Installation, Operation and Maintenance Manual

VA-DC-000-1878 Rev. 1
June 2024

Bettis G01 Through G10

Spring-Return Pneumatic Actuators With M18
Hydraulic Override
Notes Installation, Operation and Maintenance Manual
June 2024 VA-DC-000-1878 Rev. 1

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Installation, Operation and Maintenance Manual Table of Contents
VA-DC-000-1878 Rev. 1 June 2024

Table of Contents
Section 1: Introduction
1.1 General Service Information.................................................................................1
1.2 Definitions.................................................................................................................2
1.3 General Safety Information...................................................................................2
1.4 Bettis Reference Materials.....................................................................................3
1.5 Service Support Items............................................................................................3
1.6 Operating Media......................................................................................................3
1.7 Lubrication and Fluid Requirements...................................................................4
1.8 General Tool Information.......................................................................................4
1.9 Actuator Storage......................................................................................................4
1.10 Actuator Installation................................................................................................5
1.11 Actuator Start-Up.....................................................................................................5
1.12 Actuator Operation.................................................................................................7

Section 2: Actuator Disassembly

2.1 General Disassembly..............................................................................................8
2.2 Pneumatic Power Module Disassembly.............................................................9
2.3 Drive Module Disassembly................................................................................. 11
2.4 G01 Through G5 M18 Hydraulic Override Cylinder Disassembly.............. 14
2.5 G7 Through G10 M18 Hydraulic Override Cylinder Disassembly.............. 14
2.6 M18 Pump Disassembly...................................................................................... 15
2.7 M18 Reservoir Disassembly............................................................................... 16

Section 3: Actuator Reassembly

3.1 General Reassembly............................................................................................ 17
3.2 Drive Module Reassembly.................................................................................. 18
3.3 Pneumatic Power Module Reassembly........................................................... 23
3.4 G2 and G3 Early Model Pneumatic Power Module Reassembly................ 26
3.5 G01 through G5 M18 Hydraulic Override Cylinder Reassembly................ 29
3.6 G7 through G10 M18 Hydraulic Override Cylinder Reassembly................ 30
3.7 Actuator Testing.................................................................................................... 31

Section 4: Field Conversions

4.1 Fail Mode Reversal (CW to CCW or CCW to CW)............................................ 33
4.2 Converting Double-Acting Actuator to Spring-Return With
Override Cylinder Assembly............................................................................... 33

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Section 5: Module Removal and Installation

5.1 M18 Override Cylinder Removal........................................................................ 34
5.2 M18 Override Cylinder Installation................................................................... 35
5.3 Spring Module Removal...................................................................................... 37
5.4 Spring Module Installation................................................................................. 39
5.5 Pneumatic Power Module Removal.................................................................. 41
5.6 Pneumatic Power Module Installation............................................................. 42
5.7 Powr-Swivl Removal.............................................................................................. 43
5.8 Powr Swivl Module Installation.......................................................................... 43

Section 6: Actuator Support Information

6.1 M18 Hydraulic Override System Fluid Volume............................................... 45
6.2 Module Weights by Item Number and Actuator Housing Size.................. 45
6.3 G01 Tool Style and Wrench Size........................................................................ 47
6.4 G2 Tool Style and Wrench Size.......................................................................... 47
6.5 G3 Tool Style and Wrench Size.......................................................................... 48
6.6 G4 Tool Style and Wrench Size.......................................................................... 48
6.7 G5 Tool Style and Wrench Size.......................................................................... 49
6.8 G7 Tool Style and Wrench Size.......................................................................... 49
6.9 G8 Tool Style and Wrench Size.......................................................................... 50
6.10 G10 Tool Style and Wrench Size........................................................................ 50
6.11 M18 Tool Style and Wrench Size....................................................................... 51

Section 7: Troubleshooting
7.1 Fault Insertion....................................................................................................... 52
7.2 Operational Test.................................................................................................... 53

Section 8: Removal and Decommissioning

Removal and Decommissioning................................................................................... 54

Appendix A: List of Tables

List of Tables..................................................................................................................... 55

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Appendix B: List of Drawings

B.1 Part Number 121410, G1/2/3/4/5-SRX-H Pneumatic
Assembly Drawing, Sheet 1 of 2........................................................................ 56
B.2 Part Number 121410, G1/2/3/4/5-SRX-H Pneumatic
Assembly Drawing, Sheet 2 of 2........................................................................ 57
B.3 Part Number 121411, G7/8/10/13-SRX-H Pneumatic
Assembly Drawing, Sheet 1 of 2........................................................................ 58
B.4 Part Number 121411, G7/8/10/13-SRX-H Pneumatic
Assembly Drawing, Sheet 2 of 2........................................................................ 59
B.5 Part Number VA-ED-005-1120, M18 Assembly Drawing,
Sheet 1 of 7............................................................................................................ 60
B.6 Part Number VA-ED-005-1120, M18 Assembly Drawing,
Sheet 2 of 7............................................................................................................ 61
B.7 Part Number VA-ED-005-1120, M18 Assembly Drawing,
Sheet 3 of 7............................................................................................................ 62
B.8 Part Number VA-ED-005-1120, M18 Assembly Drawing,
Sheet 4 of 7............................................................................................................ 63
B.9 Part Number VA-ED-005-1120, M18 Assembly Drawing,
Sheet 5 of 7............................................................................................................ 64
B.10 Part Number VA-ED-005-1120, M18 Assembly Drawing,
Sheet 6 of 7............................................................................................................ 65
B.11 Part Number VA-ED-005-1120, M18 Assembly Drawing,
Sheet 7 of 7............................................................................................................ 66
B.12 Part Number VA122588, G1/2/3/4/5-SRX-H Hydraulic
Assembly Drawing, Sheet 1 of 2........................................................................ 67
B.13 Part Number VA122588, G1/2/3/4/5-SRX-H Hydraulic
Assembly Drawing, Sheet 2 of 2........................................................................ 68
B.14 Part Number VA138334, G Drive Module Assembly Drawing,
Sheet 1 of 1............................................................................................................ 69

Appendix C: Safety Instructions for Use in (Potential)

Explosive Atmosphere
C.1 Intended Use......................................................................................................... 70
C.2 ATEX Marking......................................................................................................... 70
C.3 Safety Instructions................................................................................................ 71
C.4 Maximum Temperatures..................................................................................... 72

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Installation, Operation and Maintenance Manual Section 1: Introduction
VA-DC-000-1878 Rev. 1 June 2024

Section 1: Introduction
1.1 General Service Information
• This service procedure is offered as a guide to enable general maintenance
to be performed on Bettis™ G01XXX-SR, G2XXX SR, G3XXX SR, G4XXX SR,
G5XXX SR, G7XXX SR, G8XXX SR and G10XXX SR Spring-Return Series Single
Pneumatic Power Module Actuators with M18 Hydraulic Override Module.
• Normal recommended service interval for this actuator series is five years.

NOTE:
Storage time is counted as part of the service interval.

• This procedure is applicable with the understanding that all electrical power
and pneumatic pressure has been removed from the actuator.
• Remove all piping and mounted accessories that will interfere with the
module(s) that are to be worked on.
• This procedure should only be implemented by a technically competent
technician who should take care to observe good workmanship practices.
• Numbers in parentheses ( ), indicate the bubble number (reference number)
used on the Bettis Assembly Drawing and Actuator Parts List.
• 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.
• Actuator module weights are listed in Section 6, Table 12.
• When removing seals from seal grooves, use a commercial seal removing tool
or a small screwdriver with sharp corners rounded off.
• Use a non-hardening thread sealant on all pipe threads.

! CAUTION
Apply the thread sealant per the manufacturer’s instructions.

• Bettis recommends that disassembly of the actuator components should be

done in a clean area on a workbench.

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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 are provided to assist maintenance personnel to
carry out maintenance procedures.

1.3 General Safety Information

Products supplied by Bettis, in its “as shipped” condition, are intrinsically safe if the
instructions contained within this Service Instruction are strictly adhered to and
executed by well-trained, equipped, prepared and competent personnel.

! WARNING
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 given to the WARNINGS, CAUTIONS and NOTES from this procedure.

! WARNING
This procedure should not supersede or replace any customer’s plant safety
or work procedures. If a conflict arises between this procedure and the
customer’s procedures, the differences should be resolved in writing between
an authorized customer's representative and an authorized Emerson Actuation
Technologies representative.

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1.4 Bettis Reference Materials

• Assembly Drawing for G2-SR-M18 through G5-SR-M18 model actuators with
one Pneumatic Power Module and one Spring Module with M18 Hydraulic
Override Module: use Part Number 121410.
• Assembly Drawing for G7-SR-M18 through G10-SR-M18 model actuators with
one Pneumatic Power Module and one Spring Module with M18 Hydraulic
Override Module: use Part Number 121411.
• M18 Manual Hydraulic Override System VCIOM-15381-EN, VA-DC-000-1879
with M18 Assembly Drawing Part Number VA-ED-005-1120.
• Assembly Drawing for G1/2/3/4/5-SRX-H Hydraulic: use Part Number 122588.
• Assembly Drawing for G Drive Module: use Part Number 138334.

1.5 Service Support Items

• Bettis module service kits
• For rod extension retainer nut tool part number, refer to Table 1.

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

Table 1. G-Series Models

Actuator Model Bettis Part Number
G01 None required
G2 123616
G3/G4 117370
G5/G7 117369
G8/G10 117368

• Commercial leak testing solution

• Non-hardening thread sealant

1.6 Operating Media

• Recommended to use clean, dry air or inert gas.
• Other gases may be used with direction from Emerson Engineering to
evaluate any possible restrictions or modifications which may need to be
made for compatibility.

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1.7 Lubrication and Fluid Requirements

NOTE:
Lubricants and Fluids, other than listed in step 1.7.1 and 1.7.2 should not be used
without prior written approval of Bettis Product Engineering.

1.7.1 Lubricants:
All temperature services -20 to 350 °F / -29 to 176 °C use Bettis ESL-5
lubricant. ESL-5 lubricant is contained in the Bettis module service kit in tubes
or cans and they are marked ESL-5 and 10 lubricant. For low temperature
service -40 to 150 °F / -40 to 66 °C, use ESL-15 lubricant. ESL-15 lubricant is
contained in low temperature Bettis module service kits in tubes or cans and
they are marked ESL-15 lubricant.
1.7.2 Fluids:
M18 Manual Hydraulic Override System Fluid Requirements: Standard and
high temperature service -20 to 350 °F / -29 to 176 °C use Shell® Tellus T-32
Automatic Transmission Fluid. For low temperature service
-40 to 150 °F / -40 to 66 °C, use Univis® J13 or HVI 13 Hydraulic Fluid.

1.8 General Tool Information

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

1.9 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.

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1.10 Actuator Installation

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.
Actuators are shipped from the factory with the travel stops adjusted for
approximately 90° rotation. Generally, it is necessary to make slight travel stop
adjustments once the actuator is installed onto the valve. Refer to the valve
manufacturer's recommendations for specific requirements. When the valve has
internal stops, the actuator should be adjusted at the same points.

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

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.

1.11 Actuator Start-Up

1.11.1 Prestart-up checks
1. Inspect to ensure the unit has been mounted onto valve properly.
Gear flange mounting bolts, stem key, set screw(s) are installed
and secured.
2. No tubing damaged or accessories dislodged during the shipping or
the installation.
3. Indicated position confirms valve position.
4. All switching valves in normal operating position as per
schematic/instructions.

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1.11.2 Check Connections

1. Pneumatic/hydraulic components connected as per schematic
enclosed or in-service manual supplied.
2. Pneumatic supply connected to the identified ports.
3. Electrical connection terminals are secured.
4. Wiring as per enclosed diagram or service manual supplied.

NOTE:
When actuator is first placed into service, it should be cycled with regulated
pneumatic pressure. This is necessary because the seals have been stationary
causing them to take a “set”. Therefore, the actuator should be operated through
several cycles to exercise the seals to achieve a service ready condition.

1.11.3 Speed of operation

The actuator's speed of operation is determined by several factors, including:
1. Power supply line length
2. Power supply line size
3. Power supply line pressure
4. Control valve and fitting orifice size
5. Torque requirements of the valve
6. Size of the actuator
7. Setting of speed controls
8. Hydraulic Manual Override (where available)
Due to the interaction of these variables, it is difficult to specify a “normal”
operating time. Faster operating time may be obtained by using one or more
of the following:
1. Larger supply lines
2. Larger control valve
3. Higher supply pressure *
4. Quick exhaust valves

NOTE: * Not to exceed maximum operating pressure of actuator or

control components.
Slower operating time may be obtained by using flow control valves to meter
the exhaust. Excessive exhaust flow metering may cause erratic operation.

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1.12 Actuator Operation

1.12.1 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.
1.12.2 Manual operation
All pressure must be vented or equalized on both sides of the pneumatic
piston prior to manual operation.

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Section 2: Actuator Disassembly

2.1 General Disassembly
! WARNING
It is possible that the actuator may contain a dangerous gas and/or liquid. 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).

! WARNING
Do not remove compressed module. Do not remove spring module while spring
is compressed.

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 reassembly — that is, with pneumatic power module or
spring module on same end of drive module as was prior to disassembly —
mark or tag right (or left) and mark mating surfaces.
2.1.5 For spring module removal and installation, refer to Section 5, steps 5.3
and 5.4.

NOTE:
Use a means of capturing the hydraulic fluid that will be lost during the removal or
disassembly of the override power module. Use a bucket, tub or large container, etc.

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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. Refer to Assembly Drawing Part
Numbers 121410 or 121411 in Appendix B for details.

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

! WARNING
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 5.3, steps 5.3.7 through 5.3.9).

2.2.1 Mark and record location of the ports on outer end cap (3-80) and
inner end cap (3-10).
2.2.2 If actuator is equipped with a power module mounted extended stop (ES)
then rotate the ES until clear of the piston rod (3-40).
2.2.3 Remove breather assembly (12) from outer end cap (3-80).
2.2.4 Refer to Assembly Drawing Part Number 121410 sheet 2 of 2 Detail “E” in
Appendix B. Remove two socket cap screws (3-130), with lock washer (3-140),
from outer end cap (3-80).
2.2.5 Remove two tie bar hex nuts (3-90) from outboard side of outer end cap (3-80).
2.2.6 The fit between cylinder (3-70) and outer end cap (3-80) is very tight. Break
end cap free by tapping with a breaker bar on lip provided on the end cap.
Remove outer end cap (3-80) from cylinder (3-70).

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

NOTE:
When removing cylinder (3-70) off 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).

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! CAUTION
Do not use pipe wrench to remove tie bars.

2.2.8 Tie bar removal:

2.2.8.1 Remove tie bars (3-20) as follows:

NOTE:
G01, G2, G3 and G4 models have flats on outboard end of tie bars (3-20) for wrench
placement. G5 through G13 models have a female square on the outboard end of tie
bars (3-20) for wrench placement.

2.2.8.2 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 2.2.10).
2.2.9.1 Refer to Assembly Drawing Part Number 121410 sheet 2 of 2
Detail “D” in Appendix B. Remove two split ring halves (3-50) and
one retainer ring (3-60) from outboard side of piston (3-30).

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

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

NOTE:
Step 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 Part Number 121410 sheet 2 of 2
Detail “D” in Appendix B. Remove two split ring halves (3-50) and one
retainer ring (3-60) from inboard side of piston (3-30).

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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 outboard
split ring halves are exposed enough for removal. Remove outboard
split ring halves from piston rod (3-40).
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 lock washers (3-110) from housing (1-10).
2.2.13 Remove inner end cap (3-10) off 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
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. Refer to Part Number VA138334, G Drive Module
Assembly Drawing.

2.3.1 If not already removed remove piston rod (3-40) from drive module.
2.3.2 Mark stop screws (1-180) left and right. 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.

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NOTE:
For steps 2.3.3 through 2.3.10, refer to Assembly Drawings Part Number 121410
sheet 2 of 2 Section A-A and Part Number 121411 Detail “F” in Appendix B.

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

NOTE:
Step 2.3.4 is used only on G01, G2 and G3 drive modules. Drive modules G4 through
G10 will skip step 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 lock washers (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 lock washers (1-115) from housing
cover (1-20).

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

2.3.11 Remove hex cap screws (1-120), with lock washers (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:
G01, G2, G3 and G4 model housing cover will have cast tabs for placing prying tools
to aid in cover removal.

2.3.13 Remove housing cover (1-20) from housing (1-10).

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NOTE:
Groove pins (1-130) will remain in housing cover (1-20) when housing cover is
removed from housing (1-10). Groove pins (1-130) should not be removed from
housing cover (1-20) unless they are damaged and require new replacements.

2.3.14 Refer to Assembly Drawing Part Number 121410 sheet 2 of 2 Detail “B” in
Appendix 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), 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 in.-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 the 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 Part Number 121410 sheet 2 of 2 Detail “B” in
Appendix B. Use Bettis tool part numbers 117368 (G8/G10), 117369 (G5/G7),
117370 (G3/G4) or 123616 (G2) and remove retention retainer nut
assemblies (1-60) and (9-60) from guide block (1-30).
2.3.24 Remove rod extension assemblies (1-50) and (9-50) from guide block (1-30).

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

2.3.25 Remove the remaining spherical washers (1-40) and (9-40) from guide
block (1-30).
2.3.26 Unscrew and remove two stop screw nuts (1-190) from stop screws (1-180).
2.3.27 Unscrew and remove two stop screws (1-180) from front of housing (1-10).

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

2.3.28.1 G01, G2 and G3 housing (1-10) unscrew and remove one vent check
assembly (13) from the front of housing (1-10).
2.3.28.2 G4 through G10 housing (1-10) unscrew and remove two vent check
assemblies (13) from the front of housing (1-10).
2.3.29 The following items do not need to be removed from their assembled
locations unless being replaced by new items: Two guide bar bearings, two
yoke bearings (2-40), yoke pin bearing, yoke pin thrust bearing (2-10) and
spring pin (1-100).

2.4 G01 Through G5 M18 Hydraulic Override

Cylinder Disassembly
NOTE:
For M18 Hydraulic Override Cylinder removal from spring cartridge, refer to
Section 5, step 5.1. Refer to Part Number VA122588, G1/2/3/4/5-SRX-H Hydraulic
Assembly Drawing.

2.4.1 Unscrew hydraulic ram cover (7-10) from hydraulic override end cap (7-70).
2.4.2 Remove hydraulic ram (7-20) from hydraulic ram cover (7-10).

2.5 G7 Through G10 M18 Hydraulic Override

Cylinder Disassembly
NOTE:
For M18 Hydraulic Override Cylinder removal from spring cartridge refer to
Section 5, step 5.1. Refer to Assembly Drawing Part Number 121411 in Appendix B
for details.

2.5.1 Unscrew and remove hex cap screws (7-80) with lock washers (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 Part Number 121411 sheet 1 of 2 Detail “G” in
Appendix B. 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 Drawing Part Number 121411 sheet 1 of 2 Detail “G” in
Appendix B. Remove two split ring halves (7-30) and one retainer ring (7-40)
from the other side of piston (7-50).
2.5.6 Remove piston (7-50) from piston rod (7-20).
2.5.7 Remove vent tube (7-60) from the hydraulic cylinder assembly.
2.5.8 Pipe plug (7-110) does not require removal for routine service.
2.5.9 Pipe plug (7-120) does not require removal for routine service.

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VA-DC-000-1878 Rev. 1 June 2024

2.6 M18 Pump Disassembly

NOTE:
Refer to Assembly Drawing Part Number VA-ED-005-1120 in Appendix B for details.

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

2.6.1 Place the M18 pump control knob (25-200) in the auto position. Use
drawing Part Number VA-ED-005-1120 in Appendix B for this section.

NOTE:
Control knob (25-200) is in front and at the bottom of the M18 pump
manifold (20-10-10). Use a means of capturing the hydraulic fluid that will be lost
during the following steps. Use a bucket, tub or large container, etc.

2.6.2 Remove all the piping from the M18 override manifold (20-10-10) to the
actuator and reservoir (10).
2.6.3 Remove mounting bracket (30-90) from the actuator.
2.6.4 Remove all counter-sunk cap screws (30-100) from the mounting
bracket (30-90).
2.6.5 Remove acorn nut (25-450), lock washer (25-460), control knob (25-200) and
control pointer (25-150) from the M18 override.
2.6.6 Remove socket cap screws (25-240) from the cover (25-140).

NOTE:
Note the bottom two access holes to reach socket cap screws are blocked by
instruction tag (25-220) and will need to be removed and replaced (new instruction
tag is provided in service kit).

2.6.7 Pull out quick release pin (20-10-110) from the pump handle lever (20-10-90).
2.6.8 Remove socket head cap screws (20-10-100) from the back brace (20-10-130).
2.6.9 Remove pipe plug (20-10-210), spring (20-10-360) and ball (20-10-350).
If the back plate (20-10-320) is not coming out, use soft mallet to gently tap
the open end of stem, control valve (20-10-280) in order to remove the back
plate assembly and stem assembly.

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June 2024 VA-DC-000-1878 Rev. 1

NOTE:
The piston, control valve (20-10-310) is under spring tension and it will eventually pop
out, user beware and find means to capture the piston (20-10-310),
spring (20-10-390), washer bearing (20-10-380) and thrust bearing (20-10-370).

2.6.10 Remove flat head screw (20-10-330) from the manifold (20-10-10).
2.6.11 Remove disc, control valve (20-10-290) from the manifold (20-10-10).
2.6.12 Remove seal O-ring (20-20-40) from the manifold (20-10-10).
2.6.13 Remove seal O-ring (20-20-90) and backup ring (20-20-100) from back plate,
control valve (20-10-320).
2.6.14 Remove seal O-ring (20-20-110) and backup ring (20-20-120) from piston,
control valve (20-10-310).
2.6.15 Remove seal O-ring (20-20-40) and backup ring (20-20-50) from stem,
control valve (20-10-280).
2.6.16 Remove pump rod (20-10-50) from pump cylinder (20-10-20).
2.6.17 Remove rod wiper (20-20-20), rod bushing (20-20-30) and PolyPak®
seal (20-20-10) from the pump cylinder (20-10-20) bore.
2.6.18 Remove retainer ring (20-10-80) from manifold (20-10-10).
2.6.19 Use 1/4-20 UNC socket cap screw (20-10-240) as provided in service kit to
remove the pin, cylinder (20-10-60) from the manifold (20-10-10). Remove the
pump cylinder (20-10-20).
2.6.20 Remove seal O-ring (20-20-40) and backup ring (20-20-50) from the pin,
cylinder (20-10-60).
2.6.21 Remove seal O-ring (20-20-60) and backup ring (20-20-70) from the
pump cylinder (20-10-20).

2.7 M18 Reservoir Disassembly

2.7.1 Remove acorn nut (10-50), countersink washer (10-60) and
thread seal (10-70) from the end cap, upper (10-10).
2.7.2 Remove end cap, bottom (10-40) by tapping from the open end of
center bar (10-30).
2.7.3 Remove seal O-ring (10-100) from the end cap, bottom (10-40).
2.7.4 Remove end cap, upper (10-10) from the reservoir cylinder (10-20).
2.7.5 Remove seal O-ring (10-100) from the end cap, upper (10-10).

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Section 3: Actuator Reassembly

3.1 General Reassembly
! CAUTION
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.

3.1.2 All parts should be cleaned to remove all dirt and other foreign material prior
to inspection.
3.1.3 All parts should be thoroughly inspected for excessive wear, stress cracking,
galling and pitting. Attention should be directed to threads, sealing surfaces
and areas that will be subjected to sliding or rotating motion. Sealing
surfaces of the cylinder, tie bars and piston rod must be free of deep
scratches, pitting, corrosion and blistering or flaking coating.

! CAUTION
Actuator parts that reflect any of the above listed characteristics should be replaced
with new parts.

3.1.4 Before installation, coat all moving parts with a complete film of lubricant.
Coat all seals with a complete film of lubricant before installing into
seal grooves.

NOTE:
The parts and seals used in the actuator will be assembled using lubricant as
identified in Section 1, step 1.7.1.

3.1.5 For spring module installation, refer to Section 5, step 5.4.

Actuator Reassembly 17
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3.2 Drive Module Reassembly

NOTE:
Review Section 3.1, General Reassembly before proceeding with Drive
Module Reassembly.

NOTE:
Refer to Assembly Drawing Part Number 121410 sheet 2 of 2 Detail "B" in Appendix B
for section drawing of guide block.

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

NOTE:
The guide bar bearing must be pressed fit into guide block guide bar bore with the
seam located 45° ±5° of the top or bottom centerline as shown in Assembly Drawing
Part Number 121410 sheet 2 of 2 Section A-A in Appendix B.

NOTE:
G01 model actuators skip steps 3.2.2 through 3.2.13 and continue reassembly at
step 3.2.14.

3.2.2 Lubricate guide block (1-30), two spherical washers (1-40) and one extension
rod assembly (1-50).
3.2.3 Install one spherical washer (1-40) into the side of guide block (1-30).3

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.

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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) 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 guide block (1-30), 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).

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

3.2.11 Install extension rod assembly (9-50) into guide block (1-30) and up against
the first spherical washer (9-40).
3.2.12 Install extension retainer nut (9-60) over extension rod assembly (9-50) and
screw into guide block (1-30).
3.2.13 Tighten extension retainer nut assembly (9-60) until extension rod
assembly (9-50) cannot move. Back off the extension retainer nut
assembly (9-60) just enough to allow for extension rod assembly (9-50) to
move freely.

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NOTE:
Consult Houston, Texas Bettis Service Coordinator for “yoke bearing, yoke pin bearing
or yoke/guide block bushing installation information”.

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

NOTE:
The yoke bearing (2-40) must be pressed fit into housing (1-10) and housing
cover (1-20). Install the yoke bearings with the bearing seam located 45° ±5° 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 (1-10).
3.2.16 Lubricate two yoke/guide block bushings (2-30) and install onto top and
bottom sides of guide block (1-30).

NOTE:
The guide block (1-30) should be already preassembled with extension rod assembly
and associated parts assembled in the guide block.

3.2.17 Install guide block (1-30), with yoke/guide block bushings (2-30), between
arms of yoke (1-70).
3.2.18 Install O-ring seal (2-50) into inner diameter O-ring groove in the bottom of
housing (1-10).
3.2.19 Coat the bearing surfaces of the yoke (1-70) with lubricant and install into
housing (1-10).
3.2.20 Align hole in guide block (1-30) with the matching holes in the two yoke/guide
block bushings (2-30) and the slots in the arms of yoke (1-70).

NOTE:
The yoke pin can be held in place by installing a screw into the 0.375-16 UNC tapped
hole in the upper end of yoke pin (1-80).

3.2.21 Install yoke pin (1-80) by inserting into the upper yoke arm, upper yoke/guide
block bushing, guide block, lower yoke/guide block bushing, lower yoke arm
and resting on lower yoke pin thrust bearing (2-10).
3.2.22 Install guide bar (1-90) into either side of housing (1-10) by inserting through
the housing, through guide block and then insert the guide bar into the
other side of housing (1-10).

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3.2.23 Refer to Assembly Drawing Part Number 121410 sheet 2 of 2 Section A-A in
Appendix B. Install spring pin (1-100) into the top of yoke (1-70).
3.2.24 Install position indicator assembly (1-140) onto the top of yoke (1-70) and
over spring pin (1-100).

NOTE:
Refer to Section 2, step 2.3.7 for correct installation position.

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

3.2.26 Install housing cover O-ring (2-60) into housing cover (1-20).
3.2.27 Install the housing cover (1-20) being careful not to damage O-ring
seals (2-50) and (2-60).
3.2.28 Place lock washers (1-115) onto hex cap screws (1-110).

NOTE:
On G7 through G10 model actuators, apply thread adhesive LOCTITE® 242 to threads
of hex cap screws (1-110). Refer to Assembly Drawing Part Number 121411
Sheet 1 of 2 Note Number 9 in Appendix B.

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

NOTE:
Leave hex cap screws (1-110) finger tight - do not tighten.

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 flushed with the cover.

3.2.30 Torque tighten hex cap screws (1-110) until a final lubricated torque, as listed
in Table 2 has been achieved.

Table 2. Housing Cover Screw Quantity and Torque

Torque (±5%) Torque (±5%)
Model Quantity Model Quantity
lb-ft Nm lb-ft Nm
G01 4 40 54 G5 8 100 136
G2 6 40 54 G7 8 100 136
G3 8 40 54 G8 12 100 136
G4 8 40 54 G10 16 100 136

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NOTE:
Complete step 3.2.31 on G5 through G10 model actuators. For G01 through G4
model actuators, skip step 3.2.31 and proceed to step 3.2.32.

3.2.31 On G5 through G10 models:

3.2.31.1 Place lock washers (1-115) onto hex cap screws (1-120).

NOTE:
Hex cap screws (1-120) are only used as “hole” fillers and to protect threads
from environment.

3.2.31.2 Install and tighten hex cap screws (1-120) with lock washers (1-115).
3.2.32 Install thrust bearing (2-110) onto position indicator (1-140).
3.2.33 Install O-ring seal (2-100) onto position indicator (1-140).
3.2.34 Install upper bearing (2-120) into yoke cover (1-150).
3.2.35 Install rod wiper (2-80) into yoke cover (1-150).
3.2.36 Install O-ring seal (2-70) into yoke cover (1-150).
3.2.37 Install yoke cover (1-150) onto housing cover (1-20) and over position
indicator assembly (1-140).

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

3.2.38 Place lock washers (1-170) onto hex cap screws (1-160).
3.2.39 Install and tighten hex cap screws (1-160) with lock washers through yoke
cover (1-150) and into housing cover (1-20).
3.2.40 Vent check assembly installation as follows:
3.2.40.1 G01, G2 and G3 housing (1-10) using pipe sealant, install one vent
check assembly (13) into the front of housing (1-10).
3.2.40.2 G01, G2 and G3 housing (1-10) using pipe sealant, install one vent
check assembly (13) into the top area of housing cover (1-20).
3.2.40.3 G4 through G10 housing (1-10) using pipe sealant, install two vent
check assemblies (13) into the front of housing (1-10).

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NOTE:
Refer to Section 2, step 2.3.3 for correct position indicator placement.

3.2.41 Install position indicator (1-220) over the exposed shaft of position indicator
assembly (1-140).
3.2.42 Install stop screw nuts (1-190) onto stop screws (1-180).
3.2.43 Install O-ring (2-90) onto stop screws (1-180).
3.2.44 Install two stop screws (1-180) into two stop screw holes on the front of
housing (1-10).
3.2.45 Adjust both stop screws (1-180) back to settings recorded earlier in
Section 2 at step 2.3.2.
3.2.46 Tighten both stop screw nuts (1-190) securely.

3.3 Pneumatic Power Module Reassembly

NOTES:
1. For early model G2 and G3 actuators with double nuts on the power module,
use Section 3.4 for reassembly.
2. Refer to Section 2, step 2.1.4 for the correct installation location for piston
rod (3-40).
3. The actuator must be in the appropriate overtravel position. Confirm
overtravel 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 thru G10 screw piston rod (3-40) onto extension rod
assembly (1-50).
3.3.1.2 G01 only screw piston rod (3-40) into guide block (1-30).
3.3.2 Torque tighten piston rod (3-40) to the lubricated torque as listed in Table 3.

Table 3. Piston Rod Torque Information

Torque (±5%) Torque (±5%)

Housing Model Housing Model
lb-ft Nm lb-ft Nm
G01 90 122 G5 240 325
G2 90 122 G7 240 325
G3 90 122 G8 240 325
G4 240 325 G10 240 325

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! CAUTION
PolyPak seal facing piston side. Install the PolyPak seal with energizer ring facing
piston side of inner end cap (3-10).

3.3.3 Install one O-ring seal (4-90) into seal groove located on the inboard face of
inner end cap (3-10).
3.3.4 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.

3.3.5 Place lock washers (3-110) onto hex cap screws (3-100).
3.3.6 Install hex cap screws (3-100), with lock washers, through housing (1-10) and
into inner end cap (3-10).
3.3.7 Refer to Assembly Drawing Part Number 121410 sheet 2 of 2 Detail “D” in
Appendix B. Install one O-ring seal (4-70) into the seal groove in piston
rod (3-40).
3.3.8 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.

3.3.8.1 Install two sets of rod T-seals (4-50) into the internal diameter seal
grooves of piston (3-30).
3.3.8.2 Install a back-up ring on each side of the T-seal.
3.3.8.3 When installing the back-up rings, do not align the skive-cuts.
3.3.8.4 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.
3.3.9 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).
3.3.10 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).

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3.3.11 Install one O-ring seal (4-40) onto the outer diameter seal groove of inner
end cap (3-10).
3.3.12 Coat one D-ring seal (4-60) with lubricant and install into the piston external
seal groove.

NOTE:
The flat side of the D-ring seal goes down into the seal groove.

3.3.13 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).
3.3.14 Screw tie bars (3-20) into inner end cap (3-10) and tighten until the threads
bottom out.
3.3.15 Refer to Assembly Drawing Part Number 121410 sheet 2 of 2 Detail “E” in
Appendix B. Coat two O-ring seals (4-80) with lubricant and install into outer
end cap (3-80).
3.3.16 Apply lubricant to one O-ring seal (4-40) and install into the outer diameter
O-ring groove of outer end cap (3-80).
3.3.17 Apply lubricant to the bore of cylinder (3-70).
3.3.18 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° to piston rod.

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

3.3.19 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.

3.3.20 Install tie bar nuts (3-90) onto tie bars (3-20). Torque tighten tie bar nuts,
alternately in 100 lb-ft / 136 Nm increments, until a final lubricated torque, as
listed in Table 4, has been achieved.

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Table 4. Tie Bar Nuts

Torque (±5%) Torque (±5%)

Housing Model Housing Model
lb-ft Nm lb-ft Nm
G01 120 163 G5 400 542
G2 120 163 G7 500 678
G3 150 203 G8 500 678
G4 150 203 G10 1,200 1,627

3.3.21 Install lock washers (3-140) onto socket cap screws (3-130).
3.3.22 Install and tighten socket cap screws (3-130) with lock washers (3-140)
into outer end cap (3-80).
3.3.23 If removed using pipe dope, install pipe plug (3-120) into outer end
cap (3-80).
3.3.24 Apply sufficient 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).
3.3.25 Remove pneumatic pressure from outer end cap (3-80).
3.3.26 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:
1. Early G2 and G3 pneumatic power modules were equipped with tie bars that
had nuts on both ends of the tie bars (3-20) – double nuts.
2. Refer to Section 2, step 2.1.4 for the correct installation location for piston
rod (3-40).
3. The actuator must be in the appropriate overtravel position. Confirm
overtravel position by observing the guide block (1-30) is against the inner wall
of housing (1-10).
4. Refer to Assembly Drawing Part Number 121410 in Appendix B for details.

3.4.1 Refer to Assembly Drawing Part Number 121410 sheet 2 of 2 Detail “C” in
Appendix B. 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 first into inner end
cap (3-10).

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! CAUTION
Install PolyPak seal correctly. Install the PolyPak seal with energizer ring facing
outboard side of inner end cap (3-10).

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

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

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 flat 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 outboard side of the piston.

3.4.8 Refer to Assembly Drawing Part Number 121410 sheet 2 of 2 Detail “D” in
Appendix B. 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).

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June 2024 VA-DC-000-1878 Rev. 1

3.4.10 Install two split ring halves (3-50) into the piston rod, behind 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.

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

3.4.14 Refer to Assembly Drawing Part Number 121410 sheet 2 of 2 Detail “E” in
Appendix B. 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).
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° to piston rod.

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

3.4.18 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 lb-ft increments, until a final lubricated torque, as listed in
the following table, has been achieved.

Table 5. G2 Tie Bar Nuts

Torque (±5%) Torque (±5%)

Housing Model Housing Model
lb-ft Nm lb-ft Nm
G2 120 163 G3 150 203

28 Actuator Reassembly
Installation, Operation and Maintenance Manual Section 3: Actuator Reassembly
VA-DC-000-1878 Rev. 1 June 2024

3.4.20 Install lock washers (3-140) onto socket cap screws (3-130).
3.4.21 Install and tighten socket cap screws (3-130), with lock washers (3-140),
into outer end cap (3-80).
3.4.22 Install pneumatic power module per Section 5, step 5.4.

3.5 G01 Through G5 M18 Hydraulic Override

Cylinder Reassembly
NOTE:
Review Section 3.1, General Reassembly before proceeding with G01 through G5
M18 Hydraulic Override Cylinder Reassembly.

3.5.1 Install ram bushing (8-20) into hydraulic ram cover (7-10).
3.5.2 Install PolyPak seal (8-30) into hydraulic ram cover (7-10).

NOTE:
The lip of PolyPak seal (8-30) are to face toward the hydraulic override end cap when
installed in the hydraulic ram cover.

3.5.3 Install rod wiper (8-10) into hydraulic ram cover (7-10).
3.5.4 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.

3.5.5 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).
3.5.6 Install hydraulic ram cover (7-10) into the hydraulic override end cap (7-70) by
screwing the ram cover into the end cap until the ram cover bottoms out into
the end cap.

NOTE:
For M18 Hydraulic Override Cylinder installations, refer to Section 5, step 5.2.

Actuator Reassembly 29
Section 3: Actuator Reassembly Installation, Operation and Maintenance Manual
June 2024 VA-DC-000-1878 Rev. 1

3.6 G7 Through G10 M18 Hydraulic Override

Cylinder Reassembly
NOTE:
Review Section 3 step 3.1, General Reassembly before proceeding with G7 through
G10 M18 Hydraulic Override Cylinder Reassembly.

3.6.1 Install PolyPak seal (8-30) into hydraulic cylinder assembly (7-10).

NOTE:
The lip of PolyPak seal (8-30) will face toward the hydraulic override end cap when
installed in the hydraulic cylinder assembly.

3.6.2 Install rod bushing (8-20) into hydraulic cylinder assembly (7-10).
3.6.3 Install rod wiper (8-10) into hydraulic cylinder assembly (7-10).
3.6.4 Install two split ring halves (7-30) into the inner most groove in piston
rod (7-20) and retain by installing retainer ring (7-40) onto the split ring halves.
3.6.5 Apply hydraulic fluid to O-ring seal (8-50) and install it into the seal groove
located between the two split ring grooves on the piston rod (7-20).
3.6.6 Install the piston (7-50) onto the piston rod (7-20) and up against the split
rings installed in step 3.6.4.
3.6.7 Install two split ring halves (7-30) into the outboard groove in piston
rod (7-20) and retain by installing retainer ring (7-40) onto the split
ring halves.
3.6.8 Install PolyPak seal (8-60) into outer diameter seal groove of piston (7-50).

NOTE:
The lip of PolyPak seal (8-60) will face toward the hydraulic override outer end
cap (7-70) when installed in the hydraulic cylinder assembly.

3.6.9 Install piston bearing (8-40) into outer diameter bearing groove of
piston (7-50).
3.6.10 Install O-ring seal (8-80) into inner diameter seal groove located in the
piston (7-50).
3.6.11 Use pipe dope on the threads install pipe plug (7-110) into the vent tube hole
in the inboard end of the hydraulic cylinder assembly (7-10).
3.6.12 Install vent tube (7-60) into the hydraulic cylinder assembly inboard end.

30 Actuator Reassembly
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3.6.13 Install the assembled piston rod (7-20) with piston (7-50) into the open end of
the hydraulic cylinder assembly and install the piston over the vent tube (7-60).
3.6.14 Install O-ring seal (8-90) into the vent tube port located in the outer end
cap (7-70).
3.6.15 Install O-ring seal (8-70) into the O-ring groove located on the inner diameter
of the hydraulic cylinder assembly flange opening.
3.6.16 Install the outer end cap (7-70), assemble piston rod (7-20) with
piston (7-50) onto the open end of the hydraulic cylinder assembly and over
the vent tube (7-60).
3.6.17 Install lock washers (7-90) onto hex cap screws (7-80).
3.6.18 Install and tighten hex cap screws (7-80) with lock washers (7-90) through
outer end cap (7-70) and into hydraulic cylinder assembly.

NOTE:
For M18 Hydraulic Override Cylinder installations, refer to Section 5, step 5.2.

3.7 Actuator Testing

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

! CAUTION
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.

3.7.2 Cycle the actuator five times at the Maximum Operating Pressure (MOP) as
listed on the actuator’s name tag or the customer's normal actuator supply
pressure. If excessive leakage across the piston is noted, generally a bubble
which breaks three seconds or less after starting to form, cycle the actuator
five times as this will allow the seals to seek their proper service condition.

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

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

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June 2024 VA-DC-000-1878 Rev. 1

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

3.7.4.1 Joint between inner end cap (3-10) and cylinder (3-70). This checks
cylinder to inner end cap O-ring seal.
3.7.4.2 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).
3.7.4.3 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).
3.7.4.4 Remove pressure from the pressure inlet port.
3.7.5 If an actuator was disassembled and repaired, the above leakage test must
be performed again.
3.7.6 Shell Pressure Test – Optional pressure test could be performed on a
Pressure Equipment Directive (PED) certified 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 must be determined and corrected.

! WARNING
The actuator's 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 field is necessary, Emerson should be contacted for guidance.

32 Actuator Reassembly
Installation, Operation and Maintenance Manual Section 4: Field Conversions
VA-DC-000-1878 Rev. 1 June 2024

Section 4: Field Conversions

4.1 Fail Mode Reversal
(CW to CCW or CCW to CW)
4.1.1 Remove spring module per Section 5.3.
4.1.2 Remove pneumatic power module per Section 5.5.
4.1.3 Reinstall the spring module onto the opposite end of housing (1-10) as it was
previously located per Section 5.4.
4.1.4 Reinstall the override cylinder assembly into spring module per Section 5.2.

4.2 Converting Double-Acting Actuator to

Spring-Return With Override
Cylinder Assembly
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 lock washers (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 pneumatic power module needs to be relocated due to fail mode
requirements (fail counterclockwise), use Section 5.5 for removal and
Section 5.6 for installation.
4.2.3 Install Powr-Swivl module per Section 5.8.
4.2.4 Install the spring module onto the end of housing (1-10) per Section 5.4.
4.2.5 Install the override cylinder assembly into spring module per Section 5.2.

Field Conversions 33
Section 5: Module Removal and Installation Installation, Operation and Maintenance Manual
June 2024 VA-DC-000-1878 Rev. 1

Section 5: Module Removal and Installation

5.1 M18 Override Cylinder Removal
5.1.1 Shut off and exhaust the operating media from both sides of the actuator’s
power cylinder.
5.1.2 Place the M18 pump control knob (25-200) in the auto position.

NOTE:
Control knob (25-200) is in front and at the bottom of the M18 pump
manifold (20-10-10).

NOTE:
Use a means of capturing the hydraulic fluid that will be lost during the following
steps. Use a bucket, tub and large container, etc.

5.1.3 Remove all the piping from the M18 override cylinder end cap (7-70).
5.1.4 M18 Hydraulic Override Cylinder removal: For models G01 through G5, use
step 5.1.5 and for G7 through G10, use step 5.1.6.

! WARNING
Confirm that the M18 pump control knob is in the auto position prior to completing
step 5.1.5. Do not stand directly in front of the M18 Override Cylinder when
completing step 5.1.5 - Stand to one side or the other.

5.1.5 G01 through G5 M18 override cylinder removal.

5.1.5.1 Unscrew and remove hex cap screws (7-80) with lock washers (7-90)
from override cylinder end cap (7-70).
5.1.5.2 Remove override cylinder assembly from spring cartridge
assembly (5-10).
5.1.6 G7 through G10 M18 override cylinder removal.

! CAUTION
Do not remove hex cap screws (7-80) from M18 Override Cylinder at this time. If hex
cap screws (7-80) are removed at this time, it is possible that hydraulic fluid will be
dumped inside the spring cartridge.

5.1.6.1 Unscrew and remove hex cap screws (7-100) with lock
washers (7-90) from override cylinder end cap (7-70).

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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 SR 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 6. Hex Cap Screw Length

Item 7-80 Length * Item 7-100 Length *

Actuator Model
in. mm in. mm
G7 2 50.8 2.75 69.85
G8 3 76.2 4.5 114.3
G10 3.5 88.9 5.0 127

Note:
* Refer to Assembly Drawing Part Number 121410 in Appendix B for details.

5.1.6.2 Remove override cylinder assembly from spring cartridge

assembly (5-10).

5.2 M18 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 M18 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 M18 Override Cylinder installation:
5.2.3.1 Insert M18 Hydraulic Override Cylinder assembly through spring
cartridge outer end.
5.2.3.2 Install lock washers (7-90) on to hex cap screws (7-80).
5.2.3.3 Install hex cap screws (7-80) with lock washers (7-90) through
hydraulic override end cap (7-70) and into outer end of spring
cartridge (5-10).
5.2.4 G7 through G10 M18 Override Cylinder installation:
5.2.4.1 Insert M18 Hydraulic Override Cylinder assembly into spring
cartridge outer end.
5.2.4.2 Install lock washers (7-90) on to eight hex cap screws (7-100).
5.2.4.3 Install hex cap screws (7-100) with lock washers (7-90) through
hydraulic override end cap (7-70) and into outer end of spring
cartridge (5-10).

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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 7. M18 Override Cylinder End Cap to SR Cartridge Screw Torque

Torque (±5%) Torque (±5%)
Housing Model Housing Model
lb-ft Nm lb-ft Nm
G01 16 21.68 G5 40 54.2
G2 16 21.68 G7 80 108.4
G3 16 21.68 G8 130 176.15
G4 40 54.2 G10 190 257.45

5.2.6 Using pipe dope on threads, reinstall all piping between hydraulic override
cylinder assembly and the M18 pump.
5.2.7 Fluid filling instructions for M18 and M18-S Hydraulic Override Sytems:
5.2.7.1 To fluid fill M18 Manual Hydraulic Override System, refer to
Installation, Operation and Maintenance Manual (IOM) with
document number VA-DC-000-1879.

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VA-DC-000-1878 Rev. 1 June 2024

5.3 Spring Module Removal

! WARNING
Check spring cartridge positioning. The spring cartridge must be checked to verify
that the spring(s) are in their extended position before the spring cartridge is
removed from the actuator.

NOTE:
1. 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. Review Section 2.1, General Disassembly before proceeding with spring
module disassembly.
3. The 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 M18 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 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.
5.3.4 Loosen the stop screw nut (1-190) located on the stop screw that is closest to
or next to spring module.
5.3.5 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).
5.3.6 Remove pneumatic pressure from pressure inlet port of inner end cap (3-10).

! CAUTION
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.

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5.3.7 The spring cartridge “pre-load” must be removed before spring cartridge
assembly (5-10) is removed from housing (1-10). Refer to steps 5.3.4 through
5.3.6 for spring cartridge “pre-load” removal.
5.3.8 Remove breather assembly (12) from outer end cap (3-80) port “B”.

! CAUTION
The maximum pressure to be applied in step 5.3.9 is 25 psig / 1.72 bar.

5.3.9 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 to move the spring cartridge tension
rod hex nut out of its cast hex seat.

5.3.10 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.
5.3.11 Remove hex cap screws (5-20) with lock washers (5-30) from housing (1-10).
5.3.12 Remove spring cartridge assembly (5-10) from actuator housing (1-10).

! WARNING
Do not cut spring cartridge assembly. 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.

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5.4 Spring Module Installation

! CAUTION
Use heavy duty support 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
Actuator must be in the appropriate overtravel position (see detail “A” on warning
tag attached to spring module access hole cover). Confirm overtravel 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.

5.4.1 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).
5.4.2 Unscrew or back out stop screw (1-180) to achieve overtravel as illustrated in
detail “A” on the warning tag attached to the spring module cover plate.
5.4.3 Install O-ring seal (6-20) into the O-ring groove in the inboard end of spring
cartridge assembly (5-10).
5.4.4 Using lifting equipment, move spring module up to housing (1-10) and align
spring cartridge tension rod with extension rod assembly (9-50).

! WARNING
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 extension (9-50) to tension rod.

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5.4.5.2 After confirming initial thread engagement, rotate tension rod into
extension rod assembly (9-50) per the following table.

! WARNING
After initial thread engagement, the tension rod must be rotated clockwise the
minimum number of turns listed in Table 8.

Table 8. Minimum Turns

Actuator Model Torque Units G01 G2 G3 G4 G5 G7 G8 G10
Minimum number
N/A N/A 10 10 10 13 14 20 25
of turns

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

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

Table 9. Spring Cartridge Tension Rod Torque

Torque (±5%) Torque (±5%)

Housing Model Housing Model
lb-ft Nm lb-ft Nm
G01 50 68 G5 240 325
G2 90 122 G7 240 325
G3 90 122 G8 240 325
G4 240 325 G10 240 325

5.4.7 Install lock washers (5-30) onto hex cap screws (5-20).
5.4.8 Install hex cap screws (5-20) with lock washers (5-30) through housing (1-10)
and into spring cartridge assembly (5-10) and tighten.
5.4.9 Install O-ring seal (6-10) into the O-ring groove in the outboard end of spring
cartridge assembly (5-10).
5.4.10 M18 Hydraulic Override Cylinder installation: For models G2 through G5, use
step 5.4.11 and for G7 through G10, use step 5.4.12.
5.4.11 G2 through G5 M18 Override Cylinder installation:
5.4.11.1 Insert M18 Hydraulic Override Cylinder assembly into spring
cartridge outer end.
5.4.11.2 Install lock washers (7-90) on to eight hex cap screws (7-80).
5.4.11.3 Install eight hex cap screws (7-80) with lock washers (7-90) through
end cap (7-70) and into outer end of spring cartridge (5-10).

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5.4.12 G7 through G10 M18 Override Cylinder installation.

5.4.12.1 Insert M18 Hydraulic Override Cylinder assembly into spring
cartridge outer end.
5.4.12.2 Install lock washers (7-80) on to eight hex cap screws (7-100).
5.4.12.3 Install eight hex cap screws (7-100) with lock washers (7-90)
through end cap (7-70) and into outer end of spring
cartridge (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 10. M18 Override Cylinder End Cap to SR Cartridge Screw Torque
Torque (±5%) Torque (±5%)
Housing Model Housing Model
lb-ft Nm lb-ft Nm
G01 16 21.68 G5 40 54.2
G2 16 21.68 G7 80 108.4
G3 16 21.68 G8 130 176.15
G4 40 54.2 G10 190 257.45

5.4.14 Using pipe dope on threads reinstall all piping between hydraulic override
cylinder assembly and the M18 pump.
5.4.15 Fluid filling instructions for M18 and M18-S Hydraulic Override Systems:
5.4.15.1 To fill fluid in M18 Manual Hydraulic Override System, refer to
instructions Part Number 126858 (Request through your local
Emerson representative).
5.4.15.2 To fill fluid in M18-S Manual Hydraulic Override System, refer to
instructions Part Number 121960 (Request through your local
Emerson representative).
5.4.16 If removed, install stop screw nuts (1-190) onto stop screws (1-180).
5.4.17 If removed, install O-ring (2-90) onto stop screws (1-180).
5.4.18 If removed, install two stop screws (1-180) into two stop screw holes on the
front of housing (1-10).
5.4.19 Adjust both stop screws (1-180) back to settings recorded earlier in Section 5.
5.4.20 Tighten both stop screw nuts (1-190) securely.

5.5 Pneumatic Power Module Removal

! CAUTION
Due to the weight and size of power module, heavy duty support equipment will be
required when removing power module from the actuator housing. Refer to Section 6
for Pneumatic Power Module Weights.

5.5.1 Remove pipe plug (3-120) from outer end cap (3-80).
5.5.2 Remove hex cap screws (3-100) with lock washers (3-110) from housing (1-10).

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5.5.3 Using a male square drive extension, go through outer end cap (3-80) and
unscrew piston rod (3-40) from extension rod assembly (1-50).

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

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

5.6 Pneumatic Power Module Installation

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

5.6.1 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 confirm that the two inboard hex nuts (3-90) flats are aligned to fit
into the slot located in the end of housing (1-10).

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) into extension rod assembly (1-50).

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

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

5.6.4.1 G2 and G3 torque to 90 lb-ft lubricated.
5.6.4.2 G4 and G10 torque to 240 lb-ft lubricated.
5.6.5 Install lock washers (3-110) onto hex cap screws (3-100).
5.6.6 Install and tighten hex cap screws (3-100) with lock washers (3-110) through
housing (1-10) and screw into inner end cap (3-10).
5.6.7 Using pipe dope, install pipe plug (3-120) into outer end cap (3-80).

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5.7 Powr-Swivl Removal

5.7.1 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.

5.7.2 Refer to Assembly Drawing Part Number 121411 sheet 2 of 2 Detail “B” in
Appendix B. Use Bettis tool part number as listed in table in Section 1,
step 1.5.2 to remove retainer nut assembly (1-60) from the guide block (1-30).

! CAUTION
Carefully handle spherical washers. When removing rod extension assembly from
guide block, be 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 Powr-Swivl Module Installation

! WARNING
The actuator must be in the appropriate overtravel position. Confirm overtravel
position by observing the guide block (1-30) is against the inner wall of housing (1-10).

5.8.1 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.

Module Removal and Installation 43

Section 5: Module Removal and Installation Installation, Operation and Maintenance Manual
June 2024 VA-DC-000-1878 Rev. 1

5.8.2 Lubricate two spherical washers (1-40) and one extension rod assembly (1-50).
5.8.3 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).

5.8.4 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.

5.8.5 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
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.

44 Module Removal and Installation

Installation, Operation and Maintenance Manual Section 6: Actuator Support Information
VA-DC-000-1878 Rev. 1 June 2024

Section 6: Actuator Support Information

6.1 M18 Hydraulic Override System
Fluid Volume
Table 11. M18 Hydraulic Override System Fluid Volume

Actuator Size G01 G2 G3 G4 G5 G7 G8 G10

Approximate Volume Fluid Quarts 1.6 1.8 2.0 3.6 10.2 9.7 15.9 27.0
for M18 Liters 1.8 1.7 1.9 3.4 9.6 9.1 15.1 25.6

6.2 Module Weights by Item Number and

Actuator Housing Size
Table 12. Module Weight by Item Number and Actuator Housing Size (1)

Item G01 G2 G3 G4 G5 G7 G8 G10

Module Description
Number Weight Weight Weight Weight Weight Weight Weight Weight
lb 83 110 162 280 545 1025 1495 2550
1 Drive module
kg 38 50 73 127 247 465 678 1157
lb 69 N/A N/A N/A N/A N/A N/A N/A
3 8 in. diameter power
kg 31 N/A N/A N/A N/A N/A N/A N/A
lb 68 80 N/A N/A N/A N/A N/A N/A
3 9 in. diameter power
kg 30.5 36 N/A N/A N/A N/A N/A N/A
lb 75 73.5 88 N/A N/A N/A N/A N/A
3 10 in. diameter power
kg 34 33 40 N/A N/A N/A N/A N/A
lb 86 86 104 130 N/A N/A N/A N/A
3 12 in. diameter power
kg 39 39 47 59 N/A N/A N/A N/A
lb 96 96 114 145 N/A N/A N/A N/A
3 14 in. diameter power
kg 44 44 51 66 N/A N/A N/A N/A
lb N/A 135 145 168 295 N/A N/A N/A
3 16 in. diameter power
kg N/A 61 66 76 134 N/A N/A N/A
lb N/A N/A 235 260 305 585 N/A N/A
3 20 in. diameter power
kg N/A N/A 107 118 138 265 N/A N/A
lb N/A N/A N/A 340 410 735 911 N/A
3 24 in. diameter power
kg N/A N/A N/A 154 186 334 413 N/A
lb N/A N/A N/A 505 590 810 1225 1120
3 28 in. diameter power
kg N/A N/A N/A 229 268 367 556 508
lb N/A N/A N/A N/A 977 1100 1260 1440
3 32 in. diameter power
kg N/A N/A N/A N/A 443 499 572 653

Actuator Support Information 45

Section 6: Actuator Support Information Installation, Operation and Maintenance Manual
June 2024 VA-DC-000-1878 Rev. 1

Table 12. Module Weight by Item Number and Actuator

Housing Size (2)

Item G01 G2 G3 G4 G5 G7 G8 G10

Module Description
Number Weight Weight Weight Weight Weight Weight Weight Weight
lb N/A N/A N/A N/A 1243 1400 1525 1755
3 36 in. diameter power
kg N/A N/A N/A N/A 564 653 692 796
lb N/A N/A N/A N/A N/A N/A 1975 2205
3 40 in. diameter power
kg N/A N/A N/A N/A N/A N/A 896 1000
lb N/A N/A N/A N/A N/A N/A N/A N/A
3 44 in. diameter power
kg N/A N/A N/A N/A N/A N/A N/A N/A
lb N/A N/A N/A N/A N/A N/A N/A N/A
3 48 in. diameter power
kg N/A N/A N/A N/A N/A N/A N/A N/A
lb N/A N/A N/A N/A N/A N/A N/A N/A
3 52 in. diameter power
kg N/A N/A N/A N/A N/A N/A N/A N/A
lb 160 225 320 564 975 2740 3545 4975
5 SR1 spring
kg 73 102 145 256 442 1243 1608 2257
lb 158 215 310 549 980 2630 2345 4515
5 SR2 spring
kg 72 98 141 249 445 1193 1064 2048
lb 153 215 295 534 925 2410 3085 4095
5 SR3 spring
kg 153 98 295 534 925 2410 3085 4095
lb 144 200 280 474 860 2210 N/A 3735
5 SR4 spring
kg 65 91 127 215 390 1002 N/A 1694
lb N/A 200 N/A N/A N/A N/A N/A N/A
5 SRA5 spring
kg N/A 91 N/A N/A N/A N/A N/A N/A
lb N/A 180 N/A N/A N/A N/A N/A N/A
5 SRA6 spring
kg N/A 82 N/A N/A N/A N/A N/A N/A
lb 18 34 47 82 100 181 270 530 M18 SR
7
kg 8.2 15.3 21.2 36.9 45 81.45 1275 239 override cylinder

lb 35 35 35 45 50 35 45 50 M18 SR
2
kg 14.5 14.5 14.5 20.4 22.7 14.5 20.4 22.7 pump/reservoir

46 Actuator Support Information

Installation, Operation and Maintenance Manual Section 6: Actuator Support Information
VA-DC-000-1878 Rev. 1 June 2024

6.3 G01 Tool Style and Wrench Size

Table 13. G01 Tool Style and Wrench Size
Item Number Wrench Size Item Quantity Location or Description Recommended Tool Style
1-110 9/16 in. 4 Hex Cap Screws Socket
1-160 1/2 in. 4 Hex Cap Screws Socket
1-180 3/8 in. (square) 2 Stop Screws Open End or Adjustable
1-190 1-15/16 in. 2 Hex Jam Nuts Open End or Adjustable
3-20 3/8 in. 2 Tie Bar (flats) Open End or Adjustable
3-40 3/8 in. (square) 1 Piston Rod Male Drive
3-90 1-1/8 in. 2 Standard Hex Nuts Socket
3-100 9/16 in. 4 Hex Cap Screws Socket
3-120 5/8 in. (square) 1 Pipe Plug Open End or Adjustable
3-130 3/16 in. 2 Socket Cap Screws Allen
5-20 9/16 in. 4 Hex Cap Screws Socket
7-80 9/16 in. 4 Hex Cap Screws Socket
7-110 1/8 in. (square) 1 Square Head Pipe Plug Open End or Adjustable
7-120 9/16 in. (square) 1 Square Head Pipe Plug Square Head Pipe Plug
12 1 in. 1 Breather Assembly Socket
13 3/4 in. 2 Vent Check Assembly Open End
- 3/8 in. (square) 1 Tension rod Male Drive

6.4 G2 Tool Style and Wrench Size

Table 14. G2 Tool Style and Wrench Size
Item Number Wrench Size Item Quantity Location or Description Recommended Tool Style
1-110 9/16 in. 6 Hex Cap Screws Socket
1-160 9/16 in. 4 Hex Cap Screws Socket
1-180 3/8 in. (square) 2 Stop Screws Open End or Adjustable
1-190 1-1/8 in. 2 Hex Jam Nuts Open End or Adjustable
3-20 3/8 in. 2 Tie Bar (flats) Open End or Adjustable
3-40 3/8 in. (square) 1 Piston Rod Male Drive
3-90 1-1/8 in. 4 Standard Hex Nuts Socket
3-100 9/16 in. 4 Hex Cap Screws Socket
3-120 5/8 in. (square) 1 Pipe Plug Open End or Adjustable
3-130 3/16 in. 2 Socket Cap Screws Allen
5-20 9/16 in. 6 Hex Cap Screws Socket
7-80 9/16 in. 4 Hex Cap Screws Socket
7-110 1/8 in. (square) 1 Square Head Pipe Plug Open End or Adjustable
7-120 1/2 in. (square) 1 Square Head Pipe Plug Open End or Adjustable
12 1 in. 1 Breather Assembly Open End
13 3/4 in. 2 Vent Check Assembly Open End
- 3/8 in. (square) 1 Tension rod Male Drive

Actuator Support Information 47

Section 6: Actuator Support Information Installation, Operation and Maintenance Manual
June 2024 VA-DC-000-1878 Rev. 1

6.5 G3 Tool Style and Wrench Size

Table 15. G3 Tool Style and Wrench Size

Item Number Wrench Size Item Quantity Location or Description Recommended Tool Style
1-110 9/16 in. 8 Hex Cap Screws Socket
1-160 9/16 in. 4 Hex Cap Screws Socket
1-180 1/2 in. (square) 2 Stop Screws Open End or Adjustable
1-190 1-5/16 in. 2 Hex Jam Nuts Open End or Adjustable
3-20 1/2 in. 2 Tie Bar (flats) Open End or Adjustable
3-40 3/8 in. (square) 1 Piston Rod Male Drive
3-90 1-5/16 in. 4 Standard Hex Nuts Socket
3-100 9/16 in. 6 Hex Cap Screws Socket
3-120 5/8 in. (square) 1 Pipe Plug Open End or Adjustable
3-130 3/16 in. 2 Socket Cap Screws Allen
5-20 9/16 in. 6 Hex Cap Screws Socket
7-80 9/16 in. 6 Hex Cap Screws Socket
7-110 1/8 in. (square) 1 Square Head Pipe Plug Open End or Adjustable
7-120 1/2 in. (square) 1 Square Head Pipe Plug Open End or Adjustable
12 1 in. 1 Breather Assembly Open End
13 3/4 in. 2 Vent Check Assembly Open End
- 3/8 in. (square) 1 Tension rod Male Drive

6.6 G4 Tool Style and Wrench Size

Table 16. G4 Tool Style and Wrench Size

Item Number Wrench Size Item Quantity Location or Description Recommended Tool Style
1-110 9/16 in. 8 Hex Cap Screws Socket
1-160 9/16 in. 4 Hex Cap Screws Socket
1-180 3/4 in. (square) 2 Stop Screws Open End or Adjustable
1-190 1-13/16 in. 2 Hex Jam Nuts Open End or Adjustable
3-20 5/8 in. 2 Tie Bar (flats) Open End or Adjustable
3-40 1/2 in. (square) 1 Piston Rod Male Drive
3- 90 1-5/8 in. 2 Standard Hex Nuts Socket
3-100 3/4 in. 6 Hex Cap Screws Socket
3-120 5/8 in. (square) 1 Pipe Plug Open End or Adjustable
3-130 3/16 in. 2 Socket Cap Screws Allen
5-20 3/4 in. 6 Hex Cap Screws Socket
7-80 3/4 in. 6 Hex Cap Screws Socket
7-110 1/8 in. (square) 1 Square Head Pipe Plug Open End or Adjustable
7-120 1/2 in. (square) 1 Square Head Pipe Plug Open End or Adjustable
12 1 in. 1 Breather Assembly Open End
13 3/4 in. 2 Vent Check Assembly Open End
- 3/4 in. 1 Tension rod Male Drive

48 Actuator Support Information

Installation, Operation and Maintenance Manual Section 6: Actuator Support Information
VA-DC-000-1878 Rev. 1 June 2024

6.7 G5 Tool Style and Wrench Size

Table 17. G5 Tool Style and Wrench Size
Item Number Wrench Size Item Quantity Location or Description Recommended Tool Style
1-110 3/4 in. 8 Hex Cap Screws Socket
1-120 3/4 in. 4 Hex Cap Screws Socket
1-160 9/16 in. 6 Hex Cap Screws Socket
1-180 7/8 in. (square) 2 Stop Screws Open End or Adjustable
1-190 2-3/8 in. 2 Heavy Hex Jam Nuts Open End or Adjustable
3-20 1/2 in. (square) 2 Tie Bar (flats) Open End or Adjustable
3-40 1/2 in. (square) 1 Piston Rod Male Drive
3-90 2 in. 2 Standard Hex Nuts Socket
3-100 3/4 in. 8 Hex Cap Screws Socket
3-120 1-1/8 in. (square) 1 Pipe Plug Open End or Adjustable
3-130 3/16 in. 2 Socket Cap Screws Allen
5-20 3/4 in. 8 Hex Cap Screws Socket
7-80 3/4 in. 8 Hex Cap Screws Socket
7-110 1/8 in. (square) 1 Square Head Pipe Plug Open End or Adjustable
7-120 1/2 in. (square) 1 Square Head Pipe Plug Open End or Adjustable
12 1 in. 1 Breather Assembly Open End
13 3/4 in. 2 Vent Check Assembly Open End
- 3/4 in. 1 Tension rod Male Drive

6.8 G7 Tool Style and Wrench Size

Table 18. G7 Tool Style and Wrench Size
Item Number Wrench Size Item Quantity Location or Description Recommended Tool Style
1-110 3/4 in. 8 Hex Cap Screws Socket
1-120 3/4 in. 4 Hex Cap Screws Socket
1-160 9/16 in. 8 Hex Cap Screws Socket
1-180 1 in. 2 Stop Screws Open End or Adjustable
3-20 3/4 in. (square) 2 Tie Bar (female square) Open End or Adjustable
3-40 3/4 in. (square) 1 Piston Rod Male Drive
3-90 2-3/8 in. 2 Standard Hex Nuts Socket
3-100 15/16 in. 8 Hex Cap Screws Socket
3-120 1-1/8 in. (square) 1 Pipe Plug Open End or Adjustable
3-130 3/16 in. 2 Socket Cap Screws Allen
5-20 15/16 in. 8 Hex Cap Screws Socket
7-80 15/16 in. 8 Hex Cap Screws Socket
7-100 15/16 in. 8 Hex Cap Screws Socket
7-110 9/16 in. 1 Flush Socket Head Pipe Plug Allen
7-130 9/32 in. (square) 1 Square Head Pipe Plug Open End or Adjustable
12 1 in. 1 Breather Assembly Open End
13 3/4 in. 2 Vent Check Assembly Open End
- 3/4 in. 2 Tension rod Male Drive

Actuator Support Information 49

Section 6: Actuator Support Information Installation, Operation and Maintenance Manual
June 2024 VA-DC-000-1878 Rev. 1

6.9 G8 Tool Style and Wrench Size

Table 19. G8 Tool Style and Wrench Size

Item Number Wrench Size Item Quantity Location or Description Recommended Tool Style
1-110 3/4 in. 12 Hex Cap Screws Socket
1-120 3/4 in. 4 Hex Cap Screws Socket
1-160 9/16 in. 8 Hex Cap Screws Socket
1-180 1-1/4 in. 2 Stop Screws Open End or Adjustable
3-20 3/4 in. (square) 2 Tie Bar (female square) Open End or Adjustable
3-40 3/4 in. (square) 1 Piston Rod Male Drive
3-90 2-3/4 in. 2 Heavy Hex Nuts Socket
3-100 1-1/8 in. 8 Hex Cap Screws Socket
3-120 1-5/16 in. (square) 1 Pipe Plug Open End or Adjustable
3-130 3/16 in. 2 Socket Cap Screws Allen
5-20 1-1/8 in. 8 Hex Cap Screws Socket
7-80 1-1/8 in. 8 Hex Cap Screws Socket
7-100 1-1/8 in. 8 Hex Cap Screws Socket
7-110 9/16 in. 1 Flush Socket Head Pipe Plug Allen
7-130 9/32 in. (square) 1 Square Head Pipe Plug Open End or Adjustable
12 1 in. 1 Breather Assembly Open End
13 3/4 in. 2 Vent Check Assembly Open End
- 3/4 in. 1 Tension rod Male Drive

6.10 G10 Tool Style and Wrench Size

Table 20. G10 Tool Style and Wrench Size
Item Number Wrench Size Item Quantity Location or Description Recommended Tool Style
1-110 3/4 in. 16 Hex Cap Screws Socket
1-120 3/4 in. 4 Hex Cap Screws Socket
1-160 9/16 in. 8 Hex Cap Screws Socket
1-180 1-1/2 in. 2 Stop Screws Open End or Adjustable
3-20 3/4 in. (square) 2 Tie Bar (female square) Open End or Adjustable
3-40 3/4 in. (square) 1 Piston Rod Male Drive
3-90 3-1/2 in. 2 Heavy Hex Nuts Socket
3-100 1-5/16 in. 8 Hex Cap Screws Socket
3-120 1-5/16 in. (square) 1 Pipe Plug Open End or Adjustable
3-130 3/16 in. 2 Socket Cap Screws Allen
5-20 1-1/8 in. 8 Hex Cap Screws Socket
7-80 1-5/16 in. 8 Hex Cap Screws Socket
7-100 1-5/16 in. 8 Hex Cap Screws Socket
7-110 9/16 in. 1 Flush Socket Head Pipe Plug Allen
7-130 9/32 in. (square) 1 Square Head Pipe Plug Open End or Adjustable
12 1 in. 1 Breather Assembly Open End
13 3/4 in. 2 Vent Check Assembly Open End
- 3/4 in. 1 Tension rod Male Drive

50 Actuator Support Information

Installation, Operation and Maintenance Manual Section 6: Actuator Support Information
VA-DC-000-1878 Rev. 1 June 2024

6.11 M18 Tool Style and Wrench Size

Table 21. M18 Tool Style and Wrench Size
Item Number Wrench Size Item Quantity Location or Description Recommended Tool Style
10-50 3/4 in. 1 Acorn Nut Socket
10-80 3/8 in. 2 Pipe Plug Socket
10-90 3/4 in. 1 Breather Socket
10-110 3/4 in. 1 Pipe Plug Socket
20-10-27 11/16 in. 1 Check Valve Socket
20-10-30 13/16 in. 1 Relief Valve Open End or Adjustable
20-10-40 11/16 in. 2 Check Valve Socket
20-10-180 1/2 in. 3 Socket Cap Screws Allen
20-10-190 5/16 in. 6 Socket Cap Screws Allen
20-10-210 3/16 in. 17 Socket Cap Screws Allen
20-10-240 3/16 in. 1 Socket Cap Screws Allen
20-10-260 7/8 in. 2 Orifice Check Valve Socket
20-10-400 1/2 in. 1 Square Head Pipe Plug Open End or Adjustable
25-240 3/16 4 Socket Cap Screws Allen
25-410 5/32 in. 2 Socket Cap Screws Allen
25-430 3/32 in. 1 Socket Cap Screws Allen
30-20 7/16 in. 4 Hex Cap Screws Socket
30-40 3/16 in. 2 Socket Cap Screws Allen
30-100 7/32 in. 4 Socket Cap Screws Allen
30-110 3/8 in. 4 Socket Cap Screws Allen
11/16 in. or
40 1 Male Elbow Open End or Adjustable
5/8 in. (square)
11/16 in. or
60 1 Male Connector Open End or Adjustable
5/8 in. (square)
80-10 3/16 in. 2 Socket Cap Screws Allen
80-20 1/2 in. 1 Elbow Open End or Adjustable
80-60 5/8 in. 1 Bulkhead Adapter Open End or Adjustable
80-70 1/2 in. 1 Hex Cap Nut Open End or Adjustable
80-120 3/8 in. 1 Pivot Pin Open End or Adjustable
90-30 11/16 in. 1 Check Valve Socket
90-40 11/16 in. 1 Male Tube Adapter Open End or Adjustable
90-50 11/16 in. 1 Male Connector Open End or Adjustable
90-60 11/16 in. 1 Check Valve Socket

Actuator Support Information 51

Section 7: Troubleshooting Installation, Operation and Maintenance Manual
June 2024 VA-DC-000-1878 Rev. 1

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's Bettis actuators as possible.
Reference to equipment not supplied should be ignored.

Table 22. Fault Location Table

Symptom Potential Causes Remedy

Irregular supply of Check operating medium for consistent supply pressure

operating medium and correct as necessary.
Inadequate lubrication Dismantle, relubricate and reassemble.
Erratic movement
Dismantle, visually inspect for significant wear. Actuator
Worn parts
replacement may be required.
Defective valve Consult the valve OEM's documentation.
Incorrectly set stops Check the position of the travel stops and readjust
(valve and/or actuator) as necessary.
Dismantle, remove any hard grease, relubricate
Hardened grease
Short stroke and reassemble.
Debris left in the cylinder or Disassemble cylinder assembly to remove debris.
housing during maintenance Reassemble cylinder assemble as necessary.
Defective valve Consult the valve manufacturer's documentation.
Ensure supply pressure is above the minimum operating
Inadequate supply pressure 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 flow.
Exhaust port blocked Remove and clean the exhaust port silencers and replace.
Pipe work blocked, crushed Examine the pipe work for blockages, crushed pipe or
or leaking leakage. Clear or replace as necessary.
Apparent lack Examine the controls, refurbish or renew as necessary.
Defective controls
of torque Refer to component manufacturer's documentation.
Dismantle the cylinder assembly, remove the defective
Defective piston seal
piston seal. Fit new seal and reassemble.
Dismantle the cylinder assembly, remove the defective
Defective rod seal
rod seal. Fit new seal and reassemble.
Dismantle the housing assembly, remove the defective
Defective housing seal
seal. Fit new seal and reassemble.
High valve torque or valve seized Consult the valve OEM documentation.

52 Troubleshooting
Installation, Operation and Maintenance Manual Section 7: Troubleshooting
VA-DC-000-1878 Rev. 1 June 2024

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 defined by the final installer to achieve the defined
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 value. A typical partial stroke value is
15% of the stroke and the recommended test interval is about everyone 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.

Troubleshooting 53
Section 8: Removal and Decommissioning Installation, Operation and Maintenance Manual
June 2024 VA-DC-000-1878 Rev. 1

Section 8: Removal and Decommissioning

! WARNING
Always follow safe work practices to remove and disassemble a G-Series actuator.

The below basic procedure should not supersede or replace any customer’s
plant safety or work procedures. If a conflict arises between this procedure
and the customer's procedures, the differences should be resolved in
writing between an authorized customer’s representative and an authorized
Emerson Actuation Technologies representative.

! CAUTION
Make sure actuator is isolated before removing from valve. Turn OFF the power
medium and bleed off all pressure first, 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 (e.g., metallic
and plastic materials, fluids, etc.) and send them to differentiated waste collection
sites, as provided for by the laws and provisions in force.
1. Drain tanks and remove tubing from actuator. Remove accessories
(if equipped) and controls from actuator.
2. Remove all equipment mounted on top of actuator (limit switches, end of
stroke valve and relevant pneumatic/electric connection, etc.).
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.

54 Removal and Decommissioning

Installation, Operation and Maintenance Manual Appendix
VA-DC-000-1878 Rev. 1 June 2024

Appendix A: List of Tables

Table 1. G-Series Models.......................................................................................................3
Table 2. Housing Cover Screw Quantity and Torque.................................................... 21
Table 3. Piston Rod Torque Information......................................................................... 23
Table 4. Tie Bar Nuts........................................................................................................... 26
Table 5. G2 Tie Bar Nuts..................................................................................................... 28
Table 6. Hex Cap Screw Length......................................................................................... 35
Table 7. M18 Override Cylinder End Cap to SR Cartridge Screw Torque................. 36
Table 8. Minimum Turns..................................................................................................... 40
Table 9. Spring Cartridge Tension Rod Torque.............................................................. 40
Table 10. M18 Override Cylinder End Cap to SR Cartridge Screw Torque................. 41
Table 11. M18 Hydraulic Override System Fluid Volume .............................................. 45
Table 12. Module Weight by Item Number and Actuator Housing Size.................... 45
Table 13. G01 Tool Style and Wrench Size........................................................................ 47
Table 14. G2 Tool Style and Wrench Size.......................................................................... 47
Table 15. G3 Tool Style and Wrench Size.......................................................................... 48
Table 16. G4 Tool Style and Wrench Size.......................................................................... 48
Table 17. G5 Tool Style and Wrench Size.......................................................................... 49
Table 18. G7 Tool Style and Wrench Size.......................................................................... 49
Table 19. G8 Tool Style and Wrench Size.......................................................................... 50
Table 20. G10 Tool Style and Wrench Size........................................................................ 50
Table 21. M18 Tool Style and Wrench Size....................................................................... 51
Table 22. Fault Location Table............................................................................................. 52
Table C-1. Ambient and ATEX Temperatures...................................................................... 69

Appendix 55
Appendix Installation, Operation and Maintenance Manual
June 2024 VA-DC-000-1878 Rev. 1

Appendix B: List of Drawings

B.1 Part Number 121410, G1/2/3/4/5-SRX-H
Pneumatic Assembly Drawing, Sheet 1 of 2

56 Appendix
Installation, Operation and Maintenance Manual Appendix
VA-DC-000-1878 Rev. 1 June 2024

B.2 Part Number 121410, G1/2/3/4/5-SRX-H

Pneumatic Assembly Drawing, Sheet 2 of 2

Appendix 57
Appendix Installation, Operation and Maintenance Manual
June 2024 VA-DC-000-1878 Rev. 1

B.3 Part Number 121411, G7/8/10/13-SRX-H

Pneumatic Assembly Drawing, Sheet 1 of 2

58 Appendix
Installation, Operation and Maintenance Manual Appendix
VA-DC-000-1878 Rev. 1 June 2024

B.4 Part Number 121411, G7/8/10/13-SRX-H

Pneumatic Assembly Drawing, Sheet 2 of 2

Appendix 59
Appendix Installation, Operation and Maintenance Manual
June 2024 VA-DC-000-1878 Rev. 1

B.5 Part Number VA-ED-005-1120, M18

Assembly Drawing, Sheet 1 of 7

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B.6 Part Number VA-ED-005-1120, M18

Assembly Drawing, Sheet 2 of 7

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B.7 Part Number VA-ED-005-1120, M18

Assembly Drawing, Sheet 3 of 7

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B.8 Part Number VA-ED-005-1120, M18

Assembly Drawing, Sheet 4 of 7

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B.9 Part Number VA-ED-005-1120, M18

Assembly Drawing, Sheet 5 of 7

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B.10 Part Number VA-ED-005-1120, M18

Assembly Drawing, Sheet 6 of 7

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B.11 Part Number VA-ED-005-1120, M18

Assembly Drawing, Sheet 7 of 7

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B.12 Part Number VA122588, G1/2/3/4/5-SRX-H

Hydraulic Assembly Drawing, Sheet 1 of 2

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B.13 Part Number VA122588, G1/2/3/4/5-SRX-H

Hydraulic Assembly Drawing, Sheet 2 of 2

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B.14 Part Number VA138334, G Drive Module

Assembly Drawing, Sheet 1 of 1

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Appendix C: Safety Instructions for

Use in (Potential)
Explosive Atmosphere
C.1 Intended Use
The actuator series have been designed to comply with the explosion safety
requirements in the Ex-standards EN IEC 60079-0:2018, EN ISO 80079-36,
EN ISO 80079-37:2016 and EN 1127-1:2019. These standards contain the
requirements for non-electrical equipment in potentially explosive atmospheres.
The actuators comply with the constructional safety type “c” requirements. The
actuators are designed for gas group IIB or IIC and dust group IIIC applications and
are applicable in temperature classes T6 to T3 depending on model. The Equipment
Protection Level is Gb for gas and Db for dust, so the actuators can be used in Ex
classified hazardous zones 1/21.

C.2 ATEX Marking

Complete ATEX Marking:
II 2 G Ex h IIB or IIC T6 to T3 Gb
II 2 D Ex h IIIC T85 °C to T200 °C Db
Ambient Temperature Ranges (Tamb):
• Standard Temperature: -20 to 200 °F / -29 to 93 °C
• Low Temperature: -40 to 150 °F / -40 to 65 °C
• High Temperature: 0 to 350 °F / -18 to 176 °C

NOTES:
1. The minimum and maximum temperatures can vary according to the project
design (gaskets, O-rings and grease used) as well as other certifications within
the given range. Please refer to the special conditions for safe use.
2. Hazardous area is likely to occur in normal operation occasionally in greater
than 10 and less than 1000 hours/year.

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C.3 Safety Instructions

1. Before the installation, please carefully read the service instructions. Emerson
is not responsible for damages caused by operations not complying with the
instructions contained in such manuals.
2. All the operations shall be done by a trained and qualified operator. All
maintenance operations must be performed in accordance with the
instructions detailed in the maintenance manual.
3. The assembly cannot be installed and used in classified areas as zone 0 to 20,
mines (group I).
4. The equipment shall be installed in a place where the risk of lightning is
covered by the relevant industrial code of practice.
5. Assembly, disassembly and maintenance is only allowed at the actuator, when
at the time of the activity, there are no explosive mixtures.
6. During maintenance operations, the user must take all appropriate measures
to prevent risks related to the toxicity of substances, using appropriate
protective equipment (e.g., gloves, goggles, face mask), according to the
extent provided the technical and organizational point of use and the
recommendations provided in the specifications of the used substances.
7. All the mechanical components do not have ignition sources during the
normal working process. The user shall check periodically the vibration
presences and/or abnormal noises and it must stop the unit immediately,
check the causes and contact the manufacturer.
8. Actuators do not have an inherent ignition source due to electrostatic
discharge, but explosion hazards may be present due to the discharge of
static electricity from other valve assembly components.
a. To avoid personal injury or property damage, make sure that the
valve is grounded to the pipeline before placing the valve assembly
into service.
b. Use and maintain alternate shaft-to-valve body bonding, such as a
shaft-to-body bonding strap assembly.
c. The equipment must be earthed through an anti-loosening and
anti-rotation device. The user must regularly check the effectiveness of
the ground connection.
d. A warning is present into the label: “Potential Electrostatic
Charging Hazard”.
9. When equipment is installed in a hazardous area location (potentially
explosive atmosphere), prevent sparks by proper tool selection and avoiding
other types of impact energy.
10. It is under end user responsibility to avoid the explosive mixture inside
the actuator.
11. To avoid increasing dust explosion risk, periodically clean dust deposits from
all equipment.
12. Proper care must be taken to avoid generation of static electricity on the
non-conductive external surfaces of the equipment (e.g., rubbing of
surfaces, etc.).

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13. The paint protection must not exceed 200 μm if the actuator is used in a
group IIC atmosphere. For group IIA or IIB atmospheres, the paint protection
must not exceed a thickness of 0.08 in. / 2 mm.
14. For single acting actuators, it is necessary to use safe air and to convey by a
piping inlet/exhaust of the cylinder outside of the Ex-zone (Safe Area).
15. After maintenance operations are carried out, perform a few actuator
operations to check that its movement is regular and that there is no air/oil
leakage through the seals/gaskets.
16. It is under end user responsibility to make sure the electrical equipment
installed on the actuators have a separated ATEX evaluation and they
are designed according to the ATEX Directive and they are suitable for
the installation zone, group of gas, temperature class, maximum surface
temperature, EPL and range of temperature.
17. It is forbidden to use this equipment in a different way if it is not included in
the instruction manual. Emerson is not responsible for damages caused by
an improper and/or dangerous use.

C.4 Maximum Temperatures

! WARNING
The actuator’s surface temperature is dependent upon process operating
conditions. Personal injury or property damage caused by fire or explosion, can
result if the actuator’s surface temperature exceeds the acceptable temperature
for the hazardous area classification. To avoid an increase of instrumentation
and/or accessory surface temperature due to process operating conditions, ensure
adequate ventilation, shielding or insulation of these actuator components installed
in a potentially hazardous or explosive atmosphere.

Table C-1. Ambient and ATEX Temperatures

Temperature

TX Valid Actuator Trim

Ambient Range ATEX Class (ATEX Surface
Temperature)

-20 to 167 °F / -29 to 75 °C T6 T185 °F / T85 °C

-20 to 194 °F / -29 to 90 °C T5 T212 °F / T100 °C Standard Temperature Trim

-20 to 200 °F / -29 to 93 °C T4 T217 °F / T103 °C

-40 to 150 °F / -40 to 65 °C T6 T167 °F / T75 °C Low Temperature Trim
0 to 257 °F / -18 to 125 °C T4 T275 °F / T135 °C
High Temperature Trim
0 to 350 °F / -18 to 176 °C T3 T367 °F / T186 °C

Note:
The specified values are valid with condition: Maximum cycle frequency of the actuator is less than 1 Hz
at a maximum of 50 cycles per hour and at maximum load.

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