3.1.4 Before installation coat all moving parts with a complete film of lubricant. Coat
all seals with a complete film of lubricant, before installing into seal grooves.
NOTE:
The parts and seals used in the actuator will be assembled using lubricant as identified
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 identified in Section 1 step 1.6.1.

Service Instructions
124843E Rev. C
August 2015
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Section 3: Actuator Reassembly
Actuator Reassembly
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).
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
first 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).

Service Instructions
124843E Rev. C August 2015
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Section 3: Actuator Reassembly
Actuator Reassembly
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
first 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.
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).

Service Instructions
124843E Rev. C
August 2015
16
Section 3: Actuator Reassembly
Actuator Reassembly
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.
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) finger 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 flush with the cover.
3.2.31 Torque tighten hex cap screws (1-110) until a final lubricated torque, as listed in
the following table, has been achieved.