Masoneilan Manual

Instruction Manual
EF35002
08/10
Putting You In Control
35002 Camflex II Series
Rugged, All-Purpose
Rotary Control Valves
Table of Contents
Page
SAFETY INFORMATION.......................................................................................................1
ABOUT THIS MANUAL.........................................................................................................1
WARRANTY...........................................................................................................................1
1. INTRODUCTION................................................................................................................2
2. GENERAL...........................................................................................................................2
3. PRINCIPLE OF OPERATION............................................................................................2
4. UNPACKING......................................................................................................................3
5. INSTALLATION..................................................................................................................3
6. AIR SUPPLY PIPING.........................................................................................................4
7. PLACING IN SERVICE......................................................................................................4
8. DISASSEMBLY..................................................................................................................4
8.1 ACTUATOR REMOVAL FROM BODY S/A...............................................................4
8.2 ACTUATOR COMPLETE DISASSEMBLY................................................................5
8.3 VALVE BODY..........................................................................................................5
9. MAINTENANCE.................................................................................................................7
9.1 SPRING DIAPHRAGM REPLACEMENT...................................................................7
9.2 BODY S/A INTERNAL PARTS.................................................................................8
9.3 YOKE ASSEMBLY...................................................................................................9
10. REASSEMBLY PROCEDURES.......................................................................................9
10.1 SPRING DIAPHRAGM ACTUATOR.......................................................................9
10.2 SPRING DIAPHRAGM ACTUATOR ON BODY S/A...............................................9
10.3 HANDWHEEL REASSEMBLY..............................................................................10
10.4 LIMIT STOP REASSEMBLY.................................................................................10
10.5 VALVE BODY REASSEMBLY..............................................................................10
10.6 SEAT RING ALIGNMENT.....................................................................................11
10.7 DVD PLATE REASSEMBLY.................................................................................12
11. ACTUATOR STEM ADJUSTMENT...............................................................................12
12. CHANGING BODY POSITION......................................................................................13
13. CHANGING ACTUATOR ACTION................................................................................14
14. MANUAL ACTUATOR OPTION....................................................................................15
14.1 DISASSEMBLY PROCEDURE.............................................................................15
14.2 MAINTENANCE...................................................................................................15
14.3 REASSEMBLY PROCEDURE..............................................................................15
Copyright
Masoneilan is a registered trademark of Dresser, Inc. All information contained herein is believed to be accurate at the time of
publication and is subject to change without notice.
Copyright 2010 by Dresser, Inc. All rights reserved.
Safety Information
About this Manual

The information in this manual is subject to change without
prior notice.
Important - Please Read Before Installation

Masoneilan 35000 Series control valve instructions contain
DANGER, WARNING, and CAUTION labels, where necessary,
to alert you to safety related or other important information. Read
the instructions carefully before installing and maintaining your
control valve. DANGER and WARNING hazards are related
to personal injury. CAUTION hazards involve equipment or
property damage. Operation of damaged equipment can, under
certain operational conditions, result in degraded process system
performance that can lead to injury or death. Total compliance
with all DANGER, WARNING, and CAUTION notices is required
for safe operation.
The information contained in this manual, in whole or part,

shall not be transcribed or copied without Masoneilans
written permission.
Please report any errors or questions about the information
in this manual to your local supplier.
These instructions are written specifically for the 35000 Series
control valve, and do not apply for other valves outside of
this product line.
Warranty
Items sold by Dresser , Inc. are warranted to be free from
defects in materials and workmanship for a period of one
year from the date of shipment provided said items are
used according to Dresser recommended usages. Dresser,
Inc. reserves the right to discontinue manufacture of any
product or change product materials, design or specifications
without notice.
This is the safety alert symbol. It alerts you to potential personal

injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.
Note: Prior to installation

The valve must be installed, put into service and
maintained by qualified and competent professionals
who have undergone suitable training.
Indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.
All surrounding pipe lines must be thoroughly flushed

to ensure all entrained debris has been removed from the
system.
Under certain operating conditions, the use of damaged
equipment could cause a degradation of the performance
of the system which may lead to personal injury or death.

could result in serious injury.
Changes to specifications, structure, and components

used may not lead to the revision of this manual unless
such changes affect the function and performance of the
product.

could result in minor or moderate injury.
When used without the safety alert symbol indicates a

potentially hazardous situation which, if not avoided, could
result in property damage.
Note: Indicates important facts and conditions.
Instructions EF35002 - 08/10

Camflex II 35002 Series Control Valves
1. Introduction
3. Principle of Operation
The following instructions are designed to assist maintenance

personnel in performing most of the maintenance required on the
Camflex II valve and if followed carefully will reduce maintenance
time.
The concept of the Camflex II valve is based on an eccentrically

rotating spherical plug contained in a free flow body design. The
plug seating surface is joined by flexible arms to a hub which
slides onto a rotating shaft. The plug is free to center itself along
the axis of the shaft. A positive seal between plug and seat is
achieved by elastic deformation of the plug arms. The chamfered
seat ring is fixed in the valve body by a threaded retainer.
Masoneilan has highly skilled Service Engineers available for

start-up, maintenance and repair of our valves and component
parts. In addition, regularly scheduled training programs are
conducted to train customer service and instrumentation
personnel in the operation, maintenance and application of
our control valves and instruments. Arrangements for these
services can be made through your Masoneilan Representative
or District Office. When performing maintenance use only
Masoneilan replacement parts. Parts are obtainable through
your local Masoneilan Representative or District Office. When
ordering parts always include Model and Serial Number
of the unit being repaired.
The plug and shaft are rotated through an angle of 50 by a lever

linked to a powerful spring-opposed rolling diaphragm actuator.
The solid disk-type handwheel and locking hex nut, optional, are
mounted on the yoke, opposite the actuator and may be used
to manually operate the valve or as a limit stop. A threaded hole
in the opposite side of the yoke is plugged but can be equipped
with an optional cap screw and locknut, which may be inserted
as a limit stop in the other direction, or in combination with the
handwheel to lock the valve in a selected position.
2. General
The handwheel on Camflex II is designed to be used for

emergency action only.
These installation and maintenance instructions apply to 1"

through 12" sizes (DN 25 through 300 sizes), all available
ratings, and pneumatic actuators. The model number, size and
rating of the valve are shown on the serial plate. Refer to Figure
1 to identify the valve model.
35002 Series Body Numbering System

Actuator Assembly Digits
1st
Body Assembly Digits
2nd
Actuator Type
20 Manual Actuator
35 Spring-opposed
rolling-diaphragm
70 Double acting
cylinder
Body
Series
35 Valve
1st
2nd
3rd
Seat Design
Actuator Mounting
1 Parallel to pipeline, valve closes
on stem extension
2 Parallel to pipeline, valve opens
on stem extension
3 Perpendicular to pipeline, valve
closes on stem extension
opens on stem extension
5 Parallel to pipeline, valve closes
on stem extension
6 Parallel to pipeline, valve opens
on stem extension
closes on stem extension
opens on stem extension
Figure 1
5th
SB
(1) optional, Camflex with separable bonnet.

4th
1
2
3
4
5
Metal
Soft seat
Metal seat Lo-dB
Soft seat Lo-dB
Ceramic TRIM
Design
Series
Design
SB(1)
Seat Ring
Plug
Fluid Flow
Shaft
Guide Bushing
Handwheel
Flexible Arms
Guide Bushing
Lever
Actuator
Air
Figure 2
The actuator is generally mounted with air-loading to counter the
dynamic torque on the plug. In Figure 2 the flow direction tends
to open the plug and the actuator is oriented to close it with
increasing air pressure. The actuator spring force assists plug offbalance forces to open the valve on air failure. If the valve is to
close on air failure, the body would be turned around in the line so
that flow tends to close the plug and the actuator position would
be reversed.
4. Unpacking
Care must be exercised when unpacking the valve to prevent
damage to the accessories and component parts. Should
any problems arise, contact the Masoneilan Representative or
District Office.
Note: For ease of shipment and to prevent damage, valves
equipped with the spring diaphragm actuator are shipped
with the handwheel unassembled. Refer to Section 10.3 for
handwheel assembly procedures.
The Camflex II valve has a modified linear flow characteristic,

which is the same in either flow direction. It can be easily
transformed to an equal percentage when equipping the valve
with a positioner [4700 series, 8000 series, SVI (Smart Valve
Interface) or FVP (Fieldbus Valve Positioner)]. Reduced TRIM
factors 0.4 and 0.6 are available on all sizes. The flow capacity
of a 0.4 factor is 40% of the nominal capacity of the valve and it
is 60% for the 0.6 factor. Factors 0.1 and 0.2 are available on the
1" (DN 25) valve.
5. Installation
The Camflex II valve has been assembled at the factory in
accordance with specific instructions concerning flow direction
and actuator mode. The valve must be installed so that the
controlled substance will flow through the valve in the direction
indicated by the flow arrow (25), which is located on the upper
part of the valve bonnet. The valve actuator should be installed
so the actuator is above the centerline of the shaft. To install the
valve in the line, proceed as follows:
WARNING
The ability of the Camflex II valve to handle a wide range of

process fluid temperatures is due to the long integrally cast
bonnet. This affords ample radiation surface to normalize the
packing temperature. Therefore, with self-lubricating TFE Aramid
fiber packing, the valve handles temperatures from -200C to
+ 400C (-320F to +750F). When insulating the valve, do not
insulate the valve bonnet (see Figure 3).
CAUTION
Any change in flow direction or actuator mode must be
accomplished as outlined in Sections 7 and 10 of this instruction
manual. Failure to follow these could result in personal injury and
equipment malfunction.
CAUTION
A. Check the model number on the serial plate (56) against the
numbering System described in Figure 1 to determine the
valve mode.
B. Clean piping and valve of all foreign material such as welding
chips, scale, oil, grease or dirt. Gasket surfaces should be
thoroughly cleaned to ensure leak proof connections.
Figure 3
C. To allow for in-line inspection, maintenance or removal of

the valve without service interruption, provide a manually
operated stop valve on each side of the Camflex II valve
with a manually operated throttling valve mounted in the
by-pass line.

7. Placing inService
With the valve properly installed in the line and all air or electrical
service connected, it is recommended that the valve be run
through one cycle to ensure proper functioning. Proceed as
follows:
Note: If a flanged Camflex II is being installed and the

distance between flanges is established by ANSI or DIN,
spool pieces (spacers) are inserted between the line flange
and the valve body flange. Gaskets and valve bolting are
then installed and torqued using standard flange and line
bolting criteria.
A. Back off the handwheel (53) so that it will not interfere with the
operation of the valve and tighten the handwheel lock (52).

D. For flangeless valves, refer to Figure 23 and determine the

correct size and quantity of bolts to be used for the valve and
flange rating.
Note: If the valve is equipped with the optional limit stop

(77), it should also be backed off to prevent interference
with the operation of the valve.
B. Apply correct air pressure to the actuator.

Note: Valve should function smoothly and with maximum

pressure, the valve indicator (6) should show full open or
full close depending on valve mode.
E. If the valve is to be installed in a horizontal position, install the

lower flange bolting to provide a cradle, which will help support
the valve while installing the remaining bolts.
C. Relieve air pressure and return valve to normal mode.
F. Place the valve in the line.
D. Gradually open process lines to place the valve in service.
G. Select and install correct gaskets.
E. Check for leaks. Repair as required.
WARNING
Note: Spiral wound gaskets, suitable for service conditions

are recommended.
H. Insert remaining flange bolting ensuring that the bolts align

with the special bosses on the body, which assure the valve is
centered in the line and also prevent rotation.

Note: For certain flange standards, through bolting is not

possible because of the valve body neck or bonnet. To
accommodate flange bolting, guide arms with threaded
holes or slots are provided on the valve body to receive
flange bolts (refer to Figure 22).
F. If desired, the handwheel may be used as a limit stop. Set in

desired position and lock.
G. If the optional limit stop (77) is used, set and tighten locknut.
I. Tighten flange bolts evenly and firmly.
8. Disassembly
CAUTION
If the valve is to be insulated, do not insulate the valve bonnet.
Note: If the valve is equipped with manual handwheel, it

may now be placed in service.
8.1 Actuator Removal From Body S/A (Refer to

Figure 16 and Figure 17)

CAUTION
WARNING
6. Air Supply Piping
CAUTION
Do not exceed maximum air pressure indicated. Personal injury
and equipment malfunction could result.
Note: When the valve is equipped with regulators or other
accessories supplied by Masoneilan, only connections to
those accessories are required since the piping to the actuator is connected at the factory. Some valves equipped with
electrical accessories will require appropriate wiring. Refer to
manufacturers instructions for correct wiring information.
CAUTION
DANGER
Maintenance required on the internal components of the

valve or re-orientation of the actuator and body, requires that
the actuator and yoke be removed from the valve. On the size
6, 7 and 9 actuators, for ease of handling and reassembly, it
is recommended that the spring barrel be removed from the
yoke and then the yoke separated from the valve body.
WARNING
DANGER
CAUTION
Air is supplied to the actuator through the 1/4" NPT tapped

connection in the diaphragm case. Refer to Figure 14 to
determine the correct supply pressure and tubing size, then
connect air supply piping.

Always ensure process pressure, air pressure and electrical

service are off and the valve is isolated and relieved of
pressure before performing maintenance on the valve.
CAUTION
WARNING
CAUTION
Prior to performing maintenance on the valve, isolate the

valve, vent the process pressure and shut off supply and
signal air lines to the actuator.
Note: If the valve will be reassembled in the same

orientation, it is recommended that the body to yoke
orientation and the actuator to yoke orientation be marked
in relation to each other. This will simplify reassembly.
CAUTION
A. If required, remove the valve from the line.

B. Remove rear cover (29) and front cover (32) by removing
the two cover screws (30).
C. Remove bottom cover (11) and spring barrel boss
cover (58).
D. Remove indicator (88) by removing the two screws (89).
8.2 Actuator Complete Disassembly
E. Loosen handwheel lock (52) and turn handwheel (53) so it

does not interfere with the movement of the lever (34).
Note: On valves supplied with the optional limit stop,

(Figure 17) loosen nut (78) and back off the limit stop
screw (77) so it will not interfere with the movement of
the lever (34).
A. If the actuator is not removed from the body proceed to

the paragraph 9.1 A. to 9.1 L.
WARNING
F. Connect an air line to the actuator supply port and using

a manual loading panel or regulated air supply, apply
enough air pressure to the actuator so the lever will
move to an intermediate position.
B. Loosen locknut (46) then remove the clevis (35) and the
locknut (46).
C. Loosen and remove capscrew (41) and remove diaphragm case (42) and diaphragm (40).
CAUTION
The spring diaphragm actuator used on the Camflex II valve

was designed basically as a low cost non-replaceable item
and therefore disassembly is not recommended. However, in
some instances and for emergency purposes, disassembly
may be required. Proceed as follows.
D. Using a deep socket, loosen and remove locknut (45)

and washer (44).
Do not exceed pressure listed in Figure 14 for actuator

used. Do not use handwheel to move the lever.
E. Remove piston (43) and spring (39) and inspect all

components.
Note: If the valve is to be reassembled using the same

orientation, it is recommended that the yoke (33) and
lever (34) alignment, in the closed position, be marked
to simplify reassembly and alignment of the lever and
shaft to ensure proper valve functioning. See Figure 17.
F. Proceed to section 10.2 for reassembly.
CAUTION
8.3 Valve Body (Refer to Figures 4 and 16)

G. Remove clevis pin clips (5).

H. Remove clevis pin (7).
I. Relieve air pressure from actuator enabling clevis (35) to
disengage from lever (34).

WARNING
WARNING
Note: If the valve is equipped with a positioner, refer to

the appropriate positioner instruction for procedures on
cam or lever removal. Then proceed to step K.
J. Remove shaft cover (9) by removing cover screw (10).
DANGER
CAUTION
Maintenance to the internal components required on

the Camflex II Valve can normally be easily determined
since the seat ring and plug can be seen once the valve
is removed from the line. Although it may be determined
that the seat ring does not need replacement, it must be
noted that the new plug and seat ring must be lapped, thus
requiring the disassembly of the body. It is recommended
that both seat ring and plug be replaced if one or the other
is damaged due to service.
After the actuator has been removed from the body, disassemble the valve using the following procedure:
CAUTION
Depending on the size and weight of the actuator. It is

recommended that proper lift and support procedures
be utilized when removing the spring barrel or yoke.
Prior to performing maintenance on the valve, isolate the

valve and vent the process pressure.
A. For 35000 SB (Separable Bonnet) versions, remove
bonnet nuts (104) and lift off bonnet (102) complete with
packing (17) and packing follower (15) from the body as
an assembly. Proceed to step D.
CAUTION
WARNING
CAUTION
K. Ensure spring barrel is properly supported.

L. Loosen and remove cap screws (36) and lockwashers
(37), then remove spring barrel (38).
B. Remove packing follower (15).
M. Loosen lever capscrew (49).
C. Remove safety pin (16).
N. Loosen the stud nuts (94) and disengage the packing

flange.
O. Loosen the stud nuts (27) to separate the actuator from
the body S/A.

Note: With body secure, grasp lever and yoke and

separate. Yoke, lever and packing flange are removed
at the same time. The yoke may have to be struck with
a soft face mallet to break it loose.
The purpose of the safety pin is to prevent the shaft from

being pushed out if the yoke is removed while the valve
is still pressurized. The internal components of the valve
cannot be removed without first removing the safety pin.
CAUTION
DANGER
D. Pull on the shaft (19) to remove it.
DANGER
CAUTION
Note: Difficulty is sometimes encountered when removing

the shaft from the plug mainly due to an excessive
accumulation of deposits between the plug splines and
the shaft. Application of heat to the plug shaft bore while
using one of the following methods will facilitate removal.
CAUTION
When using heating devices, ensure that proper safety

practices are observed. Such items as the flammability
and toxicity of the controlled substance must be
considered and proper precautions taken.
If the shaft is not removed easily, replace the lever (34)

on the splined end of the shaft (19), tighten the lever
capscrew (49) and using a mallet, tap the lever (34) as
close to the shaft as possible and remove the shaft (19).
CAUTION
Do not pry the bushing using the seat for leverage. If the
bushing cannot be easily removed, proceed to section
8.3.1 and remove the seat ring retainer and seat ring then
remove the bushing. Place a piece of soft stock (brass,
etc.) between the inner seat shoulder and prying device to
prevent damage to the seat sealing area of the body.
CAUTION
DANGER
8.3.1 Seat Ring Removal (Refer to Figure 16)
The following procedures outline the recommended

method for removing the seat ring retainer (3) with the
use of retainer wrenches. Masoneilan manufactures
and has available, for a nominal price, seat ring retainer
wrenches for the Camflex II, 1" through 4" (DN 25
through 100) sizes. It is highly recommended that
wrenches be purchased or fabricated to facilitate removal
and reassembly of the seat ring (2) since SPECIFIC
TORQUES MUST BE ACHIEVED to obtain tight shutoff
and ensure proper functioning of the valve.
Figure 5 shows the recommended materials, thickness

and method of construction along with specific
dimensions to facilitate construction.
Note: If the shaft cannot be removed by tapping the

tightened lever, Figure 20 illustrates an alternative method
of removal. Using a pipe nipple of suitable size and length
and reversing the packing flange and stud nuts as shown,
the shaft may be jacked out of the body. For larger valves,
the use of an additional washer and nipple to assist in
holding the tightened lever is recommended. The lever
should be tightened at a point where the hub on the lever
is flush with the end of the spline.
E. The components which should come out with the shaft

(19) are: the packing (17), packing box ring (23 or 100),
spacer tube (20) and upper guide bushing (21).

CAUTION
DANGER
Note: The spacer tube (20) and upper guide bushing

(21) may remain in the body. They should be removed.
The spacer tube (20) can only be removed by pulling
it out the bonnet end of the body. The upper guide
bushing (21) may be pushed through the body after
removing the plug or pulled through the bonnet end
of the body. On valves designed for use on slurry or
viscous service, the upper guide bushing has an inner
O ring (92) and an outer O ring (93) and the lower
guide bushing has inner O ring (95) and outer O ring
(96) (Refer to Figure 4).
93
21
22
3/16" STEEL PLATE

WELDED
KEY
STOCK
B
WELDED
HEX NUT
C
96
A
A = O.D. Seat Ring Retainer
B = Width of slot in Retainer
C = I.D. of Seat Ring Retainer
92
WARNING
Figure 5
95
A. Secure the valve body in a vise or appropriate holding

device with the seat ring facing up.
Figure 4 - Optional O ring arrangement
F. Remove the plug (4) through the end of the body
opposite the seat ring.
G. Remove the lower guide bushing (22).

Note: A groove is provided in the bushing for prying

out the bushing using a screwdriver. If the bushing
will be pried out it should be pried from two sides to
prevent jamming the bushing during removal. If the
bushing does not come out easily, fill the bushing with
grease, insert the shaft (19) into the valve insuring that
the machined portion of the shaft starts into the lower
guide bushing. Using a soft faced mallet, strike the
end of the shaft lightly until the bushing is pushed out
partially. Remove the shaft and complete removal of
the bushing by prying out using the groove provided.

CAUTION
Care must be taken to avoid damage to the gasket
face on the valve body.
B. Place retainer wrench so it engages retainer lugs.
CAUTION
C. Engage the retainer wrench with an impact wrench or

suitable wrench and loosen, then remove retainer (3)
by turning counterclockwise.
D. Lift out seat ring.

Note: In an emergency, drifts may be used to remove

the seat ring retainer. However, two drifts should be
used and placed in the slots 180 apart and struck
simultaneously.
8.3.2 DVD Removal (Refer to Figure 16)

In case of Camflex with the DVD option, model number
35x3x or 35x4x, the DVD is installed in the body, it is
recommended to use the DVD wrenches to remove this
device (105). Masoneilan manufactures and has available,
for a nominal price, DVD wrenches for the Camflex II, 1"
through 12" sizes (DN 25 through 300 sizes). lt is highly
recommended that wrenches be purchased or fabricated
to facilitate removal and reassembly of the DVD (105) since
SPECIFIC TORQUES MUST BE ACHIEVED to ensure
proper clamping of this DVD plate.
CAUTION
C. Engage the retainer wrench with an impact wrench or

suitable wrench and loosen, then remove DVD (105)
by turning counter-clockwise.
9. Maintenance
9.1 Diaphragm Replacement
(Refer to Figures 16 and 17)

WARNING
The recommended maintenance to be performed on the

Camflex II Spring Diaphragm Actuator is limited to the
replacement of the diaphragm (40). Removal of the actuator
from the valve is not required. To replace the diaphragm,
proceed as follows:
DANGER
CAUTION
The valve must be isolated and free from any service pressure.
All electrical or air pressure to component parts must be off.
Pressure to actuator must be relieved.
Handwheel (53) and limit stop (77) must be backed off to

allow free travel of the lever (34).
Valve
Size
Care must be taken to avoid damage to the gasket

face on the valve body.
B. Place DVD plate wrench so it engages retainer lugs.
Figure 6 shows the recommended thickness and

method of construction along with specific dimensions
to facilitate construction.
T
CAUTION
A
d
D
H
T
inches inches inches inches inches
(mm) (mm) (mm) (mm) (mm)
CAUTION
A. Bypass the valve, shut off stop valves and isolate valve in
compliance with CAUTION note listed above.
1"
(DN 25)
1.063
(27)
0.142
(3.6)
1.236
(31.4)
0.079
(2)
0.4
(10)
B. Shut off and disconnect air supply tubing to the actuator.
112"
(DN 40)
1.496
(38)
0.157
(4)
1.772
(45)
0.118
(3)
0.5
(12)
C. Remove the four capscrews (41) from diaphragm case

(42) and remove diaphragm case.
2"
(DN 50)
1.929
(49)
0.157
(4)
2.205
(56)
0.118
(3)
0.7
(18)
D. Remove diaphragm (40).
3"
(DN 80)
2.913
(74)
0.177
(4.5)
3.248
(82.5)
0.157
(4)
0.8
(20)
4"
3.858
(DN 100) (98)
0.197
(5)
4.213
(107)
0.275
(7)
0.8
(20)
6"
5.905
(DN 150) (150)
0.236
(6)
6.260
(159)
0.354
(9)
1.0
(25)
8"
7.913
(DN 200) (201)
0.236
(6)
8.268
(210)
0.394
(10)
1.0
(25)
10"
9.843
(DN 250) (250)
0.236
(6)
10.315
(262)
0.394
(10)
1.2
(30)
12"
11.732
(DN 300) (298)
0.276
(7)
12.204
(310)
0.472
(12)
1.2
(30)
Note: Diaphragm is glued to the top of the piston (43).
E. Remove tape or glue from the top of the piston and

clean thoroughly.
F. Clean diaphragm case (42) and spring barrel (38) at the
area that engages the diaphragm bead in preparation for
reassembly.
DANGER
Note: To hold the diaphragm in place on the piston, an

adhesive disc (adhesive both sides) or rubber cement
is used. If rubber cement is used, it should be applied
to both the piston and the diaphragm or in accordance
with the manufacturers directions for the adhesive
used. For recommended adhesives see Figure 15.
G. Apply adhesive tape or cement to the top of the piston.
Figure 6
H. The inscription Piston Side is located on the diaphragm

6 (40). If used, apply cement to this side of the diaphragm.
A. Secure the valve body in a vise or appropriate holding

device with the plug side facing up (refer to Figure 16).
I. Center and adhere diaphragm (40) to the top of the piston

(43) (see Figure 7, Step A).
J. Roll the diaphragm (40) inside the spring barrel (38) until
the bead on the diaphragm is located in the spring barrel
groove (see Figure 7, Step B).

WARNING
Figure 7
CAUTION
Ensure that the capscrew holes in the diaphragm case

and spring barrel are aligned to prevent twisting of the
diaphragm in aligning the holes. The diaphragm case
(42) is normally assembled with the air inlet port placed
on the bottom side of the actuator. Depending on the
desired location, it can be placed in any desired position
around the spring barrel which allows the capscrew holes
to line up. However, the drain hole in the spring barrel
must always be facing down to allow for draining of any
moisture which may enter the spring barrel cylinder (38). If
the valve is equipped with the optional purge line, that line
is inserted into the drain hole.
9.2.1 Hard Seat Lapping

Lapping is the process of working the valve sealing parts
against each other with an abrasive, to produce a close fit.
To perform the lapping operation, proceed as follows.
A. Clean the seat ring sealing surface in the valve body and
the seat ring shoulder.
CAUTION
B. Apply a small amount of fine grinding compound to the

seat ring shoulder.
K. Place the bead of the diaphragm (40) over the diaphragm

case lip (42) and carefully slide the diaphragm case (42)
down over the piston (43) until it seats on spring barrel (38).
(see Figure 7, Step C).
L. Ensure that the diaphragm case (42) is evenly seated on
the spring barrel (38), insert the four capscrews (41) and
tighten evenly.
DANGER
M. Connect air supply line to diaphragm case (42).
Figure 8
N. Turn on air supply and check for leaks.
9.2 Body S/A Internal Parts
C. Insert the seat ring into the body and lap lightly by
rotating the seat ring in the body, ensuring that the
entire seat ring sealing surface in the valve body is
lapped. Do not rotate in one place.
During a maintenance of Camflex II valve it is necessary

to inspect all the internal parts to determine if they are worn,
corroded and damaged, especially the following seating area:
body and seat ring contact area.
D. Remove seat ring and clean thoroughly.
the seating surface of the plug and seat ring.
E. Place seat ring on a flat surface with the seating area

facing up.
O. If necessary, reposition handwheel (53) and limit stop (77),

(optional) to desired location and place valve back in service.
the guide surface of the shaft and the guide bushing.

F. Apply a small amount of fine grinding compound to the

seat ring seating surface.
All parts which are damaged must be replaced by

original Masoneilan spare parts.

Note: Figure 8 illustrates a simple tool which may

be fabricated to facilitate this lapping operation on
smaller valves.
G. Lap the plug lightly against the seat ring while turning
and oscillating the plug in all directions.
H. Clean seat ring, plug and valve body thoroughly in preparation for reassembly.

9.2.2 Soft Seat
C. Ensure that grommet (12) and shaft bearing (8) are in the
yoke. Turn shaft so the plug is in the closed position.
Do not lap the soft seat ring to the plug; however, the seat
ring must be lapped to the valve body. The procedure for
lapping the seat ring to the body is the same as stated in
items A through D of Section 9.2.1 on Hard Seats.
D. Slide the valve shaft partly into the lower yoke opening,
allowing enough room to place packing flange (14) over the
shaft (19).

9.3 Yoke Assembly (Refer to Figures 16 and 17)

Maintenance required on the yoke (33) is limited to

replacement of the grommet (12) and the shaft bearing
(8). To replace either, the actuator must be separated from
the body. (Depending on the type of actuator used, refer
to appropriate section). Insert the grommet into the yoke
with the recessed part of the grommet towards the shaft
bearing. The shaft bearing (8) is slip fit into the yoke and is
removed by pushing it out towards the grommet.
F. With packing flange on the shaft, continue sliding the valve

shaft toward the yoke (33) and through the grommet (12) in
the yoke (33).
G. Place the lever (34) in the yoke and in line with the shaft so
the boss on one side of the lever shaft hole is toward the
shaft bearing (8) and engage the shaft to the lever splines.
CAUTION
Ensure the bearing seat in the yoke is clean. The bearing

should slide in easily. Do not use excessive force to push
bearing in.
CAUTION
10.1 Spring Diaphragm Actuator
When the actuator has been disassembled using Section 8.2

to reassemble the actuator, proceed as follows:
A. Replace spring (39) in piston (43).
B. Replace washer (44) and locknut (45).

Note: Locknut (45) must be threaded the full length of

the threads.
CAUTION
Do not use air pressure to check alignment, since during
normal operation and with full air pressure, the Indicator
may overshoot the closed Indicator mark on the cover.
This is acceptable.
CAUTION
C. To reassemble the diaphragm and upper diaphragm case,

refer to Section 9.1, steps E. through L.
H. Slide shaft completely through lever to engage shaft

bearing (8). Yoke should now be fully seated on the valve
bonnet flange.
D. Replace locknut (46) and clevis (35).
I. Replace and tighten body stud nuts (27).
E. Determine correct orientation and replace actuator on

yoke and replace lockwashers (37), capscrews (36) and
tighten firmly.
J. Replace packing flange stud nuts (94) and finger tighten

only.
DANGER
K. Slide the lever (34) on the shaft (19) toward the valve and
tighten lever capscrew (49).
F. Refer to Section 11. for actuator stem adjustment.
10.2 Spring Diaphragm Actuator on Body S/A


Note: Shaft must engage lever so the indicator dot on

the clevis pin, when placed in the lever hole, shows
the valve closed. Temporarily place clevis pin into lever
(34) and check indicator dot alignment. Dot should
just start touching the closed indicator line on the front
cover (32) (Refer to Figure 18). If the orientation is not
changed, align lever and mark on yoke then check
alignment. (Refer to Figure 17).
WARNING
10. Reassembly Procedures

Note: Packing flange (14) is placed on the shaft (19)

with the concave side toward the valve packing (17).
E. Ensure slots in packing flange (14) line up with packing

flange studs (13).
WARNING
Note: Depending on the actuator position, ensure that

the body studs (short studs) when placed through the
yoke holes will be positioned in the front of the yoke
opening for ease of accessibility.
L. Pull the lever and shaft toward the bearing (8) in the yoke.
After completing the required maintenance or changing

valve, actuator and yoke assembly, reassemble using the
following procedure:
DANGER
A. Determine correct valve to actuator orientation.

B. If required, reposition body studs (28) and packing
flange studs (13).

10.4 Limit Stop Reassembly

Two different types of assembly for the limit stop in function of

the actuator size: see Figure 9.
10.5 Valve Body Reassembly (Refer to Figure 16)

WARNING
Prior to reassembly, the valve body should be thoroughly

cleaned and the seat ring and plug may be lapped as
indicated in Section 9.2. Upon completion of the above,
proceed as follows:
LIMIT STOP STD CAMFLEX 6" and 7"
CAUTION
WARNING
LIMIT STOP STD CAMFLEX 4.5"
Lubricants and sealers are required during reassembly.

Figure 15 identifies recommended products for certain
service conditions. Ensure that any lubricant used is
compatible with service conditions.
WARNING
CAUTION
A. Apply a small amount of thread lubricant to the seat ring

retainer threads and install seat ring retainer (3) and hand
tighten only.
Figure 9
CAUTION
Do not tighten the seat ring retainer to torque specification

at this time.
B. Place valve body (1) on flat surface so that the seat is

down.
This is required to ensure the shaft (19) is shouldered on

the shaft bearing (8) and to ensure free operation of the
valve.
CAUTION
DANGER
C. Coat lower guide bushing (22) with recommended lubricant

and insert into the body.
CAUTION
M. Loosen lever capscrew (49) and slide lever (34) so it will

shoulder against the shaft bearing (8) and tighten capscrew
(49).

CAUTION
Note: if the actuator cylinder (38) has been removed

proceed to step N. If it has not, proceed to Section 11,
Actuator Stem Adjustment.
Note: Groove in the guide bushing (22) must be

towards the body center. Refer to Figure 10 for correct
assembly sequence. If the shaft (19) is the original
design it may have a circular grove, if so, install the
retaining ring (18).
N. Determine the desired actuator action and replace actuator

cylinder (38) on the yoke (33) and secure in place with four
capscrews (36) and lockwashers (37).
O. Proceed to Section 11, Actuator Stem Adjustment.
DANGER
10.3 Handwheel Reassembly

A. Place the valve so the position cover (11) is up.
DANGER
B. Remove Truac ring (50) and handwheel washer (51) from

the handwheel powerscrew.
Figure 10
WARNING
C. Insert handwheel powerscrew with lock (52) in place into

the appropriate hole in the yoke and screw in clockwise.
D. Coat the upper guide bushing (21) spacer tube (20) and the
shaft splines (plug side) with recommended lubricant.
D. Replace the washer (51) and Truac ring (50)
E. Insert the spacer tube (20) over the lubricated part of

the shaft.
E. Back off handwheel lightly against washer and lock in the

off position with lock (52).
F. Replace bottom cover (11) by snapping in place.

Note: To use the handwheel, loosen the lock (52) and

turn. The handwheel can be used as a limit stop on the
valve by locking it in any position.

10
CAUTION
When a recessed groove exists in the spacer tube (20),
this spacer tube (20) must be placed on the shaft (19)
so that the shaft shoulder or retaining ring fits into the
recessed groove on one end of the spacer tube (20).
CAUTION
S. Install packing (17) insuring that the skive cut of each piece
of packing is offset approximately 120 from that of the
adjacent piece of packing.
F. Place upper guide bushing (21) on the shaft (19).

G. Place plug (4) in body so it rests on the seat.
H. Insert the shaft sub-assembly into the body (1) and
engage plug (4) and lower guide bushing (22).

Note: The shaft (19) should be inserted into the plug so

that when the plug is seated, the slot at the outer end of
the shaft is perpendicular to the flow through the valve.
T. Install packing follower (15) rounded, bevel side out.

U. Proceed to Section 10.6 on seat ring alignment.
In case of 35000 SB, separable bonnet version, follow

the operations described from N to U.
10.6 Seat Ring Alignment
I. Install the packing box ring (23), bevel side out, over the shaft
(19) and into the valve bonnet being sure that the hole in the
ring is aligned with the threaded port in the bonnet.
WARNING
J. Apply a suitable lubricant to the threads of the safety pin

(16) and screw into the body neck and tighten.
Note: The casting marks (=) indicate the seat ring end
of the body.
B. Remove the retainer ring (3) and the seat ring (2).
The Safety Pin is a safety device which must not be

replaced by a plug. Use only genuine Masoneilan
supplied safety pins. Pin must engage hole in packing
box ring (23). Test by manually pulling on the shaft to
verify engagement.
C. Apply a thin coat of sealant to the seat ring shoulder that

engages the body and replace seat ring (2).
WARNING
D. Apply a small amount of thread lubricant to the seat ring

retainer threads and install seat ring retainer (3) and hand
tighten only.
CAUTION
K. Install packing (17) insuring that the skive cut of each piece
of packing is offset approximately 120 from that of the
adjacent piece of packing.

Aligning the seat ring (2) and plug (4) is required whenever
the seat ring or plug have been replaced or disassembled.
Proceed as follows:
A. Place valve on flat surface with retainer (3) and seat ring (2)
facing up.
CAUTION
Note: Sizes 1" through 3" (DN 25 through 80) use 7

pieces of packing; sizes 4" through 12" (DN100 through
300) use 6 pieces of packing.
Note: Sizes 1" thru 3" (DN 25 through 80) use 7 pieces
of packing; sizes 4" thru 12" (DN 100 through 300) use
6 pieces of packing.
L. Install packing follower (15) rounded, bevel side out.
CAUTION
Do not tighten the seat ring retainer to torque specification at this time.
E. Replace lever (34) on valve shaft (19) and tighten lever

capscrew (49).
CAUTION
M. Proceed to Section 10.6 on seat ring alignment.
F. Using the lever (34) manually close the plug with sufficient
force to allow seat ring and plug to align.
N through U apply to separable bonnet design only:

N. If necessary, install the studs (103) in the bonnet (102).
O. Install the stop ring (100).
G. Using the seat ring wrench, tighten seat ring retainer to the
minimum torque value specified in Figure 12.
P. Place the gasket (101) in the groove of the bonnet. The old
gasket (101) must not be re-used.
DANGER
Q. Place the bonnet with the studs on the body and screw the
nuts (104).
R. Tighten the nuts (104) according the table of Figure 11.
Valve Size
Torque lb.ft
Torque m.N
22
30
DANGER
1" (DN 25)

112" (DN 40)
2" (DN 50)
3" (DN 80)
55
75
4" (DN 100)
55
75
6" (DN 150)
107
145
Figure 11

Note: It is important to tighten the nuts step by step,

during the tightening the bonnet flange must keep the
shaft axis aligned.

Note: In some cases, for the valves from 3" to 12"

(DN80 to 300) with metal seat, the alignment can be
improved by placing a piece of paper 0.10mm (0.004")
thick and approximately 6mm (1/4") wide at a point
where the leading edge and the trailing edge of the plug
contacts the seat ring and close the plug. With a slight
pressure on the lever, the paper strips should both be
clamped in place. For the valve 8" to 12" (DN200 to
300), the piece of paper shall be 0.20mm (0.008") thick
and 12mm (1/4") wide.
11
Valve Size
lb.ft
m.N
60
81
112" (DN 40)
95
130
2" (DN 50)
100
135
1" (DN 25)
WARNING
C. If applicable, back off optional limit stop (77) so it will not

interfere with the operation of the lever (34).
Minimum Torque
D. Apply air pressure to the actuator and move lever (34) to an

intermediate position.
3" (DN 80)
290
395
4" (DN 100)
363
490
6" (DN 150)
825
1120
8" (DN 200)
975
1320
10" (DN 250)
1350
1830
12" (DN 300)
2250
3050
CAUTION
F. Remove clevis pin clip (5), remove clevis pin (7).

G. Relieve air pressure to the actuator to allow the clevis (35) and
lever (34) to separate.
H. Proceed to section on body to actuator assembly.
10.7 DVD Plate Reassembly
Using the same method and tooling as described in 8.3.2,

tighten the Lo-dB plate at the indicated torque given in the
table of Figure 13.
Valve Size
Note: If the unit is air-to-open, separate clevis (35) and lever

(34) then loosen clevis locknut (46) and remove clevis.
H. Insert clevis pin (7) back in lever (34).

I. Manually push the lever (34) so the valve is in the closed
position.
WARNING
Tightening Torque
J. Temporarily replace front cover (32) and check the location of

the clevis pin (7) in relation to the closed position indicator mark
on front cover (32).
lb.ft
m.N
74
100
1 2" (DN 40)
81
110
2" (DN 50)
100
135
3" (DN 80)
220
295
4" (DN 100)
363
490
6" (DN 150)
780
1050
The relationship must be as shown in Figure 18. If it is not,

the yoke must be separated from the body and the lever
(34) repositioned on the shaft. Refer to appropriate section.
Failure to comply could result in the valve short stroking or
over stroking and could damage the valve.
Note: If the unit is air-to-open, replace clevis locknut (46)

and clevis (35).
1" (DN 25)

1
8" (DN 200)
975
1320
10" (DN 250)
1320
1830
12" (DN 300)
2250
3050
WARNING
Figure 13
11. Actuator Stem Adjustment

K-1. Air-to-Open
After completing step A through J of Section 11, proceed as

follows:
B. Connect a regulated air supply directly to the actuator and

gradually apply 8 psig (.55 barg) for size 9 actuators and 7
psig (.48 barg) for the others.
CAUTION
DANGER
Correct actuator stem adjustment is imperative for proper valve

functioning. With the actuator assembled to the valve in the
desired location and orientation proceed as follows:
C. The clevis should move approximately 1/4".
D. With the lever and valve plug in the fully CLOSED position,
the holes in the clevis (35) and lever (34) should be in line.
Note: If any of the following steps were completed during

maintenance or reorientation of actuator to valve, proceed to
the next step.
A. Remove front cover (32) and rear cover (29) by removing the
two-cover screws (30).
Note: If holes are in line proceed to Step J. If not in line,

continue to next step.
E. Move lever (34) to full open position.
B. Back off handwheel (53) so it does not interfere with the

operation of the lever (34).
DANGER
CAUTION
A. Scribe a line on the clevis (35) in line with the inside of the
yoke.
The following procedures must be adhered to in order to ensure

correct valve operation. Failure to do so could result in valve
damage and equipment malfunction.

DANGER
CAUTION
K. Proceed to one of the following sections for final adjustment.

Air-to-Open, Section (K-1), Air-to-Close Section (K-2).
CAUTION
Do not exceed pressure listed in Figure 14 for the actuator

used. Do not use handwheel (53) to move lever (34).
E. Remove adjustable indicator (88) by removing the two

screws (89).
Figure 12
CAUTION
F. Gradually apply sufficient air pressure to extend clevis

locknut (46) to an accessible position.
12
CAUTION
F. Loosen clevis locknut (46).

G. Screw clevis (35) in or out so that when the air pressure
corresponding to the closed position mentioned in C above
is applied, clevis holes and lever will be in line.
Do not exceed pressure listed in Figure 14 for the

actuator used.
G. Loosen clevis locknut (46).
H. Insert clevis pin (7) so indicator dot is visible through front

cover (32) and secure with clevis pin clips (5).
H. Reduce air pressure to actuator to 7 psig.
CAUTION
I. Screw clevis (35) in or out on actuator stem so that the

holes in the clevis (35) and lever (34) are aligned with the
lever and plug in the fully closed position.
J. Insert clevis pin (7) so indicator dot is visible through front
cover (32) and secure with clevis pin clips (5).

I. Tighten clevis locknut (46).
Note: On the size 6 and 7 actuators, without the

adjustable indicator (88), the clevis pin (7) must be
installed so it protrudes toward the front cover (32). If the
indicator dot is damaged, paint may be applied to the
end facing the front cover (32) to make it more visible.
J. Relieve air pressure to actuator.

K. If used, replace adjustable indicator (88) to lever (34) with
screws (89).
WARNING
K. Gradually apply sufficient air pressure to extend clevis

locknut (46) to an accessible position and tighten firmly.
DANGER
CAUTION
M. Replace spring barrel boss cover (58) and bottom cover

(11) (Snap fit).
Do not exceed pressure listed in Figure 14 for the

actuator used.
CAUTION
N. If desired, set handwheel (53) or optional limit stop (77) to

desired position.
Note: If required, adjust indicator to front cover

indicator marks.
12. Changing Body Position
N. Replace front cover (32) and rear cover (29) and secure in
place with cover screws (30).
CAUTION
O. Replace spring barrel boss cover (58) and bottom cover

(11) (Snap fit).
Before any change in flow direction or actuator mode is made,

the valve and actuator must be resized using current process
conditions. Any change in the flow direction or actuator mode
must be accomplished as outlined in this instruction, otherwise
equipment malfunction could result.
Note: Prior to placing the valve in service, operate the

valve actuator through one complete cycle to ensure
proper functioning.
CAUTION
WARNING
P. If desired, set handwheel (53) or optional limit stop (77) to

desired position.
DANGER
K-1. Air-to-Close
After completing step A through J of Section 11, proceed

as follows:
Changing service requirements or service conditions may require

a change in flow direction through the Camflex II valve. Figure 19
illustrates the various positions and flow directions in which the
valve may be placed to accommodate requirements.
A. Manually push lever (34) to the full CLOSED position.
CAUTION
B. Connect a regulated air supply to the actuator.

C. Gradually apply the final air pressure corresponding to the
closed position. See value on the serial plate.
Changing the body position and flow direction could also require
relocating the actuator. Ensure that the actuator location and
action are in accordance with the recommended positions and
modes illustrated in Figure 19. Illustrations are shown looking
at the body through the bonnet with the actuator in front of the
valve. The plug shaft is always rotated in a clockwise direction
by the actuator to open the valve.
D. With the lever (34) and valve plug in the CLOSED position,
the holes in the clevis (35) and lever (34) should be in line.
CAUTION
DANGER
Note: If holes are in line proceed to Step H, if not in line,

continue to the next step.
E. Release air pressure so clevis (35) will separate from lever
(34).
Note: Prior to placing the valve in service, operate the

valve actuator through one complete cycle to ensure
proper functioning.
WARNING
M. If used, replace adjustable indicator (88) to lever (34) with

screws (89).
Note: If required, adjust indicator (88) to front cover

(32) indicator marks with the valve in the closed
position.
L. Replace front cover (32) and rear cover (29) and secure in
place with cover screws (30).
L. Relieve air pressure.
Note: On the size 6 and 7 actuators, without the

adjustable indicator (88), the clevis pin (7) must be
installed so it protrudes toward the front cover (32). If
the indicator dot is damaged, paint may be applied to
the end of the clevis pin (7) facing the front cover (32)
to make it more visible.
13
G. Remove Truarc ring (50) and washer (51) from handwheel

powerscrew assembly.
To change body position proceed as follows:

A. Refer to Figure 19 and determine which is the desired valve
position, flow direction and which actuator position is required.
H. Unscrew and remove handwheel powerscrew assembly from

yoke (33).
WARNING
B. Proceed to the appropriate section of this instruction for the

required disassembly and assembly procedures.
WARNING
I. Remove handwheel thread plug (48).

13. Changing Actuator Action
CAUTION
Note: If the actuator is equipped with the optional limit

stop (77), in place of the handwheel thread plug, it must
be removed.
CAUTION
Before any change in flow direction or actuator mode is made,

the valve and actuator must be resized using current process
conditions. Any change in the flow direction or actuator mode
must be accomplished as outlined in this instruction, otherwise
equipment malfunction could result.
CAUTION
Depending on the size and weight of the actuator, it is

recommended that proper lift and support procedures be
utilized when removing the spring barrel or yoke.
WARNING
CAUTION
J. Ensure spring barrel is properly supported.
A. Remove front cover (32) and rear cover (29) by removing the
two cover screws (30).
K. Loosen and remove capscrews (36) and lockwashers (37)

then remove spring barrel (38).
WARNING
B. Remove spring barrel boss cover (58) (Snap fit).

C. Remove bottom cover (11) (Snap fit).
D. Using a manual loading panel, apply sufficient air pressure to the

actuator to move the lever (34) to an intermediate position.
CAUTION
CAUTION
If the orientation of the actuator to valve requires that the

yoke be rotated about the valve, it is recommended that
Section 12 on changing yoke position be accomplished
before proceeding.
CAUTION
Do not exceed pressure listed in Figure 14 for actuator used.

Do not use handwheel to move lever.
DANGER
CAUTION
DANGER
E. Remove clevis pin clips (5) and remove clevis pin (7).
F. Position lever so it does not contact handwheel power-screw
assembly.
Maximum Air Supply
Actuator Size
Diameter
A 564 Gr 630 Shaft
inches (mm)
kPa
Psi
kPa
Psi
mm
1" (DN 25)
4 2 (114)
138
20
138
20
4x6
112" (DN 40)
412 (114)
172
25
172
25
4x6
2" (DN 50)
4 2 (114)
207
30
207
30
4x6
3" (DN 80)
6 (152)
207
30
207
30
4x6
6 (152)
310
45
310
45
4x6
Valve Size
Austenitic Stainless
Steel Shaft
Recommended Tubing
DANGER
inches
4"
4"
4"
4"
6" (DN 150)
DANGER
7 (177)
448
65
310
45
4x6
8" (DN 200)
7 (177)
517
75
379
55
4x6
10" (DN 250)
7 (177)
517
75
448
65
4x6
12" (DN 300)
7 (177)
517
75
517
75
4x6
6" (DN 150)
9 (228)
344
50
276
40
4x6
8" (DN 200)
9 (228)
344
50
276
40
4x6
10" (DN 250)
9 (228)
448
65
310
45
4x6
12" (DN 300)
9 (228)
517
75
379
55
4x6
4" (DN 100)
Figure 14

14
4"
4"
4"
4"
4"
4"
4"
4"
4"
Service
Sealant
Lubricant
Diaphragm Glue
Condensate and Steam
Silver Seal T-J, Turbo 50 or

HYLOMARSQ 32
Molykote G or
GRAPHENE 702
3M High Track adhesive

transfer tape (or equal)
Cryogenic
-20F to -320F
(-29C to -196C)
Crown N. 9008 Teflon Spray

or RODORSIL CAF 730
Crown N. 9008 Teflon Spray

or GRAPHENE 702
3M Pressure sensitive tape,

double coated (or equal)
Oxygen
Drilube type 822 or

BONNAFLON S/9
Drilube type 822 or

OXIGNENOEX FF250
Eastman 910 Cement

(or equal)
All Others*
John Crane Plastic lead N.2

HYLOMAR SQ 32
Molykote G or
GRAPHENE702
Goodyear Plibond Cement

(or equal)
* Except Food Services.
Figure 15
14. Manual Actuator Option
L. With the yoke assembled to the valve in the required orientation,

place spring barrel (38) on desired yoke location and secure
with capscrews (36) and lockwashers (37), and tighten firmly.
The manual type actuator is designed to close the valve by

rotating the handwheel in a clockwise direction. Anti-rotation
of the handwheel is obtained through a detente device located
between handwheel (53) and retainer (87).
M. Screw in handwheel powerscrew assembly into the

powerscrew hole of the yoke which is on the opposite side
of the spring diaphragm actuator.

14.1 Disassembly Procedure
Note: Handwheel action is always the same as air action

and opposes the spring.
The disassembly procedure for manual actuator is similar to

the procedure for spring diaphragm actuator see Section 8.1.
N. Replace handwheel washer (51) and Truarc ring (50) and back
off handwheel so the powerscrew will not interfere with the
operation of the lever.
14.2 Maintenance
Routine maintenance of the manual actuator requires that a
suitable lubricant be periodically applied to the handwheel
powerscrew.
O. Replace handwheel thread plug (48).

Note: If the valve is equipped with the optional limit stop

(77) instead of the thread plug, it must now be installed, but
ensure it is backed off as not to interfere with the operation
of the lever at this time.
Bearings may require replacement due to service conditions

or corrosion.
The replacement of the handwheel detent mechanism
should be required.
P. Proceed to Section 11, on Actuator Stem Adjustment.
14.3 Reassembly Procedure

There is no specific adjustment for the reassembly of manual
actuator. For details see Figure 21.

15
27
29
30
31
18
32
105
22
21
20
19
24
23
25
26
Original Design
103 104 100 101
8
10
9
16
17
28
90
91 15 14
94
13
12
38
39
43
11
Figure 16
106
N9
107
89
88
56
57
35
36
37
40
41
34
58
33
46
45
44
54
48
55
53
52
51
50
49
Figure 17

16
78
77
42
102
Parts Reference
Ref. Qty.
Part Name
Ref. Qty.
Part Name
Ref. Qty.
Part Name
Body
28
Body Stud
56
Serial Plate
Seat Ring
29
Rear Cover
57
Plate Screw
Retainer
30
Cover Screw
58
Boss Cover
Plug
31
Screw Retainer
60
Counter-Flange
Clevis Pin Clip
32
Front Cover
61
Gasket
Indicator Dot
33
Yoke
64
Stud
Clevis Pin
34
Lever
67
Stud
Bearing
35
Clevis
68
Nut
Shaft Cover
36
Cap Screw
77
Travel Stop
10
Cover Screw
37
Lock Washer
78
Nut
11
Bottom Cover
38
Spring Barrel
88
Adjustable Indicator
12
Grommet
39
Spring
89
Indicator Screw
13
Packing Flange Stud
40
Diaphragm
90
Inner O-Ring
14
Packing Flange
41
Cap Screw
91
Outer O-Ring
15
Packing Follower
42
Diaphragm Case
92
Inner O-Ring
16
Safety Pin
43
Piston-Stem
93
Outer O-Ring
17
**
Packing
44
Lock Washer
94
Nut
18*
Shaft Retaining Ring
45
Lock Nut
95
Inner O-Ring
19
Shaft
46
Lock Nut
96
Outer O-Ring
20
Spacer
48
Thread Plug
100
Stop Ring
21
Upper Guide
49
Lever Cap Screw
101
Body Gasket
22
Lower Guide
50
Truarc Ring
102
Bonnet
23
Packing Box Ring
51
Handwheel Washer
103
Bonnet Stud
24
Warning Plate
52
Handwheel Lock
104
Bonnet Nut
25
Flow Arrow
53
Handwheel Shaft
105
Lo-dB Plate
26
Plate Screw
54
Handwheel Plate
106
Adaptor Screw
27
Nut
55
Plate Screw
107
Adaptor
*Applies to original design only.

**Quantity varies by size and bonnet type. Confirm required quantity from valve serial records.

17
ACCEPTABLE
NOT ACCEPTABLE
Figure 18
AIR TO OPEN
FLOW TENDING TO CLOSE
CLOSE ON AIR FAILURE
4
2
8
6
DIRECTION OF FLOW
AIR TO CLOSE
FLOW TENDING TO OPEN
3
OPEN ON AIR FAILURE

7
1
5
DIRECTION OF FLOW
The body is shown behind the actuator.
Figure 19
PACKING FLANGE
REVERSED
LEVER ARM
PACKING
STUD NUT
STEM
PIPE
BOLT
FLAT
WASHER
BONNET
PIPE
Figure 20
Figure 21
18
Flanged Bodies
Long Stud (T) (64)
Short Stud (G) (67)
Valve Rating
Qty.
Length
inches (mm)
Nuts
Dia.
Qty.
Long Stud (T) (64)

Short Stud (G) (67)
Nuts
Length
inches (mm)
Qty.
Qty.
1" (DN 25)

150 (20)
ANSI
EN
(ISO PN)
EN
DIN
2.50 (63.5)
8T
300 (50)
3.00 (76.2)
600 (100)
8G
3.00 (76.2)
PN 10
PN 16
PN 25
PN 40
8T
(71.0)
ANSI
EN
(ISO PN)
EN
DIN
8T
1 2"
(M14)
2.75 (70.0)
16
8T
3.50 (88.9)
5 8"
(M16)
M12
3.50 (88.9)
300 (50)
16T
4.25 (108.0)
600 (100)
12T +
4G
5.00 (127.0)
4.25 (108.0)
PN 10
PN 16
PN 25
PN 40
16T
8G
3.50 (88.9)
16
8T
(84.0)
5 8"
(M16)
3 4"
(M20)
16
16T
3.50 (88.9)
M16
(M20)
M16
3.25 (82.5)
16T
3.50 (88.9)
8T +
8G
4.25 (108.0)
3.75 (95.2)
16
8T
(84.0)
3 4"
28
12T +
4G
5.75 (146.0)
5.00 (127.0)
(M24)
(84.0)
M16
28
32
(102.0)
M20
(123.0)
M24
32
24T
4.50 (114.3)
7 8"
48
32T
6.25 (158.8)
300 (50)
24T
5.50 (140.0)
20T +
4G
16T
7.50 (190.5)
6.75 (171.5)
(M24)
11 8"
(M30)
(102.0)
M20
24T
(123.0)
(137.0)
M24
M27
(M20)
44
24T
64
20T +
4G
6.75 (171.5)
6.00 (152.4)
1"
(M27)
(102.0)
M20
(119.0)
M24
(155.0)
(120.0)
M30
15T +
1G
7 8"
(M24)
1"
(M27)
(106.0)
(115.0)
(133.0)
(151.0)
3 4"
(M20)
24T
4.75 (120.6)
64
32T
6.75 (171.5)
19
48
44
31
7 8"
(M24)
11 8"
(M30)
48
64
N/A
M20
M24
M27
M30
48
1 2"
: 1 2" 13 UNC 2A/2B
5 8"
: 5 8" 11 UNC 2A/2B
3 4"
: 3 4" 10 UNC 2A/2B
7 8"
: 7 8" 9 UNC 2A/2B
Figure 22
32
32
48
11 4" : 11 4" 8 UNC 2A/2B
67
16
12" (DN 300)
11 8" : 11 8" 8 UNC 2A/2B
4.75 (120.6)
32
1" : 1" 8 UNC 2A/2B

24T
N/A
32
48
M16
4.00 (101.6)
10" (DN250)
3 4"
32
24
16T
N/A
4.25 (108.0)
5 8"
(M16)
16T
32
(M20)
7 8"
16
6" (DN 150)
5 8"
(M16)
4.50 (114.3)
16T
16T
PN 10
PN 16
PN 25
PN40
EN
DIN
8T
16
3 4"
16T
(92.0)
150 (20)
600 (100)
Qty.
Dia.
2" (DN 50)
1 2"
(M14)
32
8" (DN 200)

ANSI
EN
(ISO PN)
Length
inches (mm)
Qty.
4" (DN 100)
(84.0)
PN 63/ 64
Nuts
11 2" (DN 40)
3" (DN 80)

150 (20)
Dia.
Long Stud (T) (64)

Short Stud (G) (67)
24T
(106.0)
(115.0)
(133.0)
(151.0)
M20
M24
M27
M30
48
Flangeless Bodies
Long Stud (T) (64)
Short Bolt (G) (67)
Cap Screws (V) (68)
Valve Rating
Qty.
Length
inches (mm)
Dia.
Nuts
Qty.
Long Stud (T) (64)

Short Bolt (G) (67)
Cap Screws (V) (68)
Nuts
Length
inches (mm)
Qty.
Qty.
1" (DN 25)

ANSI
(ISO PN)
EN
DIN
150 (20)
300 (50)
400
600 (100)
PN 10
PN 16
PN 25
PN 40
4T
1 2"
7.75 (195)
5 8"
1 2"
PN 100
7.50 (190)
1 2"
8.75 (220)
3 4"
7.50 (190)
8
8.10 (205)
4T
(M12)
4T
PN 63/ 64
ANSI
(ISO PN)
4T
10.25 (260)
5 8"
400
12.0 (305)
4.50 (115)
PN 10
PN 16
PN 25
PN 40
7T
2G
10.25 (260)
5 8"
ANSI
(ISO PN)
6T
4V
300 (50)
400
10T
4V
600 (100)
PN 10
6T
4V
PN 16
EN
DIN
PN 25
PN 40
PN 63/ 64
10T
4V
13.75 (350)
3.0 (73)
16.25 (410)
3.5 (89)
17.0 (430)
4.0 (102)
18.125 (460)
4.25 (108)
13.75 (350)
3.0 (76)
14.25 (360)
3.0 (76)
15.75 (400)
3.25 (82)
17.0 (430)
3.75 (93)
7T
2G
9.0 (230)
3.75 (95)
3 4"
18
7T
2G
5 8"
(M16)
18
*A
7T
2G
3 4"
3 4"
(M20)
10 (250)
8T
8V
5 8"
12.0 (305)
4.50 (115)
3 4"
7 8"
1"
20
12T
8V
11 8"
3 4"
12
(M20)
7 8"
(M24)
1"
(M27)
7T
2G
8
14.25 (360)
5.50 (140)
7 8"
11.50 (290)
3.75 (65)
(M16)
12.0 (305)
4.50 (115)
(M20)
20
8T
8V
11 4"
(M33)
16.50 (420)
3.0 (76)
19.0 (480)
3.75 (95)
20.50 (520)
4.25 (108)
20.50 (520)
4.75 (120)
16.50 (420)
3.0 (76)
16.50 (420)
3.0 (76)
17.0 (430)
3.25 (82)
18.125 (460)
3.75 (95)
20.0 (510)
3.75 (93)
5 8"
18
*D
3 4"
18
*B
18
5 8"
(M16)
3 4"
(M20)
7 8"
(M24)
11T
2G
7 8"
13.75 (350)
4.50 (115)
16
7T
2G
1"
*C
26
14.0 (350)
4.50 (115)
(M20)
14.25 (360)
5.50 (140)
(M24)
8T
8V
18.50 (470)
11 4"
16T
8V
3 4"
7 8"
8T
8V
18.50 (470)
3.0 (76)
19.0 (480)
3.25 (82)
20.50 (520)
3.75 (95)
21.25 (540)
4.0 (100)
24
(M20)
(M24)
1"
(M27)
18
*B
26
*B
26
16.25 (410)
5.50 (140)
20.50 (520)
3.75 (95)
22.50 (570)
4.25 (108)
22.50 (570)
4.75 (120)
1"
11 8"
3 4"
3 4"
18
*B
7 8"
18
*C
12" (DN 300)
12T
8V
16
11 8"
(M30)
11 4"
(M33)
C: M22N (24x45x3)mm
D: L16N (18x40x3)mm
20
5 8"
16.0 (400)
6.0 (150)
B: M20N (22x40x3)mm
Figure 23
6" (DN 150)
10" (DN 250)

12
Dia.
4T
9.50 (240)
A: M16N (18x32x3)mm
9.0 (230)
9.0 (230)
*Use one washer (66)

for each short stud as
shown on the left figure:

4T
5 8"
11.50 (290)
3.75 (95)
8" (DN 200)

150 (20)
Qty.
4" (DN 100)
600 (100)
EN
DIN
Length
inches (mm)
2" (DN 50)
8
9.0 (230)
(M16)
300 (50)
7T
2G
Qty.
(M16)
4T
3" (DN 80)

150 (20)
Nuts
11 2" (DN 40)
7.50 (190)
7.50 (190)
Dia.
Long Stud (T) (64)

Short Bolt (G) (67)
Cap Screws (V) (68)
12T
8V
7 8"
16
1"
24
11 4"
32
7 8"
16
(M24)
1"
(M27)
11 8"
(M30)
11 4"
(M33)
1 2"
: 1 2" 13 UNC 2A/2B
5 8"
: 5 8" 11 UNC 2A/2B
3 4"
: 3 4" 10 UNC 2A/2B
7 8"
: 7 8" 9 UNC 2A/2B
1" : 1" 8 UNC 2A/2B

11 8" : 11 8" 8 UNC 2A/2B
11 4" : 11 4" 8 UNC 2A/2B
24
Notes

21
DIRECT SALES OFFICE LOCATIONS

BELGIUM
Phone:
+32-2-344-0970
Fax:
+32-2-344-1123
ITALY
Phone:
Fax:
BRAZIL
Phone:
Fax:
JAPAN
Chiba
Phone:
Fax:
CANADA
Ontario
Phone:
Fax:
CHINA
Phone:
Fax:
+55-11-2146-3600
+55-11-2146-3610
+81-43-297-9222
+81-43-299-1115
SAUDI ARABIA
Phone:
+966-3-341-0278
Fax:
+966-3-341-7624
SINGAPORE
Phone:
+65-6861-6100
Fax:
+65-6861-7172
SOUTH AFRICA
Phone:
+27-11-452-1550
Fax:
+27-11-452-6542
+905-335-3529
+905-336-7628
KOREA
Phone:
Fax:
+86-10-8486-4515
+86-10-8486-5305
MALAYSIA
Phone:
+60-3-2161-0322
Fax:
+60-3-2163-6312
SOUTH & CENTRAL

AMERICA AND THE CARIBBEAN
Phone:
+55-12-2134-1201
Fax:
+55-12-2134-1238
MEXICO
Phone:
Fax:
SPAIN
Phone:
Fax:
FRANCE
Courbevoie
Phone:
+33-1-4904-9000
Fax:
+33-1-4904-9010
GERMANY
Viersen
Phone:
+49-2162-8170-0
Fax:
+49-2162-8170-280
INDIA
Mumbai
Phone:
Fax:
New Delhi
Phone:
Fax:
+39-081-7892-111
+39-081-7892-208
+91-22-8354790
+91-22-8354791
+82-2-2274-0748
+82-2-2274-0794
+52-5-310-9863
+52-5-310-5584
+34-93-652-6430
+34-93-652-6444
THE NETHERLANDS
Phone:
+31-15-3808666
Fax:
+31-18-1641438
UNITED ARAB EMIRATES

Phone:
+971-4-8139-200
Fax:
+971-4-8838-038
RUSSIA
Veliky Novgorod
Phone:
+7-8162-55-7898
Fax:
+7-8162-55-7921
Moscow
Phone:
+7 495-585-1276
Fax:
+7 495-585-1279
UNITED KINGDOM
Wooburn Green
Phone:
+44-1628-536300
Fax:
+44-1628-536319
UNITED STATES
Massachusetts
Phone:
+1-508-586-4600
Fax:
+1-508-427-8971
Corpus Christi, Texas
Phone:
+1-361-881-8182
Fax:
+1-361-881-8246
Dresser Direct
Deer Park, Texas
Phone:
+1-281-884-1000
Fax:
+1-281-884-1010
Dresser Flow Technologies
Houston, Texas
Phone:
+1-281-671-1640
Fax:
+1-281-671-1735
California
Phone:
+1-562-941-7610
Fax:
+1-562-941-7810
+91-11-2-6164175
+91-11-5-1659635
About Dresser, Inc.

Dresser Inc. is a global leader in providing highlyengineered infrastructure products for the global energy
industry. Leading brand names within the Dresser portfolio
include Dresser Wayne retail fueling systems, Waukesha
natural gas-fired engines, Masoneilan control valves, Consolidated pressure relief valves, and ROOTS blowers
and rotary gas meters. The company has manufacturing
and customer service facilities strategically located
worldwide and a sales presence in more than 150 countries.
www.dresser.com
About Dresser Masoneilan

Dresser Masoneilan, headquartered in Houston, Texas, has
been the leading global partner in process control valves
and solutions for more than 100 years. A business segment
of Dresser, Inc., the company delivers customized products,
services and diagnostic solutions for oil and gas, process and
power generation applications. www.dresser.com
Dresser Masoneilan
Dresser, Inc., Flow Technologies
10343 Sam Houston Park Drive
Houston, Texas 77064 U.S.A
T. +1-281-671-1640
F. +1-281-671-1735
E. sales@masoneilan.com
2010 Dresser, Inc. All rights reserved.
EF35002 08/10
www.dresser.com
21000 Series
Control Valves
Complete Line of Rugged,
Top Guided, Globe Valves with
Lo-dB / Anti-Cavitation Capabilities
Instruction Manual
EH21000
09/10
Table of Contents......................................................................................... Page

Important: Safety Warning........................................................................................1
1. INTRODUCTION................................................................................................................2
2. GENERAL.........................................................................................................................2
3. UNPACKING.....................................................................................................................2
4. INSTALLATION.................................................................................................................2
5. AIR PIPING........................................................................................................................3
6. BODY DISASSEMBLY.....................................................................................................3
6.1 THREADED TRIM.................................................................................................3
6.2 QUICK-CHANGE TRIM.........................................................................................3
7. MAINTENANCE/REPAIR..................................................................................................3
7.1 THREADED SEAT RING REMOVAL.....................................................................3
7.2 BUSHING REMOVAL.............................................................................................4
7.3 LAPPING SEATS...................................................................................................4

7.3.1 THREADED TRIM....................................................................................4

7.3.2 QUICK-CHANGE TRIM............................................................................4
7.4 Lo-dB PLUG...........................................................................................................5
7.5 PLUG STEM PINNING..........................................................................................5
7.6 PACKING BOX.......................................................................................................6

7.6.1 KEVLAR/PTFE PACK. RING (STANDARD)..............................................6

7.6.2 EXPANDED GRAPHITE P. RING (OPTION)............................................6

7.6.3 LE PACKING (LOW EMISSION) (OPTION).............................................7
7.7 SOFT SEAT PLUG.................................................................................................8
8. VALVE BODY REASSEMBLY..........................................................................................8
8.1 THREADED TRIM.................................................................................................8
8.2 QUICK-CHANGE TRIM.........................................................................................9
8.3 HIGH PRESSURE & ANGLE DESIGN.................................................................9
9. ACTUATORS.....................................................................................................................9
9.1 TYPES 87/88 ACTUATORS...................................................................................9
10. Bellows Seal Assembly........................................................................................9
10.1 Bellows Valve Disassembly....................................................................14

10.1.1 Threaded trim.................................................................................14

10.1.2 Quick-change trim........................................................................14
10.2 REPAIR..............................................................................................................15

10.2.1 PLUG / STEM BELLOWS / BONNET EXTENSION S/A.....................15
10.3 PLUG AND SEAT RING SEATING SURFACES................................................16
10.4 BONNET REASSEMBLY...................................................................................16
10.5 Valve Body REASSEMBLY............................................................................16
10.6 ACTUATOR TO BODY S/A AND PLUG STEM ADJUSTMENT.........................16
Copyright
Masoneilan is a registered trademark of Dresser, Inc. All information contained herein is believed to be accurate at the time of publication and is subject to change without notice.
Safety Information
About this Manual

prior notice.
Important - Please Read Before

Installation

written permission.
Masoneilan model 21000 Series Control Valves instructions

contain DANGER, WARNING, and CAUTION labels, where
necessary, to alert you to safety related or other important
information. Read the instructions carefully before installing
and maintaining your control valve. DANGER and WARNING
hazards are related to personal injury. CAUTION hazards involve equipment or property damage. Operation of damaged
equipment can, under certain operational conditions, result
in degraded process system performance that can lead to
injury or death. Total compliance with all DANGER, WARNING, and CAUTION notices is required for safe operation.

These instructions are written specifically for the 21000
Series Control Valves, and do not apply for other valves
outside of this product line.
Warranty
Items sold by Dresser are warranted to be free from defects
in materials and workmanship for a period of one year from
the date of shipment provided said items are used according
to Dresser recommended usages. Dresser, Inc. reserves the
right to discontinue manufacture of any product or change
product materials, design or specifications without notice.
This is the safety alert symbol. It alerts you to potential

personal injury hazards. Obey all safety messages that follow
this symbol to avoid possible injury or death.
This instruction manual applies to the Masoneilan 21000 Series

Control Valves.
The control valves MUSTBE:
Installed, put into service and maintained by qualified
and competent professionals who have undergone
suitable training.


product.

All surrounding pipe lines must be thoroughly flushed to

ensure all entrained debris has been removed from the
system.

Instructions EH21000 - 09/10

21000 Series Control Valves
1st
2nd
Actuator Type
87

88

Spring Diaphragm
Air to Close
Spring Diaphragm
Air to Open
1st
Body
Series
21
4th
Flow
Characteristics
Plug Type
0.
1.
6.
7.

8.

9.

3rd
2nd
Undefined
Contoured
Soft Seat
Single Stage
Lo-dB/
Cavitation
Containment
Double Stage
Cavitation
Containment
Double Stage
Lo-dB
1. lntroduction
.
0
1.
2.

3.

Undefined
Linear
Equal
Percentage
Modified
Percent
5th
6th
Seat Type
0. Undefined
4. Quick Change
5. Threaded
Optional
Configuration
A
BS

EB

C

Angle Body
Bellows
Seal
Extension
Bonnet
Cryogenic
Extension
Bonnet
Figure 1 - Numbering System
The 21800 Series double stage anti-cavitation valve is derived

from the 21700 single stage anti-cavitation valve through a
modification to the cage and plug. Substitution of the standard
cage with an anti-cavitation cage permits the pressure drop to
be split between the two stages efficiently.
The following instructions should be thoroughly reviewed

and understood prior to installing, operating or performing
maintenance on this equipment. Throughout the text,
safety and/or caution notes will appear and must be
strictly adhered to, otherwise, serious injury or equipment
malfunction could result.
The 21900 Series double stage Lo-dB valve is also derived

from the 21700 single stage Lo-dB valve through a modification
to the cage and plug. Substitution of the standard cage, with a
Lo-dB cage permits the pressure drop to be split between the
two stages efficiently.
Masoneilan has a highly skilled After Sales Department

available for start-up, maintenance and repair of our valves
and component parts.
In the 21800/21900 Series designs, enlargement of the plug head

up to the cage diameter permits simultaneous throttling of the plug
Cv and the cage Cv. It also provides optimum allocation of the
pressure drop between the two stages along the entire plug travel.
Arrangements for this service can be made through your local

Masoneilan Representative or After Sales Department. When
performing maintenance use only Masoneilan replacement parts.
Parts are obtainable through your local Masoneilan Representative
or Spare Parts Department. When ordering parts, always
include Model and Serial Number of the unit being repaired.
Recommended spare parts required for maintenance are listed

in the Parts Reference table on page 14. The model number,
size, rating and serial number of the valve are shown on the
identification tag located on the actuator. Refer to Figure 1 for
the 21000 series numbering system.
2. General
These installation and maintenance instructions apply to all
sizes and ratings of the Masoneilan 21000 Series control
valves regardless of the type of trim used.
3. Unpacking
Care must be exercised when unpacking the valve to prevent
damage to the accessories and component parts. Should any
problems arise, contact the local Masoneilan Representative
or After Sales Department.
21000 Series single ported top guided control valves are

designed with built in versatility making them wellsuited to
handle a wide variety of process applications.
Standard construction offers a contoured plug (21100 Series) with
a threaded seat ring or a quick change seat ring. The heavy top
plug guiding provides maximum support to ensure plug stability.
4. lnstallation
4.1 Before installing the valve in the line, clean piping and
valve of all foreign material such as welding chips,
scale, oil, grease or dirt. Gasket surfaces should be
thoroughly cleaned to ensure leak-proof joints.
A series of reduced area trim is available to provide wide flow

range capabilities in all valve sizes.
Tight Shutoff Class IV leakage is standard. Optional constructions
(one of which is the 21600 Series soft seat plug) meet IEC 5344
and ANSI/FCI 70.2 Class V and Vl requirements.
An optional Low Emission LE Packing is available to assure
compliance with the fugitive emission containment requirements.
4.2 To allow for in-line inspection, maintenance or removal of

the valve without service interruption, provide a manually
operated stop valve on each side of the 21000 Series
valve with a manually operated throttling valve mounted
in the by-pass line (See Figure 2).
Replacing the conventional plug with the single stage Lo-dB

design (21700 Series) provides excellent noise attenuation or
anti-cavitation performance.
4.3 The valve must be installed so that the controlled

substance will flow through the valve in the direction
indicated by the flow arrow located on the body.

With contoured plug (21100/21600)

or Lo-dB plug (21700/21900)
G. Bonnet (8), plug (16), bushing (12) and seat ring (14)
may now be inspected for wear and service damage.
After determining the maintenance required, proceed
to the appropriate Section of this instruction manual.
:flow-to-open
On anti-cavitation design (21700/21800) :flow-to-close

4.4 For heat-insulated installation, do not insulate the valve
bonnet. Take necessary protective measures relate to
personal safety.
6.2 Quick-Change Trim (Figure 13 or 15)

5. Air Piping
After removing the actuator, disassemble the body using the

following procedure:
A. If there is a leak detection connection on the lateral
NPT port of the bonnet, disconnect this piping as well.
WARNING
The actuators are designed to accept 1/4" NPT air supply piping.
Use 1/4" OD tubing (4 x 6 mm) or equivalent for all air lines. If
the supply air line exceeds 25 feet in length (7 meters) or if the
valve is equipped with volume boosters, then 3/8" tubing (6 x 8
mm) is preferred. AII connections must be free of leaks.
B. Remove body stud nuts (10).

C. Remove bonnet (8), and plug stem (1) and plug (16)
sub-assembly together as one unit.
D. Since the cage (13), seat ring (14) and seat ring gasket (15)
are held in place by the bonnet, they may now be removed.
CAUTION
Do not exceed supply pressure indicated on serial plate located

on the yoke of the actuator.
WARNING
E. Remove packing flange stud nuts (3), packing flange

(4) and packing follower (5).
6. Body Disassembly
CAUTION
WARNING
F. Remove plug (16) and plug stem (1) sub-assembly

from the bonnet (8).
Access to the internal components of the body should be

accomplished with the actuator removed. To remove the
actuator from the body, refer to the actuator instruction No.
ER8788 for a type 87/88 multispring actuator.
CAUTION
Prior to performing maintenance on the valve, isolate the valve

and vent the process pressure. Shut off the supply air line and
the pneumatic or electric signal line.
CAUTION
Care must be taken to avoid damage to the plug and
plug guide.
G. Remove old packing (6) [and optional lantern ring (7) if

a leak detection connection has been installed]. Refer to
Figure 5.
CAUTION
CAUTION
DANGER
6.1 Threaded Trim (Figure 12 or 14)

Note: Spiral wound gaskets (11 & 15) are standard in

the 21000 Series design and it is imperative that new
gaskets be installed each time the valve is disassembled.
H. All components may now be inspected for wear and

service damage. After determining the maintenance
required, proceed to the appropriate Section of this
instruction manual.
After removing the actuator, disassemble the body using

the following procedure:
A. If there is a leak detector connection on the lateral NPT
port of the bonnet, disconnect this piping as well.
7. Maintenance & Repair
B. Remove body stud nuts (10).

C. Remove bonnet (8), and plug stem (1) and plug (16)
sub-assembly together as one unit.
The purpose of this section is to provide recommended

maintenance and repair procedures. These procedures
assume the availability of standard shop tools and equipment.
7.1 Threaded Seat Ring Removal (Figure 12 or 14)
Note: Spiral wound body gaskets (11) are standard in

the 21000 Series design and it is imperative that a new
gasket be installed each time the valve is disassembled.
WARNING
DANGER
D. Remove packing flange stud nuts (3), packing flange

(4) and packing follower (5).
Threaded seat rings (14) are installed tightly by the

manufacturer, and after years of service they may be
difficult to remove.
To facilitate removal, seat ring wrenches can be fabricated

to engage the seat ring lugs and adapted to a standard
wrench. If the seat ring is exceptionally resistant to removal,
the application of heat or penetrating oil should be helpful.
E. Remove plug (16) and plug stem (1) sub-assembly from

the bonnet (8).
CAUTION
Care must be taken to avoid damage to the plug and

plug guide.
F. Remove old packing (6) [and optional lantern ring (7) if

a leak detection connection has been installed]. Refer
to Figure 5.
CAUTION

DANGER
WARNING
CAUTION
When using heating devices, ensure that proper safety
practices are observed. Flammability and toxicity of the
process fluid must be considered and proper precautions
taken.
CAUTION
WARNING
7.2 Bushing Removal

6. Place bonnet (8) on the body and fasten the bonnet to

the body using four body stud nuts (10) spaced equally
apart. Apply slight pressure and tighten evenly.
The bushing (12) is press fit into the bonnet and does not
normally require replacement. If necessary, it may be pulled
or machined out. When machining the bushing out, care
must be taken to maintain proper dimensions and tolerances
in the bonnet. These will be furnished upon request.
7.3 Lapping Seats

Lapping is the process of working the valve plug against

the seat ring with an abrasive to produce a close fit. If valve
leakage is excessive, lapping becomes necessary. The
plug and seat ring seating surfaces should be free of large
scratches or other defects, and the contact surfaces of the
seats should be as narrow as possible. This may require
dressing both parts in a lathe. The seating surface angle
of the plug is 28 degrees and the seat ring is 30 degrees
(relative to the centerline axis). A good grade of fine
grinding compound is required for the lapping operation.
CAUTION
8. Screw a drilled and tapped rod with a T-handle onto the

plug stem and secure with a locknut (see Figure 4).

Note: Lapping should produce a line contact area, not the

entire surface, due to the difference in seat angles.
Avoid over-lapping as this can cause damage to

the seating surface rather than improve leakage
performance.
7.3.2 Quick-Change Trim (Figure 13 or 15)
7.3.1 Threaded Trim (Figure 12 or 14)
CAUTION
1. CIean body gasket surface areas.
1. CIean body gasket surface areas.
2. Install a new seat ring gasket (15) and insert seat

ring (14) in the body.
2. When seat has been removed, ensure that the

sealing surface in the body bridge and the threads
are thoroughly cleaned.
Note: A sealant compatible with the process should
be applied sparingly to the seat ring threads and
sealing shoulder.
WARNING
3. lnstall and tighten seat ring using fabricated wrench

used for removal.
CAUTION
DANGER
Note: Gasket (15) is temporarily placed to hold the

seat ring during lapping.
It is imperative to use a new gasket or a test part

having the same geometrical characteristics in
order to ensure the correct position of the seat
ring during lapping.
This gasket (or similar part) can be kept after

lapping for future use.
The gasket used for lapping must not be reused

for the body reassembly.
DANGER
3. Apply lapping compound at several spots equally

spaced around the seating area of the seat ring.
Do not over-tighten. Do not strike seat ring lugs

directly. This could distort the seat ring resulting in
seat leakage.
4. Insert the cage (13) into the body.
CAUTION
4. Apply lapping compound on the plug at several

spots equally spaced around the seating area.
5. lnsert the stem and plug sub-assembly carefully into

the body until it is seated.
5. lnsert the stem and plug sub-assembly carefully into

the body until it is seated.
DANGER
CAUTION
10.After completion of the lapping operation, remove

bonnet and plug. The seating area of the seat ring and
the plug must be cleaned of all lapping compound in
preparation for reassembly. Do not remove seat ring.
Before lapping, the plug and stem sub-assembly must be

concentric. (See pinning operation, section 7.5).
WARNING
Note: The plug should be lifted and turned 90 each

time before repeating Step (9). This intermittent lifting
is required to keep the plug and seat ring concentric
during lapping.
CAUTION
CAUTION
Note: As an alternative, drill a hole through a flat steel

plate and fasten to the plug stem using two locknuts.
9. Apply slight pressure on the stem, and rotate the

stem in short oscillating strokes (around 8 to 10
times). Repeat this step as necessary.
The compound should be mixed with a small quantity of

lubricant such as graphite. This will slow the cutting rate
and prevent tearing of the seating surfaces. The amount
of lapping required depends on the materials, condition
of seating surfaces, and accuracy of machining. lf a short
period of lapping does not visibly improve seating, there is
usually no advantage in continuing as excessive lapping
may result in rough seats. The only remedy is replacement
or re-machining of one or both parts. When lapping new
plugs and seat rings, begin with a medium fine (240 grit)
and finish with a finer grade (600 grit).
Do not tighten nuts to final torque specifications at

this time. The bonnet is used temporarily for guiding
purposes only.
7. lnsert two or three pieces of packing (6) into the packing

box to assist in guiding the stem and plug during lapping.
WARNING
CAUTION
6. PIace bonnet (8) on the body.
A. Reference Marking on the Plug Stem
CAUTION
Ensure that the seat ring (14), cage (13) and bonnet
(8) are properly aligned.
WARNING
CAUTION
7. Fasten the bonnet to the body using four body stud

nuts (10) spaced equally apart. Apply slight pressure
and tighten evenly.
CAUTION
If the plug is already fully drilled (typical for 440 C

hardened stainless steel material or solid stellite), then
drill the stem to the same diameter (Diameter C in Figure
9) as the plug shank hole.
DANGER
Note: As an alternative, drill a hole through a flat steel

plate and fasten to the plug stem using two locknuts.
If the plug guide area has a center mark,

Note: The plug should be lifted and turned 90 each

time before repeating Step (10). This intermittent
lifting is required to keep the plug and seat ring
concentric during lapping.
Match Diameter C (see Figure 9)
DANGER
Measure Dimension D based on the plug guide diameter

and stem diameter (see Figure 9).
WARNING
PIace the plug guide on a V-block, and make a center

mark on the plug guide area using a center punch.
The procedures used for performing maintenance on a valve

equipped with Lo-dB plugs (21700/21800/21900 Series) are
the same as those used for Threaded or Quick Change Trim.
Drill through the plug-stem assembly using a suitable

size drill bit.
CAUTION
In all cases after drilling: Remove any burrs from the
plug guide hole by making a slight chamfer.
D. Pinning the Plug-Stem Assembly
Maintenance of the plug should be limited to cleaning of

the ports and the procedures defined under Sections 7.3
(Lapping) and 7.5 (Pinning) as required.
1. Select the correct size pin based on the plug guide

diameter and stem diameter (see Figure 9). Apply a small
amount of grease on the pin and hand assemble it into
the hole in the plug.
CAUTION
7.5 PIug Stem Pinning
Plug stem pinning in the field may be required for the following:
2. Press fit the pin into the hole using a hammer. Complete
the pinning operation by taking care to ensure that the
pin is recessed by the same amount at both sides (see
Figure 9).
Replacing existing plug and stem, or

Replacing existing stem only
Replacing Plug and Stem

3. After the plug has been pinned, it should be placed in a

lathe to ensure it is concentric with the stem.
If it is necessary to replace the plug, then the plug stem

must be replaced at the same time. The original pin hole
in an existing stem will not provide the necessary fit, and
might seriously impair the strength of the assembly.
DANGER

Drill through the plug-stem assembly.
If the plug guide area does not have any hole or any
center mark,
7.4 Lo-dB PIug (Figure 8, 14 or 15)
PIace the plug guide on a V-block and use a suitable

drill size to either:
Match the hole size in the plug, or
11. After completion of the lapping operation, remove

bonnet and internal parts. The seating area of the
seat ring and the plug must be cleaned of all lapping
compound in preparation for reassembly.
When properly assembled, the reference mark (see Section A

above) should be flush with the end of the plug guide.
C. Drilling the New Parts
10. Apply slight pressure on the stem, and rotate the

stem in short oscillating strokes (around 8 to 10
times). Repeat this step as necessary.
Note: While pinning is being performed, care must be taken

not to damage the seating surface or plug guide. Always use
a soft metal or plastic vice jaws with cylindrical features to
hold the plug guide area (see Figure 9).
Lock two nuts against each other on the end of the new
plug stem, and screw the stem solidly into the plug using
a wrench on the upper nut.
Do not tighten nuts to final torque specifications at

this time. The bonnet is used temporarily for guiding
purposes only.
9. Screw a drilled and tapped rod with a T-handle onto the

plug stem and secure with a locknut (see Figure 4).
Hold the plug (with vise jaw assembly) in a vise.
CAUTION
Measure the depth of the pilot recess in the plug (Dimension

X in Figure 9), and make a reference mark on the plug stem
at the same distance from the thread.
B. Screwing Stem to Plug
8. Insert two or three pieces of packing into the packing

box to assist in guiding the stem and plug during lapping.
If the assembly is not running true, then the stem should

be placed in a collet with the plug guide against it and the
plug should be adjusted. Alignment of plug stem can be
performed by means of a soft faced mallet.
Replacing Existing Stem Only
C. By means of a hooked instrument, remove packing

(6) ensuring not to damage the sealing surfaces of
the packing box or plug stem.
A. Removing Existing Pin and Stem

1. Place the plug guide on a V-block and use a drift punch
to drive out the old pin.

Note: If it is necessary to drill out the pin, use a drill bit

slightly smaller than the pin diameter.
D. Replace packing rings (6).
2. Hold the plug guide in a vise (see note on opposite side

of page).
3. Lock one nut against another at the end of the plug stem.
Using a wrench on the lower nut, unscrew the stem from the
plug. The stem is removed by turning it counter-clockwise.
Note: Assemble and compress rings one at a time

into packing box. The skive cut of each packing ring
must be placed about 120 degrees apart.
Note: On valves equipped with an optional lubricator

connection, refer to Figure 10 for correct amount of
rings to place under the lantern ring (7).
B. Screwing Stem to Plug

Refer to step B of the previous section on REPLACING

PLUG AND STEM.
F. Replace and tighten packing stud nuts (3).
PIace the plug guide on a V-block and use a suitable size

drill bit to drill the stem (use the hole in the plug as a guide).
Note: If the hole in the plug guide has been slightly

damaged while removing the old pin, choose a drill bit and
a pin with a slightly larger diameter than the normal pin.
Select the correct size pin based on the plug guide diameter
and pin hole diameter. Proceed as described in part D of the
previous section, taking care not to damage the plug guide
area.
Ensure plug stem alignment following the pinning operation.
7.6 Packing Box (Figures 12 to 15)

WARNING
Valve must be isolated and the pressure vented before

performing packing box maintenance.
Proceed as follows:
7.6.1 Braided PTFE with Carbon or Aramid Core

(Standard) (Figures 12 to 15)
Note: The Braided PTFE/Carbon or Aramid packing

rings have a skive cut allowing packing replacement
without disconnecting the plug stem from the actuator
connector or actuator stem.
Note: Flexible graphite packing rings replacement may

require disconnecting the plug stem from the actuator
stem and removal of the actuator if rings are not skive cut.

connection, the lantern ring (7) must also be removed
to gain access to lower packing rings.
E. Replace new packing set (6); first assemble a backup ring (Graphite Filament Yarn braided ring), then
the flexible graphite rings (smooth rings), and finally
another braided back-up ring (refer to Figure 6).

Note: Assemble and compress rings one at a time

into packing box.

connection, refer to Figure 10 for correct arrangement
according to valve size.
F. Assemble packing follower (5) and packing flange (4).

G. Assemble and tighten packing stud nuts (3).
Note: They may be taped in place to keep them out

of the way before proceeding.
DANGER
DANGER
B. Lift the packing flange (4) and packing follower (5)

up the valve stem.

7.6.2 Flexible Graphite Rings (Optional - See Figure 6)
D. By means of a hooked instrument, remove packing

(6) ensuring not to damage the sealing surfaces of
the packing box or plug stem.
A. Loosen and remove packing flange nuts (3).
C. Remove packing flange (4) and packing follower (5)

from the plug stem.
CAUTION
CAUTION
Note: In an emergency, string packing may be used

as a temporary repair only. It must be replaced with
the correct packing as soon as possible.
B. Loosen and remove packing flange nuts (3).
CAUTION
Do not overtighten.
A. Remove actuator from the body S/A. Refer to actuator

instruction No. ER8788 for a type 87/88 actuator.
Packing box maintenance is one of the principle action items

of routine servicing. Tightness of the packing is maintained
by packing compression. Compression is achieved by evenly
tightening the packing flange nuts (3) against the packing
flange (4). Care must be taken not to over tighten as this could
prevent smooth operation of the valve. If all compression is
used up and the valve leaks, then new packing is required.
CAUTION
G. Place valve back in service and only tighten packing

as necessary to stop external leakage.
D. Pinning

WARNING
E. Replace packing follower (5) and packing flange (4).
C. Drilling the New Stem


connection, the lantern ring (7) must also be removed
to gain access to lower packing rings.
CAUTION
The packing box may be bored or honed oversize by

up to 0.015" (0.38mm) above the nominal diameter
to improve the finish. For instance, a nominal 0.875"
(22.22mm) packing box may be bored or honed up
to 0.890" (22.60mm) and the LE Packing will still
seal properly.
Packing box must be finished to the bottom of

the bore.
7.6.3.1.3 Packing
Inspect packing rings. Do not use packing if

any nicks or scratches on packing are observed.
Check packing and ensure that it is in the proper
arrangement (see Figure below). PFE material
can be identified by the gloss black molded finish.
PTFE material has a dull black machined finish.
Do not overtighten.
H. Proceed to appropriate instructions for actuator and

valve assembly adjustment.
CAUTION
I. Place valve back in service and only tighten packing

as necessary to stop external leakage.

7.6.3 LE Packing (Optional - See Figure 7)
The Masoneilan LE (Low Emissions) Packing is a high

performance packing system capable of containing
fugitive emissions well below the specifications of the
most severe recommendations. It is also available in a
firesafe configuration.
The packing is provided as a set of five pieces. It consists

of two adapter rings and three V-rings. An alternating
pattern of Perfluoroelastomer (PFE) and long carbon
fiber filled Teflon (PTFE) V-rings are used.
PTFE - female adapter

PFE - V-Ring
PTFE - V-Ring
PFE - V-Ring
Applied properly, this packing exhibits very little cold flow

(or creep). Consequently, it can effectively prevent fugitive
emissions leaks from a control valve. The LE Packing
system can directly replace conventional packing,
requiring no modification to the control valve or actuator.
DANGER
A spring loaded, two-piece follower assembly is used

to maintain a constant load on the packing, and is
necessary for thermal cycling applications. As the
definition of thermal cycling can vary, and processes are
potentially subject to unpredicted thermal gradients, LE
Packing is only available with the spring loaded follower.
Installation should be performed as detailed in the

following paragraphs.
PTFE - male adapter
7.6.3.1.4 Spring Loaded Follower
The spring loaded follower consists of an upper

and lower follower and eight (8) disc springs (see
Figure below). The springs are installed inside
the lower follower and positioned alternately. The
assembly is held together by tape, which must be
removed before installation.
Scribe
Mark
7.6.3.1 Preparation
Upper
Follower
Disc
Springs
7.6.3.1.1 Stem
Lower
Follower
Inspect stem for any nicks or scratches on the

surface finish. Reject the stem for any of these
reasons as they may damage packing.
7.6.3.2 Packing Installation
Note: A properly etched part number on the

stem in the packing area will have no adverse
effect on the performance of the packing.
a. The packing must be lubricated with Krytox fluorinated grease prior to installation (Krytox GPL206
or equivalent).
Stem finish should be 3-7 AARH (Ra0,1/0,2).
7.6.3.1.2 Packing Box
Note: Bonnets that have a lube hole or leak

detection port are unacceptable for use with the
packing arrangement shown in Figure 7.
b. Packing should be lubricated as a set (not

individually) to minimize getting lubricant
between the rings.
WARNING
c. Packing should be lubricated with a generous

application to the O.D. and I.D. of the packing set.

CAUTION
d. PFE/PTFE is to be installed as a set. Carefully

slide the packing set down the stem. Do not cock
or force the packing on the threads.
Packing box should be clean and free of burrs,

rust, and any foreign matter. Parts can be cleaned
with denatured alcohol.
CAUTION
Note: Packing box finish should be 125 AARH

(Ra3,2) or better.

Note: All exposed surfaces of the packing set must

be covered with the lubricant.
If the packing set separates while on the stem,

do not remove. Continue installing the remaining
pieces to put the set back together.
e. Gently press the packing into the packing box. Do

not tap the packing down into the box.
f. The spring loaded follower is installed on top of the

packing. This follower is installed as an assembly
held together by tape. This tape should be removed
after assembly. Proper assembly of the packing box
will leave the top of the Lower Follower 0.25 - 0.50
inches (6 to 13mm) above the bonnet.
For 3/4" 2" valves:
For 3"-8" valves:
a. Place new insert on shank and insert retainer as

shown in Figure 3.
b. lnstall plug tip into shank subassembly. Hand tighten
and ensure plug tip seats evenly against insert.
WARNING
A groove is scribed into the O.D. of the upper

follower. The packing flange is tightened evenly
until the top of the Lower Follower aligns with the
scribe mark (groove) in the Upper Follower.
a. Apply a light coat of lubricant to the O-ring and install

on insert retainer.
Note: This is the optimum loading for this packing.

Further tightening will shorten life of the packing.
Thread locking compound can be used on packing
nuts.
g. The packing should be checked for leakage.

h. Packing load should be checked after the valve
has cycled approximately 500 times. Adjust if
necessary. No further adjustment should be
required for the life of the packing.
CAUTION
WARNING
c. Install plug tip into insert retainer subassembly

insuring the plug tip seats evenly on the insert.
WARNING
F. Carefully place the plug subassembly into a soft jaw

vise, holding the plug by the flats provided on the upper
end of the shank.
The soft seat plug used in the 21000 Series valve has
a replaceable insert. To remove and replace the insert,
proceed as follows.
CAUTION
The shank OD is the plug guide. Extreme care must be

taken to prevent scoring or marring this surface. Failure
to do so could result in damage to the guide bushing and
destruction of the plug. Two flats are provided for holding.
CAUTION
Note: On 3/4"2" size valves, the plug tip has a machined

slot into which a bar can be inserted for removal. On
3"6" size valves, the plug tip has two machined holes
into which a tool (fabricated with appropriate size pins)
can be inserted for removal.
WARNING
When using a vise to hold the plug, extreme care must

be taken not to damage the plug shank.
CAUTION
DANGER
CAUTION
The plug tip must be tightened, allowed to set for

approximately 4 hours, retightened, allowed to set another
4 hours, then tightened one more time. The purpose of
this tightening sequence is to allow the insert material to
cold flow into place on the plug subassembly.
CAUTION
B. Carefully place plug subassembly into a soft jaw vise,

holding the plug by the flats provided on the upper end
of the shank.
CAUTION
WARNING
G. Using the appropriate tool used during disassembly,

firmly tighten the plug tip.
A. Loosen set screw until the head of the set screw is flush
with the OD of the shank.
Ensure any lubricant used is compatible with service

conditions.
b. Install new insert on insert retainer and assemble as

shown in Figure 3.
7.7 Soft Seat Plug (Figure 3)
CAUTION
H. Following the above tightening sequence, securely

tighten the set screw down into the plug. Plug is ready
for assembly into the valve.
CAUTION
DANGER
DANGER
8. Valve Body Reassembly
After completion of the required maintenance, the valve should

be reassembled using the following procedures:
When using a vise to hold the plug, extreme care must

be taken not to damage the plug shank.
Note: If any of the following steps were completed during

maintenance, then proceed to the next step.
C. Using the appropriate tool, unscrew plug tip (counter

clockwise) from the shank subassembly.
CAUTION
8.1 Threaded Trim (Figure 12 or 14)
D. Remove insert O-ring (for valve sizes 3"8" only) and

insert retainer. Discard existing insert and O-ring.
A. CIean all gasket mating surfaces.
DANGER
B. Apply a small amount of sealant to the seat ring threads

and sealing shoulder. Install seat ring into valve body.
E. Thoroughly clean all remaining metallic components

and install new insert and O-ring as follows (according
to valve size):
Note: A sealant compatible with the process should be

applied sparingly.
C. lnstall and tighten seat ring using wrench used for removal.
WARNING
E. Install body gasket (11).
CAUTION
F. Assemble bonnet (8) and body stud nuts (10) and

tighten. Bonnet must be positioned so the packing
flange studs are at 90 to the flow center line.
Do not over-tighten. Do not strike seat ring lugs directly.

This could distort the seat ring resulting in unwarranted
seat leakage.
CAUTION
D. Carefully install plug and stem assembly.

Note: Valve should be lapped before final assembly.

See Section 7.3.
E. Install body gasket (11).

WARNING
G. lnsert packing (6) [and lantern ring (7) on valve

equipped with an optional lubricator or leak detection
connection]. Refer to Section 7.6 for proper packing
assembly procedure for standard or optional designs.
WARNING
H. Install packing follower (5) and packing flange (4).
CAUTION
DANGER
I. Install packing flange stud nuts (3).
Tighten nuts (10) until metal to metal contact is obtained

with proper bolt torque. Refer to Figure 11 for proper bolt
torque and tightening sequence specifications.
CAUTION
WARNING
G. lnsert packing (6) [and lantern ring (7) on valve equipped

with an optional lubricator connection]. Refer to Section
7.6 for proper packing assembly procedure for standard
or optional designs.
CAUTION
8.3 High Pressure & Angle Design (Figures 16 & 17)

Do not overtighten (See Section 7.6. Packing Box).
CAUTION
DANGER
9.1 Types 87/88 Actuators
WARNING
10.Bellows Seal
Assembly
DANGER
Refer to Instruction No.ER8788 for removal, maintenance,

assembly and adjustment.
K. For actuator assembly and plug stem adjustment,

proceed to the actuator instruction No. ER8788 for a
type 87/88 actuator.
8.2 Quick-Change Trim (Figure 13 or 15)

A. CIean all gasket mating surfaces.
CAUTION
B. Install seat ring gasket (15) and seat ring (14).

Note: Spiral wound gaskets (11 & 15) are standard
in the 21000 Series design. It is imperative that a new
SINCE THIS IS A SEALING BELLOWS, THE PLUG

STEM SHOULD NEVER BE TURNED UNDER ANY
CIRCUMSTANCES.
CAUTION
C. Install cage (13).
There is a built-in anti-rotation feature, consisting of a double

flat surface machined on the plug stem that slides into a
rectangular slot machined in the upper bushing (30) of the
bellows (see Figure 19 - Section a).
DANGER
D. Carefully install plug and stem assembly.

Note: Valve should be lapped before final assembly.

See Section 7.3.
Note: For 2" valves with Cv 30 Lo-dB / Anti-Cavitation

trim only, steps C and D must be reversed such that the
plug and stem assembly is installed prior to the cage.

Standard trim is used within these optional body configurations.

Refer to the applicable sections within this instructions manual.
9. Actuators
J. If a leak detection connection was installed, connect it

on the lateral NPT port in the bonnet. If not, ensure that
the 1/4" NPT plug remained in place (Figure 5).
Do not overtighten (See Section 7.6. Packing Box).
K. For actuator assembly and plug stem adjustment,

proceed to the actuator instruction No. ER8788 for a
type 87/88 multispring actuator.
I. lnstall packing flange stud nuts (3).
CAUTION
DANGER
CAUTION
J. If a leak detection connection was installed, connect it

on the lateral NPT port in the bonnet. If not, ensure that
the 1/4" NPT plug remained in place (Figure 5).
H. Install packing follower (5) and packing flange (4).
Care must be taken to ensure that the cage, seat, and

bonnet are properly aligned in the body. Cage should be
installed with parts at lower end, near seat ring. Tighten
nuts (10) until metal to metal contact is obtained with
proper bolt torque. Refer to Figure 11 for proper bolt
torque and tightening sequence specifications.
CAUTION
Note: Spiral wound body gaskets (11) are standard

in the 21000 Series design. It is imperative that a new
F. Assemble bonnet (8) and body stud nuts (10). Bonnet

must be positioned so the packing flange studs are at
90 to the flow center line.
CAUTION
IT IS IMPORTANT TO DISCONNECT THE ACTUATOR

FROM THE VALVE BEFORE CHANGING THE ACTUATOR
ROTATIONAL POSITION.
T-Handle
Figure 2 - Typical Installation
Lock Nut
Shank
Skirt &
Insert
Retainer
Set
Screw
Set
Screw
Insert
Retainer
Insert
Plug Tip
3/4" -
Flats
Flats
2" Valve Sizes
Plug
Tip
O-ring
3" - 8" Valve Sizes
Figure 4 - Seat Lapping Device
Figure 3 - Soft Seat Plugs (Optional)
Braided
Back-up Rings
Flexible
Graphite
Rings
Figure 6 - Flexible Graphite Rings Arrangement (Optional)
Figure 5 - Lubricator Connection (Optional)
Figure 8
Lo-dB (Type 21900) and Anti-cavitation (Type 21800)
Double Stage Trim (Optional)
Figure 7
LE (Low Emission) Packing Arrangement (Optional)

10
D
X
X
B
Cylindrical machining
diameter of the jaws =
plug guide diameter A
C Dia.
Reference Mark
Plug Guide Plug Stem

Dia. A
Dia. B
Pin Hole
Dia. C
in. mm
.87 22.22
in. mm in. mm
1/2 12.70 .138 3.50
in. mm in. mm
1.25 32 .50 13
1.50 38.10
1/2 12.70 .138 3.50
1.25 32
.50
13
2.38 60.32
3/4 19.05 .197 5.00
1.88 47.5 .75
19
2.75 69.85
3/4 19.05 .197 5.00
1.88 47.5 .75
19
Soft metal
or plastic
vise jaws
Figure 9 - Plug Stem Pinning
Packing box with Kevlar/PTFE

packing rings
Valve
Size
in.
Packing box with

Flexible Graphite packing rings
and Back-up rings
Quantity of Packing Rings (6)
Braided
Back-up Rings
mm
Total
Total
Flexible
Graphite Rings
Lantern
Ring
(7)
3/4 to 4
20 to 100
6 to 8
150 to 200
Lantern
Ring
(7)
Figure 10 - Packing Ring Arrangements with Optional Lubricator Connection
200

11
Assembly Torque Requirements

Valve Size
inch
ANSI Class
mm
.75
&1
20 &
25
1.5
&2
40 &
50
Torque Requirements
Bolting Requirements
Qty.
Minimum
Size (inch)
Lbs.Ft
Maximum
N.m
Lbs.Ft
Pre-Load
N.m
Lbs.Ft
N.m
150 & 300
1/2"-13NC-2A
25
34
66
89
600
1/2"-13NC-2A
25
34
66
89
900 & 1500
1"-8NC-2A
125
169
560
759
45
61
2500
1"-8NC-2A
125
169
560
759
45
61
150 & 300
1/2"-13NC-2A
25
34
66
89
600
1/2"-13NC-2A
25
34
66
89
900 & 1500
7/8"-9NC-2A
100
136
300
407
30
41
1.5
40
2500
7/8"-9NC-2A
100
136
300
407
30
41
50
2500
1-1/8"-7NC-2A
160
217
640
868
60
81
80
100
150
200
150 & 300
5/8"-11NC-2A
45
61
132
179
10
14
600
3/4"-10NC-2A
80
108
230
312
20
27
900 &1500
1-1/8"-8NC-2A
225
305
830
1125
75
102
150 & 300
5/8"-11NC-2A
45
61
132
179
10
14
600
1"-8NC-2A
125
169
560
759
45
61
900 &1500
1-1/2"-8NC-2A
400
542
2100
2847
115
156
150 & 300
12
5/8"-11NC-2A
45
61
132
179
10
14
600
12
1"-8NC-2A
125
169
560
759
45
61
150 - 600
12
1-1/4"-8NC-2A
235
319
1200
1627
100
136
Notes: 1. Do not exceed Maximum Torque values listed.

2. Tighten in increments until required torque levels are reached.

3. Reject assembly if metal-to-metal contact is not achieved after reaching Maximum Reqd.
Torque.
Torque

4. TorqueValve
requirements shown are for standard B7 studs and 2HCarbon
nuts.
Steel Bolting
Stainless Steel Bolting
Stud (9)
Size

ANSI Class
Max.
Min.
Min.
Max.
mm
in.
Size
Qty Ft. Lbs. daN.m Ft. Lbs. daN.m Ft. Lbs. daN.m Ft. Lbs. daN.m
900
230
31
250
34
170
23
184
25
25
1
&
&
1500
1 - 8 NC - 2A
4
260
35Torque
295Requirements
40
Bolting
40Requirements
1- 1/2
295 Maximum
40
370
50 Increments
2500
Minimum
Pre-Load
150 - 300
33
4,5
37
5
26
3,5
30
4
Qty.20 to 50 3/4 Size
Lbs.Ft
Lbs.Ft
N.m
Lbs.Ft
N.m
Lbs.Ft
N.m
1/2 -13 NC - 2AN.m8
to 2 (inch)
600
40
5,5
48
6,5
8
1/2"-13NC-2A
20-11 NC - 2A 27 6
4163
74,5
7
150
5/8
6030
8
8,5 5
33
37 5
5
Bellows Bonnet Assembly Torque Requirements
300
6055
8
8,510
66
74 5
3
5/8
5/8"-11NC-2A
25-11 NC - 2A 34 6
7563
14 9
140
19
148
20
600
3/4 -10 NC - 2A
8
Notes: 1. Do not exceed Maximum
150 -Torque
300 values
5/8 -11listed.
NC - 2A
8
63
8,5
70
9,5
100 in increments
4

2. Tighten
noted
reached.
600 until required
28
220
30
170 *
184 *
23 *
1 -8 NCtorque
- 2A levels
8 are207

3. Torque requirements 150
shown
are for
standard
2H nuts.
- 300
5/8
-11 NC -B7
2A studs
12 and 63
8,5
66
9
52
59
7
150
6
600
28
207
28
221
30
207
221
1 -8 NC - 2A
12
26
200
8
150 - 300 1- 1/4 - 8 NC - 2A 12
192
26
207
28
192
207
8
80
1
6
4
4
3
6
12
12
10
3
6
Figure 11 - Bolting Torques and Tightening Sequence

28
207
* Only on 21000 threaded trim valves. For quick-change trim valves, use following torques.........
11
221
10
25 *
8
30
28
30
Figure 12
Threaded Seat Ring-Contoured Plug-Full Capacity
Figure 13
Quick Change Trim-Contoured Plug-Full Capacity
Figure 14
Threaded Seat Ring-Lo-dB Plug
Figure 15
Quick Change Trim-Lo-dB Plug
PARTS REFERENCE
Ref.
l

l

1
2
3
4
5
6
7
8
Part Name
Ref.
Plug Stem
Packing Flange Stud
Packing Flange Stud Nut
Packing Flange
Packing Follower
Packing
Lantern Ring (optional)
Bonnet
l Recommended spare parts
9
10
l 11
12
l 13
l 14
l 15
l 16
Part Name
Body Stud
Body Stud Nut
Body Gasket
Plug Guide Bushing (Incl. w/ref. 8)
Cage *
Seat Ring
Seat Ring Gasket *
Plug
* Only on Quick Change Trim

13
Ref.
Part Name
l 17
18
19
Plug Pin
Body
Drive Nut
Figure 17 - Angle Body Design

3/4" to 6" Valve Sizes ANSI Class 150 to 600
3/4" to 2" Valve Sizes ANSIClass 900 to 2500
Figure 16 - 21000 Series

3/4" to 2" Valve Sizes ANSI Class 900 to 2500
WARNING
10.1 Bellows Valve Disassembly (Figure 19)

Remove stem bellows S/A (30) by the top of the

bonnet extension (29). If necessary, disengage the
upper bushing of assembly (30) using a screwdriver
in the groove provided for this purpose.
Note: Spiral wound gaskets are standard in the 21000

BS Series design. IT IS RECOMMENDED THAT NEW
GASKETS ARE INSTALLED EACH TIME THE VALVE IS
DISASSEMBLED.
10.1.1 Threaded Trim
After removing the actuator, disassemble the body S/A

using the following procedure:
Disconnect the leak-off circuit from the bonnet (if this

option is included). Remove nuts (27) and bonnet
studs (26) from the bonnet (25).
Be careful not to damage the seating surfaces of the

bellows bushing.
Remove the bonnet and spacer gaskets (28) and

the body gasket (11).
CAUTION
Remove packing flange stud nuts (3), packing flange

(4) and packing follower (5). Remove bonnet (25).
Bonnet extension (29), plug (16), guide bushings and

seat ring (14) may now be inspected for wear and
service damage. After determining the maintenance
required, proceed to the appropriate section of these
instructions.
Remove existing packing (6).

Remove body stud nuts (10).
10.1.2 Quick-Change Trim
Remove bonnet extension (29), stem bellows S/A

(30) and plug (16) at the same time.
Removal of the quick-change trim is accomplished using

the same procedures as removal of the threaded trim.
Remove the plug pin (17), then remove the plug (16)
from the plug stem (30). (See section 10.2.1.1 for
unpinning the plug stem).

CAUTION
However, after the bonnet extension (29) has been

removed from the body, remove the cage (13), the seat
ring (14) and the seat ring gasket (15).
14
DANGER
10.2 Repair
10.2.1.3 Plug Stem Pinning
The purpose of this section is to provide recommended

maintenance and repair procedures. These procedures
assume the availability of standard shop tools and equipment.
Replacing Plug and Stem/Bellows S/A

A. Screw Stem into Plug
Replacing stem-bellows S/A only
Lock two nuts against each other on the end

of the plug stem and use a flat spanner on the
upper nut to prevent rotation of the stem-bellows
S/A. Screw the plug onto the lower part of the
stem while inserting the plug shank into the guide
bushing (12) in the bonnet extension (29).
If the plug needs replacing, the stem-bellows subassembly should be replaced at the same time.
Pull and hold the plug (16) out of the bonnet

extension (29) to allow access to the plug pin (17).
The original pin hole in a stem which is being reused

sometimes prevents a satisfactory result being obtained
and can also weaken the plug-stem assembly.
B. Drilling the New Parts
10.2.1 Plug/Stem Bellows/Bonnet Extension S/A

Plug stem pinning in the field may be required for:
Replacing existing plug and stem-bellows S/A
If the stem-bellows sub-assembly is being replaced, the

new assembly can be fitted on an existing plug as long as
it is in good condition and the removal of the pin has
not deformed the hole or damaged it in any other way.
Note: Always use soft metal vise jaws to hold the plug
guide surface. Failure to take this precaution could result
in damage to the plug guide surface during pinning (see
Figure 18).
Be careful not to damage the plug seating surface

during pin removal and assembly operations.
If the plug is already fully drilled,

If the plug guide area has a center mark,

Match Diameter C (see Figure 18),

Drill through the plug-stem assembly.
If the plug guide area has no hole or any
center mark,
Pull and hold the plug (16) out of the bonnet

extension (29) to allow access to the plug pin
(17). Place the plug guide on a V-block.
Measure Dimension D based on the plug guide

diameter and stem diameter (see Figure 18).
Note: A lower mechanical stop has been provided

to prevent damage of the bellows during this step.
Place the plug guide on a V-block, and make

a center mark on the plug guide area using a
center punch.
Using a drift punch, drive out the existing pin (17).

Place the plug guide on a V-block and use a

suitable size drill to either:
Match the hole size in the plug, or
10.2.1.1 Unpinning the Plug Stem
(typical for 440C hardened stainless steel material

or solid stellite), then drill the stem to the same
diameter (Diameter C in Figure18) as the Plug
Shank Hole.
Note: If it is necessary to drill out the pin, use a

drill bit slightly smaller than the pin diameter. Be
careful not to damage the hole of the plug guide.
Drill through the plug-stem assembly using a

suitable size drill bit.

Lock two nuts against each other on the end

of the plug stem, and use a flat spanner on the
lower nut to prevent rotation while unscrewing
the plug from the stem. The plug is removed by
turning it counter-clockwise.
In all cases after drilling: Remove any burrs from

the plug guide hole by making a slight chamfer.
C. Pinning the Plug-Stem Assembly
Remove the two nuts from the plug stem. Complete

step 10.1.1.
Select the correct size pin based on the plug

guide diameter and stem diameter (see Figure
18). Apply a small amount of grease on the pin
and hand-assemble it into the hole in the plug.
Inspect the parts and carry out any necessary

repairs, then reassemble the stem-bellows subassembly (30) through the upper hole in the
bonnet extension (29) (see section 10.2.1.2).
Press fit the pin into the hole using a hammer.

Complete the pinning operation by ensuring that
the pin is recessed by the same amount from
both sides (see Figure 18).
10.2.1.2 Mounting of the Plug-Stem/Bellows S/A

into the Bonnet Extension
Replacing Stem/Bellows S/A Only

A. Screw Stem into Plug
Clean all contact surfaces of the bonnet extension

(29) and the plug-stem/bellows S/A.
Refer to paragraph A of the previous section

REPLACING PLUG AND STEM/BELLOWS S/A.
Assemble a new gasket (28) on the upper flange

of the bonnet extension.
B. Drilling the New Stem
Insert the new stem-bellows S/A through the top

hole into the bonnet extension (29).
Place the plug guide on a V-block and use a

suitable size drill bit to drill the stem (use the
hole in the plug as a guide).
Pin the plug on the stem (See section 10.2.1.3).

15
Plug Guide Plug Stem

Dia. E
Dia. F
in.
7/8
Pin Hole
Dia. C
mm in. mm in.
22.22 1/2 12.70 .138
mm in. mm in. mm
3.50 1.65 42 .70 18
1 1/2 38.10 1/2 12.70 .138
3.50 2.17 55
1.25
32
2 3/8 60.32 3/4 19.05 .197
5.00 2.75 70
2.00
50
2 3/4 69.85 3/4 19.05 .197
5.00 2.75 70
2.00
50
Cylindrical machining
diameter of the jaws =
plug guide diameter E
Pull plug out of the Bonnet

Extension (29) for access to
the plug pin
29
16
30
17
Lower Mechanical Stop

to Protect the Bellows
28
C Dia.
E Dia.
Soft metal
or plastic
vise jaws
F Dia.
Plug and Plug Stem-Bellows S/A Stem

Figure 18 - Unpinning and Pinning of the Plug to Stem

Refer to table in Figure 11 for proper bolt torque and

tightening sequence.
Note: If the hole in the plug guide has been slightly

damaged while removing of the old pin, choose a
drill bit and a pin with a slightly larger diameter
than the normal pin.
10.5 Valve Body Reassembly

Refer to instructions stated in Section 8 for the specific trim
type involved.
C. Pinning
Select the correct size pin based on plug guide
diameter and pin hole diameter. Proceed as
described in Paragraph C above, taking care not
to damage the plug guide area.
10.6 Actuator to Body S/A and Plug Stem

Adjustment
Refer to instruction No. ER 8788.
10.3 Plug and Seat Ring Seating Surfaces

It is not possible to lap the plug and seat ring seating
surfaces after the bellows has been assembled to the
stem.
WARNING
Assembly of the No. 6 actuator on a bellows seal valve

requires a three-sectioned coupling. Follow coupling
instructions as described for the No. 10, 16 and 23 actuators.
If the seat ring shows signs of minor wear, it should be

turned on a lathe to clean up the worn area. The seating
surface of the seat ring is 30 degrees from centerline axis.
However, no more than 0.010 in. (0.25 mm) of material
should be removed.
CAUTION
In cases where the seat ring cannot be repaired, or if the plug

is also damaged the only alternative is to replace both parts.
The bellows assembly causes a spring back effect. Measure

this plug spring back before referring to Instruction No. ER
8788. Be sure to add this spring back length to the over seat
adjustment.
10.4 Bonnet Reassembly

Place new gasket (28) into the groove of the bonnet spacer.
Install the bonnet (25) and assemble nuts (27) and studs
(26). Bonnet must be positioned so the packing flange studs
are at a 90 angle to the flow centerline.

CAUTION
16
22
2
3
4
19
5
6
25
31
28
28
Section a
27
26
() 30
() 29
DETAIL OF THE PLUG

STEM ANTI-ROTATION
DEVICE
9
10
17
11
18
12
13
14
16
15
Quick Change Trim
Threaded Trim detail
Figure 19 21000 BS Valve
PARTS REFERENCE
Ref.
l 1
2
3
4
5
l 6
9
10
l 11
12
n 13
l 14
Part Name
Plug Stem
Packing Flange Stud.
Packing Flange Nut
Packing Flange
Packing Follower
Packing
Body Stud
Body Stud Nut
Body Gasket
Guide Bushing
Cage
Seat Ring
l Recommended
Spare Parts

Ref.
n 15
l 16
l 17
18
19
22
25
26
27
l 28
29
+
Part Name
Ref.
Seat Ring Gasket

Plug
Plug Pin
Valve Body
Drive Nut
Plug Stem Locknut
Valve Bonnet
Bonnet Stud
Bonnet Stud Nut
Bonnet Spacer Gasket
Bonnet Extension Assembly
Upper Flange
+ These parts included in welded subassembly
17
Part Name
+ Spacer
+ Lower Flange
30 Bellow and Stem Assembly
+ Stem
Guide Bushing
+ Bellows
+ Upper Adapter (Bellows)
+ Lower Adapter (Bellows)
31 1/8" NPT Plug
Quick change trim only

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EH21000 09/10
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Instructions N ES70004E
09/96
Masoneilan
Models 496-1 and 496-2
Rotary Electric Switches
Instructions
description and operation

Series 496 switches may be mounted on the CamflexII
rotary valves (35002 Series) or Varimax (30000 Series),
Control BallII valves (36002 Series), butterfly valves as
M i n i To r k II (37002 Series) or HPBV (39002 Series)
valves.
Description (Figure 2)
Series 496 rotary switches are used for electrically
indicating one or two predetermined positions in the
stroke of a control valve. They may be connected to
audible alarms or signal lights for warning of valve or
system malfunction. These switches may also be used
to actuate solenoids, relays and other electrical devices.
Also, they may be used on valves as the 11 000, 21000

and 41000 Series and all other linear motion valves. A
parts list for the Series 496 switch appears in page 4.
Basic switches (4) in the unit are single pole, double

throw snap acting and are individually adjusted by cams
(13) on the rotating shaft (11). Vernier adjustment is
made by means of locking type set screws (Nylock) (2)
in the cams and these screws actuate the switches by
contacting the switch spring levers (5).
Operation (Figure 2)
The motion of the control valve turns (by means of a
linkage the switch shaft (11). Cams (13), fastened to the
shaft by screws (1), actuate microswitches (4) by
pushing levers (5).
The spring levers provide overtravel protection and allow

maintained contact when required.
The series 496 is available with either one or two
switches, each with an adjustable cam to actuate it.
Each switch may be wired to either open or close the

circuit when the lever is depressed.
The housing and cover are of anodized aluminum,

epoxy painted.
NUMBERING SYSTEM OF THE 496 SERIE
496
Instrument Type
1. Mechanical switch with one single pole,
double throw contact arrangement
2. Mechanical switch with two single poles,
1st
2nd
Protection
55. Weatherproof (E)
56. Weatherproof, oxygen
environment (E)
3. Potentiometric Position Transmitter
57. Explosionproof and

weatherproof (E)
4. Electronic switch with one proximity

detector
58. Intrinsically safe and

weatherproof (E)
5. Electronic switch with two proximity

detectors
These two digits are used

only when European
standards are concerned.
6. Mechanical switch with one double pole,

Otherwise the instrument is

explosionproof and
weatherproof (US)
7. Mechanical switch with two double poles,

E= European standards
8. Optoelectronic Position Transmitter

Caution: Electrical protection of some of the above mentioned equipment
combinations, can be not in accordance with all protection standards.
Consult Masoneilan.
3rd
Additional Switch* (if any)

1. Mechanical switch with one single pole,
2. Mechanical switch with two single poles,
4. Electronic switch with one proximity
detector
5. Electronic switch with two proximity
detectors
6. Mechanical switch with one double pole,
7. Mechanical switch with two double poles,
* This digit and its oblique bar is only used when the
transmitter is provided with an auxiliary switch
installation and adjustments

The cable entry is also available in 3/4NPT threaded
connection form. This can be designed to answer most
of the customer requests.
Installation
Electrical Protection
Each microswitch has three terminals (common,

normally open and normally closed), (See Figure 3).
Electrical rating of switches is stamped on serial plate.
The microswitches and other parts are protected by a

flameproof housing
EN 50014 & 50018
EExdIICT6 (ambient temperature 70C)
EExdIICT5 (ambient temperature 80C)
The installation in hazardous locations should be

according to the regulations in force concerning
flameproof material.
Beside, a tight degree up to IP65 following to standard

CEI 144 and IP657 following to standard NF C 20.010 is
ensured by the O-rings (7& 10) located between body
and cover and on the switch shaft.
Coupling
The coupling of the switch shaft to the valve is made by
means of a back lever and a motion linkage proper to
each valve configuration. The back lever is fastened to
the switch shaft (11) with a washer and a hex. head
screw. Figures 3 to 6 show installation details on the
various valves.
Installation of the rotary limit switches into i n t r i n s i c

safety circuit according to following European
standards (CENELEC):
EN 50014 & 50020
EExiaIICT6 (ambient temperature 55C +80C)
N o t e : The load must be controlled through a
certified transistorized relay located outside the
hazardous area.
Electrical Connection-Wiring (Figure 1)

A cable entry is integrated at the bottom of the housing
and includes a cable clamping device. Dif f e r e n t
leakproof packings allow the adaptation of diameters of
unarmed cables from 6 to 15mm.
Figure 1
Wiring Diagram and Dimensions for Mounting
This assures that when the valves is throttling, the

screw (2) is completely free of the lever. The
concave part of the lever is only to maintain contact
during over-travel (if any). Similarly, the cam
operating the left-hand switch should make
contact with lever (5) only at the end of a
clockwise rotation. (Refer to face view of the
Figure 2).
Adjustments
The Series 496 switch is normally mounted and adjusted
on a control valve at the factory. To adjust the instrument
in the field, proceed as follows:
1. The concave part of the levers (5) should be
exactly concentric with the cams (13) when the
switch is actuated.
If there is only one switch (Model 496-1) it may be

necessary to reverse the position of the switch from
left to right or vice versa depending on the rotation
and stroke position.
This is an important step to assure that once the

lever is depressed, it stays depressed when the
screw (2) is completely free.
If not, loosen screws (3 and 17) and slide the levers
up or down slightly. Tighten screws.
5. Turn the cam (13) on the shaft until the switch is

activated. (If the click switch cannot be heard, use a
voltmeter). Lock the cam (13) with screw (1).
2. Unscrew slightly the cam locking screws (1) using a

3/32 Allen wrench.
6. Make a fine adjustment with screw (2) using a 1/16

Allen wrench. The screw (2) must extend out from
the cam far enough to assure sufficient depression
of lever (5).
3. Actuate the valve to the desired position (usually the

full opened or full closed position).
4. It is important to note that the cam operating the
right-hand switch should make contact with
lever (5) only at the end of a counterclockwise
rotation. (Refer to detail of the Figure 2).
Contact point
for left switch
Figure 2
Cutaway Views of Types 496-1/2 Switches
Contact point
for right switch
PARTS REFERENCE
Ref.
1
2
3
4
5
6
7
Part Name
Screw
Screw
Fastening Screw (only one switch)
Microswitch
Lever
Body
O-Ring
Ref.
Part Name
8 Snap Ring
9 Screw
10 O-Ring
11 Shaft
12 Cover
13 Cam
14 Serial Plate
15
16
17
18
*19
Recommended Spare Parts

Only on 496-2 Model
Ref.
Part Name
Drive Screw
Insulator
Fastening Screw (second switch
on 496-2)
Washer
Spacer (Not shown)
Mounting arrangements
On 35002 Series Camflex II Valves (Figure 3):
6. Mount switch (1) on bracket (3) using the four cap

screws (4) and the four hex. nuts (8).
1. Remove shaft cover, or if equipped with a positioner,

remove positioner and mounting plate.
7. For 3 (80mm) valve and larger, slip slotted bottom

cover (2) over the lever (10) and push in place.
2. Remove bottom cover (2).
8. Place slotted end of the back lever (9) over pin (12)
of the switch lever (10). Secure with washer (13)
and clip (14).
3. Install mounting bracket (3) using two flat head

screws (7).
4. Screw pin (12) to switch lever (10).
9. Attach the back lever (9) to the switch shaft using

lock washer (5) and cap screw (6).
5. Remove cap screw (11) from switch lever (10) and

slide switch lever onto shaft, behind the main lever
of the valve. Position switch lever (10) in line with
main lever. Replace and tighten cap screw (11).
10. Refer to pages 3 & 4 to proceed with wiring and

adjusting switches.
CamflexII Valve
Opening by Air Failure
Val ve
Val ve
The linkage parts are shown

WHEN NO SUPPLY PRESSURE ON ACTUATOR
CamflexII Valve
Closing by Air Failure
Figure 3
35002 Serie
Camflex II Valve
On valv e size 3
PARTS REFERENCE
Ref.
1
2
3
4
5
Part Name
496 Rotary Switch
Bottom Cover
Mounting Bracket
Cap Screw
Lock Washer
Ref.
6
7
8
9
10
Part Name
Cap Screw
Flat Head Screw
Hex. Nut
Back Lever
Switch Lever
Ref.
11
12
13
14
Part Name
Cap Screw (Switch Lever)
Lever Pin
Washer
Retaining Clip
On 30000 Series Varimax Valves (Figure 4):
4. Install the mounting bracket (3) by means of the

spacer (15) and the two flat head screws (7).
5. Mount switch (1) on bracket (3) using the four cap
screws (4) and the four hex. nuts (8).

6. Attach the back lever (9) to the switch shaft using

lock washer (5) and hex. head screw (6).
2. Screw the index-screw (17), with its lock washer

(18), into one of the two threaded holes of the switch
lever (10).
N o t e : The head of the index-screw (17) will be
engaged in the slot located on the valve shaft end
to ensure the proper position of the switch lever
(10). The proper hole to the used configuration can
be easily identified referring to the below Figure 4
and presenting the lever in the shown position.
7. Connect the back lever (9) to the switch lever (10)

by means of link (20), two driving pins (12), four
washers (13) and two retaining clips (14).
adjusting switches.
3. By means of the hex. head screw (19), fit the switch

lever (10) on the valve shaft end in the proper
position relating to the valve operating way.
Varimax Valve
Opening
by Air Failure

Varimax Valve
Closing
by Air Failure
Figure 4
30000 Series
Varimax Valves
Ref.
1
3
4
5
6
7
Part Name
496 Rotary Switch
Mounting Bracket
Cap Screw
Lock Washer
Hex. Head Screw
Flat Head Screw
PARTS REFERENCE
Ref.
8
9
10
12
13
14
Part Name
Hex. Nut
Back Lever
Switch Lever
Lever Pin
Washer
Retaining Clip
Ref.
15
17
18
19
20
Part Name
Spacer (Mounting Bracket)
Index-screw (Switch Lever)
Lock Washer
Hex. Head Screw
Link
On 36002 Series Ball II, 37002 Series MiniTork II and

39002 Series HPBV Valves (Figure 5):
6. Install front cover.

7. Install mounting plate (3) using the two flat head
screws (1).

2. Remove plastic panels for access, bottom, front and
sides.
3. Admit supply pressure on actuator until the actuator
pivot pin (8) is in intermediate position, such that
every load is removed from the pin.
4. Remove existing pivot pin and install special pin (8)
with switch mounting pivot pin.
8. Mount switch (2) to plate (3) using the four hex.

head screws (5) and four nuts (12).
9. Assemble back lever (14) to the switch shaft using
cap screw (15) and lock washer (16).
10. Replace the bottom cover (4) having proper holes.
11. Screw the clevis (11) on the turnbuckle (10). Rotate
clevis to equalize the length of two engaged
threaded ends.
12. Insert the clevis (11) through the proper hole of
bottom cover (4) and connect to back lever (14)
using clevis pin (13) and retaining clip (7).
13. Admit supply pressure on actuator until the travel
indicator is on mid-stroke position. Turn the
turnbuckle one way or another until the back lever
(14) is parallel to bottom cover (4). Lock the locknut
(9). Replace the side covers.
5. Assemble take off link (6), locknut (9) and turnbuckle

(10), without tighten. Slide assembly over pivot pin
(8) and push on retaining clip (7).
Ball II and
MiniTork II Valves

adjusting switches.
HPBV Valves

Ball II and
MiniTork II Valves
HPBV Valves
Figure 5
36002 Series Ball II Valves
37002 Series MiniTork II Valves
39002 Series HPBV Valves
PARTS REFERENCE
Ref.
Part Name
1
2
3
4
5
6
Flat Head Screw

496 Rotary Switch
Mounting Bracket
Bottom Cover (Actuator)
Hex. Head Screw
Take Off Link
Ref.
Part Name
7 Retaining Clip
8 Pivot Pin (Actuator)
9 Locknut
10 Turnbuckle
11 Clevis
12 Hex. Nut
Ref.
13
14
15
16
Part Name
Clevis Pin
Back Lever
Hex. Head Screw
Lock Washer
On No 37 and 38 Spring Diaphragm Actuators

(Figure 6):
The back lever (9) is fastened to the end of the switch

shaft with spring washer (15) and cap screw (17).
The 496 switch is rigidly mounted on the spring barrel of

the diaphragm actuator by means of a bracket (7)
fastened to the mounting pad with cap screws (8).
The turnbuckle (6) must be adjusted before adjusting the

switches. Apply air pressure to the actuator until the
actuator stem has traveled exactly half the rated stroke.
Loosen locknut (5) and turn the turnbuckle (6) until the
back lever (9) is level. Tighten locknut (5), then
proceed with wiring and adjusting switches
according to instructions on pages 3 & 4

WHEN NO SUPPLY PRESSURE
ON ACTUATOR
On Type 38 Actuator
With
Stem Extracting
by Air Failure
On Type 37 Actuator
With
Stem Retracting
by Air Failure
Act uat or
Act uat or
Valve
FASTENING
OF THE CLAMP
ROD
( Right Hand
Act uat or
Coupling
FASTENING
OF THE CLAMP
ROD
Valve
PARTS REFERENCE
Ref.
1
2
3
4
5
6
Part Name
Clamp
Clamp
Screw
Turnbuckle Screw
Locknut
Turnbuckle
Ref.
7
8
9
10
11
12
Part Name
Mounting Bracket
Hex. Head Screw
Back Lever
Clevis
Retaining Clip
Clevis Pin
Figure 6
No 37 and 38
Spring Diaphragm Actuators
Ref.
14
15
16
17
18
Part Name
Hex. Head Screw
Lock Washer
Washer
Hex. Head Screw
Clamp Rod
4, place de Saverne - 92971 PARIS LA DFENSE CEDEX-Tel. (01)49 04 90 00-Telecopier(01)49 04 90 10-Telex 620046F
FRANCE
PLANTS, SPARE PARTS and AFTER SALES DEPARTMENTS: 3, rue SaintPierre14110 CondsurNoireau
Tel.(02)31 69 59 00-Telecopier(02)31 69 38 44-Telex 170728F
Model 78 Series
Air Filter Regulators
Instruction Manual
EY7840
02/10
Product Description
Operation
The 78 Series pressure regulators are compact, lightweight,

high-performance pressure reducing valves. They are used
primarily for supplying a stable source of air to process control equipment such as current to pneumatic transducers and
control valve positioners.
Prior to applying supply pressure, loosen knob lock screw (see

figure 1) and turn pressure set knob counterclockwise. Turn on
supply pressure. Output pressure should be zero. Slowly rotate
set knob clockwise until desired pressure is reached. Tighten
knob locking screw to ensure that pressure remains set at
desired value. When changing output from a higher to lower pressure, initially go to lower than desired pressure, then increase to
desired pressure. Re-tighten knob lock-screw.
Numbering System
Model
No.
Pressure Range
78-4
5-40 psi (35-280 kPa),

(0.35-2.8 bar)
Air Loading with

Relief and Filter
78-40
5-100 psi (35-700 kPa),

(0.35-7 bar)
Air Loading with

Relief and Filter
Description
Specifications
Inlet Pressure
Rating
210 psi (1.5 MPa, 14.5 bar) maximum
Pressure Set
Range
5-40 psi (35-280 kPa, 0.35-2.8 bar)

5-100 psi (35-700 kPa, 0.35-7 bar)
Connection
1/4 NPT
Rated Cv
0.25
Filter Element
Sintered Porous Polyethylene (5)
Ambient
Temperature
Range
-40 to +83C (-40 to +182F)
Air Consumption
0.004 scfm (100 sccm)
Weight
14 oz. (0.4 kg)
Materials of
Construction
See figure 2 and table 2
WARNING
Do not install this Regulator in air lines which exceed 215 psi
(1.5 Mpa, 15 bar) pressure.
Installation
Clean the lines thoroughly to remove all dirt, scale or other foreign
matter before installing the regulator. Install with flow in direction
of flow arrows on regulator body. The airset should be installed
with the drain cock facing down. Regulator should be installed
as close as possible to device utilizing the reduced pressure to
minimize pressure drop. Do not use piping or tubing smaller than
the regulator connections since this will restrict flow and reduce
capacity.
It is recommended that pressure gauges be installed on the inlet
and outlet sides of the regulator as an aid in adjusting the pressure and in monitoring of working pressures.
2 | Dresser Masoneilan
Maintenance
It is recommended that the drain cock be opened at regular intervals to drain any fluid that may have collected in the dripwell. The
interval between draining will have to be determined based on the
actual rate of accumulation of fluid.
WARNING
The relief valve feature should not be confused with any
auxiliary safety valve which might be needed for complete
protection of air operated equipment. It is intended only to
provide more uniform controlled pressure and to permit
adjusting the outlet pressure downward without venting the
line.
WARNING
Prior to performing maintenance on the regulator, shut off
the inlet and outlet pressures and remove the spring compression by turning the setting knob fully counterclockwise.
Open the drain cock carefully to relieve any retained pressure and drain the dripwell. It is recommended that the
regulator be removed from the line for repairs.
CAUTION
When draining the dripwell, open the drain cock slowly and
collect the fluid in a suitable container for safe disposal.
NOTE:
Considering the high labor costs involved in replacing internal
parts, it may be more economical to stock complete units.
Care must be taken to avoid damage to the plug and stem
assembly.
Troubleshooting
If at any time the regulator fails to function properly it is recommended
to replace rather than repair the device.
Materials of Construction
No. Part
Standard Material
Body
Aluminum Die Casting
Spring Casing
Bottom Cap
Knob
VALOX 420
Lock Screw
Stainless Steel
Adjusting Screw
Stainless Steel
Spacer
VALOX 420
Spring Button
Zn-Cr Plated Carbon Steel
Spring
Coated Spring Steel
10*
Diaphragm
NBR
15
Plug Guide
VALOX 420
16*
Plug
Neoprene/416 Stainless Steel
17*
Filter
Sintered Polyethylene
18*
Port Spring
Stainless Steel
19*
O-Ring
NBR
21
Drain Cock
Stainless Steel
22
Screw
Stainless Steel
23
Pipe Plug
Zinc Plated Carbon Steel
24
Aspirator
VALOX 420
25
Nameplate
Aluminum
* Recommended Spare Parts
Dimensions
EY7840 / 11/09 / Model 78 Series Air Filter Regulator | 3

BELGIUM
Phone:
+32-2-344-0970
Fax:
+32-2-344-1123
ITALY
Phone:
Fax:
BRAZIL
Phone:
Fax:
JAPAN
Chiba
Phone:
Fax:
+55-11-2146-3600
+55-11-2146-3610
+39-081-7892-111
+39-081-7892-208
+81-43-297-9222
+81-43-299-1115
SAUDI ARABIA
Phone:
+966-3-341-0278
Fax:
+966-3-341-7624
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Phone:
+65-6861-6100
Fax:
+65-6861-7172
CANADA
Ontario
Phone:
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Fax:
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Phone:
Fax:
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Phone:
Fax:
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Phone:
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Fax:
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SOUTH & CENTRAL

Phone:
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Fax:
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Phone:
Fax:
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Phone:
Fax:
+86-10-8486-4515
+86-10-8486-5305
FRANCE
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Phone:
+33-1-4904-9000
Fax:
+33-1-4904-9010
GERMANY
Viersen
Phone:
+49-2162-8170-0
Fax:
+49-2162-8170-280
INDIA
Mumbai
Phone:
Fax:
New Delhi
Phone:
Fax:
+91-22- 8354790
+91-22-8354791
+82-2-2274-0748
+82-2-2274-0794
+52-5-310-9863
+52-5-310-5584
SOUTH AFRICA
Phone:
+27-11-452-1550
Fax:
+27-11-452-6542
+34-93-652-6430
+34-93-652-6444
THE NETHERLANDS
Phone:
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Fax:
+0031-18-1641438

Phone:
+971-4-8139-200
Fax:
+971-4-8838-038
RUSSIA
Veliky Novgorod
Phone:
+7-8162-55-7898
Fax:
+7-8162-55-7921
Moscow
Phone:
+7 495-585-1276
Fax:
+7 495-585-1279
UNITED KINGDOM
Wooburn Green
Phone:
+44-1628-536300
Fax:
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UNITED STATES
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Phone:
+1-508-586-4600
Fax:
+1-508-427-8971
Phone:
+1-361-881-8182
Fax:
+1-361-881-8246
Dresser Direct
Deer Park, Texas
Phone:
+1-281-884-1000
Fax:
+1-281-884-1010
Houston, Texas
Phone:
+1-281-671-1640
Fax:
+1-281-671-1735
California
Phone:
+1-562-941-7610
Fax:
+1-562-941-7810
+91-11-2-6164175
+91-11-5-1659635
About Dresser, Inc.

Dresser, Inc. is one of the leading providers of reliable,
highly engineered infrastructure products for the global
energy industry. Dressers highly regarded portfolio of
brands includes Wayne payment and fueling systems;
Waukesha natural gas-powered engines and generator
sets, Masoneilan control valves, Consolidated pressure
relief valves, and Roots blowers and compressors. With
locations worldwide, Dresser, Inc. serves customers in
more than 100 countries. www.dresser.com.

Dresser Masoneilan, headquartered in Houston, Texas,
has been the leading global partner in process control
valves and solutions for more than 100 years. A business
segment of Dresser, Inc., the company delivers customized
products, services and diagnostic solutions for oil
and gas, process and power generation applications.
www.dresser.com
Dresser Masoneilan
T. +1-281-671-1640
F. +1-281-671-1735
www.dresser.com
87/88 Series
Spring Diaphragm Actuator
Instruction Manual
ER8788
09/10
Table of Contents
Page
IMPORTANT: SAFETY WARNING.........................................................................................1

NUMBERING SYSTEM..........................................................................................................2
1.0 Introduction..............................................................................................................3
2.0 GENERAL........................................................................................................................3
3.0 Actuator Description............................................................................................3
4.0 Unpacking....................................................................................................................3
5.0 Air Piping......................................................................................................................3
6.0 Actuator Removal...................................................................................................3
7.0 Maintenance...............................................................................................................5
8.0 Actuator Range......................................................................................................10
9.0 Air Action Changes................................................................................................14
10.0 Valve Mounting.....................................................................................................18
PARTS REFERENCE TABLES............................................................................................21

Copyright
Masoneilan is a registered trademark of Dresser, Inc. All information contained herein is believed to be accurate at the time of
publication and is subject to change without notice.
Safety Information
About this Manual

prior notice.
Important - Please Read Before

Installation

written permission.
Masoneilan model 87/88 Series actuator instructions contain

DANGER, WARNING, and CAUTION labels, where necessary,
to alert you to safety related or other important information. Read
the instructions carefully before installing and maintaining
your control valve. DANGER and WARNING hazards are
related to personal injury. CAUTION hazards involve equipment or property damage. Operation of damaged equipment
can, under certain operational conditions, result in degraded process system performance that can lead to injury or
death. Total compliance with all DANGER, WARNING, and
CAUTION notices is required for safe operation.

These instructions are written specifically for the 36005
Series control valves, and do not apply for other valves
outside of this product line.
Warranty
Items sold by Dresser are warranted to be free from defects
in materials and workmanship for a period of one year from
the date of shipment provided said items are used according
to Dresser recommended usages. Dresser, Inc. reserves the
right to discontinue manufacture of any product or change
product materials, design or specifications without notice.
This is the safety alert symbol. It alerts you to potential

personal injury hazards. Obey all safety messages that follow
this symbol to avoid possible injury or death.
This instruction manual applies to the Masoneilan 87/88 Series

actuator.
The Control Valve MUSTBE:
Installed, put into service and maintained by qualified
and competent professionals who have undergone
suitable training.


product.

All surrounding pipe lines must be thoroughly flushed to

ensure all entrained debris has been removed from the
system.

Instructions ER8788 09/10

87/88 Series Spring Diaphragm Actuator
Numbering System
1st DIGIT
2nd DIGIT
Actuator Type
87 Air to Close (extend stem)
88 Air to Open (retract stem)

1. Introduction
6. Actuator Removal
The following instructions are designed to assist maintenance

personnel in performing most of the maintenance required
on the Model 87/88 actuator. Masoneilan has highly skilled
service engineers available for start-up, maintenance and
repair of our actuators and component parts. In addition,
a regularly scheduled training program is conducted at the
Training Center to train customer service and instrumentation
personnel in the operation, maintenance and application
of our control valves and instruments. Arrangements for
these services can be made through your Masoneilan
Representative or Sales Office. When performing
maintenance, use only Masoneilan replacement parts. Parts
are obtainable through your local Masoneilan Representative
or Sales Office. When ordering parts, always include Model
and Serial Number of the unit being repaired.
Maintenance on the valve body normally requires removal of

the valve actuator. The steps in removal of the actuator are
different depending on whether the actuator is air to close or
air to open.
Note: Actuator action may be checked by referring to the
valve identification tag. Model 87 indicates unit is air to close
and Model 88 indicates unit is air to open.
6.1 Air to close (Model 87), size 3 (Figure 9), and size 6
(Figure 2), with or without handwheel
A. Shut off air supply to actuator and rotate handwheel
to the neutral position. [No force exerted on the stem
flange.]
B. Disconnect air piping from diaphragm case.
2. General
C. Check the stem position against the travel scale to

ensure that the plug is up (off the seat).
These installation and maintenance instructions apply to the

Masoneilan Model 87/88 actuator regardless of the valve body
on which it is used. Actuator part numbers and recommended
spare parts required for maintenance are listed in the Part
Reference Table on page 21 and 22. The model number and
action of the actuator are shown as part of the model number
listed on the identification tag located on the actuator.
Note: No air pressure is required to the actuator since

the spring force acts to open the valve.
D. Loosen stem lock nuts (1).

E. Re-tighten lock nuts (1) against each other so they will
lock at a point that is not against the stem flange (2).
3. Actuator Description
The 87/88 Series is a pneumatic spring diaphragm actuator.
The multiple spring design configuration provides four
standard spring ranges are achieved by varying spring
quantity and placement. A molded rolling diaphragm and deep
cases minimize area change, resulting a linear relationship
between travel and air pressure.
F. Loosen and remove drive nut.
For full automatic operation, the handwheel must be placed

in the neutral position. Travel will be limited If the handwheel
is not in the neutral position.
4. Unpacking
Care must be exercised when unpacking the equipment
to prevent damage to the accessories and component
parts. Should any problems arise, contact your Masoneilan
Representative or District Office.
Depending on stem length, it may be required to raise

the actuator off the body slightly to enable the plug stem
to disengage from the actuator stem. The actuator must
be raised straight off the body to prevent side loading on
the plug stem.
G. Turn the stem lock nut (1), counterclockwise and loosen

the plug stem until it disengages from the actuator stem
(10).

5. Air Piping
Note: Do not allow the valve plug to drop or turn against

the seat ring, as this could damage the seat and plug.
H. Remove actuator from the valve body.
The Model 87/88 actuator is designed to accept 1/4" NPT air

supply connections. Accessories supplied with the actuator
are mounted and connected at the factory.

Do not exceed pressure indicated on identification tag.

At this time provisions must be made to support and

lift the actuator off the body using recommended lift
supports and procedures.
Care should be taken in handling the actuator to prevent

damage to gauges, tubing, and component parts.
6.2 Air to open (Model 88), size 3 and size 6, with

handwheel

The stem flange (2) on these size are not fixed to the actuator
stem and are loose parts with the plug stem removed. For
safety, the handwheel must be in a free position and the
actuator removed from the valve using procedure 6.3 Air to
Open without handwheel.
Depending on stem length, it may be required to raise

the actuator off the body slightly to enable the plug stem
to disengage from the actuator stem. The actuator must
be raised straight off the body to prevent side loading
on the plug stem.
H. Turn the upper stem lock nut (1) counterclockwise and

unscrew the valve plug stem until disengaged from the
actuator stem (10).
6.3 Air to open (Model 88), size 3 (Figure 10) and size 6
(Figure 4) without handwheel
Since removal of the valve plug stem from the actuator stem
connector requires that the valve plug be off the seat, special
provisions are necessary to assure that the valve is in the
opened position. Proceed as follows for an actuator without
a handwheel.
I. Remove actuator from the valve body and shut off air
supply pressure.
Note: Since air supply piping connected to the actuator is

normally rigid, it is required that a manual loading panel
with suitable flex tubing be used or some suitable type of
flex connections be made between the supply piping and
the actuator connection to accommodate movement of the
actuator.
Note: Do not allow the plug to drop or turn against the

seat ring, as this could damage the seat and plug.
Care should be taken in handling the actuator to prevent

damage to gauges, tubing, and component parts. In
addition, since a flex connection is made between the
actuator and air piping, care must be taken not to exert
pressure on the flex tubing or air piping.
6.4 Air to close (Model 87), sizes 10, 16, and 23, with and
without handwheel (Figure 3)
A. Shut off air supply to actuator and rotate handwheel to
the neutral position.
High stress placed on rigid piping could cause breaking of the

air supply line. A flex connector is required.
B. Disconnect air piping from diaphragm case.
A. Shut off air supply to the actuator.
C. Check the travel indicator (7) against the travel scale (9)
to ensure that the plug is up (off the seat).
B. Disconnect air supply piping to the actuator.

C. Connect manual loading panel tubing to the lower
diaphragm case or yoke (size 3) tubing connector.
D. Apply required air pressure through the manual loading

panel to open the valve as is indicated by the stem
position relative to the travel scale (9).
D. Loosen stem lock nut (1).
E. Remove cap screws (5) from stem connector (2, 4).
Do not exceed pressure indicated on the tag (63) on the

diaphragm case.
E. Loosen stem lock nuts (1).

F. Re-tighten stem lock nuts (1) against each other so they
will lock at a point that is not against the actuator stem
flange (2).

the spring pressure tends to open the valve.


F. Loosen and remove drive nut.

G. Loosen and remove drive nut.
Progressively raise actuator off the body to enable the

top stem connector (4) to disengage the bottom stem
connector (2). The actuator must be raised straight off
the body to prevent stress on the plug stem.
G. Remove bottom stem connector parts (1, 2, 6) from

plug stem.
H. Remove actuator from the valve.

6.5 Air to open (Model 88), size 10, 16, and 23, with or
without handwheel (Figure 5)
I. Remove actuator from the valve and shut off air supply
pressure.
Since removal of the valve plug stem from the actuator stem
connector requires that the valve plug be off the seat, special
provisions are necessary to assure that the valve is in the
opened position. Proceed as follows:
7. Maintenance
Note: Since air supply piping connected to the actuator is

normally rigid and the actuator will be moved, it is required
that a manual loading panel with suitable flex tubing be used
or some suitable type of flex connections be made between
the supply piping and the actuator connection.
It is recommended that the actuators are placed in an upright

position for all disassembly or assembly
Do not use the silicone grease for the silicone rubber of high
and low temperature option.
Unreasonably high stress placed on rigid piping could cause

breaking of the air supply line. A flex connector is required.
Use fluorine grease of NIPPON KOYU LTD. LOGENEST

LAMBDA [or equal] as substitute for Dow Corning Valve
Lubricant and Sealant Compound III [or equal].
A. Shut off air supply to the actuator and rotate handwheel to the neutral position.
B. Disconnect air supply piping to the actuator.
C. Connect manual loading panel tubing to the lower
diaphragm case tubing connector.
D. Apply required air pressure through the manual loading
panel to open the valve as is indicated by the travel
indicator (7) and travel scale (9).
Standard NBR [Black]
Do not exceed pressure indicated on the tag (63) on the

diaphragm case.
E. Loosen stem lock nuts (1).

F. Remove cap screws (5) from stem connector (2, 4).

High and low temperature option

Silicone Rubber [Orange]

7.1 Replacing diaphragm air to open actuators (Model 88)
with or without handwheel (Figure 4, 5 and 10)
A. Shut off air supply to the actuator, isolate the control

valve process pressure to eliminate the valve from
moving with spring tension removed.

B. If valve is equipped with a handwheel, rotate handwheel

to a neutral position.
G. Loosen and remove drive nut.
Progressively raise actuator off the body to enable the

top stem connector (4) to disengage the bottom stem
connector (2). The actuator must be raised straight off
the body to prevent stress on the plug stem.
Spring under Load. Before removing the Actuator,

ensure that the valve plug is off the seat by pressurizing
the diaphragm case. It is now safe to disconnect the
valve stem and clamp nut.
C. Remove diaphragm case cap screws and nuts (20 and

19). Tension bolts (27 and 28) must be removed last.
Note: Size 3 actuator remove four diaphragm case
cap screws and nuts (27 and 28) leaving the other four
tension bolts equally spaced around the case.
Diaphragm case is under spring tension and is equipped

with tension bolts which must be removed last.
D. Remove tension bolts (27 and 28) in multiple steps

to relieve spring tension gradually. Remove upper
diaphragm case (24).
H. Remove bottom stem connector parts (1, 2, 6) from

plug stem.
E. Note position of springs (21) and spring spacers (18)

[if equipped] in the diaphragm plate (26), before you
remove these parts.
The handwheel assembly can hold spring tension in the
actuator when the diaphragm case is removed. To prevent
possible injury, remove handwheel per the following
procedure.
F. Remove hex nut (23) [size 3] or jam nut (23) [all other
sizes]. Also remove spacer (22) [size 3] and diaphragm
washer (22) [all sizes].
G. Remove diaphragm plate (26) and diaphragm (25).

process pressure to eliminate the valve plug from
B. Rotate the handwheel (41) to a neutral position.
C. For size 3 actuator, remove one of the two retaining
rings (46) which are mounted on lever pin (45).
Spring coil ends Pointed towards actuator stem
Removing the lever pin (45) will disconnect the

handwheel assembly from the actuator. Support the
handwheel assembly to avoid possible injury.
For all other sizes, remove two cap screw (93) and
washer (94), and remove two handwheel pivot pins (33)
which are mounted through the yoke and secure the
handwheel pivot (36) in place, (see Figure 8).
Figure1
H. Replace the new diaphragm (25) on the diaphragm
plate (26).
D. For size 3 actuator, remove lever pin (45) and secure

the handwheel holder (40) in place (see Figures 11 and
12).
I. Size 3 actuator, coat the threads of hex nut (23) and

the surfaces of spacer (22) with Chesterton 725 nickel
compound or equivalent. All other sizes, coat the
actuator stem threads (10) and the surfaces of washer
(22) with Dow Corning Sealant Compound III or equal.
E. Proceed with the instructions for air to close actuators

without handwheel (7.3).
J. Check placement of spacer (14 and 22), reassemble

diaphragm (25), diaphragm plate (26), and washer (22)
then tighten fastener (23) in proper locations.
7.3 Replacing diaphragm air to close actuator (Model 87),

size 3 without handwheel (Figures 9, 11 and 12)
K. Position springs (21) and spring spacers (18) [if used] in

the diaphragm plate.

A. Shut off air supply to the actuator and remove air piping
from the upper diaphragm case (24).
Note: Arrange springs so that the coil ends are pointed

toward the actuator stem as shown in Figure1. This step
assures best actuator performance.
B. Check the travel indicator on stem flange (2) against the

travel scale (9) to ensure that the plug is up (off the seat).

L. Replace upper diaphragm case (24) and tension bolts.

For all other sizes, let the complete handwheel

assembly swing down and out of the way of the top
stem connector (4) [stem flange (2) on size 6 actuator].
Note: Tension bolts should be spaced equally around

the bolt circle of the case.

C. Loosen stem lock nuts (1).

D. Re-tighten lock nuts (1) against each other so they will
M. Tighten the tension bolts in equal steps until the cases

meet. Replace the remaining cap screws and nuts.
E. Turn the stem lock nut (1) counterclockwise and loosen

(10).

Tighten cap screws and nuts evenly. Do not over tighten

as this could possibly warp the diaphragm cases. See
Table 3 for torque values.
N. If so equipped, rotate handwheel to the desired position.

7.2 Replacing diaphragm air to close actuator (Model 87),
with handwheel (Figures 2, 3, 8, 9, 11 and 12)

Note: Depending on stem length, it may be required

to separate the size 3 actuator off the valve body, as
indicated in Section 6.1.

F. Remove four diaphragm case cap screws and nuts (27

and 28) leaving the other four installed on the case
equally spaced.

19).

Diaphragm case is under spring tension. The remaining

four screws and nuts are tension bolts.
G. Remove tension bolts (four remaining 27 and 28)

in multiple steps to relieve spring tension gradually.
Remove upper diaphragm case (24).
H. Remove hex nut (23) and spacer (14).

with tension bolts (27 and 28) which must be removed
last.

I. Replace the new diaphragm (25) on the diaphragm

plate (26).
J. Coat the threads of hex nut (23) and the surfaces of
spacer (14) with Chesterton 725 nickel compound or
equivalent. Install spacer (14) and tighten hex nut (23)
per Table 3.
E. Remove jam nut (23) and diaphragm washer (22).
K. Replace upper diaphragm case (24) and tension bolts

(four cap screws and nuts 27 and 28).
G. Coat the actuator stem threads (10) and the surfaces of

washer (22) with Dow Corning Sealant Compound III or
its equivalent. Install washer (22) and tighten fastener
(23).
F. Replace new diaphragm (25) on the diaphragm plate

(26).

H. Replace upper diaphragm case (24) and tension bolts

(27 and 28).
L. Tighten the tension bolts (27and 28) in equal steps until

the cases meet. Replace the remaining cap screws (27)
and nuts (28).

I. Tighten the tension bolts (27 and 28) in equal steps

until the cases meet. Replace the remaining cap screws
(20) and nuts (19).


M. Screw the plug stem back into the actuator stem (10)
thru the stem flange (2) and recalibrate the seated
position of the valve.

Note: If the actuator has been removed from the valve

body, reinstall it as indicated in Section 10.2.
Note: If the actuator has a handwheel (Section 7.2),

continue with the following steps:
J. Position top and bottom stem connectors (2 and 4)

and replace the two socket head cap screws (5) and
recalibrate the seated position of the valve, (Section
10.2).
N. Hold the handwheel holder (40) in position between the

yoke legs and slide the lever pin (45) through the hole in
the yoke and lever. Be sure that levers (44) are above
the stem flange (2).
O. Secure the lever pin (45) with the second retaining ring
(46).
7.4 Replacing diaphragm air to close actuator (Model
87), size 6, 10, 16 and 23 without handwheel (Figures 2,
3 and 8)
Note Size 6 actuator - Screw the plug stem back into the
actuator stem (10) thru the stem flange and recalibrate
the seated position of the valve. If the actuator has been
removed from the valve body, re-install it as indicated in
Section 10.2).

L. Install the two pivot pins (33) in the yoke and engage
them into the handwheel pivot (36). And install the two
washer (94) and cap screw (93) through the handwheel
cover (57).
B. Remove the two socket head cap screws (5) which hold
the top and bottom stem connector (2 and 4) together.
7.5 Replace or repack handwheel bearing, size 3

actuators (Figures 11,12 and 13)
Note: The size 6 actuator only has a stem flange. For

diaphragm replacement, the stem lock nuts (1) must be
loosened. The plug stem is turned out at the actuator
stem (10) in order to allow the actuator stem to rise with
release of spring tension. Depending on stem length, it
may be required to separate the size 6 actuator off the
valve body, as indicated in Section 6.1.

K. Swing handwheel assembly back up into place.

A. Rotate handwheel to a free position.

B. Remove handwheel cap screw (20) and washer (42).
C. Remove handwheel (41) and key (47).
D. Remove one of the two retaining rings (46) which are
mounted on lever pin (45).
7.7 Replace or repack handwheel bearing size 16 and 23

actuators (Figures 7 & 8)


B. Remove lock pin (91), cap screw (93), and washer (94)
to release handwheel cover (57).
E. Remove lever pin (45) and secure the handwheel holder

(40) in place.
C. Remove pivot pins (33) which engage the handwheel

pivot (36) thru the yoke.
F. Remove the complete handwheel assembly from the

actuator.
D. Remove snap rings (46) and remove lever pin (45) to

release complete handwheel assembly.
G. Remove both cover cap screw (20) and handwheel

cover (57).
E. Remove cap screw (97) and end flange (96) to release

the handwheel stem (39) from the bearing.
H. Remove retaining ring (35), handwheel pivot (36) and

bushing (37) to release the bearing.
F. Remove snap ring (35) to release bearing (34).
I. Remove single row ball and shaft ring bearing (34) from
handwheel stem (39) and bearing ball housing ring
from the handwheel pivot (36).
H. Pack bearing (34) with Mobilux No. 2 grease or equal.
G. Replace or clean to repack the bearing with new grease.

J. Replace or clean to repack bearing (34) with new

grease.
I. For remounting, reverse removal procedures from step

(F) through (B).
K. Bearing should be packed with Mobilux No. 2 grease or

equivalent.

Note: It is important that bearing is packed with grease,

and not just coated.
7.8 Replace diaphragm seal and stem seal, air to open

actuators (Model 88), size 3 (Figure 10)


L. To reassemble, reverse removal procedures from step

(I) through (B).

to a free position.
7.6 Replace or repack handwheel bearing, size 6 and 10

actuators (Figure 6)
C. Remove four diaphragm case cap screws and nuts (27

equally spaced

B. Remove handwheel cap screw (20) and washer (42).
C. Remove handwheel (41) and lock nut (43).
D. Remove lock pin (91), cap screw (93), and washer (94)
to release handwheel cover (57). Remove cover.
E. Remove pivot pins (33) from the yoke which hold the
handwheel pivot (36).
F. Remove snap rings (46) and remove lever pin (45) to

release handwheel assembly.
D. Remove tension bolts (four remaining 27 and 28)

G. Turn handwheel stem (39) until it clears traveling nut (40).

H. Remove snap ring (38) and bearing ring (37) to release

the handwheel stem (39) from the bearing.
E. Note position of springs (21) and spring spacers (18)

[if equipped] in the diaphragm plate (26), before you
remove these parts.
I. Remove snap ring (35) to release bearing (34).
F. Remove springs (21) and spring spacers (18) if used.
J. Replace or clean to repack bearing (34) with new

grease.
G. Loosen lock nuts (1). Re-tighten lock nuts against each

other so they will lock at a point that is not against
the stem flange (2). By means of a wrench, hold the
nuts (1) and plug stem. Turn the actuator stem (10)
subassembly until it disengages from the plug stem and
remove completely from actuator.
K. Bearing should be packed with Mobilux No. 2 grease or

equal.


H. Remove case cap screws (16) and spring guide (29).
L. To reassemble, reverse removal procedures from step

(I) through (B).

I. Remove lower diaphragm case (17) to gain access to

O-ring (13).
Note: Mark orientation of the case to the yoke.
Note: If diaphragm case O-ring (13) replacement is the

only maintenance, proceed to Step N.
J. Remove stem wiper (11) and O-rings (12).

K. Clean stem wiper and O-ring grooves of the yoke (31).
L. Apply a generous coating of Dow Corning Compound
III (or equivalent) to a new O-ring (12) and insert it into
the yoke (31).
M. Insert a new stem wiper (11) into the lower groove of

the yoke (31).

N. Clean cap screws (16) and their threaded holes on the

yoke (31).
E. Note position of springs (21) and spring spacers (18) [if

equipped] in the diaphragm plate (26).
O. Coat a new O-ring and the stem bushing (30) and

O-ring (12) in the yoke with Dow Corning Compound III
(or equivalent).
F. Remove springs (21) and spring spacers (18) if used.

On size 6 actuator:
P. Insert a new O-ring (12) in the yoke groove.
G. Loosen lock nuts (1). Re-tighten lock nuts against each

other so they will lock at a point that is not against the
stem flange (2). By means of a wrench, hold the lock
nuts (1) and plug stem. Turn the actuator stem (10)
subassembly until it disengages from the plug stem and
remove completely from actuator.
Q. Place the diaphragm case (17) on the yoke.

R. Apply Never-Seez (anti-seize compound or equivalent)
to cap screw threads (16).
S. Assemble spring guides (29) and cap screws (16).
T. Re-install the actuator stem (10) sub-assembly into the
yoke bushing. Turn actuator stem on the plug stem after
installing the stem flange (2). Turn until stem spacer
(14) contacts the lower diaphragm case (17).
On size 10,16 and 23 actuators:

G. Loosen lock nut (32) on actuator stem (10). Hold the
connector device (2, 4, 6). Turn the actuator stem(10)
sub-assembly and remove it when it clears the connector
insert (6), (on size 10), or the top stem connector (4),
(on sizes 16 & 23).
U. Lock the stem flange (2) and the two lock nuts (1)
against the lower part of actuator stem.
V. Position springs (21) and spring spacers (18) [if used] in


last.
On size 6,10,16 and 23

H. Remove case cap screws (16) to gain access to seal
washers (15).

Note: If seal washers (15) replacement is the only

maintenance, proceed to Step M.
W. Replace upper diaphragm case (24) and the tension

bolts (four cap screws 27 and 28).
I. Remove lower diaphragm case (17).

Note: Mark orientation of the case to the yoke.
J. Replace stem wiper (11) and O-rings (12 and 13).
X. Tighten the tension bolts (27 and 28) in equal steps

(27) and nuts (28).
K. Coat O-rings (12 and 13) and inside of yoke O-ring

groove (31) with Dow Corning Compound III (or
equivalent).
L. Place the diaphragm case (17) on the yoke.
M. Coat the surface of the spring guides (29) in contact

with the diaphragm case with Dow Corning Sealant
Compound III or equivalent. Assemble spring guides
(29), new seal washers (15), and cap screws (16) in
this order.

N. Re-install the actuator stem (10) sub-assembly into the

yoke bushing. Turn actuator stem into insert (6), (size
10), or into the top stem connector (4), (size 16 & 23). In
case of size 6 actuator, turn actuator stem on the plug
stem after installing the stem connector(2). Turn until
stem spacer (14) contacts the lower diaphragm case
(17).
Y. If necessary, recalibrate the seated position of the valve

(Section 10.1).
7.9 Replace diaphragm seal and stem seal, air to open
(Model 88) actuators (Figure 4 and 5)
O. Tighten lock nut (32) against connector insert (6), (size

10), or against the top stem connector (4), (on sizes 16
& 23). In case of size 6 actuator, lock the stem flange
(2) and the two lock nuts (1) against the lower part of
actuator stem.

to a free position.
19).
P. Position springs (21) and spring spacers (18) [if used] in



19). Tension bolts (27 and 28) must be removed last.

toward the actuator stem as shown in Figure 1. This
step assures best actuator performance.
Note: Size 3 actuator Remove four diaphragm case

cap screw and nuts (27 and 28) leaving the other four
tension bolts equally spaced around the case.

with tension bolts which must be removed last.
Q. Replace upper diaphragm case (24) and the tension

bolts (27 and 28).


R. Tighten the tension bolts (27 and 28) in equal steps

(20) and nuts (19).

E. Position springs (21) [and spring spacers (18) if new
range use them] in the diaphragm plate.
F. Refer to Tables 1, 2 and 4 for spring information:

a. For 11 and 21 psi (0,759 and 1,448bar) initials, the

springs are placed directly on the upper pedestals in
the diaphragm plate (26).
S. If necessary, recalibrate the seated position of the valve

(Section 10.1).
Size 3 actuator - For 11 and 21 psi (0,759 and

1,448bar) initials, the springs are installed with spring
spacers (18). The spring spacers (18) are placed as
shown in the cross sectional view, Figure 10.
8. Actuator Range
b. For 3 and 6 psi (0,207 and 0,414bar) initials, the

springs are placed in the bottom cavity in the
diaphragm plate.
Size 3 actuator - For 3 and 6 psi (0,207 and

0,414bar) initials, the springs are installed without
spring spacers.

c. For 11 and 21 psi (0,759 and 1,448bar) initials and

travel ranges larger than 0.8" (20mm), the spring
spacers (18) are placed as shown in the cross
sectional view, Figure 5.

Note: Spring spacers (18) are not required for the No.6
actuator.

G. Replace upper diaphragm case (24) and tension bolts

(27, and 28).


H. Tighten the tension bolts (27 and 28) in equal steps

(20) and nuts (19) [Screw (27) and nuts (28) for size 3].

8.1 Actuator range change, air to open (Model 88).

to a free position.


I. If so equipped, rotate handwheel to the desired position.
10
8.2 Actuator range change, air to close (Model 87), size

6,10,16 and 23
L. Replace upper diaphragm case (24) and the tension

bolts (27and 28).
Note: If actuator is equipped with a handwheel, please follow

steps 7.2 A, B, C and D to disengage this assembly.
M. Tighten the tension bolts (27 and 28) in equal steps

(20) and nuts (19).

Note: The size 6 actuator only has a stem flange (2).

For access to springs, the stem lock nuts (1) must be
loosened. The plug stem is turned out at the actuator
stem (10) to allow the actuator stem to rise with release
of spring tension. Depending on stem length, it may be
required to separate the size 6 actuator off the valve
body, as indicated in Section 6.1.
Note: Size 6 actuator-Screw the plug stem back

into the actuator stem (10) thru the stem flange (2)
and recalibrate the seated position of the valve. If
the actuator has been removed from the valve body,
re-install it as indicated in Section 10.2).


last.
D. Remove tension bolts (27 and 28) and compression

nuts (28) in multiple steps to relieve spring tension
gradually. Remove upper diaphragm case (24).
F. Remove diaphragm plate (26) and diaphragm (25).
G. Place springs (21) over the spring guides (29).
H. Refer to Tables 1, 2 and 4 for spring information:
springs are placed directly on the upper pedestals in
the diaphragm plate (26).
springs are placed in the bottom cavity in the
diaphragm plate.
c. For 11 and 21 psi (0,759 and 1,448bar) initials and
travel ranges larger than 0.8" (20mm), the spring
spacers (18) are placed as shown in the cross

Note: Spring spacers (18) are not required for 0.8"

(20mm) travel ranges.

I. Replace the diaphragm plate (26) on the actuator stem

(10) and over the springs. To ensure the springs are
properly located, check the view hole in the diaphragm
plate. A spring should be visible.
J. Install the diaphragm (25).
K. Coat the actuator stem threads (10) and the surfaces of
equivalent.


N. Position top and bottom stem connectors (2 and 4)

recalibrate the seated position of the valve (Section
10.2).

19).

11
Table 1
Table 2
ACTUATOR TRAVEL
in. (mm)
SPRING COLOR
SPRING RANGE
Psi (bar)
NO.OF SPRINGS SPRING SPACER

REQUIRED
(18) REQUIRED
0.8 (20)
RED
3-15
(0.207-1.034)
NO
1.5 (38)
BLUE
6-30
(0.414-2.069)
NO
2.0 (51)
GREEN
11-23
(0.759-1.586)
YES*
2.5 (64)
YELLOW
21-45
(1.448-3.103)
YES*
* A
spring spacer (18) is required on Size 10 for 1.5 in.
(38mm) travel only, and on Size 16 and 23, for 1.5 in.
(38mm), 2.0 in. (51mm) and 2.5 in. (64mm) travels.
Table 3 ACTUATOR ASSEMBLY TORQUES

ACTUATOR SIZE
REF. NO.
10
16
N-m
ft-lbs
N-m
ft-lbs
N-m
ft-lbs
N-m
ft-lbs
N-m
25
34
25
34
25
34
25
34
25
34
Hex Nut .625 - 18 UNF
55
74
55
74
55
74
95
129
95
129
95
129
150
203
150
203
Hex Nut 1.00 - 14 UNS

5
Connecter Cap Screw
16
Yoke Cap Screw
22
Case Bolting or Tension

Bolting
23
Jam Nut, Hex Nut
32
Stem Lock Nut
33
Pivot Pin
20
Handwheel Cap Screw
97
Handwheel Stem Cap Screw
19,20,27,28
23
ft-lbs
1
DESCRIPTION
35*
47*
35
47
125
169
125
169
30
37
50
37
50
59
80
59
80
22
30
21
28
25
34
30
40
31
42
48
65
37
50
66
90
95
129
150
203
55
74
95
129
150
203
53**
60
81
60
81
80
108
80
108
25
34
25
34
66
90
66
90
300
407
300
407
* Torque shown is for size 6 actuator with Bellows Seal design requiring Stem Connector Option.
** Torque value in units of in-lbs.
Listed values are nominal torques. Tolerance is +/- 10%.

12
Actuator
No.
Travel &
Color Code
0.8"
(20mm)
Red
0.8"
(20mm)
Red
0.8"
(20mm)
Red
10
1.5"
(38mm)
Blue
0.8"
(20mm)
Red
1.5"
(38mm)
Blue
16
2.0"
(51mm)
Green
2.5"
(64mm)
Yellow
0.8"
(20mm)
Red
1.5"
(38mm)
Blue
23
2.0"
(51mm)
Green
2.5"
(64mm)
Yellow
Range
(psi)
Qty.
Springs
Position
3-15
6-30
11-23
21-45
3-15
6-30
11-23
21-45
3-15
6-30
11-23
21-45
3-15
6-30
11-23
21-45
3-15
6-30
11-23
21-45
3-15
6-30
11-23
21-45
3-15
6-30
11-23
21-45
3-15
6-30
11-23
21-45
3-15
6-30
11-23
21-45
3-15
6-30
11-23
21-45
3-15
6-30
11-23
21-45
3-15
6-30
11-23
21-45
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
3
6
A
B
E
F
A
B
C
D
A
B
C
D
A
B
E
F
A
B
C
D
A
B
E
F
A
B
E
F
A
B
E
F
A
B
C
D
A
B
E
F
A
B
E
F
A
B
E
F
TABLE 4
Diaphragm plate Spring arrangement

13
O. Replace upper diaphragm case (24) and tension bolts

8.3 Actuator range change, air to close (Model 87), size 3

Note: If actuator is equipped with a handwheel, please follow
steps 7.2 A, B, C and D to disengage this assembly.
P. Tighten the tension bolts (27 and 28) per Table 3 in

equal steps until the cases meet. Replace the remaining
cap screws (27) and nuts (28) and tighten per Table 3.






(10).




Q. Screw the plug stem back into the actuator stem (10)
thru the stem flange and recalibrate the seated position
of the valve.



R. Hold the handwheel holder (40) in position between the

yoke legs and slide the lever pin (45) through the hole in
the yoke and lever. Be sure that levers (44) are above
the stem flange (2).

equally spaced.
S. Secure the lever pin (45) with the second retaining ring
(46).

9. Air Action Changes


H. Remove hex nut (23) and spacer (14).

I. Remove diaphragm (25) and diaphragm plate (26).

J. Place springs (21) over the spring guides (29).

K. Refer to Tables 1, 2 and 4 for spring information:
springs are installed with spring spacers (18). The
spring spacers (18) are placed as shown in the cross
springs are installed without spring spacers.


L. Replace the diaphragm plate (26) on the actuator stem

(10) and over the springs.
M. Install the diaphragm (25).
N. Coat the threads of hex nut (23) and the surfaces of
per Table 3.


14
9.1 Air to open to air to close (Model 88 to Model 87),

size 6,10,16 and 23

O. Tighten the tension bolts (27 and 28) in equal steps

(20) and nuts (19).

to a neutral position.
C. Remove snap rings (46) and remove lever pin (45) to
allow handwheel assembly to swing away from the
stem connector (2-4).
D. Remove the two socket head cap screws (5) which hold


P. Position top and bottom stem connectors (2 and 4)

recalibrate the seated position of the valve (Section
10.2).

For changing of action, the stem lock nuts (1) must
be loosened. The plug stem is turned out at the
actuator stem (10) in order to allow the actuator stem
to rise with springs installed in Model 87. Depending on
stem length, it may be required to separate the size 6
actuator off the valve body, as indicated in Section 6.3.
E. Remove diaphragm case cap screws and nuts (20 and

19) and vent cap (59).
Note Size 6 actuator Screw the plug stem back

reinstall it as indicated in Section 10.2.
Note: If the actuator has a handwheel, continue with

the following steps:
Q. Swing handwheel assembly back up into place. The

handwheel (41) may have to be turned in order to
position the lower pivot pins (33).


last.
R. With the pivot pins positioned on top of the stem

connector (2 and 4), replace the lever pin (45) and snap
rings (46).
F. Remove tension bolts (27 and 28) in multiple steps

diaphragm case (24). Remove springs (21) and spacer
(18) [if equipped].
9.2 Air to close to air to open (Model 87 to Model 88),

size 6,10,16 and 23 with handwheel
G. Remove jam nut (23) and diaphragm washer (22) and

travel stop (71) [if equipped].
H. Remove diaphragm plate (26) and diaphragm (25).
The handwheel assembly can hold spring tension in the

actuator when the diaphragm case is removed. To prevent
possible injury, remove handwheel per the following
procedure.
I. Place springs (21) over the spring guides (29).

J. Refer to Tables 1, 2 and 4 for spring information. Refer
also to Section 8.2 H


(20mm) travel ranges

toward the actuator as shown in Figure 1. This step

C. Remove snap rings (46) and lever pins (45).
D. The complete handwheel assembly can now swing out
of the way of the top stem connector (2 and 4) [stem
flange (2) on the size 6 actuator].
K. Invert and replace the diaphragm plate (26) on the

actuator stem (10) and over the springs.

Note: To ensure the springs are properly located, check

the view hole in the diaphragm plate. A spring should be
visible.
E. Proceed with the instructions for actuators without

handwheel (9.3 Step B).
size 6,10,16 and 23 without handwheel
L. Install the diaphragm (25).

M. Coat the actuator stem threads (10) and the surfaces of
equivalent. Then place and tighten the jam nut (23).
N. Replace upper diaphragm case (24) and tension bolts

(27 and 28).

15

For changing of action, the stem lock nuts (1) must be
loosened. The plug stem is disconnected from the
actuator stem (10) in order to allow the actuator stem
to rise with release of spring tension during disassembly.
Actuator
Size
Stroke
Air to open
Model 88
20.32
mm [0.8"]
Jam nut (23)
20.32
mm [0.8"]
Jam nut (23) and

Travel stop (71)
38.1 mm
[1.5"]
Jam nut (23)
Depending on stem length, it may be required to

separate the size 6 actuator off the valve body, as
10

19).
20.32
mm [0.8"]
16

last.
23
F. Remove the diaphragm (25), diaphragm plate (26),

spring (21) and spring spacers (18) [if used].
H. Coat the actuator stem threads (10) and the surfaces of
equivalent.
Note: The model 88 size 10, 20.32mm [0.8"] stroke only

uses Jam nut (23) and Travel stop (71).
Jam nut (23)

Jam nut (23)
38.1 mm
[1.5"]
Travel stop (71)
50.8 mm
[2.0"]
Jam nut (23)
J. Position springs (21) and spring spacers (18) [if used] in

K. Refer to Tables 1, 2 and 4 for spring information. Refer
also to Section 8.1 F.
I. Checking placement of spacer (14) reassemble

diaphragm (25), diaphragm plate (26), washer (22),
jam nut (23) or travel stop (71) [see Note] in proper
locations.
For other stroke, the travel stop (71) is used to replace

the Jam nut (23).
50.8 mm
[2.0"]
63.5 mm
[2.5"]
G. Invert the diaphragm (25) and diaphragm plate (26).
Travel stop (71)
20.32
mm [0.8"]
Note: The maximum stroke of each actuator size for

model 88 uses Jam nut (23).
38.1 mm
[1.5"
63.5 mm
[2.5"]

Air to close
Model 87

(20mm) travel ranges.

L. Replace upper diaphragm case (24) and tension bolts

(27 and 28).


M. Tighten the tension bolts (27 and 28) in equal steps

(20) and nuts (19).

N. Position top and bottom stem connectors (2 and 4)

recalibrate the seated position of the valve, (Section
10.1).


16
Note Size 6 actuator Screw the plug stem back

re-install it as indicated in Section 10.1).
M. Install spacer (22) on the actuator stem (10).

the following steps.
N. Invert and replace the diaphragm plate (26) on the

actuator stem (10) and over the springs.
O. Swing the handwheel assembly back into place.
O. Install the diaphragm (25).
P. It may require turning the handwheel (41) to position

the lower pivot pins (33) under the stem connector
(2-4), [stem flange (2) on the size 6 actuator].
P. Coat the threads of hex nut (23) and the surfaces of

per Table 3.
Q. Install the lever pin (45) and snap rings (46).

R. Add the vent cap (59) to the top of upper diaphragm
case.
Q. Replace upper diaphragm case (24) and tension bolts

(four cap screws and nuts 27 and 28), and tighten per
Table 3.
9.4 Air to open to air to close (Model 88 to Model 87),

size 3


R. Tighten the tension bolts (27 and 28) per Table 3 in

equal steps until the cases meet. Replace the remaining
cap screws (27) and nuts (28) and tighten per Table 3.
B. If valve is equipped with a handwheel, please follow

steps 7.2 B, C and D to disengage this assembly.
C. Check the travel indicator on stem flange (2) against the
D. Loosen stem lock nuts (1).
E. Re-tighten lock nuts (1) against each other so they will

F. Turn the stem lock nut (1) counterclockwise and loosen
(10).




S. Screw the plug stem back into the actuator stem (10)
of the valve.



T. Hold the handwheel holder (40) in position between the

yoke legs as shown in Figure 12 and slide the lever pin
(45) through the hole in the yoke and lever. Be sure that
levers (44) are above the stem flange (2).
G. Remove four diaphragm case cap screws and nuts (27

equally spaced.
U. Secure the lever pin (45) with the second retaining ring
(46).


size 3 with handwheel

H. Remove tension bolts (four remaining 27 and 28)


I. Remove hex nut (23) and spacer (22), Figure 10.

J. Remove diaphragm plate (26), diaphragm (25), and
spacer (14), Figure 10.
K. Place springs (21) [and spring spacers (18) if new
range uses them] over the spring guides (29), Figure 9.

L. Refer to Tables 1, 2 and 4 for spring information. Refer

also to Section 8.3 K.


(20mm) travel ranges


The handwheel assembly can hold spring tension in

the actuator when the diaphragm case is removed.
To prevent possible injury, remove handwheel per the
following procedure.

C. Remove one of the two retaining rings (46) which are
mounted on lever pin (45), Figure 12.
17
N. Position springs (21) and spring spacers (18) [if used] in

O. Refer to Tables 1, 2 and 4 for spring information. Refer

also to Section 8.1.

D. Remove lever pin (45) and secure the handwheel holder

(40) in place (see Figures 11 and 12). The handwheel
assembly will be disconnected from the actuator.

P. Replace upper diaphragm case (24) and tension bolts


E. Proceed with the instructions for actuators without

handwheel (9.6 Step B).

Q. Tighten the tension bolts (27 and 28) in equal steps

(27) and nuts (28).

size 3 without handwheel

R. Screw the plug stem back into the actuator stem (10)
of the valve.

(10).





S. Hold the handwheel holder (40) in position between the

yoke legs as shown in Figure 12 and slide the lever pin
(45) through the hole in the yoke and lever. Be sure that
levers (44) are below the stem flange (2).

equally spaced.
T. Secure the lever pin (45) with the second retaining ring
(46).
10. Valve Mounting

These installation and plug stem adjustment procedures are

for mounting of the 87/88 Actuators on most metal seated
reciprocating valves. Refer to the specific valve instructions
for other trim types, such as pilot operated valves (41405)
and soft seat designs.


H. Remove hex nut (23) and spacer (14), Figure 9.
I. Remove the diaphragm (25), diaphragm plate (26),
spacer (22), spring (21) and spring spacers (18) [if
used], Figure 9.
The stem flange (2) on the size 3 and 6 is not fixed to the
actuator stem and is a loose part with the stem nuts (1)
backed off. For safety reasons, adjustments should only be
made pneumatically.
J. Install spacer (14) on the actuator stem (10), Figure 10.

K. Invert the diaphragm (25) and diaphragm plate (26),
Figure 10.
10.1 Air to open (Model 88)
L. Coat the threads of hex nut (23) and the surfaces of

equivalent.
A. Connect manual loading panel tubing to the lower

diaphragm case or yoke connection (size 3).
B. Apply required air pressure through the manual loading
panel to completely retract the actuator stem (10).
M. Check placement of spacers (14 and 22), reassemble

diaphragm (25), diaphragm plate (26), and spacer (22)
then tighten hex nut (23) per Table 3.

C. Install actuator on the valve body with drive nut. Tighten

the drive nut.
18
Note: Size 3 and Size 6 actuator Screw the plug

stem into the actuator stem (10) thru the stem flange
(2). Depending on stem length, it may be required to
progressively lower the actuator forwards the body
while screwing the plug stem into the actuator stem.
F. Unscrew the stem 1/2 turn and lock the stem in place by
tightening the lock nuts (1) against the stem connector
(2 or 6).

D. On size 10, 16 and 23 actuators:

Apply initial air pressure and position top stem
connector (4). Refer to Figure 14 and 16 for stem
connector positioning.
H. Line up the travel scale (9) with the pointer and check
actuator for proper operation.
On size 3 and 6 actuators:

Apply initial air pressure. Adjust the plug stem to position
of stem flange (2) as shown in Figure 14.
DO NOT TURN the plug against the seat as damage to

the parts can occur.
E. Release air pressure.

F. Using the stem lock nuts (1), unscrew the plug stem
until the plug touches the seat.
G. Pneumatically or with the handwheel, stroke the actuator
to raise the plug off the seat. Unscrew the plug stem
one full turn and lock the stem in place with the lock
nut(s) (1) against the stem connector or flange (2 or 6).
H. Line up the travel scale (9) with the pointer and check
actuator for proper operation.
10.2 Air to close (Model 87)
A. Install actuator on the valve body with drive nut. Tighten
the drive nut.
B. Position top and bottom stem connectors (2 and 4) and
replace the two socket head cap screws (5).Turn the
plug stem as far as possible into lower part of the stem
connector (2 or 6). Refer to Figure 15 and Figure 16 for
stem connector positioning.

Note: Size 3 and Size 6 actuator Screw the plug

stem into the actuator stem (10) thru the stem flange
(2). Depending on stem length, it may be required to
progressively lower the actuator forwards the body
while screwing the plug stem into the actuator stem.
Refer to Figure 15 for size 6 stem connector positioning.
C. Pneumatically or with the handwheel, stroke the

actuator to the rated spring range or stroke (if using the
handwheel).
D. Using the stem lock nuts (1) unscrew the plug stem until
the plug touches the seat.
DO NOT TURN the plug against the seat as damage to

the parts can occur.
E. Release the pressure in the actuator or back off the

handwheel to raise the stem.

Note: Size 3 and Size 6 actuator Lock the plug stem

in place by tightening the lock nut (1) against the stem
flange (2).
19
Figure 2
Figure 3
Size 6 Actuator
Air to Close (Model 87)
Size 10, 16 and 23 Actuator

Air to Close (Model 87)
Figure 4
Figure 5
Size 6 Actuator
Air to Open (Model 88)
Size 10, 16 and 23 Actuator

Air to Open (Model 88)

20
Figure 6
Figure 7
Size 6 and 10 Actuator

with optional Handwheel
Size 16 and 23 Actuator

with optional Handwheel
Parts Reference Table
Ref.No
Description
Ref.No
Description
Ref.
No
Description
1
2
Lock Nut
22
Washer-Flat
43
HW Limitation Nut
Stem Connector-Bottom
23
Nut-Jam
44
HW Lever
3
4
Cap Screw-Pointer
Upper Diaphragm Case
45
Lever Pin
Stem Connector-Top
24
25
Diaphragm
46
Retaining Ring-Lever Pin
Cap Screw-Connecter
26
Diaphragm Plate
57
HW Cover
Connector Insert
27
Cap Screw-Comp
59
Vent Plug
Pointer
28
Compression Nut
60
Screw-Pan Head
29
Spring Guide
63
Information Seal
Travel Scale
30
Bushing
67
Warning Seal
Yoke
68
Warning Seal - Arrow
Lock Nut
69
Warning Seal
10
11
Actuator Stem
12
13
Oring
33
Pivot Pin
88
Plate-Rotation Arrow
Oring
34
Thrust Bearing
90
Pivot Pin-HW Lock
14
15
Spacer
35
Retaining Ring
91
Handwheel Lock Pin
Seal Washer
36
HW Pivot
92
Information Plate-HW
16
Cap Screw-Yoke
37
Bearing Ring
93
Cap Screw-Hex Head
17
Lower Diaphragm Case
38
Retaining Ring
94
Washer-Flat
18
Spring Spacer
39
HW Stem
96
End Flange
19
Hex Nut
40
Traveling Nut
97
Cap Screw-HW Stem
20
Cap Screw-Hex Head
41
Handwheel
Stem Wiper
21
Spring
Recommended Spare Parts
Not provided for Size 6
Stem Flange on Size 6 Actuator
31
32
Pipe Fitting
42
Washer-Flat
Not provided for Size 16 and 23
21
Not provided for Size 6 and 10
Figure 9
Figure 10
Size 3 Actuator Air to Close

(Model 87)
Size 3 Actuator Air to Open

(Model 88)
Figure 11
Figure 12
Size 3 Actuator Air to Close

With optional Handwheel
Size 3 Actuator Handwheel

sectional view

22
Figure 13
Size 3 Actuator Air to Open
With optional Handwheel
Parts Reference Table Size 3

Ref.
No
Description
Ref.
No
Description
Ref.
No
Description
Ref.
No
Description
Stem Flange
27
Cap Screw, Hex

head
37
Bushing
44
Handwheel
Lever
20
Cap Screw, Hex

head
28
Hex Nut
40
Handwheel
Holder
47
Key
22
Spacer
30
Bushing
43
Lever Assembly
49
Retaining Ring
23
Hex Nut
35
Retaining Ring
Underlined: Optional Handwheel Only.

Note: All other Ref. Numbers and Description are the same as listed for other size.

23
Xat0PSI
XatInitial
PSI
Figure 14
Figure 15
Model 88 Actuator
Air to Open
Actuator
Model 87 Actuator
Air to Close
Actuator
ACTUATOR
SIZE
STROKE
X at Initial PSI
ACTUATOR
SIZE
STROKE
X at 0l PSI
0.8" (20mm)
3.55" (90.2mm)
0.8" (20mm)
4.56" (115.7mm)
0.8" (20mm)
3.54" (89.9mm)
0.8" (20mm)
4.48" (113.9mm)
10
0.8"-1.5" (20-38mm)
4.62" (117.4mm)
0.8" (20mm)
5.12" (130.0mm)
1.5" (38mm)
5.44" (138.2mm)

10
24
Figure 16
Figure 17
Model 88 Actuator
Air to Open
Model 87 Actuator
Air to Close
ACTUATOR
SIZE
STROKE
X at Initial PSI
16 & 23
0.8"-2.5 (20-64mm)
7.02" (178.3mm)
ACTUATOR
SIZE
16
23

25
STROKE
X at 0 PSI
0.8" (20mm)
8.00" (203.2mm)
1.5" (38mm)
8.50" (215.9mm)
2.0" (51mm)
9.28" (235.7mm)
2.5" (64mm)
9.50" (241.3mm)
0.8" (20mm)
8.25" (209.6mm)
1.5" (38mm)
8.62" (218.9mm)
2.0" (51mm)
9.12" (231.6mm)
2.5" (64mm)
9.59" (243.6mm)

BELGIUM
Phone:
+32-2-344-0970
Fax:
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Phone:
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Phone:
Fax:
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Phone:
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Phone:
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Fax:
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Phone:
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Phone:
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Fax:
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Phone:
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Fax:
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Phone:
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Fax:
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Phone:
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Fax:
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Phone:
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Fax:
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Phone:
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Fax:
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Phone:
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Fax:
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+91-11-2-6164175
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About Dresser, Inc.

www.dresser.com

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and power generation applications. www.dresser.com
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ER8788 09/10
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Instruction Manual

Putting You In Control

35002 Camflex II Series

About this Manual

Important - Please Read Before Installation

The information contained in this manual, in whole or part,

This is the safety alert symbol. It alerts you to potential personal

Note: Prior to installation

Indicates a potentially hazardous situation which, if not avoided,

All surrounding pipe lines must be thoroughly flushed

Indicates a potentially hazardous situation which, if not avoided,

Changes to specifications, structure, and components

Indicates a potentially hazardous situation which, if not avoided,

When used without the safety alert symbol indicates a

Instructions EF35002 - 08/10

The following instructions are designed to assist maintenance

The concept of the Camflex II valve is based on an eccentrically

Masoneilan has highly skilled Service Engineers available for

The plug and shaft are rotated through an angle of 50 by a lever

The handwheel on Camflex II is designed to be used for

These installation and maintenance instructions apply to 1"

35002 Series Body Numbering System

Body Assembly Digits

(1) optional, Camflex with separable bonnet.

Instructions EF35002 - 08/10

The Camflex II valve has a modified linear flow characteristic,

The ability of the Camflex II valve to handle a wide range of

C. To allow for in-line inspection, maintenance or removal of

Note: If a flanged Camflex II is being installed and the

D. For flangeless valves, refer to Figure 23 and determine the

Note: If the valve is equipped with the optional limit stop

B. Apply correct air pressure to the actuator.

Note: Valve should function smoothly and with maximum

E. If the valve is to be installed in a horizontal position, install the

C. Relieve air pressure and return valve to normal mode.

F. Place the valve in the line.

D. Gradually open process lines to place the valve in service.

G. Select and install correct gaskets.

E. Check for leaks. Repair as required.

Note: Spiral wound gaskets, suitable for service conditions

H. Insert remaining flange bolting ensuring that the bolts align

Note: For certain flange standards, through bolting is not

F. If desired, the handwheel may be used as a limit stop. Set in

I. Tighten flange bolts evenly and firmly.

If the valve is to be insulated, do not insulate the valve bonnet.

Note: If the valve is equipped with manual handwheel, it

8.1 Actuator Removal From Body S/A (Refer to

6. Air Supply Piping

Maintenance required on the internal components of the

Air is supplied to the actuator through the 1/4" NPT tapped

Instructions EF35002 - 08/10

Always ensure process pressure, air pressure and electrical

Prior to performing maintenance on the valve, isolate the

Note: If the valve will be reassembled in the same

A. If required, remove the valve from the line.

D. Remove indicator (88) by removing the two screws (89).

8.2 Actuator Complete Disassembly

E. Loosen handwheel lock (52) and turn handwheel (53) so it

Note: On valves supplied with the optional limit stop,

A. If the actuator is not removed from the body proceed to

F. Connect an air line to the actuator supply port and using

The spring diaphragm actuator used on the Camflex II valve

D. Using a deep socket, loosen and remove locknut (45)

Do not exceed pressure listed in Figure 14 for actuator

8.1 Actuator Removal From Body S/A (Refer to