Emerson 117368 Disassembly And Reassembly Download Page 27

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October 2015

Service Instructions

127072E Rev. C

Section 5: Module Removal and Installation

Module Removal and Installation

NOTE:

To identify hex cap screws (7-100) from hex cap screws (7-80), hex cap screws (7-100) will

be located to the left and right of spring-return cartridge top dead center and will then be

counted as every other hex cap screw. To verify correct hex cap screws check the following

table for screw length.

Table 4�

Wire Length Requirements

MODEL

G/GC/GH/

GHC

ITEM 7-80 LENGTH

ITEM 7-100 LENGTH

Inches

50.8

2.75

69.85

76.2

4.5

114.3

G10

3.5

88.9

5.0

127

5�1�6�2

Remove override cylinder assembly from spring cartridge assembly (5-10).

5�2

M11 Override Cylinder Installation

5�2�1

Install O-ring seal (6-10) into the O-ring groove in the outboard end of spring
cartridge assembly (5-10).

5�2�2

M11 hydraulic override cylinder installation: For models G01 through G5 use step
5.2.3 and for G7 through G10 use step 5.2.4.

5�2�3

G01 through G5 M11 override cylinder installation

5�2�3�1

Insert M11 hydraulic override cylinder assembly through spring cartridge
outer end.

5�2�3�2

Install lockwashers (7-90) on to hex cap screws (7-80).

5�2�3�3

Install hex cap screws (7-80) with lockwashers (7-90) through hydraulic

override end cap (7-70) and into outer end of spring cartridge (5-10).

5�2�4

G7 through G10 M11 override cylinder installation

5�2�4�1

Insert M11 hydraulic override cylinder assembly into spring cartridge
outer end.

5�2�4�2

Install lockwashers (7-90) on to eight hex cap screws (7-100).

5�2�4�3

Install hex cap screws (7-100) with lockwashers (7-90) through hydraulic

override end cap (7-70) and into outer end of spring cartridge (5-10).

5�2�5

Torque tighten hex cap screws (7-100 and 7-80), alternately until a final lubricated

torque, as listed in the following table, has been achieved.

Table 5�

M11 Override Cylinder End Cap to SR Cartridge Screw Torque

Model

TORQUE (±5%)

Model

TORQUE (±5%)

Lbf-ft�

N-m

Lbf-ft�

N-m

G01

21.68

54.2

21.68

108.4

21.68

130

176.15

54.2

G10

190

257.45

Summary of Contents for 117368

Page 1: ...Service Instructions 127072E Rev C October 2015 G01 through G10 Series Hydraulic Actuators Spring Return Actuators with M11 Hydraulic Override Disassembly and Reassembly ...

Page 2: ......

Page 3: ...0 2 5 G7 through G10 M11 Hydraulic Override Cylinder Disassembly 10 Section 3 Actuator Reassembly 3 1 General Reassembly 11 3 2 Drive Module Disassembly 11 3 3 Hydraulic Power Module Reassembly 16 3 4 G01 through G5 M11 Hydraulic Override Cylinder Reassembly 18 3 5 G7 through G10 M11 Hydraulic Override Cylinder Reassembly 18 3 6 Actuator Testing 20 Section 4 Field Conversions 4 1 Fail Mode Reversa...

Page 4: ... Table 33 6 4 G2 Tool Table 33 6 5 G3 Tool Table 34 6 6 G4 Tool Table 34 6 7 G5 Tool Table 35 6 8 G7 Tool Table 35 6 9 G8 Tool Table 36 6 10 G10 Tool Table 36 Section 7 Troubleshooting 7 1 Fault Insertion 37 7 2 Operational Test 38 Section 8 Removal and Decommissioning 8 1 Removal and Decommissioning 39 Section 9 Document Revision 40 Appendix A List of Tables 41 Appendix B List of Drawings 42 ...

Page 5: ...s 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 f...

Page 6: ...uators this procedure should be reviewed and implemented for safe disassembly and reassembly Close attention should be noted to the WARNINGS CAUTIONS and NOTES contained in this procedure WARNING FOLLOW PLANT SAFETY PROCEDURES This procedure should not supersede or replace any customer s plant safety or work procedures If a conflict arises between this procedure and the customer s procedures the d...

Page 7: ...ontained in the Bettis module service kit in tubes or cans and they are marked ESL 4 5 and 10 lubricant 1 7 Fluid Requirements 1 7 1 For use in the hydraulic power cylinder The following listed fluids are recommended fluids only and do not limit the use of other hydraulic fluids compatible with supplied seals and coatings 1 7 1 1 Standardtemperatureservice 20 Fto 350 F 28 9 Cto 176 6 C useShell Te...

Page 8: ...ossible to keep guess work out of installation 1 10 2 Actuators are shipped from the factory with the travel stops adjusted to approximately ninety degree rotation Generally it is necessary to make slight travel stop adjustments once the actuator is installed on the valve Refer to the valve manufacturer s recommendations for specific requirements When the valve has internal stops the actuator shou...

Page 9: ... Power supply line size 3 Power supply line pressure 4 Control valve and fitting orifice size 5 Torque requirements of the valve 6 Size of the actuator 7 Setting of speed controls 1 11 5 Due to the interaction of these variables it is difficult to specify a normal operating time Faster operating times may be obtained by using one or more of the following 1 Larger supply lines 2 Larger control valv...

Page 10: ...ydraulic power module removal or disassembly 2 1 3 The hydraulic power module can be disassembled while still attached to the drive module or the hydraulic power module can be removed from the drive module and disassembled separate to the actuator refer to Section 5 Module Removal and Installation 2 1 4 To ensure correct reassembly that is with hydraulic power module or spring module on same end o...

Page 11: ...from piston rod 3 40 2 2 9 Refer to assembly drawing page 2 of 2 Detail D Remove two split rings 3 50 and one retainer ring 3 60 from piston rod 3 40 2 2 10 Remove hex cap screws 3 115 with lockwashers 3 110 from inner end cap 3 10 2 2 11 Remove hex nuts 3 105 from hex cap screws 3 100 2 2 12 Remove hex cap screws 3 100 with lockwashers 3 110 from inner end cap 3 10 and housing 1 10 2 2 13 Remove ...

Page 12: ... with lockwashers 1 115 or with lockwashers 1 170 from housing cover 1 20 NOTE Steps 2 3 11 and 2 3 12 are used only on G7 G8 and G10 Drive Modules Drive modules G01 G2 G3 G4 and G5 will skip steps 2 3 11 and 2 3 12 and continue with step 2 3 13 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 ...

Page 13: ... nut assemblies 1 60 from guide block 1 30 On spring return actuators also remove retention retainer nut assemblies 9 60 2 3 24 Remove rod extension assembly 1 50 from guide block 1 30 On spring return actuators also remove rod extension assembly 9 50 NOTE Spherical washers 1 40 and 9 40 will be removed from guide block 1 30 when the extension rod assemblies are removed 2 3 25 Remove the remaining...

Page 14: ... 5 1 2 5 1 Unscrew and remove hex cap screws 7 80 with lockwashers 7 90 from outer end cap 7 70 2 5 2 Remove outer end cap 7 70 from hydraulic cylinder assembly 7 10 2 5 3 Remove piston rod 7 20 from hydraulic cylinder assembly 7 10 2 5 4 Refer to assembly drawing sheet 1 Detail G Remove two split ring halves 7 30 and one retainer ring 7 40 from one side of piston 7 50 2 5 5 Refer to assembly draw...

Page 15: ...corrosion and blistering or flaking coating CAUTION REPLACE WORN PARTS Actuator parts that reflect any of the above listed characteristics should be replaced with new parts 3 1 4 Before installation coat all moving parts with a complete film of lubricant Coat all seals with a complete film of lubricant before installing into seal grooves NOTE The parts and seals used in the actuator housing module...

Page 16: ...sembly 3 2 5 Install extension rod assembly 1 50 into guide block 1 30 and up against the first spherical washer 1 40 3 2 6 Install extension retainer nut 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 is immovable Back off the extension retainer nut assembly 1 60 just enough to allow for ex...

Page 17: ...into housing cover 1 20 and housing 1 10 NOTE The yoke bearing 2 40 must be pressed fit into housing 1 10 and housing cover 1 20 Install the yoke bearings with the bearing seam located 45 5 degrees from the yoke arm slot when yoke 1 70 is rotated to its full clockwise position 3 2 15 If the two yoke pin thrust bearings 2 10 are being replaced install new bearing into housing cover 1 20 and housing...

Page 18: ...indicator assembly 1 140 onto the top of yoke 1 70 and over spring pin 1 100 NOTE Refer to Section 2 step 2 3 7 for correct installation position 3 2 25 Install O ring 2 50 into housing cover 1 20 3 2 26 Install housing cover O ring 2 60 into housing cover 1 20 3 2 27 Install the housing cover 1 20 while being careful not to damage O ring seals 2 50 and 2 60 3 2 28 Place lockwashers 1 115 onto hex...

Page 19: ...2 110 onto position indicator 1 140 3 2 34 Install O ring seal 2 100 onto position indicator 1 140 3 2 35 Install upper bearing 2 120 into yoke cover 1 150 3 2 36 Install rod wiper 2 80 into yoke cover 1 150 3 2 37 Install O ring seal 2 70 into yoke cover 1 150 3 2 38 Install yoke cover 1 150 onto housing cover 1 20 and over position indicator assembly 1 140 NOTE During yoke cover installation be ...

Page 20: ...3 40 with fluid 3 3 2 Install O ring seal 4 70 into the seal groove in piston rod 3 40 3 3 3 Install two split ring halves 3 50 into the inner most groove in piston rod 3 40 and retain with one retainer ring 3 60 3 3 4 Install piston 3 30 onto piston rod 3 40 and up against split rings install as instructed in step 3 3 3 3 3 5 Install two split ring halves 3 50 into the outer most groove in piston...

Page 21: ... bars 3 20 into inner end cap 3 10 NOTE The tie bars should be installed across from each other 3 3 18 Install one O ring seal 4 40 into inboard face of outer end cap 3 80 3 3 19 Install outer end cap 3 80 into open end of cylinder 3 70 NOTE The pressure inlet ports of the inner and outer end caps should be positioned in the same position as recorded in Section 2 step 2 2 1 3 3 20 Install the rema...

Page 22: ... 8 10 into hydraulic ram cover 7 10 3 4 4 Install hydraulic ram 7 20 into hydraulic ram cover 7 10 NOTE When installing the hydraulic ram 7 20 push it through the hydraulic ram cover until the ram is at least flush with the outboard ram cover 3 4 5 Install O ring seal 8 35 into inner diameter seal groove located at the outboard end of the threads in the hydraulic override end cap 7 70 3 4 6 Instal...

Page 23: ... override outer end cap 7 70 when installed in the hydraulic cylinder assembly 3 5 9 Install piston bearing 8 40 into outer diameter bearing groove of piston 7 50 3 5 10 Install O ring seal 8 80 into inner diameter seal groove located in the piston 7 50 3 5 11 Use pipe dope on the threads and install pipe plug 7 110 into the vent tube hole in the inboard end of the hydraulic cylinder assembly 7 10...

Page 24: ...he cylinder name tag to both sides of the piston simultaneously for a period of two 2 minutes NOTE If any leakage occurs during step 3 6 6 the actuator must be disassembled and the cause of leakage must be determined and corrected 3 6 7 If an actuator was disassembled and repaired the above testing must be performed again 3 6 8 Shell Pressure Test Optional pressure test could be performed on the a...

Page 25: ...Section 5 2 4 2 Convert Double Acting Actuator to Spring Return with M11 Module 4 2 1 Remove blind end cap per steps 4 2 1 1 and 4 2 1 2 4 2 1 1 Remove hex cap screws 5 20 with spring lockwashers 5 30 from blind end cap 5 10 4 2 1 2 Remove blind end cap 5 10 from end of housing 1 10 4 2 2 If hydraulic power module needs to be relocated due to fail mode requirements fail counterclockwise use Sectio...

Page 26: ...se step 5 1 5 and for G7 through G10 use step 5 1 6 WARNING CONFIRM PUMP CONTROL KNOB POSITION Confirm that the M11 pump control knob is in the auto position prior to completing step 5 1 5 Do not stand directly in front of the M11 override cylinder when completing step 5 1 5 Stand to one side or the other 5 1 5 G01 through G5 M11 override cylinder removal 5 1 5 1 Unscrew and remove hex cap screws ...

Page 27: ...3 and for G7 through G10 use step 5 2 4 5 2 3 G01 through G5 M11 override cylinder installation 5 2 3 1 Insert M11 hydraulic override cylinder assembly through spring cartridge outer end 5 2 3 2 Install lockwashers 7 90 on to hex cap screws 7 80 5 2 3 3 Install hex cap screws 7 80 with lockwashers 7 90 through hydraulic override end cap 7 70 and into outer end of spring cartridge 5 10 5 2 4 G7 thr...

Page 28: ...setting of stop screws 1 180 should be checked and setting recorded before stop screws are loosened or removed 5 3 1 Shut off and exhaust the operating media from both sides of the actuator s power cylinder 5 3 2 The M11 override cylinder must be removed prior to spring module removal Proceed to section 5 1 and complete all steps 5 1 1 through 5 1 6 and then continue with step 5 3 3 5 3 3 Apply hy...

Page 29: ...9 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 3 10 Remove hex cap screws 5 20 with lockwashers 5 30 from housing 1 10 5 3 11 Remove spring cartridge assembly 5 10 from actuator housing 1 10 WARNING DO NOT CUT SPRING CARTRIDGE Under no circums...

Page 30: ...STEP 5 4 5 Complete step 5 4 5 to avoid severe injury to personnel or incur major damage to the actuator 5 4 5 Spring cartridge tension rod to rod extension installation as follows 5 4 5 1 Using a male square drive extension go through the open end of spring module 5 10 and rotate the tension rod nut until initial thread engagement is achieved NOTE Confirm initial thread engagement of rod extensio...

Page 31: ... tighten hex cap screws 7 80 with lockwashers 7 90 through end cap 7 70 and into spring cartridge assembly 5 10 5 4 13 Torque tighten hex cap screws 7 100 and 7 80 alternately until a final lubricated torque as listed in the following table has been achieved Table 8 Spring Cartridge Tension Rod Torque Table Housing Model TORQUE 5 Housing Model TORQUE 5 Lbf ft N m Lbf ft N m G01 16 21 68 G5 40 54 2...

Page 32: ...eedingwithhydraulicpowermoduleinstallation 5 6 1 Check to verify if O ring seal 4 90 is properly seated in its seal groove located on the housing side of inner end cap 3 10 5 6 2 Using lifting equipment move the power module up to housing 1 10 and align piston rod 3 40 with extension rod assembly 1 50 5 6 3 Using a male square drive extension go through outer end cap 3 80 and screw piston rod 3 40...

Page 33: ...e careful not to drop one of the spherical washers inside the housing 5 7 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 7 4 Remove the remaining spherical washer 1 40 from guide block 1 30 5 8 G2 through G10 Powr Swivl Module Installation WARNING CONFIRM OVERTRAVEL POSITION Th...

Page 34: ...her will go on the extension rod assembly facing the head of the extension rod assembly 5 8 5 Install extension rod assembly 1 50 into right of guide block 1 30 and up against the first spherical washer 1 40 5 8 6 Install extension retainer nut assembly 1 60 over extension rod assembly 1 50 and screw into guide block 1 30 5 8 7 Tighten extension retainer nut assembly 1 60 until extension rod assem...

Page 35: ...bs 26 29 43 N A N A N A N A N A 2 0 Dia Power Module Kg 11 7 13 19 5 N A N A N A N A N A 3 Lbs 27 30 45 N A N A N A N A N A 2 2 Dia Power Module Kg 12 2 13 6 20 4 N A N A N A N A N A 3 Lbs 28 31 48 71 N A N A N A N A 2 5 Dia Power Module Kg 12 7 14 1 21 7 32 N A N A N A N A 3 Lbs 29 35 48 84 5 N A N A N A N A 3 0 Dia Power Module Kg 13 15 8 21 7 38 N A N A N A N A 3 Lbs 32 38 52 83 160 N A N A N A...

Page 36: ... N A N A N A N A N A N A N A 3 Lbs N A N A N A N A N A N A N A N A 18 0 Dia Power Module Kg N A N A N A N A N A N A N A N A 5 Lbs 160 225 320 564 975 2740 3545 4975 SR1 Spring Kg 73 102 145 256 442 1243 1608 2257 5 Lbs 158 215 310 549 980 2630 2345 4515 SR2 Spring Kg 72 98 141 249 445 1193 1064 2048 5 Lbs 153 215 295 534 925 2410 3085 4095 SR3 Spring Kg 153 98 295 534 925 2410 3085 4095 5 Lbs 144 ...

Page 37: ...ead Pipe Plug Open End or Adjustable 7 120 9 16 Sq 1 Square Head Pipe Plug Square Head Pipe Plug 13 3 4 2 Vent Check Assembly Open End 3 8 1 Pull Rod Male Drive 6 4 G2 Tool Table Table 12 G2 Tool Style and Wrench Size ITEM NO WRENCH SIZE ITEM QTY LOCATION OR DESCRIPTION RECOMMENDED TOOL STYLE 1 110 9 16 6 Cover Screws Socket 1 160 9 16 4 Yoke Cover Screws Socket 1 180 3 8 Sq 2 Stop Screws Open End...

Page 38: ...Head Pipe Plug Open End or Adjustable 7 120 1 2 Sq 1 Square Head Pipe Plug Open End or Adjustable 13 3 4 2 Vent Check Assembly Open End 3 8 1 Pull Rod Male Drive 6 6 G4 Tool Table Table 14 G4 Tool Style and Wrench Size ITEM NO WRENCH SIZE ITEM QTY LOCATION OR DESCRIPTION RECOMMENDED TOOL STYLE 1 110 9 16 8 Cover Screws Socket 1 160 9 16 4 Yoke Cover Screws Socket 1 180 3 4 Sq 2 Stop Screws Open En...

Page 39: ...8 Sq 1 Square Head Pipe Plug Open End or Adjustable 7 120 1 2 Sq 1 Square Head Pipe Plug Open End or Adjustable 13 3 4 2 Vent Check Assembly Open End 3 4 1 Pull Rod Male Drive 6 8 G7 Tool Table Table 16 G7 Tool Style and Wrench Size ITEM NO WRENCH SIZE ITEM QTY LOCATION OR DESCRIPTION RECOMMENDED TOOL STYLE 1 110 3 4 8 Cover Screws Socket 1 120 3 4 4 Yoke Cover Screws Socket 1 160 9 16 8 Hex Cap S...

Page 40: ... 7 120 9 16 Sq 2 Square Head Pipe Plug Open End or Adjustable 7 130 9 32 Sq 1 Square Head Pipe Plug Open End or Adjustable 13 3 4 2 Vent Check Assembly Open End 3 4 1 Pull Rod Male Drive 6 10 G10 Tool Table Table 18 G10 Tool Style and Wrench Size ITEM NO WRENCH SIZE ITEM QTY LOCATION OR DESCRIPTION RECOMMENDED TOOL STYLE 1 110 3 4 16 Cover Screws Socket 1 120 3 4 4 Yoke Cover Screws Socket 1 160 9...

Page 41: ...nance 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 IncorrectSpeedControlSettings Adj...

Page 42: ...uator 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 ...

Page 43: ...Turn off the power medium and bleed off all pressure first including storage tank if present Next bleed off pilot pressure and disconnect pneumatic pressure supply pilot tubing and electrical wiring if equipped Before starting the disassembly a large area should be created around the actuator to allow any kind of movement Separate the parts comprising the actuator according to their nature e g met...

Page 44: ...nt Revision Section 9 Document Revision Table 20 Revision Overview ECN DATE REVISION STATUS BY DATE Released December 2001 A B Cornelius December 2001 19110 July 2006 B UPDATED C Ross July 2006 VAWCO2794 October 2015 C UPDATED C Rico October 2015 Signatures on file Emerson Houston Texas ...

Page 45: ...Torque Table 27 Table 8 Spring Cartridge Tension Rod Torque Table 27 Table 9 M11 Hydraulic Override System Fluid Volume Table 31 Table 10 Module Weights by item Number and Actuator Housing Size 31 Table 11 G01 Tool Style and Wrench Size 33 Table 12 G2 Tool Style and Wrench Size 33 Table 13 G3 Tool Style and Wrench Size 34 Table 14 G4 Tool Style and Wrench Size 34 Table 15 G5 Tool Style and Wrench ...

Page 46: ...October 2015 Service Instructions 127072E Rev C 42 Appendix Appendix Appendix B List of Drawings B 1 Part No 122588 G1 2 3 4 5 SRX H Hydraulic Assembly Drawing Sheet 1 of 2 ...

Page 47: ...October 2015 Service Instructions 127072E Rev C 43 Appendix Appendix B 2 Part No 122588 G1 2 3 4 5 SRX H Hydraulic Assembly Drawing Sheet 2 of 2 ...

Page 48: ...October 2015 Service Instructions 127072E Rev C 44 Appendix Appendix B 3 Part No 126567 M11 Assembly Drawing Sheet 1 of 5 ...

Page 49: ...October 2015 Service Instructions 127072E Rev C 45 Appendix Appendix B 4 Part No 126567 M11 Assembly Drawing Sheet 2 of 5 ...

Page 50: ...October 2015 Service Instructions 127072E Rev C 46 Appendix Appendix B 5 Part No 126567 M11 Assembly Drawing Sheet 3 of 5 ...

Page 51: ...October 2015 Service Instructions 127072E Rev C 47 Appendix Appendix B 6 Part No 126567 M11 Assembly Drawing Sheet 4 of 5 ...

Page 52: ...October 2015 Service Instructions 127072E Rev C 48 Appendix Appendix B 7 Part No 126567 M11 Assembly Drawing Sheet 5 of 5 ...

Page 53: ...October 2015 Service Instructions 127072E Rev C 49 Appendix Appendix B 8 Part No VA ED 000 8765 00 G7 8 10 SRX H Hydraulic Assembly Drawing Sheet 1 of 2 ...

Page 54: ...October 2015 Service Instructions 127072E Rev C 50 Appendix Appendix B 9 Part No VA ED 000 8765 00 G7 8 10 SRX H Hydraulic Assembly Drawing Sheet 2 of 2 ...

Page 55: ...October 2015 Service Instructions 127072E Rev C 51 Appendix Appendix B 10 Part No 121107 Remote Mount Assembly Drawing for M11 S G4 G8 Fire Safe Sheet 1 of 2 ...

Page 56: ...October 2015 Service Instructions 127072E Rev C 52 Appendix Appendix B 11 Part No 121107 Remote Mount Assembly Drawing for M11 S G4 G8 Fire Safe Sheet 2 of 2 ...

Page 57: ......

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