Emerson Bettis GTD Series Operating instructions

Service Instructions
133893 Rev. C
January 2013
GTD Series Actuators

I
Service Instructions
133893 Rev. C
Table of Contents
January 2013
Table of Contents
Table of Contents
Section 1: Introduction
1.1 General Service Information ......................................................................... 1
1.2 Denitions .................................................................................................... 2
1.3 General Safety Information ............................................................................ 2
1.4 Bettis Reference Materials .............................................................................. 3
1.5 Service Support Items ................................................................................... 3
1.6 Lubrication Requirements ............................................................................. 3
1.7 Fluid Requirements ....................................................................................... 3
1.8 General Tool Information ............................................................................... 3
Section 2: Actuator Disassembly
2.1 General Disassembly ..................................................................................... 4
2.2 GTD Gas Cylinder Disassembly ....................................................................... 4
2.3 GTO Oil Cylinder Disassembly ........................................................................ 5
2.4 Drive Module Disassembly ............................................................................. 6
Section 3: Actuator Reassembly
3.1 General Reassembly ...................................................................................... 9
3.2 Drive Module Reassembly .............................................................................. 9
3.3 GTD Gas Cylinder Reassembly ...................................................................... 12
3.4 GTO Oil Cylinder Reassembly ....................................................................... 16
3.5 Actuator Testing .......................................................................................... 18
Section 4: Module Removal and Installation
4.1 GTO Oil Cylinder Removal ............................................................................ 19
4.2 GTO Oil Cylinder Installation ........................................................................ 20
Section 5: Actuator Support Information
5.1 Weights By Item Number And Actuator Housing Size .................................. 22
5.2 GTD01 Tool Style And Wrench Size .............................................................. 23
5.3 GTD2 Tool Style and Wrench Size ................................................................ 24
5.4 GTD3 Tool Style and Wrench Size ................................................................ 25
5.5 GTD4 Tool Style And Wrench Size ................................................................ 26
5.6 GTD5 Tool Style And Wrench Size ................................................................ 27
5.7 GTD7 Tool Style and Wrench Size ................................................................ 28
Section 6: Document Revision ��������������������������������������������29
Appendix A: List of Tables ���������������������������������������������������30
Appendix B: List of Drawings ����������������������������������������������31

Service Instructions
133893 Rev. C
January 2013
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 GTD01X0X, GTD2X0X, GTD3X0X, GTD4X0X, GTD5X0X,
and GTD7X0X Double Acting Series Actuators. These actuators will have one
single GTD gas cylinder (Gas) utilizing tie bar construction and one single GTO oil
cylinder (Hydraulic) utilizing tie bar construction.
1.1.2 Normal recommended service interval for this actuator series is ve years to
maximum total life cycle.
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
gas pressure has been removed from the actuator.
1.1.4 Remove all piping and mounted accessories that will interfere with the actuator
assemblies(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 plug 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 Cylinder/Module weights are listed in Section 5 Table 5.1.
1.1.9 When removing seals from seal grooves, use a commercial seal removing tool or a
small screwdriver with sharp corners rounded off.
1.1.10 Use a non-hardening thread sealant on all pipe threads.
CAUTION: FOLLOW MANUFACTURER'S INSTRUCTIONS
Apply the thread sealant per the manufacture’s instructions.
1.1.11 Bettis recommends that disassembly of the actuator should be done in a clean
area on a work bench.

Service Instructions
133893 Rev. C January 2013
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 xed installations excluded from the
scope of Directive 2011/65/EU on the restriction of the use of certain hazardous substances
in electrical and electronic equipment (RoHS 2).
1�3 General Safety Information
Products supplied by Bettis, in its "as shipped" condition, are intrinsically safe if the instruc-
tions contained within this service instruction are strictly adhered to and executed by well-
trained, equipped, prepared and competent personnel.
WARNING: READ WARNING MESSAGES CAREFULLY
For the protection of personnel working on Bettis actuators, this procedure should be
reviewed and implemented for safe disassembly and reassembly. Close attention should be
noted to the WARNINGS, CAUTIONS and NOTES contained in this procedure.
WARNING: FOLLOW PLANT SAFETY PROCEDURES
This procedure should not supersede or replace any customers plant safety or work
procedures. If a conict arises between this procedure and the customers procedures
the differences should be resolved in writing between an authorized customers
representative and a authorized Bettis representative.

Service Instructions
133893 Rev. C
January 2013
3
Section 1: Introduction
Introduction
1�4 Bettis Reference Materials
1.4.1 Assembly Drawing for GTD01 through GTD7 Series Actuators use part number
133202.
1�5 Service Support Items
1.5.1 Bettis Service Kits.
1.5.2 Non-hardening thread sealant.
1�6 Lubrication Requirements
1.6.1 Bettis ESL-4, 5 & 10 lubricant. This lubricant is to be used in the Drive Module and
GTD Gas Cylinder.
NOTE:
Bettis ESL-4, 5 & 10 lubricant tube(s) are contained in the Bettis Service Kits.
1.6.2 Lubricants, other than listed in step 1.6.1, should not be used without prior written
approval of Bettis Product Engineering.
1�7 Fluid Requirements
1.7.1 For use in the GTO Oil Cylinder use Dexron Automatic Transmission Fluid, or as
specied.
1.7.2 This uid is the recommended uid only and does not limit the use of other
hydraulic uids compatible with supplied seals and coatings.
1�8 General Tool Information
1.8.1 Tools: All tools 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 5,000 inch pounds), breaker bar, and a 1/2" drive
socket set. For recommended tool and wrench sizes refer to Section 5 Tables 5.2
through 5.7

Service Instructions
133893 Rev. C January 2013
4
Section 2: Actuator Disassembly
Actuator Disassembly
Section 2: Actuator Disassembly
2�1 General Disassembly
WARNING: CHECK FOR DANGEROUS GAS AND LIQUIDS
It is very possible, that the actuator may contain a dangerous gas such as (Sour gas/H2S,
Oxygen, Nitrogen, etc.) and/or liquids such as (Condense, Descalers, Petroleum bases,
etc.). Ensure that all proper measures have been taken to prevent dangerous exposure or
release of these types of residues 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 actuator assemblies as
needed (i.e., GTD Gas Cylinder, Drive Module or GTO Oil Cylinder).
2.1.2 The GTD gas cylinder is to be disassembled while still attached to the Drive
Module.
2.1.3 The GTO oil cylinder can be disassembled while still attached to the Drive Module
or it can be removed from the Drive Module and disassembled separate to the
actuator (refer to Section 5 – Module, Cylinder Removal And Installation).
CAUTION: CONTAIN HYDRAULIC FLUID
Using some means to contain hydraulic uid as the tubing (piping) is disconnect
from the GTO outer end cap (7-80) and inner end cap (7-10).
2.1.4 Disconnect all hydraulic uid lines to GTO oil cylinder outer end cap (7-80) and
inner end cap (7-10). Drain as much of the hydraulic uid as possible.
2.1.5 To ensure correct re-assembly; that is, with GTO oil cylinder or GTD gas cylinder
on same end of Drive Module as was, mark or tag right (or left) and mark mating
surfaces.
2�2 GTD Gas Cylinder Disassembly
NOTE:
Review Section 2 notes and steps 2.1.1 through 2.1.5 General Disassembly before
proceeding with GTD gas cylinder disassembly.
WARNING: DISCONNECT HYDRAULIC PRESSURE
If not already removed disconnect all operating pressure from actuator GTD gas cylinder.
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 The setting of stop screw (3-180) should be checked and setting recorded before
loosened or removed.

Service Instructions
133893 Rev. C
January 2013
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Section 2: Actuator Disassembly
Actuator Disassembly
NOTE:
The stop screw will be removed later in this procedure.
2.2.3 Remove the jam nut (3-190) and o-ring seal (4-100) from stop screw (3-180).
2.2.4 Remove hex nuts (3-90), with lockwashers (3-95), from tie bars (3-20).
2.2.5 Remove outer end cap (3-80) from cylinder (3-70). and tie bars (3-20).
2.2.6 Remove stop screw assembly (3-180) from the inboard side of outer end cap (3-80).
2.2.7 Unscrew and remove tie bars (3-20) from inner end cap (3-10).
2.2.8 Remove cylinder (3-70) from piston (3-30) and inner end cap (3-10).
2.2.9 Refer to assembly drawing page 2 of 2 Detail "C". Remove two split ring halves (3-
50) and one retainer ring (3-60) from outboard end of piston rod assembly (3-40).
2.2.10 Remove the piston (3-30) from piston rod assembly (3-40).
2.2.11 On model GTD4008.0 remove the end cap/cylinder adapter (3-260) from inner
end cap (3-10).
2.2.12 Remove o-ring seal (4-70) from piston rod assembly (3-40).
2.2.13 Remove the remaining two split ring halves (3-50) and one retainer ring (3-60)
from piston rod assembly (3-40).
2.2.14 Remove socket cap screws (3-115) with lockwashers (3-110) from
inner end cap (3-10).
2.2.15 Refer to assembly drawing page 2 of 2 Detail "B". Remove hex nuts (3-105) from
socket cap screws (3-100).
2.2.16 Remove socket cap screws (3-100) with lockwashers (3-110) from
inner end cap (3-10).
2.2.17 Remove inner end cap (3-10) off of piston rod assembly (3-40).
2.2.18 Unscrew and remove piston rod assembly (3-40) from drive module.
2.2.19 It is not necessary to remove pipe plugs (3-210) from inner end cap (3-10) and
outer end cap (3-80) for normal or routine actuator service.
2�3 GTO Oil Cylinder Disassembly
NOTE:
Review Section 2 notes and steps 2.1.1 through 2.1.4 General Disassembly before
proceeding with GTO oil cylinder disassembly.
The GTO oil cylinder can either be disassembled piece by piece or removed per
Section 4.1 and disassembled on a work bench per the following steps.
2.3.1 Mark and record location of the ports on outer end cap (7-80) and
inner end cap (7-10).
2.3.2 The setting of stop screw (7-180) should be checked and setting recorded before
loosened or removed.
NOTE:
The stop screw will be removed later in this procedure.

Service Instructions
133893 Rev. C January 2013
6
Section 2: Actuator Disassembly
Actuator Disassembly
2.3.3 Remove the jam nut (7-190) from stop screw (7-180).
2.3.4 Remove stop screw (7-180) from outer end cap (7-80).
2.3.5 Remove hex nuts (7-90), with lockwashers (7-95), from tie bars (7-20).
2.3.6 Remove outer end cap (7-80) from cylinder (7-70) and tie bars (7-20).
2.3.7 Unscrew and remove tie bars (7-20) from inner end cap (7-10).
2.3.8 Remove the cylinder (7-70) from piston (7-30) and inner end cap (7-10).
2.3.9 Refer to assembly drawing page 2 of 2 Detail "E". Remove two split ring halves (7-
50) and one retainer ring (7-60) from outboard end of piston rod assembly (7-40).
2.3.10 Remove the piston (7-30) from piston rod assembly (7-40).
2.3.11 Remove the o-ring seal (8-70) from piston rod assembly (7-40).
2.3.12 Remove the remaining two split ring halves (7-50) and one retainer ring (7-60)
from piston rod assembly (7-40).
2.3.13 Remove socket cap screws (7-115) with lockwashers (7-110) from
inner end cap (7-10).
2.3.14 Refer to assembly drawing page 2 of 2 Detail "D". Remove hex nuts (7-105) from
socket cap screws (7-100).
2.3.15 Remove socket cap screws (7-100) with lockwashers (7-110) from
inner end cap (7-10).
2.3.16 Remove inner end cap (7-10) off of piston rod assembly (7-40).
2.3.17 Unscrew and remove piston rod assembly (7-40) from drive module.
2.3.18 It is not necessary to remove pipe plugs (7-210) from inner end cap (7-10) and
outer end cap (7-80) for normal or routine actuator service.
2�4 Drive Module Disassembly
NOTE:
Review Section 2 notes and steps 2.1.1 through 2.1.5 General Disassembly before proceed-
ing with Drive Module Disassembly.
2.4.1 If not already removed remove piston rod assemblies (3-40) and (7-40) from drive
module (1-10).
NOTE:
For steps 2.4.2 through 2.4.9 refer to assembly drawing page 2 of 2 Section A-A and Detail “A”.
2.4.2 Before removing position indicator (1-220), record or mark it's position. Remove
position indicator (1-220).
NOTE:
Step 2.4.3 is used only on GTD01, GTD2 and GTD3 Drive Modules. Drive Modules GTD4
and GTD5 will skip steps 2.4.3 and continue with step 2.4.4.

Service Instructions
133893 Rev. C
January 2013
7
Section 2: Actuator Disassembly
Actuator Disassembly
2.4.3 Remove one vent check assembly (13) from top of housing cover (1-20).
2.4.4 Unscrew and remove hex cap screws (1-160) with lockwashers (1-170) from yoke
cover (1-150).
2.4.5 Remove yoke cover (1-150) from housing cover (1-20).
2.4.6 Mark and record the orientation of the position indicator assembly (1-140) in
relation to the top of yoke (1-70).
2.4.7 Remove position indicator assembly (1-140) from top of yoke (1-70).
2.4.8 Remove spring pin (1-100) from top of yoke (1-70).
2.4.9 Remove hex cap screws (1-110), with lockwashers (1-115) or with lockwashers
(1-170), from housing cover (1-20).
NOTE:
Steps 2.4.10 and 2.4.11 are used only on GTD7 drive module (refer to assembly drawing
note number ve). Drive modules GTD01, GTD2, GTD3, GTD4 and GTD5 will skip steps
2.4.10 and 2.4.11 and continue with step 2.4.12.
2.4.10 Remove hex cap screws (1-120), with lockwashers (1-115), from housing cover (1-20).
2.4.11 Using hex cap screws (1-110), install into holes vacated by hex cap screws (1-120).
Use these hex cap screws to jack the housing cover up for removal. Alternately
rotate the hex cap screw clockwise until housing cover (1-20) is clear of groove
pins (1-130).
NOTE:
GTD01, GTD2, GTD3 and GTD4 model housing cover (1-20) will have cast tabs for placing
prying tools to aid in cover removal.
2.4.12 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.
2.4.13 Remove guide bar (1-90) from housing (1-10).
2.4.14 Rotate the arms of yoke (1-70) to the center position of housing (1-10).
2.4.15 Remove yoke (1-70) with yoke pin (1-80), guide block assembly (1-30) and two
yoke/guide block bushings (2-30) by lifting yoke up and out of the housing (1-10).
2.4.16 Remove yoke pin (1-80) by inserting 3/8"-16 UNC screw into top of the yoke pin
and pull straight up and out.
2.4.17 Remove the guide block assembly (1-30) from between the arms of yoke (1-70).
2.4.18 Remove the yoke/guide block bushing (2-30) from top of guide block assembly
(1-30).
2.4.19 Remove the yoke/guide block bushing (2-30) from the top of the lower yoke arm
of yoke (1-70).

Service Instructions
133893 Rev. C January 2013
8
Section 2: Actuator Disassembly
Actuator Disassembly
2.4.20 Unscrew and remove two stop screw plugs (1-180) from housing (1-10).
2.4.21 Housing (1-10) vent check assembly removal as follows:
2.4.21.1 GTD01, GTD2 and GTD3 housing (1-10) unscrew and remove one vent
check assembly (13) from the front of housing (1-10).
2.4.21.2 GTD4 through GTD7 housing (1-10) unscrew and remove two vent check
assemblies (13) from the front of housing (1-10).
2.4.22 The following items do not need to be removed from their assembled locations
unless being replaced by new items: Two yoke bearings (2-40), yoke pin bearing
and yoke pin thrust bearing (2-10).

Service Instructions
133893 Rev. C
January 2013
9
Section 3: Actuator Reassembly
Actuator Reassembly
Section 3: Actuator Reassembly
3�1 General Reassembly
CAUTION: CHECK SHELF LIFE OF SEALS
Only new seals, that are still within the seals expectant shelf life, should be installed into
actuator being refurbished.
3.1.1 Remove and discard all old seals and gaskets.
3.1.2 All parts should be cleaned to remove all dirt and other foreign material prior to
inspection.
3.1.3 All parts should be thoroughly inspected for excessive wear, stress cracking,
galling and pitting. Attention should be directed to threads, sealing surfaces and
areas that will be subjected to sliding or rotating motion. Sealing surfaces of the
cylinder and piston rod assembly must be free of deep scratches, pitting, corrosion
and blistering or aking coating.
CAUTION: CHECK PARTS FOR SIGNS OF WEAR
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 drive module and GTD gas cylinder will be assembled
using lubricant as identied in Section 1 step 1.6.1. The parts and seals used in the actuator
GTO oil cylinder will be assembled using lubricant as identied in Section 1 step 1.7.1.
3�2 Drive Module Reassembly
NOTE:
Review section 3.1 General Reassembly before proceeding with Drive Module Reassembly.
3.2.1 If the guide bar bearings are being replaced install new bearings into guide block
assembly (1-30).
NOTE:
The guide bar bearing must be press t into guide block guide bar bore with the seam
located ±5° degrees of the top or bottom centerline as shown in section A-A.

Service Instructions
133893 Rev. C January 2013
10
Section 3: Actuator Reassembly
Actuator Reassembly
3.2.2 If the two yoke bearings (2-40) are being replaced, install new bearing into housing
cover (1-20) and housing (1-10).
NOTE:
The yoke bearing (2-40) must be press t into housing (1-10) and housing cover (1-20).
Install the yoke bearings with the bearing seam located 45° ±5° degrees from the yoke arm
slot when yoke (1-70) is rotated to its full clockwise position.
3.2.3 If the two yoke pin thrust bearings (2-10) are being replaced install new bearing
into housing cover (1-20) and housing (1-10).
3.2.4 Lubricate two yoke/guide block bushings (2-30) and install onto top and bottom
sides of guide block assembly (1-30).
3.2.5 Install guide block assembly (1-30), with yoke/guide block bushings (2-30),
between arms of yoke (1-70).
3.2.6 Install o-ring seal (2-50) into inner diameter o-ring groove in the bottom of
housing (1-10).
3.2.7 Coat the bearing surfaces of the yoke (1-70) with lubricant and install into housing
(1-10).
3.2.8 Align hole in guide block assembly (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).
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).
3.2.9 Install yoke pin (1-80) by inserting into the upper yoke arm, upper yoke/guide
block bushing, guide block assembly, lower yoke/guide block bushing, lower yoke
arm and resting on lower yoke pin thrust bearing (2-10).
3.2.10 Install guide bar (1-90) into either side of housing (1-10) by inserting through the
housing, through guide block assembly and then insert the guide bar into the
other side of housing (1-10).
3.2.11 Refer to assembly drawing page 2 of 2 Section A-A. Install spring pin (1-100) into
the top of yoke (1-70).
3.2.12 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 2.4.6 for correct installation position.
3.2.13 Install o-ring (2-50) into housing cover (1-20).
3.2.14 Install housing cover o-ring (2-60) into housing cover (1-20).
3.2.15 Install the housing cover (1-20), being careful not to damage o-ring seals (2-50)
and (2-60).
3.2.16 Place lockwashers (1-115) onto hex cap screws (1-110).

Service Instructions
133893 Rev. C
January 2013
11
Section 3: Actuator Reassembly
Actuator Reassembly
NOTE:
On GTD7 model actuators apply thread adhesive, Locktite 242, to threads of hex cap
screws (1-110). Reference assembly drawing note number seven.
3.2.17 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.
3.2.18 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.
3.2.19 Torque tighten hex cap screws (1-110) until a nal lubricated torque, as listed in
the following table, has been achieved.
Table 1� Housing Cover Screw Quantity and Torque
Model Qty TORQUE (±5%) Model Qty TORQUE (±5%)
FT-lb N-m FT-lb N-m
GTD01 4 40 54 GTD7 8 100 136
GTD2 6 40 54 GTD8 12 100 136
GTD3 8 40 54 GTD10 16 100 136
GTD4 8 40 54 GTD13 20 340 461
GTD5 8 100 136
NOTE:
Complete step 3.2.20 on GTD5, through GTD7 model actuators. For GTD01 through
GTD4 model actuators skip step 3.2.20 and proceed to step 3.2.21.
3.2.20 On GTD5 through GTD7 models (refer to assembly drawing note number ve).
3.2.20.1 Place lockwashers (1-115) onto hex cap screws (1-120).
NOTE:
Hex cap screw (1-120) are only used as hole llers and to protect threads from environ-
ment.
3.2.20.2 Install and tighten hex cap screws (1-120) with lockwashers (1-115).
NOTE:
For steps 3.2.21 through 3.2.25 refer to assembly drawing page 2 of 2 Section A-A and
Detail “A”.

Service Instructions
133893 Rev. C January 2013
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Section 3: Actuator Reassembly
Actuator Reassembly
3.2.21 Install thrust bearing (2-110) onto position indicator (1-140).
3.2.22 Install o-ring seal (2-100) onto position indicator (1-140).
3.2.23 Install upper bearing (2-120) into yoke cover (1-150).
3.2.24 Install rod wiper (2-80) into yoke cover (1-150).
3.2.25 Install o-ring seal (2-70) into yoke cover (1-150).
3.2.26 Install yoke cover (1-150) onto housing cover (1-20) and over position indicator
assembly (1-140).
NOTE:
During yoke cover installation be careful not to damage o-ring seal (2-70) and rod wiper (2-80).
3.2.27 Place lockwashers (1-170) onto hex cap screws (1-160).
3.2.28 Install and tighten hex cap screws (1-160) with lockwashers through yoke cover
(1-150) and into housing cover (1-20).
3.2.29 Vent check assembly installation as follows:
3.2.29.1 GTD01, GTD2 and GTD3 housing (1-10) using pipe sealant install one
vent check assembly (13) into the front of housing (1-10).
3.2.29.2 GTD01, GTD2 and GTD3 housing (1-10) using pipe sealant install one
vent check assembly (13) into the top area of housing cover (1-20).
3.2.29.3 GTD4 through GTD7 housing (1-10) using pipe sealant install two vent
check assemblies (13) into the front of housing (1-10).
3.2.30 NOTE: Refer to Section 2 step 2.4.2 for correct position indicator placement. Install
position indicator (1-220) over the exposed shaft of position indicator assembly
(1-140).
3.2.31 Install o-ring seals (2-90) onto stop screw plugs (1-180).
3.2.32 Install and tighten two stop screw plugs (1-180) into two stop screw plug holes on
the front of housing (1-10).
3�3 GTD Gas Cylinder Reassembly
NOTE:
Review Section 3.1 General Reassembly before proceeding with GTD gas cylinder reas-
sembly.Reassemble the GTD gas cylinder on a work bench per the following steps and then
install on the Drive Module per this section.
In Section 3.3 where the step indicates to "lubricate or coat with lubricant", use lubricant as
listed in Section 1.6 for lubricating of the part being installed.
For steps 3.3.2 through 3.3.5 refer to assembly drawing page 2 of 2 Detail “C”.
3.3.1 Lubricate piston rod assembly (3-40) with lubricant.
3.3.2 Install o-ring seal (4-70) into the seal groove in piston rod assembly (3-40).
3.3.3 Install two split ring halves (3-50) into the inner most groove in piston rod
assembly (3-40) and retain with one retainer ring (3-60).
3.3.4 Install piston (3-30) onto piston rod assembly (3-40) and up against split rings
installed in step 3.3.3.

Service Instructions
133893 Rev. C
January 2013
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Section 3: Actuator Reassembly
Actuator Reassembly
3.3.5 Install two split ring halves (3-50) into the outer most groove in piston rod
assembly (3-40) and retain with one retainer ring (3-60).
3.3.6 Apply lubricant to the bore of cylinder (3-70).
3.3.7 Coat one piston bearing (4-45) with lubricant and install into the piston external
bearing groove.
3.3.8 Install piston (3-30), with piston rod assembly (3-40), into cylinder (3-70) leave the
inner most piston seal groove exposed outside of the cylinder.
3.3.9 Coat one piston seal (4-60) with lubricant and install into the exposed piston
external seal groove.
CAUTION: INSTALL PISTON SEAL CORRECTLY
Install the piston seal with energizer ring facing outside edge of piston (3-30).
3.3.10 Push the piston through the cylinder (3-70) until the outboard piston seal groove
is exposed.
NOTE:
To move the piston (3-30) through the bore of cylinder (3-70) may require mechanical
assistance.
3.3.11 Coat one piston seal (4-60) with lubricant and install into the piston external seal
groove.
CAUTION: INSTALL PISTON SEAL CORRECTLY
Install the piston seal with energizer ring facing outside edge of piston (3-30).
NOTE:
Step 3.3.12 is used only on GTD4008.0 actuator Models. All other actuator models will
skip steps 3.3.12 and continue with step 3.3.13.
3.3.12 GTD4008.0 actuator Models.
3.3.12.1 Install o-ring seal (4-40) onto outboard side of end cap/cylinder adapter
(3-260).
3.3.12.2 Refer to assembly drawing page 1 of 2 Detail "F". Install o-ring seal (4-35)
onto inboard face of end cap/cylinder adapter (3-260).
3.3.12.3 Install end cap/cylinder adapter (3-260) over piston rod assembly (3-40)
and into inboard end of cylinder (3-70).
3.3.13 Refer to assembly drawing page 2 of 2 Detail "B". Coat Polypak seal (4-30) with
lubricant and install, lip rst, into inner end cap (3-10).

Service Instructions
133893 Rev. C January 2013
14
Section 3: Actuator Reassembly
Actuator Reassembly
CAUTION: INSTALL POLYPAK SEAL CORRECTLY
Install Polypak seal with energizer ring facing piston side of inner end cap.
3.3.14 Install rod bushing (4-20) into inner end cap (3-10).
3.3.15 Install rod wiper (4-10) into inner end cap (3-10).
3.3.16 Install one o-ring seal (4-90) into inboard face of inner end cap (3-10).
3.3.17 Install one o-ring seal (4-40) into outboard face of inner end cap (3-10).
3.3.18 Install inner end cap (3-10) onto piston rod assembly (3-40) and into inboard end
of cylinder (3-70).
3.3.19 Install tie bars (3-20) through outer end cap (3-80) and into inner end cap (3-10).
Screw all tie bars (3-20) into inner end cap (3-10) per instructions given in note
number eight located on the assembly drawing page 1 0f 2.
3.3.20 Temporarily install outer end cap (3-80) into open end of cylinder (3-70).
3.3.21 Install the hex nuts (3-90) onto tie bars (3-20) and temporarily tighten against
outer end cap (3-80).
3.3.22 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).
3.3.23 Using lifting equipment move the power module up to housing (1-10) and align
piston rod assembly (3-40) with guide block assembly (1-30).
3.3.24 Using a male square drive extension, go through outer end cap (3-80) and screw
piston rod assembly (3-40) into guide block assembly (1-30).
WARNING: DO NOT CROSS-THREAD PISTON ROD ASSY
When screwing piston rod assembly into guide block assembly (1-30) make certain that
the piston rod assembly threads do not cross-thread.
3.3.25 Torque tighten piston rod assembly (3-40) until a nal lubricated torque, as listed
in the following table, has been achieved.
Table 2� Piston Rod Assembly Torque Information
Housing
Model
TORQUE (±5%) Housing
Model
TORQUE (±5%)
FT-lb N-m FT-lb N-m
GTD01 131 178 GTD7 240 325
GTD2 196 266 GTD8 240 325
GTD3 240 325 GTD10 240 325
GTD4 240 325 GTD13 240 325
GTD5 240 325
3.3.26 Install lock washers (3-110) onto socket cap screws (3-115).
3.3.27 Install socket cap screws (3-115), with lockwashers (3-110), through inner end cap
(3-10) and screw into housing (1-10).
3.3.28 Refer to assembly drawing page 2 of 2 Detail "B". Install lock washers (3-110) onto
socket cap screws (3-100).
3.3.29 Install socket cap screws (3-100), with lockwashers (3-110), through inner end cap
(3-10) and housing (1-10).

Service Instructions
133893 Rev. C
January 2013
15
Section 3: Actuator Reassembly
Actuator Reassembly
3.3.30 Install hex nuts (3-105) onto socket cap screws (3-100).
3.3.31 Remove hex nuts (3-90) from tie bars (3-20).
3.3.32 Remove outer end cap (3-80) from cylinder (3-70). and tie bars (3-20).
3.3.33 Lubricate stop screw (3-180) and install into the outer end cap (3-80).
NOTE:
The stop screw is installed from the inboard side or cylinder side of the outer end cap (3-80).
3.3.34 Install o-ring seal (4-100) onto the out board side of the stop screw (3-180).
3.3.35 Install jam nut (3-190) onto the out board side of the stop screw (3-180).
NOTE:
The pressure inlet ports of the inner and outer end caps should be positioned in the same
position as recorded in Section 2 step 2.2.1.
3.3.36 Install outer end cap (3-80) over tie bars (3-20) and into open end of cylinder (3-
70).
3.3.37 Install lockwashers (3-95) onto tie bars (3-20) and up against outer end cap (3-80).
3.3.38 Install hex nuts (3-90) onto tie bars (3-20) and up against lockwashers (3-95).
3.3.39 Torque tighten hex nuts (3-90) until a nal lubricated torque, as listed in the
following table, has been achieved.
Table 3� Tie Bar Nuts (3-90) Torque Table
Housing
Model
TORQUE (±5%) Housing
Model
TORQUE (±5%)
FT-lb N-m FT-lb N-m
GTD01 70 95 GTD7 466 632
GTD2 70 95 GTD8 680 922
GTD3 125 169 GTD10 875 1186
GTD4 190 258 GTD13 1367 1854
GTD5 330 447
3.3.40 Adjust stop screw (3-180) back to settings recorded earlier in Section 2 at step
2.2.2.
3.3.41 Tighten jam nut (3-190) securely.
3.3.42 If removed apply thread sealant to two pipe plugs (3-210) and install into the ports
of outer end cap (3-10) and inner end cap (3-80).

Service Instructions
133893 Rev. C January 2013
16
Section 3: Actuator Reassembly
Actuator Reassembly
3�4 GTO Oil Cylinder Reassembly
NOTE:
Review section 3.1 General Reassembly before proceeding with Hydraulic Power Module
Installation.
Reassemble the GTO oil cylinder on a work bench per the following steps and then install
on the Drive Module per Section 4.
In section 3.4 where the step indicates to "lubricate, coat or apply uid", use hydraulic uid
for lubricating the part being installed.
3.4.1 Lubricate piston rod assembly (7-40) with uid.
NOTE:
For steps 3.4.2 through 3.4.7 refer to assembly drawing page 2 of 2 Detail “E”.
3.4.2 Install o-ring seal (8-70) into the seal groove in piston rod assembly (7-40).
3.4.3 Install two split ring halves (7-50) into the inner most groove in piston rod
assembly (7-40) and retain with one retainer ring (7-60).
3.4.4 Install piston (7-30) onto piston rod assembly (7-40) and up against split rings
installed in step 3.4.3.
3.4.5 Install two split ring halves (7-50) into the outer most groove in piston rod
assembly (7-40) and retain with one retainer ring (7-60).
3.4.6 Apply uid to the bore of cylinder (7-70).
3.4.7 Coat one piston bearing (8-45) with uid and install into the piston external seal
groove.
3.4.8 Install piston (7-30), with piston rod assembly (7-40), into cylinder (7-70) leave the
inner most piston seal groove exposed out side of the cylinder.
3.4.9 Coat one piston seal (8-60) with uid and install into the exposed piston external
seal groove.
CAUTION: INSTALL PISTON SEAL CORRECTLY
Install the piston seal with energizer ring facing outside edge of piston (7-30).
3.4.10 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.
3.4.11 Coat one piston seal (8-60) with uid and install into the exposed piston external
seal groove.

Service Instructions
133893 Rev. C
January 2013
17
Section 3: Actuator Reassembly
Actuator Reassembly
CAUTION: INSTALL PISTON SEAL CORRECTLY
Install the piston seal with energizer ring facing outside edge of piston (7-30).
3.4.12 Refer to assembly drawing page 2 of 2 Detail "D". Coat Polypak seal (8-30) with
hydraulic uid and install, lip rst, into inner end cap (7-10).
CAUTION: INSTALL POLYPAK SEAL CORRECTLY
Install the Polypak seal with energizer ring facing piston side of inner end cap (7-10).
3.4.13 Install rod bushing (8-20) into inner end cap (7-10).
3.4.14 Install rod wiper (8-10) into inner end cap (7-10).
3.4.15 Install one o-ring seal (8-90) into inboard face of inner end cap (7-10).
3.4.16 Install one o-ring seal (8-40) into outboard face of inner end cap (3-10).
3.4.17 Install inner end cap (7-10) onto piston rod assembly (7-40) and into inboard end
of cylinder (7-70).
3.4.18 Install two tie bars (7-20) into inner end cap (7-10).
NOTE:
The tie bars should be installed across from each other.
3.4.19 Install one o-ring seal (8-40) into inboard face of outer end cap (7-80).
3.4.20 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 2.2.3.
3.4.21 Install the remaining tie bars (7-20) through outer end cap (7-80) and into inner
end cap (7-10). Screw all tie bars (7-20) into inner end cap (7-10) per instructions
given in note number eight located on the assembly drawing page 1 of 2.
3.4.22 Install lockwashers (7-95) onto tie bars (7-20) and up against outer end cap (7-80).
3.4.23 Install hex nuts (7-90) onto tie bars (7-20) and up against lockwashers (7-95).
3.4.24 Torque tighten hex nuts (7-90) until a nal lubricated torque, as listed in the
following table, has been achieved.