BETTIS G13 D102754x012

User Manual: BETTIS G13

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www.Fisher.com

Service Instructions for Fisher™ G01 through

G13 Pneumatic Actuators

This instruction manual was prepared by Actuation

Technologies.

Do not install, operate or maintain this product

without being fully trained and qualified in valve,

actuator and accessory installation, operation and

maintenance.

To avoid personal injury or property damage it is

important to carefully read, understand, and follow all

of the contents of this manual, including all safety

cautions and warnings.

If you have any questions about these instructions,

contact your Emerson sales office or Local Business

Partner before proceeding.

Fisher G2 Pneumatic Actuator

X1407

Instruction Manual

D102754X012

G01 through G13

September 2017

Instruction Manual

D102754X012

G01 through G13

November 2016

Emerson Automation Solutions

Marshalltown, Iowa 50158 USA

Sorocaba, 18087 Brazil

Cernay, 68700 France

Dubai, United Arab Emirates

Singapore 128461 Singapore

www.Fisher.com

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not

to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are

governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such

products at any time without notice.

Fisher is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. Emerson Automation Solutions,

Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners.

Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance

of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.

Service Instructions

124840E Rev. G

March 2017

G/GH/GHC Series Pneumatic Actuators

Disassembly and Reassembly

Service Instructions

124840E Rev. G

Table of Contents

March 2017

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 ............................................................................ 4

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

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

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

1.10 Actuator Start-up .......................................................................................... 5

1.11 Actuator Operation ....................................................................................... 6

Section 2: Actuator Disassembly

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

2.2 Pneumatic Power Module Disassembly ......................................................... 8

2.3 Drive Module Disassembly .......................................................................... 11

2.4 Blind End Cap Module Removal ................................................................... 14

2.5 M3 Handwheel or M3 Hex Drive Hub Removal ........................................... 14

2.6 M3 Jackscrew Disassembly .......................................................................... 14

2.7 Extended Stop Blind End Cap Disassembly .................................................. 15

Section 3: Actuator Reassembly

3.1 General Reassembly .................................................................................... 16

3.2 Drive Module Reassembly ........................................................................... 16

3.3 Pneumatic Power Module Reassembly ........................................................ 21

3.4 G2 and G3 Early Model Pneumatic Power Module Reassembly..................... 26

3.5 Blind End Cap Module Reassembly .............................................................. 29

3.6 M3 Jackscrew Reassembly ........................................................................... 29

3.7 M3 Handwheel or M3 Hex Drive Hub Installation ......................................... 31

3.8 Extended Stop Blind End Cap Reassembly .................................................... 32

3.9 Actuator Testing ......................................................................................... 32

Section 4: Field Conversions

4.1 Fail Mode Reversal (CW to CCW, Or CCW to CW) For G and GH Only ............ 34

4.2 Converting Double-Acting Actuator to Spring-Return ................................. 34

4.3 Converting Spring-Return Actuator to Double-Acting ................................. 34

4.4 Add an M3 Jackscrew to Blind End Cap Module ............................................ 35

4.5 Add an M3 Jackscrew to Power Module Outer End Cap ................................ 35

4.6 Add an M3 Jackscrew to Spring Module ....................................................... 35

4.7 Add an Extended Stop (ES) to Blind End Cap Module ................................... 35

4.8 Add an Extended Stop (ES) to Power Module Outer End Cap ........................ 35

4.9 Add an Extended Stop (ES) to Spring Module .............................................. 36

Table of Contents

March 2017

Service Instructions

124840E Rev. G

Table of Contents

Section 5: Module Removal and Installation

5.1 Spring Module Removal .............................................................................. 37

5.2 Spring Module Installation .......................................................................... 39

5.3 Pneumatic Power Module Removal ............................................................. 43

5.4 Pneumatic Power Module Installation ......................................................... 44

5.5 G2 Thru G13 Powr Swivl Removal (Excludes GH/GHC Model Actuators) ...... 46

5.6 G2 Thru G13 Powr Swivl Module Installation

(Excludes GH/GHC Model Actuators) ........................................................... 46

Section 6: Actuator Support Information

6.1 G/GC/GH/GHC Module Weights By Item Number

And Actuator Housing Size .......................................................................... 48

6.2 G01 Tool Style and Wrench Size .................................................................. 49

6.3 G/GC2 Tool Style and Wrench Size............................................................... 50

6.4 G/GC3 Tool Style and Wrench Size GH2/GHC2 for Item No 3-20 to 3-130 .... 50

6.5 G/GC4 Tool Style and Wrench Size GH3/GHC3 For Item No 3-20 to 3-130 ... 51

6.6 G/GC5 Tool Style and Wrench Size GH4/GHC4 For Item No 3-20 to 3-130 ... 51

6.7 G/GC7 Tool Style and Wrench Size GH5/GHC5 For Item No 3-20 to 3-130 ... 52

6.8 G/GC8 Tool Style and Wrench Size GH7/GHC7 For Item No 3-20 to 3-130 ... 52

6.9 G/GC10 Tool Style and Wrench Size GH8/GHC8 For Item No 3-20 to 3-130 . 53

6.10 G13 Tool Style and Wrench Size GH10/GHC10 For Item No 3-20 to 3-130 ... 53

Section 7: Troubleshooting

7.1 Fault Insertion ............................................................................................. 54

7.2 Operational Test .......................................................................................... 55

Section 8: Removal and Decommissioning

8.1 Removal and Decommissioning .................................................................. 56

Section 9: Document Revision ............................................57

Appendix A: List of Tables ...................................................58

Appendix B: List of Drawings ..............................................59

Service Instructions

124840E Rev. G

March 2017

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™ G/GC01XXX, G/GC2XXX, G/GC3XXX, G/GC4XXX, G/

GC5XXX, G/GC7XXX, G/GC8XXX, G/GC10XXX, G13XXX, and GH/GHC2XXX, GH/

GHC3XXX, GH/GHC4XXX, GH/GHC5XXX, GH/GHC7XXX, GH/GHC8XXX Spring-

Return (SR) Series Single Power Module Pneumatic Actuators. These procedures

can also be used on Bettis GXX2XX Double-Acting Series Twin Power Modules

Pneumatic Actuators.

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

NOTE:

Storage time is counted as part of the service interval.

1.1.3 This procedure is applicable with the understanding that all electrical power and

pneumatic pressure has been removed from the actuator.

1.1.4 Remove all piping and mounted accessories that will interfere with the module(s)

that are to be worked on.

1.1.5 This procedure should only be implemented by a technically competent technician

who should take care to observe good workmanship practices.

1.1.6 Numbers in parentheses, ( ) indicate the bubble number (reference number) used

on the Bettis Assembly Drawing and Actuator Parts List.

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

reference and this side will be considered the front side of the actuator.

The housing cover (1-20) will be the top of the actuator.

1.1.8 Actuator module weights are listed in Section 6 Table 6.1.

1.1.9 When removing seals from seal grooves, use a commercial seal removing tool or a

small screwdriver with sharp corners rounded off.

1.1.10 Use a non-hardening thread sealant on all pipe threads.

CAUTION: FOLLOW MANUFACTURER'S INSTRUCTIONS

Apply the thread sealant per the manufacturer’s instructions.

1.1.11 Bettis recommends that disassembly of the actuator should be done in a clean

area on a workbench.

March 2017

Service Instructions

124840E Rev. G

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).

ES:

Extended stop screw (for travel stop adjustment over a full 100° degree travel range).

ES is not intended for use as a manual override.

M3:

Manual jackscrew override

GC/GH/GHC:

Canted / High pressure / High Pressure Canted (Canted Yoke) G-Series actuator

1.3 General Safety Information

1.3.1 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: FOLLOW WARNING AND CAUTION SIGNS

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.

Service Instructions

124840E Rev. G

March 2017

Section 1: Introduction

Introduction

WARNING: FOLLOW COMPANY 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.

1.4 Bettis Reference Materials

1.4.1 Assembly Drawing for G/GC01 through G/GC10 and G13 Double-Acting One

Power Module Pneumatic Series Actuators use part number 116422.

1.4.2 Assembly Drawing for G01 through G13 Double-Acting Twin Power Module

Pneumatic Series Actuators use part number 115678.

1.4.3 Assembly Drawing for G/GC01 through G/GC10 and G13 Spring-Return One

Power Module Pneumatic Series Actuators use part number 115674.

1.4.4 Assembly Drawing for GH/GHC 2 through 10, Spring-Return One Power Module

Pneumatic Series Actuators use part number 140952.

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 Kit.

NOTE:

Although the below part numbers say GXX, they can also be used on G/GC/GH/GHCXX

actuators.

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

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. Rod Extension Retainer Nut Tool Part Number

ACTUATOR

MODEL

BETTIS

PART NUMBER

ACTUATOR

MODEL

BETTIS

PART NUMBER

G01 None Required G5/G7 117369

G2 123616 G8/G10 117368

G3/G4 117370 G13 122849

1.5.3 Commercial leak testing solution.

1.5.4 Non-hardening thread sealant.

March 2017

Service Instructions

124840E Rev. G

Section 1: Introduction

Introduction

1.6 Lubrication Requirements

NOTE:

Lubricants other than those listed in steps 1.6.1 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 and

the tubes are marked ESL-4, 5 and 10 lubricant.

1.7 General Tool Information

1.7.1 Tools: All tools/Hexagons are American Standard inch (Imperial). Large adjustable

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

wrenches, rubber or leather mallet, torque wrench (up to 1600 foot pounds / 2169

N-m), breaker bar, and a drive socket set. For recommended tool and wrench sizes

refer to Section 6, Tables 6.2 through 6.10.

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

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.

Service Instructions

124840E Rev. G

March 2017

Section 1: Introduction

Introduction

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.

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)

March 2017

Service Instructions

124840E Rev. G

Section 1: Introduction

Introduction

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.

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

124840E Rev. G

March 2017

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, etc.).

WARNING: BEWARE OF COMPRESSED SPRING

Do not remove spring module while spring is compressed

WARNING: READ WARNING TAGS

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

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

2.1.2 When the spring module is to be removed it should be removed from the drive

module prior to the pneumatic power module removal or disassembly.

2.1.3 The pneumatic power module can be disassembled while still attached to the drive

module or the pneumatic power module can be removed from the drive module and

disassembled separate to the actuator (refer to Section 5 - Module Removal

And Installation).

2.1.4 To ensure correct re-assembly; that is, with pneumatic power module or spring

module on same end of drive module as was, mark or tag right (or left) and mark

mating surfaces.

2.1.5 For spring module removal refer to Section 5 step 5.1.

March 2017

Service Instructions

124840E Rev. G

Section 2: Actuator Disassembly

Actuator Disassembly

2.2 Pneumatic Power Module Disassembly

NOTE:

Review Section 2 steps 2.1.1 through 2.1.5 General Disassembly before proceeding with

Pneumatic Power Module Disassembly.

NOTE:

If the actuator model is a GXX2XX Series (two same size power modules with one module

mounted on each side of the drive module) then do the following steps on both power

modules simultaneously or complete one power module and then repeat section 2.2 on

the second power module

WARNING: REMOVE PRESSURE FROM CYLINDERS

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

WARNING: FOLLOW CORRECT DISASSEMBLY STEPS

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

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

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

2.2.1 Mark and record location of the ports on outer end cap (3-80) and inner end cap (3-10).

NOTE:

If actuator is equipped with a spring module complete step 2.2.2. If actuator is a double-

acting model skip step 2.2.2 and go to step 2.2.3.

2.2.2 Remove breather assembly (12) from outer end cap (3-80).

2.2.3 Refer to Assembly Drawing page 2 of 2 Detail "E". Remove two socket cap screws

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

NOTE:

If the power module is equipped with an M3 jackscrew remove the M3 jackscrew using

Section 2.6.5 for G/GH01 models and Section 2.6.6 for G/GH2 and G/GH3 models.

2.2.4 Outer end cap (3-80) removal as follows:

2.2.4.1 G/GC01 through G/GC10, G13, and GH/GHC2 through GH/GHC10

standard end cap (3-80) removal. Continue at step 2.2.5.

2.2.4.2 G/GC01-M3 jackscrew disassembly from outer end cap (3-80)

2.2.4.2.1 Remove M3 handwheel or M3 hex drive hub from M3 (3-290)

per Section 2.5.

Service Instructions

124840E Rev. G

March 2017

Section 2: Actuator Disassembly

Actuator Disassembly

2.2.4.2.2 Refer to Assembly Drawing page 2 of 2 Detail "E". If not already

removed unscrew and remove two socket cap screws (3-130),

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

2.2.4.2.3 Remove socket cap screw (3-130) with lockwasher (3-140)

from keeper (3-360).

2.2.4.2.4 Remove keeper (3-360) from outer end cap (3-80).

2.2.4.2.5 Push jackscrew (3-290) back into the outer end cap far enough

so that the jackscrew adapter (3-280) will not interfere with the

removal of hex nuts (3-90). Continue at step 2.2.5.

2.2.4.3 G/GC/GH/GHC02 & G/GC/GH/GHC3-M3 jackscrew disassembly from

outer end cap (3-80)

2.2.4.3.1 Remove M3 handwheel or M3 hex drive hub from M3 (3-290)

per Section 2.5.

2.2.4.3.2 Unscrew and remove hex at nut (3-300) from G2/G3 M3

jackscrew (3-290).

2.2.4.3.3 Unscrew and remove two socket cap screws (3-320) from G2/

G3 M3 adapter (3-280).

2.2.4.3.4 Remove M3 jackscrew (3-290) from outer end cap (3-80).

Continue at step 2.2.5.

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

2.2.6 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).

CAUTION: CAREFULLY REMOVE END CAP CYLINDER

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

NOTE:

When removing cylinder (3-70) off of piston (3-30), tilt the cylinder 15° to 30° with respect

to actuator centerline.

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

CAUTION: USE CORRECT TOOLS

Do not use pipe wrench to remove tie bars.

2.2.8 TIE BAR REMOVAL:

NOTE:

G/GC01, G/GC/GH/GHC2 and G/GC/GH/GHC3 models have ats on outboard end

of tie bars (3-20) for wrench placement.

March 2017

Service Instructions

124840E Rev. G

Section 2: Actuator Disassembly

Actuator Disassembly

2.2.8.1 Remove G/GC01, G/GC/GH/GHC2 and G/GC/GH/GHC3 tie bars (3-20) as follows:

2.2.8.1.1 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).

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

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

piston (3-30).

NOTE:

G/GC4 models have ats on outboard end of tie bars (3-20) for wrench placement.

NOTE:

G5 through G13, and GH/GHC5 through GH/GHC10 models have a female square

on the out board end of tie bars (3-20) for wrench placement.

2.2.8.2 Remove G4 through G13 tie bars (3-20) as follows: Unscrew and remove

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

2.2.9 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 2.2.11).

2.2.9.1 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 remov-

ing the piston be careful to not lose inboard split ring halves (3-50).

2.2.9.2 Remove piston (3-30) and two split ring halves (3-50) from piston rod (3-40).

NOTE:

Steps 2.2.10 is used only on early G2 and G3 models equipped with outboard and inboard

tie bar nuts.

2.2.10 Remove early model G2 and G3 pistons as follows:

2.2.10.1 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).

2.2.10.2 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).

Service Instructions

124840E Rev. G

March 2017

Section 2: Actuator Disassembly

Actuator Disassembly

2.2.10.3 Remove piston (3-30) and two split ring halves (3-50) from piston rod (3-40).

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

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

2.2.13 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 2.2.8.1 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 2.2.14 is only required when the piston

rod is being replaced or when the drive module is to be disassembled.

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

2.3 Drive Module Disassembly

NOTE:

Review Section 2 steps 2.1.1 through 2.1.5 general disassembly before proceeding with

drive module disassembly.

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

NOTE:

If the actuator is equipped with submerged stop screws with stop screw covers (1-195)

then proceed to and complete steps 2.3.2.1 and 2.3.2.2 prior to doing step 2.3.2.

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

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

NOTE:

Stop screws will be removed later in this procedure.

2.3.2.1 Hold stop screw cover (1-195) in place and remove pipe plug (1-260).

2.3.2.2 Hold submerged stop screw (1-180) in place and remove stop screw

cover (1-195).

March 2017

Service Instructions

124840E Rev. G

Section 2: Actuator Disassembly

Actuator Disassembly

NOTE:

For steps 2.3.3 through 2.3.10 refer to Assembly Drawing page 2 of 2 Section A-A, Detail

“F” on drawing part number 115674 and Detail “G” on drawing part number 116422.

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, GH/GHC 2 and GH/GHC 3 drive modules. Drive modules GH/

GHC4 through G/GC/GH/GHC10 and G13 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 G/GC/GH/GHC5, G/GC/GH/GHC7, G/GC/GH/

GHC8 & 10 drive modules. Drive modules G/GC01, G/GC/GH/GHC2 through 4 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).

NOTE:

G/GC01, G/GC/GH/GHC2 through 4 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.

Service Instructions

124840E Rev. G

March 2017

Section 2: Actuator Disassembly

Actuator Disassembly

2.3.14 Refer to Assembly Drawing page 2 of 2 Detail "B". Remove guide bar (1-90) from

housing (1-10).

2.3.15 Remove top yoke pin thrust bearing (2-10) from top of yoke pin (1-80).

2.3.16 Rotate the arms of yoke (1-70) to the center position of housing (1-10).

2.3.17 Remove yoke (1-70) with yoke pin (1-80), guide block (1-30) and two yoke/guide

block bushings (2-30), by lifting yoke up and out of the housing (1-10).

2.3.18 Remove bottom yoke pin thrust bearing (2-10) from inside bottom of housing (1-10).

2.3.19 Remove yoke pin (1-80) by inserting 3/8"-16 UNC screw into top of the yoke pin

and pull straight up and out.

2.3.20 Remove guide block (1-30) from between the arms of yoke (1-70).

2.3.21 Remove yoke/guide block bushing (2-30) from top of guide block (1-30).

2.3.22 Remove yoke/guide block bushing (2-30) from the top of the lower yoke arm of yoke (1-70).

NOTE:

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

2.3.23 Refer to Assembly Drawing page 2 of 2 Detail "B". Use Bettis tool part numbers

117368 (G8/G10), 117369 (G5/G7), 117370 (G3/G4), 122849 (G13) or 123616

(G2) and remove retention retainer nut assemblies (1-60) from guide block (1-30).

On spring-return actuators also remove retention retainer nut assemblies (9-60).

These tools can be used for GC/GH/GHC models of equivalent size.

2.3.24 Remove extension rod assembly (1-50) from guide block (1-30). On spring-return

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

NOTE:

On G/GC models only (Non GH/GHC): One spherical washer (1-40) will be removed from guide

block (1-30) when extension rod assembly is removed. On spring-return actuators also one spherical

washer (9-40) will be removed from guide block (1-30). On GH/GHC actuators, there is no extension

rod assembly; the piston rod is fastened directly into the guide block assembly instead.

2.3.25 Remove the remaining spherical washer (1-40) from guide block (1-30). On spring-

return actuators also remove the remaining spherical washer (9-40) from guide

block (1-30).

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

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

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

2.3.28.1 G01, G/GC/GH/GHC2 and G/GC/GH/GHC3 housing (1-10) unscrew and

remove one vent check assembly (13) from the front of housing (1-10).

2.3.28.2 G/GC/GH/GHC4 through G/GC/GH/GHC10 and G13 housing (1-10)

unscrew and remove two vent check assembly’s (13) from the front of

housing (1-10).

2.3.29 The following items do not need to be removed from their assembled locations

unless being replaced by new items: Two guide bar bearings, two yoke bearings

(2-40), yoke pin bearing and yoke pin thrust bearing (2-10).

March 2017

Service Instructions

124840E Rev. G

Section 2: Actuator Disassembly

Actuator Disassembly

2.4 Blind End Cap Module Removal

2.4.1 Remove hex cap screws (5-20), with spring lockwashers (5-30), from blind end cap (5-10).

2.4.2 Remove blind end cap (5-10) from end of housing (1-10).

2.5 M3 Handwheel or M3 Hex Drive Hub Removal

2.5.1 M3 HANDWHEEL OR HEX DRIVE HUB REMOVAL FROM M3 STUD.

2.5.1.1 Using pin punch drive out two grooved pins (10-20) and (10-30) from

handwheel hub or hex drive hub (10-10).

2.5.1.2 Remove handwheel or hex drive hub (10-10) from M3 stud (5-50).

2.5.2 EARLY MODEL G2 & G3 M3 HANDWHEEL AND HEX NUT REMOVAL FROM

JACKSCREW

2.5.2.1 Remove hex nut, lockwasher from M3 jackscrew.

2.5.2.2 Remove handwheel from M3 jackscrew.

2.5.2.3 Using pin punch drive out spiral pin from outboard end of M3 jackscrew

2.5.2.4 Remove hex nut from M3 jackscrew, and handwheel.

2.6 M3 Jackscrew Disassembly

NOTE:

The jackscrew bearing retainer (7-110) / (5-110), needle bearing thrust washer assembly

(7-100) / (5-100) or retainer ring (7-90) / (5-90) does not require disassembly from the

jackscrew assembly (7-40) / (5-50) except for the need to replace worn parts.

For disassembly of these items refer to step 2.6.7. Remove M3 handwheel or M3 hex drive

hub per Section 2.5.

2.6.1 G01-M3 JACKSCREW DISASSEMBLY FROM BLIND END CAP

2.6.1.1 Remove M3 handwheel or M3 hex drive hub per Section 2.5.

NOTE:

See note 2.6 before proceeding with step 2.6.1.2 through 2.6.1.4.

2.6.1.2 Unscrew and remove socket cap screw (5-120) with lockwasher (5-130)

from keeper (5-140).

2.6.1.3 Remove keeper (5-140) from blind end cap (5-10).

2.6.1.4 Remove M3 jackscrew (5-50) from blind end cap (5-10).

2.6.2 G2-M3 and G3-M3 JACKSCREW DISASSEMBLY FROM BLIND END CAP

2.6.2.1 Remove M3 handwheel or M3 hex drive hub per Section 2.5.

NOTE:

See 2.6 note before proceeding with step 2.6.2.2 through 2.6.2.4.

Service Instructions

124840E Rev. G

March 2017

Section 2: Actuator Disassembly

Actuator Disassembly

2.6.2.2 Unscrew and remove hex at nut (5-60) from G2/G3 M3 jackscrew.

2.6.2.3 Unscrew and remove two socket cap screws (5-120) from G2/G3 M3

adapter.

2.6.2.4 Remove M3 jackscrew (5-50) from blind end cap (5-10).

2.6.3 G01-SR-M3 JACKSCREW DISASSEMBLY FROM SR-M3 ADAPTER PLATE

2.6.3.1 Remove M3 handwheel or M3 hex drive hub per Section 2.5.

NOTE:

See 2.6 note before proceeding with step 2.6.3.2 through 2.6.3.4.

2.6.3.2 Unscrew and remove hex at nut (7-50) from M3 jackscrew assembly

(7-40).

2.6.3.3 Remove retainer ring (7-55) from M3 adapter (7-45).

2.6.3.4 Remove M3 jackscrew assembly (7-40) from M3-SR adapter plate (7-10).

2.6.4 G2 AND G3-SR-M3 JACKSCREW DISASSEMBLY FROM SR-M3 ADAPTER PLATE

2.6.4.1 Remove M3 handwheel or M3 hex drive hub per Section 2.5.

NOTE:

See 2.6 note before proceeding with step 2.6.4.2 through 2.6.4.4.

2.6.4.2 Unscrew and remove hex at nut (7-50) from M3 jackscrew assembly

(7-40).

2.6.4.3 Unscrew and remove two socket cap screws (7-120) from M3 adapter

(7-40).

2.6.4.4 Remove M3 jackscrew (7-40) from M3-SR adapter plate (7-10).

2.6.5 M3 THRUST BEARING DISASSEMBLY FROM M3 JACKSCREW ASSEMBLY

2.6.5.1 Remove M3 bearing retainer (5-110) / (7-110) from inboard end of M3

jackscrew assembly (5-50) / (7-40).

2.6.5.2 Remove needle roller thrust bearing (5-100) / (7-100) from M3 bearing

retainer (5-110) / (7-110).

2.6.5.3 Remove retainer ring (5-90) / (7-90) from M3 jackscrew assembly

(5-50) / (7-40).

2.7 Extended Stop Blind End Cap Disassembly

2.7.1 Unscrew and remove hex nut (5-60) from ES stop screw (5-50).

2.7.2 Remove ES stop screw (5-50) from ES blind end cap (5-10).

March 2017

Service Instructions

124840E Rev. G

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 aking coating.

CAUTION: REPLACE WITH NEW PARTS

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

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

Coat all seals with a complete lm of lubricant, before installing into seal grooves.

NOTE:

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

section 1 step 1.6.1.

3.1.5 For spring module installation refer to Section 5 step 5.2.

3.2 Drive Module Reassembly

NOTE:

Review section 3.1 General Reassembly before proceeding with Drive Module Reassembly

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

3.2.1 If guide bar bearing (2-20) is being replaced install new bearing into guide block (1-30).

NOTE:

The guide bar bearing (2-20) 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.

Service Instructions

124840E Rev. G

March 2017

Section 3: Actuator Reassembly

Actuator Reassembly

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 (G/GC only)(1-40), and one

extension rod assembly (G/GC only)(1-50).

NOTE:

STEPS 3.2.3 – 3.2.13 FOR G/GC MODELS ONLY (Not GH/GHC):

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

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.

NOTE:

Steps 3.2.8 through 3.2.13 are to be completed when the actuator is equipped with a

spring module. If the actuator is double-acting then skip steps 3.2.8 through 3.2.13 and

continue actuator reassembly starting with step 3.2.14.

3.2.8 Lubricate 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).

March 2017

Service Instructions

124840E Rev. G

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

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:

Steps 3.2.14 and 3.2.15 are to be completed when the actuator is double-acting and

equipped with a Blind end cap extended stop screw.

3.2.14 Install guide block stop plug (5-50) into guide block (1-30).

3.2.15 Install and tighten rod extension retainer nut assembly (5-80) over guide block

stop plug (5-50) and screw into guide block (1-30).

NOTE:

Consult Houston, Texas Bettis Service Coordinator for “yoke bearing, yoke pin bearing or

yoke/guide block bushing installation information.

3.2.16 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.

3.2.17 If the two yoke pin bearings (2-10) are being replaced install new bearing into

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

3.2.18 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.

3.2.19 Install guide block (1-30), with yoke guide block bearings (2-30), between arms of

yoke (1-70).

Service Instructions

124840E Rev. G

March 2017

Section 3: Actuator Reassembly

Actuator Reassembly

3.2.20 Install one O-ring seal (2-50) into inner diameter seal groove in the bottom of

housing (1-10).

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

3.2.22 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).

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).

3.2.23 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).

3.2.24 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).

3.2.25 Refer to Assembly Drawing page 2 of 2 Section A-A. Install spring pin (1-100) into

the top of yoke (1-70).

3.2.26 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.

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

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

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

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

NOTE:

On G/GC/GH/GHC7,8,10 and G13 model actuators apply thread adhesive, Loctite 242, to

threads of hex cap screws (1-110). Reference Assembly Drawing note number 8.

3.2.31 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.

March 2017

Service Instructions

124840E Rev. G

Section 3: Actuator Reassembly

Actuator Reassembly

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.

3.2.32 Torque tighten hex cap screws (1-110) until a nal lubricated torque, as listed in

the following table, has been achieved.

Table 2. Housing Cover Screw Quantity and Torque Table

MODEL

G/GC/

GH/GHC

QTY

TORQUE

(±5 % Percent)

MODEL

G/GC/

GH/GHC

QTY

TORQUE

(±5 % Percent)

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

G01 4 40 54 7 8 100 136

2 6 40 54 8 12 100 136

3 8 40 54 10 16 100 136

4 8 40 54 G13 20 340 461

5 8 100 136

NOTE:

Complete step 3.2.34 on G/GC/GH/GHC5, 7, 8, 10 and G13 model actuators. For G01 and

G/GC/GH/GHC2 through G/GC/GH/GHC4 model actuators skip step 3.2.34 and proceed to

step 3.2.35.

3.2.33 On G/GC/GH/GHC5, 7,8,10 and G13 models

3.2.33.1 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 environment.

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

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

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

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

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

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

3.2.39 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).

Service Instructions

124840E Rev. G

March 2017

Section 3: Actuator Reassembly

Actuator Reassembly

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

3.2.41 Install and tighten hex cap screws (1-160) with lockwashers through yoke cover

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

3.2.42 Vent check assembly installation as follows:

3.2.42.1 G01, G/GC/GH/GHC2 and G/GC/GH/GHC3 housing (1-10) using pipe sealant

install one vent check assembly (13) into the front of housing (1-10).

3.2.42.2 G01, G/GC/GH/GHC2 and G/GC/GH/GHC3 housing (1-10) using pipe sealant

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

3.2.42.3 G/GC/GH/GHC4,5,7,8,10 and G13 housing (1-10) using pipe sealant

install two vent check assemblies (13) into the front of housing (1-10).

3.2.43 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).

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

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

3.2.46 Install two stop screws (1-180) into two stop screw holes on the front of

housing (1-10).

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

step 2.3.2.

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

3.3 Pneumatic Power Module Reassembly

NOTE:

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

3.4 for reassembly.

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

THE ACTUATOR MUST BE IN THE APPROPRIATE OVERTRAVEL POSITION. Conrm over-travel

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

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

3.3.1.1 G2 through G13 screw piston rod (3-40) onto extension rod assembly

(1-50).

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

3.3.2 After conrming initial thread engagement rotate piston rod into extension rod

assembly (1-50) as listed in the following table.

WARNING: TURN ACCORDING TO TABLE

After initial thread engagement the Piston rod must be rotated clockwise the minimum

number of turns listed in the following table.

March 2017

Service Instructions

124840E Rev. G

Section 3: Actuator Reassembly

Actuator Reassembly

Table 3. Piston Rod Torque Information

ACTUATOR

MODEL

G/GC/GH/

GHC

12345 7 8 10 G13

MINIMUM

NO TURNS 610 10 10 13 14 20 25 31

3.3.3 Torque tighten piston rod (3-40) to the lubricated torque as listed in the

following table.

Table 4. Torque Tighten Piston Rod

HOUSING

MODEL

G/GC/GH/

GHC

TORQUE

(±5 % Percent)

HOUSING

MODEL

G/GC/GH/

GHC

TORQUE

(±5 % Percent)

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

G01 90 122 7 240 325

2 90 122 8 240 325

3 90 122 10 240 325

4 240 325 G13 240 325

5 240 325

3.3.4 Refer to Assembly Drawing page 2 of 2 Detail "C". Install one rod wiper (4-10) into

inner end cap (3-10).

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

3.3.6 Coat one Polypak seal (4-30) with lubricant and install, lip rst, into inner

end cap (3-10).

CAUTION: CHECK SEAL DIRECTION

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

3.3.7 Install one O-ring seal (4-90) into seal groove located on the inboard face of inner

end cap (3-10).

3.3.8 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.

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

3.3.10 Install and tighten hex cap screws (3-100)(GH/GHC7 model will have 4 more bolts

than the standard G and 2 more bolts on the GH/GHC8,10 models than the standard

G), with lockwashers, through housing (1-10) and into inner end cap (3-10).

3.3.11 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).

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

Service Instructions

124840E Rev. G

March 2017

Section 3: Actuator Reassembly

Actuator Reassembly

NOTE:

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

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

grooves of piston (3-30).

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

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

3.3.12.4 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.

3.3.13 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).

3.3.14 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).

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

3.3.16 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.

3.3.17 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).

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

out.

3.3.19 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).

3.3.20 Apply lubricant to one O-ring seal (4-40) and install into the outer diameter O-ring

groove of outer end cap (3-80).

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

CAUTION: CAREFULLY INSTALL THE CYLINDER

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

metallic object.

3.3.22 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.

3.3.23 OUTER END CAP (3-80) INSTALLATION AS FOLLOWS: G01-M3 use step 3.3.23.1,

G2-M3 and G3-M3 use step 3.3.23.2 and standard outer end cap use step 3.3.23.3.

NOTE:

The outer end cap (3-80) pressure inlet port should be positioned in the same position as

recorded in Section 2.2 step 2.2.1.

March 2017

Service Instructions

124840E Rev. G

Section 3: Actuator Reassembly

Actuator Reassembly

3.3.23.1 G01-M3 OUTER END CAP INSTALLATION

3.3.23.1.1 Apply a light coating of lubricant to threads of jackscrew (3-290).

3.3.23.1.2 Screw jackscrew adapter (3-280) onto jackscrew (3-290).

NOTE:

The smaller round end of the jackscrew adapter will install on

the jackscrew pointing to the outboard end of the jackscrew.

3.3.23.1.3 Position the jackscrew with the inboard end of the jackscrew

located with the needle bearing thrust washer assembly (3-

350) up against or near the jackscrew adapter (3-280).

3.3.23.1.4 Lightly lubricate O-ring seal (6-20) and install into O-ring

groove on the outboard side of the jackscrew adapter (3-280).

3.3.23.1.5 Insert jackscrew (3-290) through inboard side of the outer end

cap (3-80).

3.3.23.1.6 Install outer end cap (3-80) over tie bars (3-20) and into

cylinder (3-70).

3.3.23.1.7 Install tie bar nuts (3-90) onto tie bars (3-20).

NOTE:

Do not tighten nuts.

3.3.23.1.8 Install the jackscrew adapter keeper (3-360) into the groove

exposed on the outboard side of the jackscrew adapter (3-280).

3.3.23.1.9 Lightly lubricate O-ring seal (6-30) and install onto the

outboard end of the jackscrew. Push the O-ring (6-30) down

the jackscrew until it contacts the jackscrew adapter (3-280).

3.3.23.1.10 Install at hex nut (3-300) onto jackscrew (3-290). Rotate the

at hex nut (3-290) until it is up against O-ring seal (6-30).

3.3.23.1.11 Install outer end cap (3-80) over tie bars (3-20) and into

cylinder (3-70). Continue at step 3.3.24.

3.3.23.2 G/GC/GH/GHC 2 & G/GC/GH/GHC 3-M3 OUTER END CAP INSTALLATION

3.3.23.2.1 Lightly lubricate O-ring seal (6-10) and install into O-ring

groove in the M3 hole in the outer end cap (3-80).

3.3.23.2.2 Install the jackscrew (3-290) through the outboard side of the

outer end cap (3-80).

3.3.23.2.3 Apply a light coating of lubricant to threads of jackscrew (3-290).

3.3.23.2.4 Screw jackscrew adapter (3-280) onto jackscrew (3-290).

NOTE:

The small round end of the M3 adapter will install on the jack-

screw pointing to the inboard end of the jackscrew.

Service Instructions

124840E Rev. G

March 2017

Section 3: Actuator Reassembly

Actuator Reassembly

3.3.23.2.5 Position the jackscrew with the inboard end of the jackscrew

located with the needle bearing thrust washer assembly (3-340)

up against or near the jackscrew adapter (3-280).

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

(3-70).

3.3.23.2.7 Install tie bar nuts (3-90) onto tie bars (3-20).

NOTE:

Do not tighten nuts.

3.3.23.2.8 Install two socket cap screws (3-320) through jackscrew

adapter (3-280) and tighten into the outer end cap (3-80).

3.3.23.2.9 Lightly lubricate O-ring seal (4-150) and install onto the

outboard end of the jackscrew. Push the O-ring (4-150) down

the jackscrew until it contacts the jackscrew adapter (3-280).

3.3.23.2.10 Install at hex nut (3-300) onto jackscrew (3-290). Rotate the

at hex nut (3-300) until it is up against the O-ring seal (4-150).

WARNING: DO NOT OVERTIGHTEN NUT (3-300)

Excessive tightening could damage the seal (4-150) and prevent it from sealing properly.

Nut should be hand-tight plus 1/4 to 1/2 turn.

3.3.23.2.11 Install outer end cap (3-80) over tie bars (3-20) and into

cylinder (3-70). Continue at step 3.3.24.

3.3.23.3 STANDARD OUTER END CAP INSTALLATION Install outer end cap (3-80)

over tie bars (3-20) and into cylinder (3-70).

3.3.24 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 5. Tie Bar Nuts

HOUSING

MODEL

TORQUE

(±5 % Percent) HOUSING

MODEL

TORQUE

(±5 % Percent)

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

G01 120 163 G7/GH5 500 678

G2 120 163 G8/GH7 500 678

G3/GH2 150 203 G10/GH8 1200 1627

G4/GH3 150 203 G13/GH10 1600 2169

G5/GH4 400 542

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

3.3.26 Install and tighten socket cap screws (3-130), with lockwashers (3-140), into outer

end cap (3-80).

March 2017

Service Instructions

124840E Rev. G

Section 3: Actuator Reassembly

Actuator Reassembly

NOTE:

If the outer end cap (3-80) has an ES stop screw completed steps 3.3.26 through 3.3.29.

3.3.27 If not already removed then remove hex nut (3-190) and old O-ring seal (4-100).

3.3.28 Install new O-ring seal (4-100) onto the ES stop screw and up against outer end cap

(3-80).

3.3.29 Install hex nut (3-140) on to ES. After adjusting to proper position tighten ES stop

screw.

NOTE:

Step 3.3.29 is not required if the power module is equipped with an ES stop screw or a M3

jackscrew.

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

3.3.31 Apply sufcient pneumatic pressure to outer end cap (3-80) pressure inlet port to

move the piston to its full inboard position (next to inner end cap).

3.3.32 Remove pneumatic pressure from outer end cap (3-80).

3.3.33 Install breather assembly (12) in outer end cap (3-80).

NOTE:

Individual actuators may not have reducer bushing (14) depending on port and breather

size.

3.4 G2 and G3 Early Model Pneumatic Power

Module Reassembly

NOTE:

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.

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

THE ACTUATOR MUST BE IN THE APPROPRIATE OVERTRAVEL POSITION. Conrm 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: CHECK SEAL DIRECTION

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

Service Instructions

124840E Rev. G

March 2017

Section 3: Actuator Reassembly

Actuator Reassembly

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).

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.

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-

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.

March 2017

Service Instructions

124840E Rev. G

Section 3: Actuator Reassembly

Actuator Reassembly

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 THE 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.

NOTE:

If the power module is equipped with a M3 jackscrew pre-assemble the M3 jackscrew to

the outer end cap (3-80) per Section 3.6.

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,

alternately in 100 foot pound increments, until a nal lubricated torque, as listed in

the following table, has been achieved.

Table 6. Early G2 and G3 Tie Bar Nuts

HOUSING

MODEL

TORQUE

(±5 % Percent) HOUSING

MODEL

TORQUE

(±5 % Percent)

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

G2 120 163 G3 150 203

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 5.4.

Service Instructions

124840E Rev. G

March 2017

Section 3: Actuator Reassembly

Actuator Reassembly

3.5 Blind End Cap Module Reassembly

NOTE:

If the blind end cap has an M3 jackscrew or ES stop screw that has been removed from the

blind end cap then pre-assemble the M3 or ES into the blind end cap per Section 3.6 or 3.8.

3.5.1 Install O-ring seal (6-10) into the O-ring groove in blind end cap (5-10).

3.5.2 Install lockwashers (5-30) onto hex cap screws (5-20).

NOTE:

Verify that steps 3.2.14 and 3.2.15 have been completed prior to commencing with step 3.5.3.

3.5.3 Install blind end cap (5-10) onto end of housing (1-10).

3.5.4 Install and tighten hex cap screws (5-20) with lockwashers (5-30) through housing

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

3.6 M3 Jackscrew Reassembly

NOTE:

This section is to be completed when the M3 jackscrew has been disassembled from the

blind end cap or from the SR-M3 adapter plate (7-10).

If the thrust bearing assembly has been disassembled from the M3 jackscrew stud then pre

assemble the thrust bearing assembly to the M3 jackscrew stud as per Section 3.6.5.

3.6.1 G01-M3 JACKSCREW REASSEMBLY TO M3 BLIND END CAP

3.6.1.1 Apply a light coating of lubricant to threads of M3 assembly (5-50).

3.6.1.2 Screw M3 adapter (5-45) onto M3 assembly (5-50).

NOTE:

The smaller round end of the M3 adapter will install on the M3 assembly

pointing to the outboard end of the M3 assembly.

3.6.1.3 Position the M3 assembly with the inboard end of the M3 located with

the needle bearing thrust washer assembly (5-100) up against or near the

M3 adapter (5-45).

3.6.1.4 Lightly lubricate O-ring seal (6-20) and install into O-ring groove on the

outboard side of the M3 adapter (5-45).

3.6.1.5 Insert M3 assembly (5-50) through inboard side of the M3 blind

end cap (5-10).

3.6.1.6 Install the jackscrew adapter keeper (5-140) into the groove exposed on

the outboard side of the M3 adapter (5-45).

March 2017

Service Instructions

124840E Rev. G

Section 3: Actuator Reassembly

Actuator Reassembly

3.6.1.7 Lightly lubricate O-ring seal (6-30) and install onto the outboard end of

the M3 jackscrew assembly. Push the O-ring (6-30) down the M3 until it

contacts the M3 adapter (5-45).

3.6.1.8 Install at hex nut (5-60) onto M3 assembly (5-50). Rotate the at hex

nut (5-60) until it is up against the O-ring seal (6-30).

3.6.2 G2-M3 & G3-M3 JACKSCREW REASSEMBLY TO M3 BLIND END CAP

3.6.2.1 Lightly lubricate O-ring seal (6-10) and install into O-ring groove in the

M3 hole in the blind end cap (5-10).

3.6.2.2 Install the M3 jackscrew assembly (5-50) through the inboard side of the

blind endcap (5-10).

3.6.2.3 Apply a light coating of lubricant to threads of M3 assembly (5-50).

3.6.2.4 Screw M3 adapter (5-45) onto M3 jackscrew assembly (5-50).

NOTE:

The small round end of the M3 adapter will install on the M3 assembly

pointing to the inboard end of the M3 assembly.

3.6.2.5 Position the M3 assembly with the inboard end of the M3 located with

the needle bearing thrust washer assembly (5-100) up against or near the

M3 adapter (5-45).

3.6.2.6 Install two socket cap screws (5-120) through jackscrew adapter (5-45)

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

3.6.2.7 Lightly lubricate O-ring seal (6-30) and install onto the outboard end of

the M3 jackscrew assembly. Push the O-ring (6-30) down the M3 until it

contacts the M3 adapter (5-45).

3.6.2.8 Install at hex nut (5-60) onto M3 assembly (5-50). Rotate the at hex

nut (5-60) until it is up against the O-ring seal (6-30).

3.6.3 G01-SR-M3 JACKSCREW REASSEMBLY TO M3-SR ADAPTER PLATE

3.6.3.1 Apply a light coating of lubricant to the threads of jackscrew assembly

(7-40).

3.6.3.2 Install jackscrew adapter (7-45) onto the nonbearing end of jackscrew

assembly (7-40).

3.6.3.3 Install jackscrew adapter (7-45) through M3 adapter plate (7-10).

3.6.3.4 Retain jackscrew adapter (7-45) with retainer ring (7-55).

3.6.4 G2-M3 & G3-SR-M3 JACKSCREW REASSEMBLY TO M3-SR ADAPTER PLATE

3.6.4.1 Apply a light coating of lubricant to the threads of jackscrew assembly

(7-40).

3.6.4.2 Install jackscrew adapter (7-45) onto the nonbearing end of M3 assembly (7-40).

3.6.4.3 Install jackscrew adapter (7-45) through adapter plate (7-10).

3.6.4.4 Install two socket cap screws (7-120) through jackscrew adapter (7-45)

and tighten into adapter plate (7-10).

3.6.5 M3 THRUST BEARING REASSEMBLY TO JACKSCREW ASSEMBLY

3.6.5.1 Apply a coating of lubricant to the internal hole located on the inboard

end of M3 assembly (5-40) / (7-50).

Service Instructions

124840E Rev. G

March 2017

Section 3: Actuator Reassembly

Actuator Reassembly

3.6.5.2 Install the wire retainer ring (5-90) / (7-90) into the internal hole of

M3 assembly until retainer ring opens up into its groove inside the M3

assembly.

3.6.5.3 Pre-assemble the needle bearing thrust washer assembly (5-100) / (7-

100) as follows:

3.6.5.3.1 Apply lubricant to one thrust washer and install onto bearing

retainer (5-110) / (7-110).

3.6.5.3.2 Apply lubricant to needle bearing and install onto bearing

retainer (7-110) and up against thrust washer installed in step

3.6.5.3.1.

3.6.5.3.3 Apply lubricant to the remaining thrust washer and install onto

bearing retainer (5-110) / (7-110) and up against the needle

bearing installed in step 3.6.1.3.2.

3.6.5.4 Install the pre-assembled needle bearing thrust washer assembly (5-100)

/ (7-100) into the open hole located on the inboard end of M3 assembly

(5-50) / (7-40).

NOTE:

Press or push the bearing retainer (5-110) / (7-110) into the M3 assem-

bly forcing the retainer ring (5-90) / (7-90) onto the neck of the bearing

retainer (5-110) / (7-110).

3.7 M3 Handwheel or M3 Hex Drive Hub

Installation

3.7.1 M3 HANDWHEEL OR HEX DRIVE HUB INSTALLATION TO M3 JACKSCREW

3.7.1.1 Install handwheel or hex drive hub (10-10) onto M3 jackscrew (7-40).

3.7.1.2 Install two grooved pins (10-20) and (10-30) through handwheel hub or

hex drive hub (10-10) and through M3 jackscrew (7-40).

3.7.2 EARLY MODEL G2 & G3 M3 HANDWHEEL AND HEX NUT INSTALLATION

3.7.2.1 Screw the slotted nut onto the outboard end of the M3 jackscrew with

the slot facing toward the cylinder end cap. Screw the nut until one of the

slots in the nut is aligned with the cross drilled "through hole" in the stud.

CAUTION: CHECK SLOT ALIGNMENT

When aligning the slot and the cross drilled hole make certain that the back of the slot is at

least one thread from being aligned with the hole.

3.7.2.2 Insert the spiral pin through the slotted nut and through the jackscrew

stud making sure that equal amounts of the spiral pin is exposed on both

sides of the slotted nut and the jackscrew stud.

3.7.2.3 For actuators equipped with a M3 jackscrew and require an optional

handwheel, install handwheel using the following procedure:

3.7.2.3.1 Place the handwheel onto M3 jackscrew and over the pinned

slotted nut.

March 2017

Service Instructions

124840E Rev. G

Section 3: Actuator Reassembly

Actuator Reassembly

NOTE:

The hub of handwheel has a cast hexagon hole that ts over the

pinned slotted nut.

3.7.2.3.2 Place lockwasher onto M3 jackscrew up against handwheel

hub.

3.7.2.3.3 Install and tighten hex nut onto M3 jackscrew and screw nut up

against the lockwasher.

3.8 Extended Stop Blind End Cap Reassembly

3.8.1 Apply a light coating of lubricant to the threads of ES stop screw (5-50).

3.8.2 Install hex nut (5-60) onto the ES stop screw (5-50).

3.8.3 Install ES stop screw (5-50) through ES blind end cap (5-10).

3.9 Actuator Testing

3.9.1 Leakage Test - All areas where leakage to atmosphere may occur are to be

checked, using a commercial leak testing solution.

CAUTION: DO NOT EXCEED OPERATING 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.

3.9.2 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.

3.9.3 Apply NOP pressure to the pressure port in inner end cap (3-10) and allow the

actuator to stabilize.

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

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

cylinder to inner end cap O-ring seal.

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

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

NOTE:

If excessive leakage across the piston remains, the actuator must be disassembled and the

cause of leakage must be determined and corrected.

3.9.4.3 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).

3.9.4.4 Remove pressure from the pressure inlet port.

Service Instructions

124840E Rev. G

March 2017

Section 3: Actuator Reassembly

Actuator Reassembly

3.9.5 If an actuator was disassembled and repaired, the above leakage test must be

performed again.

3.9.6 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.

March 2017

Service Instructions

124840E Rev. G

Section 4: Field Conversions

Field Conversions

Section 4: Field Conversions

4.1 Fail Mode Reversal (CW to CCW, Or CCW to

CW) For G and GH Only

NOTE:

GC/GHC actuators must not undergo fail mode reversal without specic knowledge and

acceptance of the resulting torque output. If a symetrical yoke is being used during the

process, then fail mode reversal will not affect the torque output.

4.1.1 Remove spring module per Section 5.1.

4.1.2 Remove pneumatic power module per Section 5.3.

4.1.3 Reinstall the spring module onto the opposite end of housing (1-10), as it was

previously located per Section 5.2.

4.1.4 Reinstall the pneumatic power module onto the opposite end of housing (1-10) as

it was previously located per Section 5.4.

4.2 Converting Double-Acting Actuator

to Spring-Return

4.2.1 Remove the blind end cap module per Section 2.4.

4.2.2 If pneumatic power module needs to be relocated due to fail mode requirements

(fail counter-clockwise) use Section 5.3 for removal and Section 5.4 for installation.

NOTE:

Skip step 4.2.3 when working on G01-SR models and continue at step 4.2.4.

4.2.3 Install the SR Powr Swivl Module per Section 5.6.

4.2.4 Install the spring module per Section 5.2.

4.3 Converting Spring-Return Actuator

to Double-Acting

4.3.1 Remove the spring cartridge per Section 5.1.

4.3.2 If pneumatic power module needs to be relocated due to fail mode requirements

(fail counter-clockwise) use Section 5.3 for removal and Section 5.4 for installation.

NOTE:

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

Service Instructions

124840E Rev. G

March 2017

Section 4: Field Conversions

Field Conversions

4.3.3 Remove the spring cartridge Powr Swivl Module per Section 5.5.

4.3.4 Install the blind end cap module per Section 3.5.

4.4 Add an M3 Jackscrew to Blind End Cap Module

4.4.1 Remove blind end cap module per Section 2.4.

4.4.2 If new M3 blind end cap module is not pre assembled with the M3 then assembly

M3 to the blind end cap (5-10) per Section 3.6 steps 3.6.1 or 3.6.2.

4.4.3 Install the assembled M3 blind end cap module per Section 3.5.

4.4.4 To install the M3 Handwheel or M3 drive hub refer to Section 3.7.

4.5 Add an M3 Jackscrew to Power Module Outer End Cap

4.5.1 Remove outer end cap (3-80) per Section 2.2 steps 2.2.5 and 2.2.6.

4.5.2 If new M3 outer end cap (3-80) is not pre assembled with the M3 then assembly

M3 to the outer end cap (3-80) per Section 3.3 steps 3.3.22.1 or 3.3.22.2.

4.5.3 Install the assembled M3 outer end cap (3-80) per Section 3.3 steps 3.3.23.1.11 or

3.3.22.2.11 and 3.3.24 through 3.3.26.

4.5.4 To install the M3 Handwheel or M3 drive hub refer to Section 3.7.

4.6 Add an M3 Jackscrew to Spring Module

4.6.1 Remove G-SR (7-10) adapter plate per Section 5.1 steps 5.1.2 and 5.1.3.

4.6.2 If new M3 G-SR adapter plate (7-10) is not pre assembled with the M3 then

assembly M3 to the G-SR cover plate (7-10) per Section 3 steps 3.6.3 or 3.6.4.

4.6.3 Install the assembled M3 adapter plate (7-10) onto the spring cartridge out end

per Section 5.2 steps 5.2.11 through 5.2.15.

4.6.4 To install the M3 Handwheel or M3 drive hub refer to Section 3.7.

4.7 Add an Extended Stop (ES) to Blind

End Cap Module

4.7.1 Remove blind end cap module per Section 2.4.

4.7.2 If new ES blind end cap module is not pre assembled with the ES then assembly ES

to the blind end cap per Section 3.8.

4.7.3 Install the assembled ES blind end module per Section 3.5.

4.8 Add an Extended Stop (ES) to Power Module

Outer End Cap

4.8.1 Remove outer end cap per Section 2.2 steps 2.2.5 and 2.2.6.

4.8.2 If new ES outer end cap is not pre assembled with the ES then assembly ES to the

end cap per Section 3.8.

4.8.3 Install the assembled ES outer end (3-80) per Section 3.3 steps 3.3.22.3, 3.3.24

through 3.3.26.

March 2017

Service Instructions

124840E Rev. G

Section 4: Field Conversions

Field Conversions

4.9 Add an Extended Stop (ES) to Spring Module

4.9.1 Remove G-SR (7-10) adapter plate per Section 5.1 steps 5.1.2 and 5.1.3.

4.9.2 If new ES G-SR adapter plate (7-10) is not pre assembled with the ES then assembly

ES to the G-SR cover plate as follows:

4.9.2.1 Install ES stud (7-40) into adapter plate (7-10).

4.9.2.2 Install O-ring seal (6–30) onto outboard end of ES (7-40) and up against

outboard side of adapter plate (7-10).

4.9.2.3 Install stop screw nut (7-50) onto outboard end of ES (7-40).

4.9.3 Install the assembled ES adapter plate (7-10) onto the spring cartridge out end per

Section 5.2 steps 5.2.11 through 5.2.15.

Service Instructions

124840E Rev. G

March 2017

Section 5: Module Removal and Installation

Module Removal and Installation

Section 5: Module Removal and Installation

NOTE:

When the spring module is to be removed it should be removed from the drive module prior to the pneu-

matic power module removal or disassembly.

WARNING: DO NOT REMOVE COMPRESSED SPRING

Do not remove spring module while spring is compressed.

WARNING: READ WARNING TAGS

Actuators equipped with a spring cartridge mounted M3 jackscrew or an extended stop (ES) read warning

tag wired to the spring cartridge cover plate.

5.1 Spring Module Removal

WARNING: DO NOT REMOVE COMPRESSED SPRING

Do not remove spring module while spring is compressed.

NOTE:

Review section 2.1 General Disassembly before proceeding with Spring Module Disassembly.

NOTE:

The setting of stop screws (1-180) should be checked and setting recorded before stop

screws are loosened or removed.

NOTE:

G2-SRF and G3-SRF use step 5.1.1. G01-SR, G2-SR, G3-SR through G13 skip step 5.1.1 and

start at step 5.1.2.

5.1.1 G2-SRF and G3-SRF unscrew and remove pipe plug (7-10) from spring cartridge

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

WARNING: CAREFULLY MOUNT ON COVER PLATE

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

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

March 2017

Service Instructions

124840E Rev. G

Section 5: Module Removal and Installation

Module Removal and Installation

5.1.2 Unscrew hex cap screws (7-20) with lockwashers (7-30) from cover plate (7-10) or

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

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

5.1.3 Remove the cover plate (7-10) from spring cartridge assembly (5-10).

5.1.4 Apply pneumatic pressure to inner end cap (2-40) port “A” to compress the spring

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

module.

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

next to spring module.

5.1.6 Unscrew stop screw (1-180) that is closest to or next to spring module (unscrew or

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

5.1.7 Remove pneumatic pressure from pressure inlet port of inner end cap (3-10).

CAUTION: CAREFULLY MOUNT ON COVER PLATE

Due to the weight and size of spring cartridge assembly (5-10), heavy duty support

equipment will be required when removing spring cartridge assembly from the actuator

housing. Refer to section 6 for spring cartridge module weights.

5.1.8 The spring cartridge "pre-load" must be removed before spring cartridge assembly

(5-10) is removed from housing (1-10). Refer to steps 5.1.4 through 5.1.6 for

spring cartridge "pre-load" removal.

5.1.9 Remove breather assembly (12) from outer end cap (3-80) port “B”.

CAUTION: DO NOT EXCEED OPERATING PRESSURE

The maximum pressure to be applied in step 5.1.10 is 25 PSIG.

5.1.10 Apply pneumatic pressure, not to exceed the maximum as indicated in the above

“CAUTION”, to the pressure inlet port “B” of outer end cap (3-80) to move the

spring cartridge tension rod hex nut out of its cast hex seat.

NOTE:

If pneumatic pressure is not available to apply to the pressure inlet port “B” located in outer

end cap (3-80) then remove pipe plug (3-120) or if equipped with an extended stop (ES)

remove the ES. Using a long rod go through the outer end cap pipe plug or ES vacant port

hole and push on the piston rod so as to move the spring cartridge tension rod hex nut out

of its cast hex seat.

5.1.11 Unscrew the spring cartridge tension rod from the drive module. The tension rod

can be rotated for removal by going through the open end of spring cartridge

assembly with a square male drive extension.

5.1.12 Remove hex cap screws (5-20) with lockwashers (5-30) from housing (1-10).

5.1.13 Remove spring cartridge assembly (5-10) from actuator housing (1-10).

Service Instructions

124840E Rev. G

March 2017

Section 5: Module Removal and Installation

Module Removal and Installation

WARNING: DO NOT CUT SPRING CARTRIDGE

Under no circumstances should the spring cartridge assembly (5-10) be cut apart, as the

spring is pre-loaded and the spring cartridge is a weld assembly.

5.2 Spring Module Installation

CAUTION: USE LIFTING EQUIPMENT

Due to the weight and size of spring module, heavy duty support equipment will be

required when installing spring cartridge module to the actuator housing. For the

approximate weight of the spring cartridge refer to Section 6.

WARNING: CHECK OVERTRAVEL POSITION

Actuator must be in the appropriate overtravel position (Refer to detail “A” on warning

tag attached to spring module access hole cover or to Bettis drawing part number 130084

for G01 models or part number 123650 for G2 through G13 models). Conrm over-travel

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

NOTE:

The setting of stop screws (1-180) should be checked and setting recorded before stop

screws are loosened or removed.

5.2.1 On stop screw (1-180), that is located on the same side of the housing as spring

cartridge (5-10), loosen stop screw nut (1-190).

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

detail “A” on warning tag attached to spring module cover plate or to Bettis

drawing part number 123650.

5.2.3 Install O-ring seal (6-20) into the O-ring groove in the inboard end of spring

cartridge assembly (5-10).

5.2.4 Using lifting equipment move spring module up to housing (1-10) and align spring

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

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

WARNING: EXECUTE STEPS CAREFULLY

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

5.2.5 SPRING CARTRIDGE TENSION ROD TO ROD EXTENSION INSTALLATION AS

FOLLOWS:

5.2.5.1 Using a male square drive extension, go through the open end of

spring odule (5-10) and rotate the tension rod nut until initial thread

engagement is achieved.

March 2017

Service Instructions

124840E Rev. G

Section 5: Module Removal and Installation

Module Removal and Installation

NOTE:

Conrm initial thread engagement of rod extension (9-50) to tension rod; or for

GH/GHC models, conrm initial thread engagement of tension rod to guide block.

5.2.5.2 After conrming initial thread engagement rotate tension rod into

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

WARNING: CHECK TENSION ROD TURNS

After initial thread engagement the tension rod must be rotated clockwise the minimum

number of turns listed in the following table.

Table 7. Rod Rotation

ACTUATOR

MODEL

G/GC/GH/GHC

1 2 3 4 5 7 8 10 G13

MINIMUM NO

TURNS 6 10 10 10 13 14 20 25 31

WARNING: CHECK TENSION ROD INSTALLATION

When screwing tension rod into extension rod assembly (9-50) make certain that the

tension rod and extension rod assembly threads do not cross-thread.

5.2.6 Torque tighten the spring cartridge tension rod as listed in the following table.

Table 8. Spring Cartridge Tension Rod Torque Table

HOUSING

MODEL

G/GC/GH/

GHC

TORQUE

(±5 % Percent)

HOUSING

MODEL

G/GC/GH/

GHC

TORQUE

(±5 % Percent)

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

G01 50 68 7 240 325

2 90 122 8 240 325

3 90 122 10 240 325

4 240 325 G13 240 325

5 240 325

5.2.7 Install lock washers (5-30) onto hex cap screws (5-20).

5.2.8 Install hex cap screws (5-20) with lockwashers (5-30) through housing (1-10) and

into spring cartridge assembly (5-10) and tighten.

5.2.9 Install O-ring seal (6-10) into the O-ring groove in the outboard end of spring

cartridge assembly (5-10).

Service Instructions

124840E Rev. G

March 2017

Section 5: Module Removal and Installation

Module Removal and Installation

NOTE:

G2-SRF and G3-SRF use step 5.2.10. G01-SR, G2-SR, G3-SR through G13-SR skip step

5.2.10 and start at step 5.2.11.

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

board end of spring cartridge assembly (5-10). Skip steps 5.2.10 through 5.2.13

and start at step 5.2.14.

5.2.11 Install lockwashers (7-30) onto hex cap screws (7-20).

5.2.12 Install the cover plate (7-10) or install M3 adapter plate (7-10) onto the outboard

end of spring cartridge assembly (5-10).

5.2.13 Install and tighten hex cap screws (7-20) with lockwashers (7-30) through cover

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

5.2.14 Torque tighten hex cap screws (7-20) until a nal lubricated torque, as listed in the

following table, has been achieved.

Table 9. Hex Cap Screws (7-20) Torque Table

HOUSING

MODEL

G/GC/GH/

GHC

TORQUE

(±5 % Percent)

HOUSING

MODEL

G/GC/GH/

GHC

TORQUE

(±5 % Percent)

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

G01 30 41 7 135 183

2 30 41 8 240 325

3 30 41 10 285 386

4 65 88 G13 340 461

5 65 88

5.2.15 On M3, M3HW and ES models install Monel wire (6-130) through each hex cap

screw (7-20) per the following steps:

NOTE:

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

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

5.2.15.1 Make sure hex cap screws are tightened to their specied torque.

5.2.15.2 Using required lengths of .31 diameter Monel wire as provided in the

module ordered. When replacing Monel wire use the following table for

wire length requirements.

March 2017

Service Instructions

124840E Rev. G

Section 5: Module Removal and Installation

Module Removal and Installation

Table 10. Wire Length Requirements

MODEL

G/GC/

GH/GHC

LENGTH MODEL

G/GC/

GH/GHC

LENGTH

Inch mm Inch mm

G01-SR 36 914.4 5-SR 66 1676.4

2-SR 44 1117.6 7-SR 79 2006.6

3-SR 48 1219.2 8-SR 88 2235.2

4-SR 55 1397.0 G10-SR 110 2794.0

5.2.15.3 Twist the end of both wires together and insert one through the drilled

hole in the hex cap screw head, pass the second wire over the screw head

and twist it three (3) times around the rst wire at a location where the

rst wire exits the screw head.

5.2.15.4 Repeat the procedure until the second wire is twist tied to the screw head

through wire of the last screw head.

5.2.15.5 Attach caution tag and twist tie the wires from the last screw head to the

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

Figure 1 Tag Attachment Guide

TWIST FOUR ENDS

TOGETHER

TAG

Service Instructions

124840E Rev. G

March 2017

Section 5: Module Removal and Installation

Module Removal and Installation

5.2.16 If removed install stop screw nuts (1-190) onto stop screws (1-180).

5.2.17 If removed install O-ring (2-90) onto stop screws (1-180).

5.2.18 If removed install two stop screws (1-180) into two stop screw holes on the front

of housing (1-10).

5.2.19 Adjust both stop screws (1-180) back to settings recorded earlier in Section 5.

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

5.3 Pneumatic Power Module Removal

CAUTION: USE LIFTING EQUIPMENT

Due to the weight and size of spring module, heavy duty support equipment will be

required when installing spring cartridge module to the actuator housing. For the

approximate weight of the spring cartridge refer to Section 6.

5.3.1 Standard Outer end cap with pipe plug use step 5.3.1.1, outer end cap with

extended stop (ES) use step 5.3.1.2, G2 or G3 outer end cap with M3 or M3HW use

step 5.3.1.3 and G01 outer end cap with M3 or M3HW use step 5.3.1.4.

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

5.3.1.2 ES outer end cap:

5.3.1.2.1 Loosen ES nut (3-190).

5.3.1.2.2 Unscrew ES (3-180) and remove from outer end cap (3-80).

5.3.1.3 G2 or G3 M3/M3HW outer end cap:

5.3.1.3.1 Remove socket cap screws (3-320) from M3 adapter (3-280).

5.3.1.3.2 Remove M3 adapter (3-280) from outer end cap (3-80).

5.3.1.4 G01M3/M3HW outer end cap:

5.3.1.4.1 Remove socket cap screw (3-130) from M3 keeper (3-360).

5.3.1.4.2 Remove M3 keeper (3-360) from M3 adapter (3-360) and outer

end cap (3-80).

5.3.1.4.3 Remove M3 jackscrew (3-290) with M3 adapter (3-360) from

outer end cap (3-80).

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

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

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

NOTE:

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

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

March 2017

Service Instructions

124840E Rev. G

Section 5: Module Removal and Installation

Module Removal and Installation

5.4 Pneumatic Power Module Installation

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

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

NOTE:

G2 and G3 models (older 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).

5.4.2 Using lifting equipment move the power module up to the drive module and align

piston rod (3-40) as follows:

5.4.2.1 G2 through G13 models align piston rod (3-40) with power module

extension rod assembly (1-50).

5.4.2.2 G01 models align piston rod (3-40) with the drive module guide block

(1-30).

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

piston rod (3-40) as follows:

WARNING: CHECK TENSION ROD TURNS

After initial thread engagement the tension rod must be rotated clockwise the minimum

number of turns listed in the following table.

Table 11. Rod Rotation

ACTUATOR

MODEL

G/GC/GH/GHC

1 2 3 4 5 7 8 10 G13

MINIMUM

NO. TURNS 6 10 10 10 13 14 20 25 31

5.4.3.1 G2 through G13 screw piston rod (3-40) onto extension rod assembly (1-

50). GH/GHC2 through GH/GHC10, screw Piston Rod (3-40) directly into

Guide Block (1-30)

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

CAUTION: DO NOT CROSS THREAD PISTON RODS

When screwing piston rod into the G2 through G13 extension rod assembly (1-50) and G/

GC/GH/GHC piston rod into guide block (1-30) or G01 guide block (1-30) make certain that

the piston rod and extension rod assembly/guide block threads do not cross-thread.

5.4.4 Torque tighten piston rod (3-40). Refer to Section 3 step 3.3.2 for correct torque

value.

Service Instructions

124840E Rev. G

March 2017

Section 5: Module Removal and Installation

Module Removal and Installation

Table 12. Spring Cartridge Tension Rod Torque Table

HOUSING

MODEL

G/GC/GH/

GHC

TORQUE

(±5 % Percent)

HOUSING

MODEL

G/GC/GH/

GHC

TORQUE

(±5 % Percent)

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

G01 90 122 7 240 325

2 90 122 8 240 325

3 90 122 10 240 325

4 240 325 G13 240 325

5 240 325

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

5.4.6 Install hex cap screws (3-100) with lockwashers (3-110) through housing (1-10)

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

5.4.7 Standard Outer end cap with pipe plug use step 5.4.7.1, outer end cap with

extended stop (ES) use step 5.4.7.2, G2 or G3 outer end cap with M3 or M3HW use

step 5.4.7.3 and G01 outer end cap with M3 or M3HW use step 5.4.7.4.

5.4.7.1 Standard outer end cap - Using pipe dope, install pipe plug (3-120) into

outer end cap (3-80).

5.4.7.2 ES outer end cap:

5.4.7.2.1 Screw ES (3-180) into outer end cap (3-80).

5.4.7.2.2 Install ES nut (3-190) on to ES (3-180).

5.4.7.3 G2 or G3 M3/M3HW outer end cap:

5.4.7.3.1 Install M3 adapter (3-280) into outer end cap (3-80).

5.4.7.3.2 Install socket cap screws (3-320) through M3 adapter (3-280)

and into outer end cap (3-80).

5.4.7.4 G01M3/M3HW outer end cap:

5.4.7.4.1 Remove socket cap screw (3-130) from M3 keeper (3-360).

5.4.7.4.2 Remove M3 keeper (3-360) from M3 adapter (3-360) and outer

end cap (3-80).

5.4.7.4.3 Remove M3 jackscrew (3-290) with M3 adapter (3-360) from

outer end cap (3-80).

March 2017

Service Instructions

124840E Rev. G

Section 5: Module Removal and Installation

Module Removal and Installation

5.5 G2 Thru G13 Powr Swivl Removal

(Excludes GH/GHC Model Actuators)

CAUTION: MAINTAIN GUIDE BAR RETENTION

While step 5.5.1 is in progress be sure to maintain guide bar retention when moving the guide block.

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

rod assembly (1-50).

NOTE:

The guide block can be moved by inserting a long non metallic rod through the

hole where the blind end cap was removed and pushing on the guide block.

5.5.2 Refer to Assembly Drawing page 2 of 2 Detail "B". Use Bettis tool part number as

listed in chart in section 1 step 1.2.1 to remove retainer nut assembly (1-60) from

the guide block (1-30).

CAUTION: DO NOT DROP SPHERICAL WASHERS

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

spherical washers inside the housing.

5.5.3 Remove rod extension assembly (1-50) from guide block (1-30).

NOTE:

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

assembly is removed.

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

5.6 G2 Thru G13 Powr Swivl Module Installation

(Excludes GH/GHC Model Actuators)

WARNING: CONFIRM OVER-TRAVEL POSITION

The actuator must be in the appropriate over-travel position. Conrm over-travel position

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

Service Instructions

124840E Rev. G

March 2017

Section 5: Module Removal and Installation

Module Removal and Installation

CAUTION: MAINTAIN GUIDE BAR RETENTION

While step 5.6.1 is in progress be sure to maintain guide bar retention when moving the guide block.

5.6.1 Push the guide block to the required side of the housing (1-10).

NOTE:

The guide block can be moved by inserting a long rod through either end of the

housing and pushing on the guide block.

5.6.2 Lubricate two spherical washers (1-40), and one extension rod assembly (1-50).

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

NOTE:

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

5.6.4 Install second spherical washer (1-40) over threaded end of extension rod assembly

(1-50).

NOTE:

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

head of the extension rod assembly.

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

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

5.6.6 Install extension retainer nut assembly (1-60) over extension rod assembly (1-50)

and screw into guide block (1-30).

5.6.7 Tighten extension retainer nut assembly (1-60) until extension rod assembly (1-

50) cannot move. Back off the extension retainer nut assembly (1-60) just enough

to allow for extension rod assembly (1-50) to move freely.

March 2017

Service Instructions

124840E Rev. G

Section 6: Actuator Support Information

Actuator Support Information

Section 6: Actuator Support Information

6.1 G/GC/GH/GHC Module Weights By Item

Number And Actuator Housing Size

Table 13. G/GC/GH/GHC Module Weights by Item Number and Actuator Housing Size

ITEM

NO.

G01

WT.

G13

WT.

MODULE

DESCRIPTION

1Lbs. 83 110 162 280 545 1025 1495 2550 4625 Drive Module

Kg 38 50 73 127 247 465 678 1157 2098

3Lbs. 69 N/A N/A N/A N/A N/A N/A N/A N/A 8” Dia. Power

Module

Kg 31 N/A N/A N/A N/A N/A N/A N/A N/A

3Lbs. 68 80 N/A N/A N/A N/A N/A N/A N/A 9” Dia. Power

Module

Kg 30.5 36 N/A N/A N/A N/A N/A N/A N/A

3Lbs. 75 73.5 88 N/A N/A N/A N/A N/A N/A 10” Dia. Power

Module

Kg 34 33 40 N/A N/A N/A N/A N/A N/A

3Lbs. 86 86 104 130 N/A N/A N/A N/A N/A 12” Dia. Power

Module

Kg 39 39 47 59 N/A N/A N/A N/A N/A

3Lbs. 96 96 114 145 N/A N/A N/A N/A N/A 14” Dia. Power

Module

Kg 44 44 51 66 N/A N/A N/A N/A N/A

3Lbs. N/A 135 145 168 295 N/A N/A N/A N/A 16” Dia. Power

Module

Kg N/A 61 66 76 134 N/A N/A N/A N/A

3Lbs. N/A N/A 235 260 305 585 N/A N/A N/A 20” Dia. Power

Module

Kg N/A N/A 107 118 138 265 N/A N/A N/A

3Lbs. N/A N/A N/A 340 410 735 911 N/A N/A 24” Dia. Power

Module

Kg N/A N/A N/A 154 186 334 413 N/A N/A

3Lbs. N/A N/A N/A 505 590 810 1225 1120 N/A 28” Dia. Power

Module

Kg N/A N/A N/A 229 268 367 556 508 N/A

3Lbs. N/A N/A N/A N/A 977 1100 1260 1440 N/A 32” Dia. Power

Module

Kg N/A N/A N/A N/A 443 499 572 653 N/A

3Lbs. N/A N/A N/A N/A 1243 1400 1525 1755 N/A 36” Dia. Power

Module

Kg N/A N/A N/A N/A 564 653 692 796 N/A

3Lbs. N/A N/A N/A N/A N/A N/A 1975 2205 - 40” Dia. Power

Module

Kg N/A N/A N/A N/A N/A N/A 896 1000 -

3Lbs. N/A N/A N/A N/A N/A N/A N/A N/A 3120 44” Dia. Power

Module

Kg N/A N/A N/A N/A N/A N/A N/A N/A 1415

3Lbs. N/A N/A N/A N/A N/A N/A N/A N/A - 48” Dia. Power

Module

Kg N/A N/A N/A N/A N/A N/A N/A N/A -

3Lbs. N/A N/A N/A N/A N/A N/A N/A N/A 4130 52” Dia. Power

Module

Kg N/A N/A N/A N/A N/A N/A N/A N/A 1873

5Lbs. 160 225 320 564 975 2740 3545 4975 10010 SR1 Spring

Module

Kg 73 102 145 256 442 1243 1608 2257 4541

5Lbs. 158 215 310 549 980 2630 2345 4515 9275 SR2 Spring

Module

Kg 72 98 141 249 445 1193 1064 2048 4207

Table 10 (continued).......

Service Instructions

124840E Rev. G

March 2017

Section 6: Actuator Support Information

Actuator Support Information

ITEM

NO.

G01

WT.

G13

WT.

MODULE

DESCRIPTION

5Lbs. 153 215 295 534 925 2410 3085 4095 8060 SR3 Spring

Module

Kg 153 98 295 534 925 2410 3085 4095 8060

5Lbs. 144 200 280 474 860 2210 N/A 3735 7325 SR4 Spring

Module

Kg 65 91 127 215 390 1002 N/A 1694 3323

5Lbs. N/A 200 N/A N/A N/A N/A N/A N/A N/A SRA5 Spring

Module

Kg N/A 91 N/A N/A N/A N/A N/A N/A N/A

5Lbs. N/A 180 N/A N/A N/A N/A N/A N/A N/A SRA6 Spring

Module

Kg N/A 82 N/A N/A N/A N/A N/A N/A N/A

5Lbs. N/A 220 310 N/A N/A N/A N/A N/A N/A SRF1 Spring

Module

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

5Lbs. N/A 210 300 N/A N/A N/A N/A N/A N/A SRF2 Spring

Module

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

5Lbs. N/A 210 285 N/A N/A N/A N/A N/A N/A SRF3 Spring

Module

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

5Lbs. N/A 195 270 N/A N/A N/A N/A N/A N/A SRF4 Spring

Module

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

5Lbs. N/A 205 N/A N/A N/A N/A N/A N/A N/A SRF5 Spring

Module

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

5Lbs. N/A 185 N/A N/A N/A N/A N/A N/A N/A SRF6 Spring

Module

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

6.2 G01 Tool Style and Wrench Size

Table 14. G01 Tool Style and Wrench Size

ITEM

NO.

WRENCH

SIZE

ITEM

QTY LOCATION OR DESCRIPTION RECOMMENDED TOOL STYLE

1-110 9/16" 4 Hex Cap Screws Socket

1-160 1/2" 4 Hex Cap Screws Socket

1-180 3/8” Sq. 2 Stop Screws Open End or Adjustable

1-190 1-15/16” 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

5-20 9/16” 4 Hex Cap Screws Socket

7-20 9/16” 4 Hex Cap Screws Socket

12 1” 1 Breather Assembly Socket

13 3/4” 2 Vent Check Assembly Open End

- 3/8” Sq. 1 Tension rod Male Drive Extension

March 2017

Service Instructions

124840E Rev. G

Section 6: Actuator Support Information

Actuator Support Information

6.3 G/GC2 Tool Style and Wrench Size

Table 15. G/GC2 Tool Style and Wrench Size

ITEM

NO.

WRENCH

SIZE

ITEM

QTY LOCATION OR DESCRIPTION RECOMMENDED TOOL STYLE

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

5-20 9/16” 6 Hex Cap Screws Socket

7-20 9/16” 4 Hex Cap Screws Socket

12 1” 1 Breather Assembly Socket

13 3/4” 2 Vent Check Assembly Open End

- 3/8” Sq. 1 Tension rod Male Drive Extension

6.4 G/GC3 Tool Style and Wrench Size

GH2/GHC2 for Item No 3-20 to 3-130

Table 16. G/GC3 Tool Style and Wrench Size, GH2/GHC2 for Item No 3-20 to 3-130

ITEM

NO.

WRENCH

SIZE

ITEM

QTY LOCATION OR DESCRIPTION RECOMMENDED TOOL STYLE

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 Extension

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

5-20 9/16” 6 Hex Cap Screws Socket

7-20 9/16” 4 Hex Cap Screws Socket

12 1” 1 Breather Assembly Socket

13 3/4” 2 Vent Check Assembly Open End

- 3/8” Sq. 1 Tension rod Male Drive Extension

Service Instructions

124840E Rev. G

March 2017

Section 6: Actuator Support Information

Actuator Support Information

6.5 G/GC4 Tool Style and Wrench Size

GH3/GHC3 For Item No 3-20 to 3-130

Table 17. G/GC4 Tool Style and Wrench Size GH3/GHC3 for Item No 3-20 to 3-130

ITEM

NO.

WRENCH

SIZE

ITEM

QTY LOCATION OR DESCRIPTION RECOMMENDED TOOL STYLE

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 Extension

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

5-20 3/4" 6 Hex Cap Screws Socket

7-20 9/16” 4 Hex Cap Screws Socket

12 1” 1 Breather Assembly Socket

13 3/4" 2 Vent Check Assembly Open End

- 3/4” 1 Tension rod Male Drive Extension

6.6 G/GC5 Tool Style and Wrench Size

GH4/GHC4 For Item No 3-20 to 3-130

Table 18. G/GC5 Tool Style and Wrench Size GH4/GHC4 for Item No 3-20 to 3-130

ITEM

NO.

WRENCH

SIZE

ITEM

QTY LOCATION OR DESCRIPTION RECOMMENDED TOOL STYLE

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 Extension

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

5-20 3/4” 8 Hex Cap Screws Socket

7-20 9/16” 4 Hex Cap Screws Socket

12 1” 1 Breather Assembly Socket

13 3/4” 2 Vent Check Assembly Open End

- 3/4” 1 Tension rod Male Drive Extension

March 2017

Service Instructions

124840E Rev. G

Section 6: Actuator Support Information

Actuator Support Information

6.7 G/GC7 Tool Style and Wrench Size

GH5/GHC5 For Item No 3-20 to 3-130

Table 19. G/GC7 Tool Style and Wrench Size GH5/GHC5 for Item No 3-20 to 3-130

ITEM

NO.

WRENCH

SIZE

ITEM

QTY LOCATION OR DESCRIPTION RECOMMENDED TOOL STYLE

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) Male Drive Extension

3-40 3/4” Sq. 1 Piston Rod Male Drive Extension

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

5-20 15/16” 8 Hex Cap Screws Socket

7-20 9/16” 8 Hex Cap Screws Socket

12 1" 1 Breather Assembly Socket

13 3/4” 2 Vent Check Assembly Open End

- 3/4” 1 Tension rod Male Drive Extension

6.8 G/GC8 Tool Style and Wrench Size

GH7/GHC7 For Item No 3-20 to 3-130

Table 20. G/GC8 Tool Style and Wrench Size GH7/GHC7 for Item No 3-20 to 3-130

ITEM

NO.

WRENCH

SIZE

ITEM

QTY LOCATION OR DESCRIPTION RECOMMENDED TOOL STYLE

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) Male Drive Extension

3-40 3/4” Sq. 1 Piston Rod Male Drive Extension

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

5-20 1-1/8” 8 Hex Cap Screws Socket

7-20 1-1/8” 8 Hex Cap Screws Socket

12 1” 1 Breather Assembly Socket

13 3/4” 2 Vent Check Assembly Open End

- 3/4” 1 Tension rod Male Drive Extension

Service Instructions

124840E Rev. G

March 2017

Section 6: Actuator Support Information

Actuator Support Information

6.9 G/GC10 Tool Style and Wrench Size

GH8/GHC8 For Item No 3-20 to 3-130

Table 21. G/GC10 Tool Style and Wrench Size GH8/GHC8 for Item No 3-20 to 3-130

ITEM

NO.

WRENCH

SIZE

ITEM

QTY LOCATION OR DESCRIPTION RECOMMENDED TOOL STYLE

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) Male Drive Extension

3-40 3/4” Sq. 1 Piston Rod Male Drive Extension

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

5-20 1-1/8” 8 Hex Cap Screws Socket

7-20 1-5/16” 8 Hex Cap Screws Socket

12 1” 1 Breather Assembly Socket

13 3/4” 2 Vent Check Assembly Open End

- 3/4” 1 Tension rod Male Drive Extension

6.10 G13 Tool Style and Wrench Size

GH10/GHC10 For Item No 3-20 to 3-130

Table 22. G13 Tool Style and Wrench Size GH10/GHC10 for Item No 3-20 to 3-130

ITEM

NO.

WRENCH

SIZE

ITEM

QTY LOCATION OR DESCRIPTION RECOMMENDED TOOL STYLE

1-110 1-1/8” 20 Hex Cap Screws Socket

1-120 1-1/8” 4 Hex Cap Screws Socket

1-160 9/16” 12 Hex Cap Screws Socket

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

3-20 3/4” Sq. 2 Tie Bar (female square) Male Drive Extension

3-40 3/4” Sq. 1 Piston Rod Male Drive Extension

3-90 4-1/4” 2 Heavy Hex Nuts Socket

3-100 1-11/16” 8 Hex Cap Screws Socket

3-120 1-7/8” Sq. 1 Pipe Plug Open End or Adjustable

3-130 3/16” 2 Socket Cap Screws Allen

5-20 1-13/16” 8 Hex Cap Screws Socket

7-20 1-1/8” 8 Hex Cap Screws Socket

12 1” 1 Breather Assembly Socket

13 3/4” 2 Vent Check Assembly Open End

- 3/4” 1 Tension rod Male Drive Extension

March 2017

Service Instructions

124840E Rev. G

Section 7: Troubleshooting

Troubleshooting

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 23. Fault Location Table

SYMPTOM POTENTIAL CAUSES REMEDY

Erratic movement

Irregular supply of operating

medium

Check operating medium for consistent

supply pressure and correct as necessary

Inadequate lubrication Dismantle, relubricate and reassemble

Worn parts

Dismantle. Visually inspect for

signicant wear. Actuator replacement

may be required

Defective valve Consult the valve OEM's documentation

Short stroke

Incorrectly set stops

(valve and /or actuator)

Check the position of the travel stops and

readjust as necessary

Hardened grease Dismantle, remove any hard grease,

Relubricate and reassemble

Debris left in the cylinder or

housing during maintenance

Disassemble cylinder assembly to remove

debris. Reassemble cylinder assemble as

necessary

Defective valve Consult the valve manufacturer's

documentation

Apparent lack

of torque

Inadequate supply pressure

Ensure supply pressure is above the minimum

operating pressure of the actuator and that

output torque produced at supply pressure

exceeds valve torque demand

Incorrect speed control settings Adjust speed controls to increase ow

Exhaust port blocked Remove and clean the exhaust port silencers

and replace

Pipe work blocked, crushed

or leaking

Examine the pipe work for blockages,

crushed pipe or leakage. Clear or replace as

necessary

Defective controls

Examine the controls, refurbish or renew as

necessary. Refer to component

manufacturer's documentation

Defective piston seal

Dismantle the cylinder assembly, remove

the defective piston seal. Fit new seal and

reassemble

Defective rod seal Dismantle the cylinder assembly, remove the

defective rod seal. Fit new seal and reassemble

Defective housing seal

Dismantle the housing assembly, remove the

defective seal. Fit new seal

and reassemble

High valve torque or valve seized Consult the valve OEM documentation

Service Instructions

124840E Rev. G

March 2017

Section 7: Troubleshooting

Troubleshooting

7.2 Operational Test

7.2.1 Full Stroke Test

The “Full Stroke Test” (“On-line”) must be performed to satisfy the PFDAVG (average

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 PFDAVG value

and to satisfy PFDAVG (average probability of failure on demand) value. A typical

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

cycles 15% of the stroke.

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

locally, or automatically via logic solver, or via the PST system

the correct movement of the actuator/valve was 15% of the

stroke).

NOTE:

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

March 2017

Service Instructions

124840E Rev. G

Section 8: Removal and Decommissioning

Removal and Decommissioning

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.

Service Instructions

124840E Rev. G

March 2017

Section 9: Document Revision

Document Revision

Section 9: Document Revision

Table 24. Revision Overview

ECN DATE REV BY * DATE

Released Sept.1998 A B. Cornelius Sept.1998

17787 Dec. 2001 B UPDATED C. Ross Dec. 2001

18190 Aug. 2003 C UPDATED B. Jumawan Aug. 2003

VAWCO252 Dec. 2009 D UPDATED D. Blahnik Dec. 2009

VAWCO1779 Nov. 2012 E UPDATED C. Rico Nov. 2012

VAWCO2746 June 2015 F UPDATED C. Rico June 2015

* Signatures on le Bettis, Houston, Texas

March 2017

Service Instructions

124840E Rev. G

Appendix

Appendix A: List of Tables

Table 1 Rod Extension Retainer Nut Tool Part Number ....................................................... 3

Table 2 Housing Cover Screw Quantity and Torque Table ................................................. 20

Table 3 Piston Rod Torque Information ............................................................................ 22

Table 4 Torque Tighten Piston Rod .................................................................................. 22

Table 5 Tie Bar Nuts ......................................................................................................... 25

Table 6 Early G2 and G3 Tie Bar Nuts ............................................................................... 28

Table 7 Rod Rotation ....................................................................................................... 40

Table 8 Spring Cartridge Tension Rod Torque Table ......................................................... 40

Table 9 Hex Cap Screws (7-20) Torque Table .................................................................... 41

Table 10 Wire Length Requirements .................................................................................. 42

Table 11 Rod Rotation ....................................................................................................... 44

Table 12 Spring Cartridge Tension Rod Torque Table ......................................................... 45

Table 13 G/GC/GH/GHC Module Weights By Item Number And Actuator Housing Size ...... 48

Table 14 G01 Tool Style and Wrench Size ........................................................................... 49

Table 15 G/GC2 Tool Style and Wrench Size ....................................................................... 50

Table 16 G/GC3 Tool Style and Wrench Size GH2/GHC2 For Item No 3-20 to 3-130 ........... 50

Table 17 G/GC4 Tool Style and Wrench Size GH3/GHC3 For Item No 3-20 to 3-130 ........... 51

Table 18 G/GC5 Tool Style and Wrench Size GH4/GHC4 For Item No 3-20 to 3-130 ........... 51

Table 19 G/GC7 Tool Style and Wrench Size GH5/GHC5 For Item No 3-20 to 3-130 ........... 52

Table 20 G/GC8 Tool Style and Wrench Size GH7/GHC7 For Item No 3-20 to 3-130 ........... 52

Table 21 G/GC10 Tool Style and Wrench Size GH8/GHC8 For Item No 3-20 to 3-130 ......... 53

Table 22 G13 Tool Style and Wrench Size GH10/GHC10 For Item No 3-20 to 3-130 ........... 53

Table 23 Fault Location Table ............................................................................................. 54

Table 24 Revision Overview ............................................................................................... 57

Service Instructions

124840E Rev. G

March 2017

Appendix

Appendix B: List of Drawings

B.1 Part No. 116422, GXXXX Pneumatic Assembly

Drawing, Sheet 1 of 2

March 2017

Service Instructions

124840E Rev. G

Appendix

B.2 Part No. 116422, GXXXX Pneumatic Assembly

Drawing, Sheet 2 of 2

Service Instructions

124840E Rev. G

March 2017

Appendix

B.3 Part No. 115678, GXX2XX Pneumatic Assembly

Drawing, Sheet 1 of 2

March 2017

Service Instructions

124840E Rev. G

Appendix

B.4 Part No. 115678, GXX2XX Pneumatic Assembly

Drawing, Sheet 2 of 2

Service Instructions

124840E Rev. G

March 2017

Appendix

B.5 Part No. 115674, GXXXX-SRX Pneumatic

Assembly Drawing, Sheet 1 of 2

March 2017

Service Instructions

124840E Rev. G

Appendix

B.6 Part No. 115674, GXXXX-SRX Pneumatic

Assembly Drawing, Sheet 2 of 2

Service Instructions

124840E Rev. G

March 2017

Appendix

B.7 Part No. 140952, GH/GHCXXXX-SRX Pneumatic

Assembly Drawing, Sheet 1 of 2

March 2017

Service Instructions

124840E Rev. G

Appendix

B.8 Part No. 140952, GH/GHCXXXX-SRX Pneumatic

Assembly Drawing, Sheet 2 of 2

For complete list of sales and manufacturing sites, please visit

www.emerson.com/actuationtechnologieslocations or contact us at

info.actuationtechnologies@emerson.com

World Area Configuration Centers (WACC) offer sales support, service,

inventory and commissioning to our global customers.

Choose the WACC or sales office nearest you:

NORTH & SOUTH AMERICA

19200 Northwest Freeway

Houston TX 77065

USA

T +1 281 477 4100

F +1 281 477 2809

Av. Hollingsworth

325 Iporanga Sorocaba

SP 18087-105

Brazil

T +55 15 3238 3788

F +55 15 3228 3300

ASIA PACIFIC

No. 9 Gul Road

#01-02 Singapore 629361

T +65 6777 8211

F +65 6268 0028

No. 1 Lai Yuan Road

Wuqing Development Area

Tianjin 301700

P. R. China

T +86 22 8212 3300

F +86 22 8212 3308

MIDDLE EAST & AFRICA

P. O. Box 17033

Dubai

United Arab Emirates

T +971 4 811 8100

F +971 4 886 5465

P. O. Box 10305

Jubail 31961

Saudi Arabia

T +966 3 340 8650

F +966 3 340 8790

24 Angus Crescent

Longmeadow Business Estate East

P.O. Box 6908 Greenstone

1616 Modderfontein Extension 5

South Africa

T +27 11 451 3700

F +27 11 451 3800

EUROPE

Berenyi u. 72- 100

Videoton Industry Park

Building #230

Székesfehérvár 8000

Hungary

T +36 22 53 09 50

F +36 22 54 37 00

www.emerson.com/bettis

The Emerson logo is a trademark and service mark of Emerson Electric Co.

BettisTM is a mark of one of the Emerson family of companies.

All other marks are property of their respective owners.

The contents of this publication are presented for information purposes

only, and while every effort has been made to ensure their accuracy,

they are not to be construed as warranties or guarantees, express or

implied, regarding the products or services described herein or their use

or applicability. All sales are governed by our terms and conditions, which

are available on request. We reserve the right to modify or improve the

designs or specifications of our products at any time without notice.

BETTIS G13 D102754x012

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