P/N 3121269

MARCH 2000

A ssembly and D isassembly Instructions

A C T U A T O R P/N 3121269

These instructions are for use with Hydril Actuator

P/N 3121269 & P/N 3126581
To be used as a guideline for the Disassembly and
Assembly of prior Hydril Actuator models P/N
3115185, P/N 3117775, and P/N 3120335
Refer To Hydril Kellyguard and Actuator Manual
Manual 9602B to determine P/Ns, bolt and nut
torque's, and lubricant requirements

H A N D T O O L S NEEDED
Tools needed in addition to the
required tool list in the Hydril Kelly
Guard Actuator Manual (# 9602b):
(1) PLASTIC MALLET
(2) BLADE SCREW DRIVERS
(1) 2.0 X 2.0 X 18.0 WOODEN BLOCK
(1) 3/4 X 3/4 X 4.0 BRASS ROD
(1) 1.0 X 3.0 NYLON STRAP
(1) 2,000 LB. JIB HOIST
3

FULLY ASSEMBLIED HYDRIL ACTUATOR

WITH THE ACTUATOR IN THIS POSITION

REMOVE (4) TIE ROD NUTS.

AFTER (4) TIE ROD NUTS ARE LOOSE REMOVE

UPPER STATOR HOUSING
6

SET UPPER ROTOR ASSY ON TABLE

BE CAREFUL TO KEEP CLEAN

ACTUATOR ASSEMBLY WITH UPPER

ROTOR REMOVED

REMOVE CRANK RETAINER PLATE NUTS

(4) RETAINER NUTS

REMOVE (2) CRANK RETAINER PLATES

10

USE PLASTIC MALLET TO REMOVE

(2) CRANK SHAFTS

11

UNSCREW (2) LOCATING PINS

12

REMOVE (2) LOCATING PINS COMPLETELY

13

USING A PLASTIC HAMMER AND PIECE OF WOOD,

DRIVE PISTON DOWNWARD
ALTERNATE HITTING PISTON AT 180 DEGREES
INTERVALS

14

ALTERNATE HITTING 180 DEGREES UNTIL

PISTON IS IN THE DOWN POSITION
15

LIFT OUTER CYLINDER UNTIL FREE

16

OUTER CYLINDER NOW FREE TO REMOVE

17

MAY NEED TO
DRIVE
PISTON FROM
OUTER
CYLINDER
USING A
PLASTIC
HAMMER AND
WOOD WITH
THE OUTER
CYLINDER
SUSPENDED

18

COMPLETELY REMOVE OUTER CYLINDER

AND SET ASIDE
KEEP CLEAN

19

LIFT INNER CYLINDER TILL FREE THEN

COMPLETELY REMOVE

20

REMOVE (4) TIE RODS

21

(4) TIE RODS REMOVED

22

REMOVE CRANKS ARMS FROM BOTH SIDES

23

REMOVE PISTON AND SET ASIDE

24

LIFT AND TURN OVER LOWER ROTOR AND

STATOR ASSEMBLY

25

WITH THE LOWER ROTOR AND STATOR

ASSEMBLY TURNED OVER, SET ON TABLE

26

REMOVE (8) HEX HEAD SCREWS FROM UPPER

27
ROTOR AND STATOR ASSEMBLY

USING A SMALL CHISEL AND PLASTIC HAMMER BEND

BACK WASHER TABS TO ALLOW ACCESS TO REMOVE
(8) HEX HEAD BOLTS FROM THE LOWER ROTOR
28
AND STATOR ASSEMBLY

REMOVE (8) HEX HEAD SCREWS FROM LOWER

ROTOR AND STATOR ASSEMBLY
29

WITH (2) SCREW DRIVERS 180 DEGREES APART

SEPARATE LOWER ROTOR AND STATOR 30
ASSEMBLY

LIFT LOWER STATOR FROM LOWER ROTOR

AND SET ASIDE
31

REMOVE THE UPPER STATOR FROM UPPER

32
ROTOR AND SET ASIDE

USING A SCREW DRIVER CAREFULLY PRY OUT

RETAINING RING FROM UPPER ROTOR
33

USING (2) SCREW DRIVERS CAREFULLY REMOVE

THE RETAINING RING FROM THE UPPER ROTOR

34

RETAINING RING REMOVED FROM THE

UPPER ROTOR

35

REMOVE RETAINING RING FROM LOWER ROTOR

36

USING A PLASTIC HAMMER AND A BRASS BAR,

CAREFULLY DRIVE DOWN BEARING RETAINER
RING AND BALL BEARING FROM UPPER ROTOR

37

USING A PLASTIC HAMMER AND A BRASS ROD,

DRIVE DOWN BEARING RETAINER RING AND BALL
38
BEARING FROM LOWER ROTOR

REMOVE BALL BEARING FROM UPPER ROTOR39

REMOVE RING BEARING RETAINER FROM

UPPER ROTOR

40

REMOVE BALL BEARING FROM LOWER ROTOR

41

REMOVE BEARING RETAINER RING FROM

LOWER ROTOR

42

REMOVE (2) UPPER POLYPAK ROTATING INNER SEALS43

FROM BOTH THE UPPER AND LOWER STATORS

REMOVE (2) LOWER POLYPAK ROTATING INNER SEALS

FROM BOTH THE UPPER AND LOWER STATORS
44

DISCARD (4) OLD/USED POLYPAK ROTATING

INNER SEALS

45

CAREFULLY REMOVE (2) OUTER PISTON SEALS

46
AND DISCARD

REMOVE AND DISCARD (2) INNER

PISTON SEALS

47

ACTUATOR COMPLETELY DISASSEMBLIED AND

LAY OUT ON TABLE READY FOR REASSEMBLY 48

INSTALLATION OF POLYPAK ROTATING SEALS IN

UPPER AND LOWER STATORS
INSTALL FRONT OF SEAL IN BOTTOM AREA OF UPPER
AND LOWER STATORS AND WORK SEAL CLOSE TO YOU
49
INTO THE UPPER GROOVE

PULL SEAL INTO UPPER GROOVE AND WORK THE SEAL

INTO UPPER GROOVE AROUND THE ROTOR
INSTALL POLYPAK ROTATING SEAL INTO LOWER
50
GROOVE OF BOTH UPPER AND LOWER STATORS

GREASE ROTATING SEAL AREA OF UPPER AND

51
LOWER ROTORS

PLACE UPPER BEARING RETAINER RING

INSIDE BOTTOM AREA OF UPPER ROTOR

52

INSTALL BALL BEARING IN UPPER ROTOR

53

USING A PLASTIC MALLET, TAP BALL

BEARING INTO PLACE

54

USING HANDS, INSTALL RETAINING RING

INTO GROOVE

55

LOWER UPPER STATOR DOWN ONTO

UPPER ROTOR

56

INSTALL (8) HEX HEAD CAP SCREWS

AND TIGHTEN

57

TIGHTEN (8) HEX HEAD BOLTS

58

PLACE LOWER BEARING RETAINER RING INTO

59
BOTTOM OF LOWER ROTOR

PLACE AND INSTALL BALL BEARING INTO LOWER

ROTOR
USING A PLASTIC MALLET, TAP BALL BEARING
60
INTO PLACE

USING HANDS INSTALL RETAINING RING INTO

61
LOWER ROTOR

PLACE LOWER STATOR OVER LOWER ROTOR62

INSTALL (8) TAB WASHERS AND (8) HEX HEAD

63
SCREW AND TIGHTEN

USING A SMALL METAL CHISEL, BEND WASHER

TABS INTO A LOCK POSITION AROUND
HEX HEAD SCREWS

64

INSTALL OUTER PISTON SEALS

65

INSTALL INNER PISTON SEALS

66

NOTE LOCATION OF LOCATING SLOT

67

PLACE PISTON ONTO LOWER STATOR AND ROTOR

ASSEMBLY
NOTE: PISTON LINK MUST BE POINTING AWAY FROM
LOCATING PIN AS SHOWN IN PICTURE

68

INSTALL (4) TIE RODS AND TIGHTEN

69

(4) TIE RODS INSTALLED

70

INSTALL (4) CRANK ARMS

71

(4) CRANK ARMS INSTALLED

72

GREASE OUTSIDE OF INNER CYLINDER PRIOR

73
TO INSTALLATION

LOWER INNER CYLINDER INTO LOWER ROTOR74

NOTE: INNER CYLINDER LOCATING PIN AT BOTTOM I.D.

OF CYLINDER AND THE LOCATING GROOVE IN ROTOR 75

USING A PLASTIC MALLET, TAP INNER CYLINDER INTO

POSITION
WATCH TO MAKE CERTAIN LOCATING PIN ON BOTTOM
OF INNER CYLINDER LINES UP WITH LOCATING
76
GROOVE IN ROTOR

GREASE I.D. OF OUTER CYLINDER

77

LOWER OUTER CYLINDER DOWN ONTO LOWER ROTOR

NOTE: MAKE CERTAIN TO LINE UP THE LOCATING
NOTCH IN THE OUTER CYLINDER WITH THE LOCATING
78
PIN ON THE LOWER ROTOR, SEE PICTURE

ONCE AGAIN: MAKE CERTAIN LOCATING NOTCH

AND PIN ARE LINED UP CORRECTLY AS OUTER
79
CYLINDER IS LOWERED INTO PLACE

USING A PLASTIC MALLET TAP OUTER

CYLINDER IN PLACE

80

INSTALL (2) LOCATING PINS AND TIGHTEN

81

INSTALL 2ND LOCATING PIN

82

PREPARE FOR ISTALLATION OF (2) CRANK SHAFTS

NOTE LOCATION OF THE (2) KEYS IN THE SHAFTS
PRIOR TO INSTALLATION

83

PRIOR TO INSTALLING CRANK SHAFTS USE FINGER

TO POSITION CRANK ARMS PRIOR TO THE
84
INSTALLION OF THE CRANK SHAFT

INSTALL (2) CRANK SHAFT

NOTE: POSITION OF INDICATING NOTCH ON CRANK
SHAFT MUST BE IN THE UP POSITION

85

BOTH CRANK SHAFTS INSTALLED

86

INSTALL (2) CRANK RETAINER, (4) CRANK

LOCKWASHERS, (4) CRANK RETAINER
LOCKNUTS AND TIGHTEN

87

LOWER UPPER ROTOR ASSEMBLY DOWN ONTO (4) TIE

ROD BOLTS
NOTE: PLACE (4) TIE ROD HEX NUTS LAYING LOOSE IN
THE (4) MILLED SLOT AREAS IN ROTOR PRIOR TO
LOWERING ROTOR INTO PLACE
88

NOTE: MAKE CERTAIN TO LINE UP THE

LOCATING NOTCH AND LOCATING PIN
BEFORE TAPPING INTO PLACE

89

NOW CAREFULLY START THE (4) TIE ROD HEX

90
NUTS AND TIGHTEN EVENLY

A FULLY ASSEMBLIED UNIT

91

PRIOR TO MOUNTING ONTO A KELLY GUARD

PLACE (2) MOUNTING SLEEVE HALVES TOGETHER
WITH THE RETAINING GROOVE UP
INSTALL RETAINING RING

92

PRIOR TO PLACING ACTUATOR OVER THE MOUNTING

SLEEVES AND KELLY GUARD USE (2) ALLEN WRENCHS
TO ROTATE THE CRANKS IN THE POSITION SHOWN

93

IF FU R T H E R INFO R M A TION IS
NEEDED REGARDING THE
HYDRIL ACTUATOR,
C O N T A C T H Y D R I L C O M PA N Y , HTC,

H O U STON, T E X A S
PHONE # 1-281-449-2000
SA L ES A N D M A R K E T I N G
FA X # 1-281-985-8665
OR CONTACT THE
L O C A L H Y D R I L SA L ES A N D SERV I C E
.
C E N T E R IN Y O U R A R E A

94