Dresser Masoneilan V-Max 36005 Series User manual

36005 Series V-Max®
High Capacity Control Ball Valve
Putting You In Control
Instruction Manual
EM36005
07/10

Table of Contents Page
IMPORTANT: SAFETY WARNING ........................................................................................1
1.0 INTRODUCTION
NUMBERING SYSTEM ......................................................................................2
2.0 INSTALLATION
2.1 GENERAL ..........................................................................................................4
2.2 PIPELINE MOUNTING .......................................................................................4
2.3 AIR PIPING .......................................................................................................4
2.4 CHANGING ACTUATOR POSITION .................................................................4
2.5 CHANGING VALVE ACTION .............................................................................6
3.0 MAINTENANCE
3.1 BRACKET SUBASSEMBLY ...............................................................................7
3.3 BODY SUBASSEMBLY .....................................................................................9
3.3.1 PACKING ...........................................................................................................9
3.3.2 MN-7 SEAL RING .............................................................................................9
3.3.3 STANDARD METAL SEAL RING .....................................................................9
3.3.4 HEAVY DUTY METAL SEAL RING ................................................................10
3.3.5 BALL PLUG ......................................................................................................10
3.4 ACTUATOR SUBASSEMBLY ..........................................................................11
3.5 HANDWHEEL SUBASSEMBLY .......................................................................13
3.6 DIAPHRAGM REPLACEMENT ........................................................................13
LIST OF FIGURES
FIGURE 1 — NUMBERING SYSTEM AND STANDARD
MOUNTING POSITIONS ....................................................................2
FIGURE 2 — GENERAL ASSEMBLY .....................................................................15
FIGURE 3 — ACTUATOR SIZES B & C BRACKET & LINKAGE ..........................16
FIGURE 4 — HANDWHEEL ASSEMBLY, ACTUATOR SIZES B & C ...................16
FIGURE 5 — HANDWHEEL DETAIL, ACTUATOR SIZES B & C ..........................16
FIGURE 6 — HANDWHEEL BRACKET DETAIL, SIZES B & C ............................16
FIGURE 7 — HANDWHEEL LEVER DETAIL, SIZES B & C ..................................16
FIGURE 8 — HANDWHEEL CLEVIS DETAIL, SIZES B & C .................................16
FIGURE 9 — ACTUATOR GENERAL ASSEMBLY, SIZES B & C ........................17
FIGURE 10 — LEVER POSITION AIR TO OPEN, SIZES B & C ............................17
FIGURE 11 — LEVER POSITION AIR TO CLOSE, SIZES B & C ...........................17
FIGURE 12 — POSITION INDICATOR DETAIL, SIZES B & C ...............................18
FIGURE 13 — SIZE AC ACTUATOR ASSEMBLY ...................................................18
FIGURE 14 — SIZE AC ACTUATOR BOTTOM VIEW .............................................19
FIGURE 15 — SIZE AC ACTUATOR LINKAGE DETAIL .........................................19
FIGURE 16 — SIZE AC HANDWHEEL DETAIL.......................................................20
FIGURE 17 — INSULATION DETAIL .......................................................................20
LIST OF TABLES
TABLE 1 — BODY PARTS LIST ...............................................................................21
TABLE 2 — BRACKET AND LINKAGE PARTS LIST ..............................................21
TABLE 3 — HANDWHEEL PARTS LIST ..................................................................22
TABLE 4 — ACTUATOR PARTS LIST .....................................................................22
TABLE 5 — LINE BOLTING ......................................................................................23
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.
Helpful Hints
1. Have spare parts on hand before starting.
2. Read the instructions carefully.
3. Study the figures carefully and identify each part.
4. Use the right tools for the job.
5. Be careful not to score the shaft, ball and guiding
surfaces.
6. Ensure all lubricants, gaskets and packing are
compatible with the service.
7. Don’t overtighten nuts or bolts.
8. Clean valve parts thoroughly before reassembly.
9. Work safely.

1
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
Safety Information
Important - Please Read Before Installation
Masoneilan 36005 Series 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.
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.
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
could result in serious injury.
Indicates a potentially hazardous situation which, if not avoided,
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.
About this Manual
• The information in this manual is subject to change without
prior notice.
• The information contained in this manual, in whole or part,
shall not be transcribed or copied without Masoneilan’s
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 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 instruction manual applies to the Masoneilan 36005 Series
control valves.
The Control Valve MUST BE:
• Installed, put into service and maintained by qualified
and competent professionals who have undergone
suitable training.
• 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.
• 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.
• All surrounding pipe lines must be thoroughly flushed to
ensure all entrained debris has been removed from the
system.
Based on general field failure data and product design analysis, a useful life period of 25 years or longer can be expected for the 36005 series V-Ported control ball valves. To
maximize the useful life of the product it is essential to conduct annual inspections, routine maintenance and ensure proper installation to avoid any unintended stresses on the
product. The specific operating conditions will also impact the useful life of the product. Consult the factory for guidance on specific applications if required prior to installation.

2
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
1.0 Introduction
The following instructions are designed to assist maintenance
personnel in performing most of the maintenance required on
the 36005 V-Max® valve and if followed carefully will reduce
maintenance time.
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.
Numbering System
2nd
DIGIT
6
5th
DIGIT
5
4th
DIGIT
3rd
DIGIT
2nd
DIGIT 1st
DIGIT
3
1st
DIGIT
0 Undefined
1 Valve closes on stem
extension
(Air to Close, Fail Open)
2 Valve opens on stem
extension
(Air to Open, Fail Closed)
3 Valve closes on stem
extension
(Air-to-Close, Fail Open)
4 Valve opens on stem
extension
(Air-to-Open, Fail Closed)
7 Valve closes on stem
extension
(Air-to-Close, Fail Open)
8 Valve opens on stem
extension
(Air-to-Open, Fail Closed)
33 Spring Diaphragm.
Air to extend
action only.
Actuator Type Actuator Mounting
(See guide on page 4)
Body
Series
36
Design
Series
5
1 MN-7 Seal
Ring
2
316 SS
Seal Ring
3
Heavy Duty
Metal Seal
Ring
Seal Type
Figure 1

3
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
3 X 3 6 X 0 5
Actuator Position in Relation to Valve Body
Numbering System: 1 to 8
Actuator Model 33, Size AC
V-Max Valves
Actuator Model 33, Sizes B and C

4
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
2.0 Installation
2.1 General
2.1.1 Unpack valve carefully to avoid damage to valve,
accessories, or tubing.
2.1.2 Record all valve and accessory serial plate data
for future reference. Always provide serial and model
numbers when ordering spare parts.
2.2 Pipeline Mounting
Do not remove button head screw (9) and washer (10)
during installation. The function of these parts is to hold
the retainer (3) and seal ring (8) in place and should be
removed only when the valve is to be disassembled for
maintenance (Figure 2).
A. Before installing the valve in the line, clean pipe and
valve of all foreign materials such as welding chips,
scale, oil, grease or dirt. Gasket surfaces must be
thoroughly cleaned to ensure leak free joints.
B. Install valve in a horizontal or vertical line with the flow
tending to push the seal ring (8) against the ball (2)
as indicated by the flow arrow cast into the body. It is
recommended that if adjacent walls and piping permit,
the valve be oriented such that the ball opens upward.
This is especially important when handling slurries.
See Figure 1 for actuator mounting positions and for
flow direction and Table 5 for line flange bolting lengths.
Note: Flange bolt lengths are non-standard on inlet and
standard on outlet side.
C. Tighten bolting evenly and in crisscross fashion so that
the retainer (3) held in place by the line flange will bear
evenly against the seal ring (8).
D. The linkage of the 36005 V-Max valve has been properly
adjusted at the factory and requires no further adjustment.
E. Where insulation of the valve body is required, do not
insulate the valve bonnet. See Figure 17.
2.3 Air Piping
2.3.1 Air piping must be adequately sized to provide the
regulated supply pressure specified on the nameplate.
As a general guideline, use 1/4" O.D. tubing or
equivalent for all air lines. If supply air line exceeds 25
feet in length, use 3/8" O.D. tubing.
2.3.2 The actuator is furnished with a 1/4" NPT instrument
air port on the upper case.
Do not exceed loading pressure specified on the valve
nameplate.
2.4 Changing Actuator Position
2.4.1 Model 33, sizes B & C. For Size AC, refer to
section 2.4.2.
Before proceeding with changing actuator position, air
action or valve maintenance, isolate valve, vent process
pressure and shut off air supply and signal air lines or
electrical lines to unit. It is recommended that the valve
be removed from the pipeline prior to maintenance work.
Keep hands and tools away from the segmental ball,
particularly when disconnecting the actuator stem from
shaft arm as ball may rotate freely to its lowest position
For each valve action (air to open/air to close) the actuator
may be positioned to either side of the pipe. Actuator
position is usually determined by adjacent piping,
obstacles of various types or air piping arrangements.
To reposition the actuator and/or bracket follow the
disassembly and reassembly instructions below.
Note: Actuator positioning should be performed prior to
installing the valve in the pipeline. To change actuator
position and/or valve action refer to Figure 1 for desired
position.
A. Remove valve from process line after closing isolating
valves and disconnecting all pneumatic tubing and
electrical wiring.
B. If valve is equipped with a handwheel (Figure 4)
disengage handwheel and remove retaining clips
(63), clevis pin (66) and pivot pins (72); remove entire
hand- wheel assembly from bracket (62).
C. Remove pivot pin retaining clips (40), pivot pin (39)
and spacer rings (69). Remove actuator hex nuts
(75) and washers (76). Remove actuator.
Note: Spacer rings apply only on handwheel option.
D. Remove shaft cover (42) and screw (43). Loosen lever
cap screw (33). Remove packing flange stud nuts
(24), bracket mounting stud nuts (24) and washers
(18). Loosen ball plug indicator arm (35).
E. If necessary, scribe a witness line on the lever (32) in
relation to the slot on the end of the shaft (5).
Note: Standard lever has arrows stamped into it for
alignment. For handwheel lever use slot for alignment.
F. Slide bracket (31) away from body until it clears
bracket and packing flange studs (26 and 25),
allowing lever (32) lever arm (64) and indicator arm
(35) to be removed from shaft. Total removal of the
bracket is not required.
Before proceeding determine valve action (air to open/
air to close), refer to the appropriate figure (Figure 10 to
open, Figure 11 to close). To obtain proper alignment,
the lever must be oriented on the shaft so that the slot
in the end of the shaft and arrows or indicator lines are
aligned as shown; with the ball in the closed position,
the distance between the top of the bracket and the
top of the pivot pin must be as shown.
G. Slide lever (32) and lever arm (64) back onto
shaft in desired position. Slide indicator arm (35)

5
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
For each valve action (air to open/air to close) the actuator
may be positioned to either side of the pipe. Actuator
position is usually determined by adjacent piping,
obstacles of various types or air piping arrangements.
To reposition the actuator and/or bracket follow the
disassembly and reassembly instructions below.
Note: Actuator positioning should be performed prior to
installing the valve in the pipeline. To change actuator
position and/or valve action refer to Figure 1 for desired
position.
A. Remove valve from process line after closing isolating
valves and disconnecting all pneumatic tubing and
electrical wiring.
B. If valve is equipped with a handwheel (Figures 13 &
16) disengage handwheel and remove retaining clip
(54-7) and washer (54-4). Remove entire handwheel
assembly from actuator housing (31).
C. Remove pivot pin retaining clips (40), pivot pin (39).
Remove actuator hex nuts (75) and washers (76).
Remove actuator.
D. Remove shaft cover (42) and screw (43). Loosen lever
cap screw (33). Remove packing flange stud nuts
(24), bracket mounting stud nuts (24) and washers
(18). Loosen ball plug indicator arm (35).
E. If necessary, scribe a witness line on the lever (32) in
relation to the slot on the end of the shaft (5).
F. Slide housing (31) away from body until it clears
bracket and packing flange studs (26 and 25), allowing
lever (32) and indicator arm (35) to be removed from
shaft. Total removal of the bracket is not required.
Before proceeding determine valve action (air to
open/air to close).
G. Slide lever (32) back onto shaft in desired position.
Slide indicator arm (35) back onto shaft. Align
bracket and slide back onto mounting studs (26)
and packing flange studs (25). Replace mounting
stud nuts (24) and washers (18). Slide packing
flange (23) back onto packing flange studs (25) and
replace packing flange stud nuts (24).
H. Remount actuator onto housing and replace actuator
mounting hex nuts (75) and washers (76). Position
lever (32) so that rod end bearing (94) lines up in
lever (32) and that the pads on the lever will contact
the stop bolts (102). Tighten lever cap screw (33).
I. Rotate ball plug (2) to closed position. Adjust closed
position travel stop (102) until it contacts the pad on
lever (32). Tighten locknut (101).
J. Rotate ball plug (2) to open position. Adjust open
position travel stop until it contacts pad on lever (32).
Tighten locknut (101).
back onto shaft. Align bracket and slide back onto
bracket mounting studs (26) and packing flange
studs (25). Replace bracket mounting stud nuts (24)
and washers (18). Slide packing flange (23) back
onto packing flange studs (25) and replace packing
flange stud nuts (24).
H. Remount actuator onto bracket and replace
actuator mounting hex nuts (75) and washers (76).
Position lever (32) and lever arm (64) so that rod
end bearing (94) lines up in lever (32). Tighten lever
cap screws (34).
I. Rotate ball plug (2) to closed position. If actuator
action is air to open loosen rod end bearing locknut
(93) and adjust position of rod end bearing (94) so
that holes in lever (32) and rod end bearing (94) line
up. Insert pivot pin (39) and replace spacer rings
(69) and retaining rings (40).
When stroking valve keep hands and equipment clear
of ball plug and seal ring to avoid injury or damage to
personnel and equipment.
J. If action is air to close place ball plug (2) in closed
position and pneumatically stroke actuator fully.
Do not exceed maximum air supply pressure. Keep
hands clear of actuator stem and linkage.
Loosen rod end bearing locknut (93) and adjust rod
end bearing (94) so that holes in lever (32) and rod
end bearing (94) line up. Insert pivot pin (39) and
spacers (69) and replace retaining rings (40).
K. For both air to open and air to close action, stroke
valve fully to ensure proper closure of ball plug and
operation of valve. It may be necessary to readjust
rod end bearing slightly by loosening locknut and
rotating stem.
L. Replace handwheel assembly in bracket (62), pivot
pins (72) and retaining clips (63).
M. Replace shaft cover (42) and screw (43).
N. Set and lock indicator arm (35) to indicate plug position.
2.4.2 Changing Actuator Position Model 33, size
AC only.
Before proceeding with changing actuator position, air
action or valve maintenance, isolate valve, vent process
pressure and shut off air supply and signal air lines or
electrical lines to unit. It is recommended that the valve
be removed from the pipeline prior to maintenance work.
Keep hands and tools away from the segmental ball,
particularly when disconnecting the actuator stem from
shaft arm as ball may rotate freely to its lowest position.

6
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
Ensure rotation of AC actuator does not exceed
90deg. Damage to actuator rod may result.
K. If actuator action is air to open, rotate ball plug (2) to
open position. Pneumatically stroke actuator to open
position. Loosen rod end bearing locknut (93) and
adjust position of rod end bearing (94) so that holes
in lever (32) and rod end bearing (94) line up. Insert
pivot pin (39) and retaining rings (40).
When stroking valve keep hands and equipment
clear of ball plug and seal ring to avoid injury or
damage to personnel and equipment.
L. If action is air to close place ball plug (2) in closed
position. The pad on lever should contact the closed
position travel stop (102). If it does not, repeat
adjustment as noted in step I above. Return ball plug
(2) to open position. Pneumatically stroke actuator to
open position.
Do not exceed maximum air supply pressure. Keep
hands clear of actuator stem and linkage.
Loosen rod end bearing locknut (93) and adjust rod
end bearing (94) so that holes in lever (32) and rod
end bearing (94) line up. Insert pivot pin (39) and
replace retaining rings (40).
M. For both air to open and air to close action, stroke valve
fully to ensure proper closure of ball plug and operation
of valve. It may be necessary to readjust rod end
bearing slightly by loosening locknut and rotating stem.
N. Replace handwheel assembly in housing (31),
washer (54-7) and retaining clip (54-4).
O. Replace shaft cover (42) and screw (43).
P. Set and lock indicator arm (35) to indicate plug position.
2.5 Changing Valve Action
Note: If the valve action is to be changed it should be done
before the valve is installed in the line. This allows a positive
visual check to ensure that the ball plug is fully closed when
the actuator is in the proper position.
2.5.1 Model 33, sizes B & C only. For size AC refer
to section 2.5.2
A. If the valve is equipped with a handwheel disengage
the handwheel and remove retaining clips (63), clevis
pin (66), and pivot pins (39). Remove cap screws
(70), washers (71) and handwheel bracket (62).
B. If necessary, scribe a witness mark on the lever (32)
in relation to the slot on the end of the shaft (5).
Note: Standard lever has arrows stamped into it for
alignment. For handwheel lever use slot for alignment.
C. Remove pivot pin retaining clips (40), pivot pin (39)
and spacer rings (69). Remove shaft cover (42)
and screw (43). Remove actuator hex nuts (75) and
washers (76). Remove actuator.
Note: Spacer rings apply only on handwheel option.
D. Loosen lever cap screw (33). Remove packing flange
stud nuts (24), bracket mounting stud nuts (24) and
washers (18). Loosen ball plug indicator arm (35).
E. Slide bracket (31) away from body until it clears bracket
and packing flange mounting studs. Remove lever
(32), lever arm (64) and indicator arm (35) from shaft.
Before proceeding determine valve action (air to open/
air to close), refer to the appropriate figure (Figure 10 to
open, Figure 11 to close). To obtain proper alignment,
the lever must be oriented on the shaft so that the slot
in the end of the shaft and arrows or indicator lines are
aligned as shown; with the ball in the closed position,
the distance between the top of the bracket and the
top of the pivot pin must be as shown.
F. Flip lever (32) and lever arm (64) and replace on
shaft 90 away from original position. Replace
indicator arm (35). Slide bracket back onto bracket
mounting studs (26), replace washers (18) and nuts
(24) and tighten. Slide packing flange (23) back
over packing flange studs (25) and replace packing
flange stud nuts (24) and tighten.
G. Replace actuator on bracket in correct mounting
position for air action. Replace actuator stud nuts
(75) and washers (76). Position lever (32) and lever
arm (64) so that rod end bearing (94) lines up in lever
(32). Tighten lever cap screw (33).
H. Place ball plug (2) in closed position. If actuator
action is air to open, loosen rod end bearing nut (93)
and adjust position of rod end bearing (94) so that
holes in lever (32) and rod end bearing (94) line up.
Insert pivot pin (39) and replace retaining rings (40).
I. If action is air to close, place ball plug (2) in closed
position and pneumatically stroke actuator fully.
Do not exceed maximum air supply pressure.
J. For both air to open and air to close action, stroke valve
fully to ensure proper closure of ball plug and operation
of valve. Tighten rod end bearing locknut (93).
When stroking valve keep hands and equipment
clear of ball plug and seal ring to avoid injury or
damage to personnel or equipment.
K. Replace handwheel bracket (62), cap screws (70)
and lockwashers (71) on opposite side of actuator
bracket from where originally found. Insert handwheel
assembly in bracket and replace clevis pin (66),
retaining rings (63), lever arm bearing (65) and pivot
pins (72). Replace shaft cover (42) and screw (43).

7
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
Do not exceed maximum air supply pressure. Keep
hands clear of actuator stem and linkage.
Loosen rod end bearing locknut (93) and adjust rod
end bearing (94) so that holes in lever (32) and rod
end bearing (94) line up. Insert pivot pin (39) and
replace retaining rings (40).
I. For both air to open and air to close action, stroke
valve fully to ensure proper closure of ball plug and
operation of valve. It may be necessary to readjust
rod end bearing slightly by loosening locknut and
rotating stem.
J. Replace handwheel assembly (54) in bracket (31),
washer (54-7) and retaining clip (54-4).
K. Set and lock indicator arm (35) to indicate plug
position.
3.0 MAINTENANCE
3.1 Bracket Subassembly – Model 33, sizes B &
C only. Refer to section 3.2 for size AC
3.1.1 Disassembly
When disconnecting actuator rod end bearing from
shaft arm, the ball is likely to rotate toward the bottom of
the valve body. Keep hands and tools away from the ball.
A. Remove screw (43) and shaft cover (42) or positioner
if so equipped.
B. Remove retaining clips (40), pivot pin (39) and spacer
rings (69).
Note: Spacer rings apply only on handwheel option.
C. Remove actuator mounting nuts (75) and washers
(76) and remove actuator from bracket (31).
D. If valve has handwheel, remove retainer clips (63),
clevis pin (66), pivot pins (72). Remove handwheel
assembly from bracket.
E. Loosen cap screw (33) and indicator arm (35).
Remove packing flange stud nuts (24) and bracket
mounting stud nuts (26) and washers (18).
F. Scribe a witness mark on the lever (32) indicating
relative position to the slot in the end of the shaft (5).
G. Slide bracket (31) off studs and shaft, removing
indicator arm (35), lever (32), lever arm (64) and
packing flange (23).
H. Remove bearing (47) from bracket. Examine all
parts for wear and/or damage. Replace if necessary.
3.1.2 Reassembly
Note: If the valve is equipped with a handwheel the
lever consists of two separate arms which are a
MATCHED PAIR and are not interchangeable with any
other pair. The sequence of assembly is to place one
lever over the shaft then the lever arm (64) insert pin
L. Set and lock indicator (35) to indicate plug position.
2.5.2 Model 33, size AC only. For sizes B & C refer
to section 2.5.1 above.
A. If the valve is equipped with a handwheel disengage
the handwheel and remove retaining clip (54-7) and
washer (54-4). Remove handwheel assembly (54)
from housing (31) by rotating counter-clockwise.
B. Remove pivot pin retaining clips (40), pivot pin (39).
Remove actuator hex nuts (75) and washers (76).
Remove actuator.
C. Remove cover (48) from opposite side of bracket (31)
and install on side actuator was just removed from.
Note: Cover (48) is attached to yoke with contact
adhesive that is pre-applied. If a new cover is not
available, it can be re-installed by applying contact
adhesive to the cover and bracket following the
instructions for the specific adhesive used.
D. Install actuator on opposite side of yoke than it was
removed from. Attach using washers (76) and hex
nuts (75).
Before proceeding determine valve action (air to
open/air to close).
E. Rotate ball plug (2) to closed position. Verify closed
position travel stop (102) contacts the pad on lever
(32). Adjust as necessary. Tighten locknut (101).
Ensure rotation of AC actuator does not exceed
90deg. Damage to actuator rod may result.
F. Rotate ball plug (2) to open position. Verify open
position travel stop contacts pad on lever (32). Adjust
as necessary. Tighten locknut (101).
G. If actuator action is air to open, rotate ball plug (2)
to open position. Pneumatically stroke actuator to
open position. Loosen rod end bearing locknut (93)
and adjust position of rod end bearing (94) so that
holes in lever (32) and rod end bearing (94) line up.
Insert pivot pin (39) and retaining rings (40).
When stroking valve keep hands and equipment
clear of ball plug and seal ring to avoid injury or
damage to personnel and equipment.
H. If action is air to close place ball plug (2) in closed
position. The pad on lever should contact the closed
position travel stop (102). If it does not, repeat
adjustment as noted in step I above. Return ball plug
(2) to open position.

8
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
When disconnecting actuator rod end bearing from
shaft arm, the ball is likely to rotate toward the bottom of
the valve body. Keep hands and tools away from the ball.
A. Remove screw (43) and shaft cover (42) or positioner
if so equipped.
B. Remove retaining clips (40), pivot pin (39).
C. Remove actuator mounting nuts (75) and washers
(76) and remove actuator from bracket (31).
D. If valve has handwheel, remove retainer clip (54-7)
and washer (54-4). Remove handwheel assembly
(54) from bracket.
E. Loosen cap screw (36) and indicator arm (35).
Remove packing flange stud nuts (24) and bracket
mounting stud nuts (26) and washers (18).
F. Scribe a witness mark on the lever (32) indicating
relative position to the slot in the end of the shaft (5).
Loosen cap screw (11).
G. Slide bracket (31) off studs and shaft, removing
indicator arm (35), lever (32) and packing flange (23).
H. Remove bearing (47) and grommet (106) from
bracket. Examine all parts for wear and/or damage.
Replace if necessary.
3.2.2 Reassembly
A. Replace ball bearing (47) and grommet (106) in the
housing (31). Note, the grommet has a recessed
area on one side. It should be installed with that side
should be toward the inside of the bracket.
B. Place ball plug (2) in closed position. Slide bracket
(31) partially over shaft. Ensure all packing box
parts are in place and then slide packing flange
(23) onto shaft. Slide lever (32) onto shaft on its
former position. Replace indicator arm (35). Slide
bracket fully onto mounting studs (26); ensure shaft
(5) is properly located in bearing (47). Replace lock-
washer (18) and bracket mounting stud nuts (24)
and tighten. Replace packing flange stud nuts (24).
C. Pull shaft out to bottom against bearing. Replace
actuator and install washers (76) and nuts (75). Slide
lever (32) on shaft so that it is lined up with rod end
bearing (94). Tighten lever locking screw (33).
D. Place ball plug (2) in closed position. If valve action
is air to close, pneumatically stroke actuator fully.
Loosen rod end bearing locknut (93) and adjust rod
end bearing until holes in lever (32) and rod end
bearing (94) line up. Install pivot pin (39) and clips (40).
Do not exceed maximum air supply pressure specified
on the valve nameplate.
E. For both air to open and air to close action, stroke valve
fully to ensure proper closure of ball plug and operation
of valve. Tighten rod end bearing locknut (93).
(68), and then the second lever arm onto the shaft then
slide the shaft into the bracket and bearing.
A. Replace ball bearing (47) in the bracket (31).
B. Place ball plug (2) in closed position. Slide bracket
(31) partially over shaft. Ensure all packing box
parts are in place and then slide packing flange
(23) onto shaft. Slide lever (32) onto shaft on its
former position. Slide handwheel lever arm (64) and
second lever (32) onto shaft if valve has handwheel.
Replace indicator arm (35). Slide bracket fully onto
mounting studs (26); ensure shaft (5) is properly
located in bearing (47). Replace lock-washer (18)
and bracket mounting stud nuts (24) and tighten.
Replace packing flange stud nuts (24).
C. Pull shaft out to bottom against bearing. Replace
actuator and install washers (76) and nuts (75). Slide
lever (32) on shaft so that it is lined up with rod end
bearing (94). Tighten lever locking screw (33).
D. If valve action is air to open place ball plug (2) in closed
position. Loosen rod end bearing locknut (93) and
adjust rod end bearing until holes in lever (32) and rod
end bearing (94) line up. Install pivot pin (39), spacers
(69) (handwheel only) and retainer rings (40). If valve
action is air to close, place ball plug (2) in closed
position and pneumatically stroke actuator fully.
Do not exceed maximum air supply pressure
specified on the valve nameplate.
E. For both air to open and air to close action, stroke valve
fully to ensure proper closure of ball plug and operation
of valve. Tighten rod end bearing locknut (93).
When stroking valve keep hands and equipment
clear of ball plug and seal ring to avoid injury or
damage to personnel or equipment. Do not exceed
pressure specified on the valve nameplate.
F. Replace shaft cover (42) and screw (43) (or positioner
if so equipped).
G. Replace handwheel assembly in bracket (62) and
replace clevis pin (66), retaining clips (63), and
pivot pins (72).
H. Set and lock indicator arm (35) to indicate plug
position.
I. Check that handwheel operates valve through full
range of travel. There is a 1/2" adjustment available
at the end of the handwheel extension. Retract
handwheel, remove end cap (51) and cap screw
(55B). Rearrange stop (55A) and/or spacer (55C)
to obtain desired extension.
3.2 Bracket Subassembly – Model 33, size AC
only. Refer to section 3.1 for sizes B & C
3.2.1 Disassembly

9
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
3.3.2 Seal Ring – MN-7 Seal
3.3.2.1 Disassembly
Note: Seal ring removal, inspection and reinstallation
must be done with the valve removed from the pipeline.
A. Remove screws (9) and washers (10), retainer
(3), MN-7 seal ring (8) and downstream back-up
ring (32).
B. Remove gasket (4) residue from body and
retainer taking care not to damage seal surfaces.
3.3.2.2 Reassembly
A. Move ball to the closed position.
Note: Use a light coating of Dow-Corning 111® or
equal on the ball plug to break in seat.
B. Replace backup ring (32), seal assembly, gasket
(4) and retainer (3). Take care that beveled edges
of seal (8) and backup ring (32) are facing the ball.
C. Replace set screws (9) and washers (10) and
tighten.
3.3.3 Seal Ring – Standard Metal Seal
3.3.3.1 Disassembly
Note: Seal ring removal, inspection and reinstallation
must be done with the valve removed from the pipeline.
A. Remove screws (9) and washers (10).
Note: The flexible metal seal assembly consists
of a seal ring (8), gasket (7), and backup ring (6).
B. Mark flexible metal seal ring (8) so that, if
reinstalled, the same side will be in contact
with the ball. Remove retainer, seal assembly
and downstream back-up ring (32). If difficulty is
encountered in removing seal assembly, rotate
the ball to open position and pull out the seal ring.
C. Remove gasket (4) residue from body and
retainer taking care not to damage seal surfaces.
D. If replacing MN-7 or flat metal seal with HD metal
version, upper and lower guide bushings (16,
17) should be replaced with satellite material.
3.3.3.2 Reassembly
Note: If retrofitting a valve originally equipped with
an MN-7 seal ring follow steps A through D. If valve
was originally supplied with a metal seal, please
proceed to step C.
A. Clean the contact surfaces of the ball plug
(2) with alcohol or other suitable degreaser to
facilitate application of the dry graphite spray
lubricant. If necessary, very mild abrasive pads
such as Scotch-Brite™ may be used to remove
any oxide layers on the ball plug (2).
B. Apply the dry graphite lubricant spray (Dow-
Corning 321®) in several light coats on the
plated seal contact surfaces of the ball plug (2).
Allow the graphite spray to dry fully – which will
produce a dull gray finish on the coated parts.
C. Move ball to the closed position.
When stroking valve keep hands and equipment clear
of ball plug and seal ring to avoid injury or damage to
personnel or equipment. Do not exceed pressure
specified on the valve nameplate.
F. Replace shaft cover (42) and screw (43) (or positioner
if so equipped).
G. Replace handwheel assembly (54) in housing (31)
and replace washer (54-4) and retaining clip (54-7).
H. Set and lock indicator arm (35) to indicate plug
position.
I. Check that handwheel operates valve through full
range of travel.
3.3 Body Subassembly
3.3.1 Packing
Note: The packing follower should be held firmly, but
not too tightly against the packing.
Overtightening of the packing causes excessive friction
and may affect valve operation. The packing in a new
V-Max valve has not been tightened prior to shipment.
It is recommended that further adjustments be made
when the valve is put into service. If necessary to add
packing, proceed as follows:
Valve must be isolated and process pressure vented
before performing packing box maintenance.
3.3.1.1 Disassembly
A. Loosen and remove packing flange nuts (24) and
slide packing flange (23) and packing follower
(20) toward shaft lever (32).
Note: The lever (32) may be disconnected
from the actuator stem and pushed up against
the shaft bearing (47) (refer to section 3.1), if
necessary for clearance.
B. Using a packing hook, remove the top pieces of
packing rings.
3.3.1.2 Reassembly
A. Install new packing ring(s), making sure the skive
cut in adjacent packing rings is offset 120° apart.
B. Replace packing follower (20) packing box
flange (23) and packing nuts (24).
C. Evenly tighten packing nuts (24).
DO NOT overtighten packing nuts.
D. Place valve into service and tighten packing
nuts (24) only as much as necessary to stop any
leakage.

10
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
D. Replace downstream back-up ring (32), seal
assembly, gasket (4) and retainer (3). Take care
that beveled edge flexible metal seal (8) and
backup rings (6 & 32) are facing the ball.
E. Replace set screws (9) and washers (10) and
tighten.
3.3.4 Seal Ring – Heavy Duty Metal Seal
3.3.4.1 Disassembly
Note: Seal ring removal, inspection and reinstallation
must be done with the valve removed from the pipeline.
A. Remove screws (9) and washers (10).
Note: The Heavy Duty Metal Seal assembly
consists of a seal ring (8), radial seal (30) and
wave spring (31).
B. Note the orientation of the radial seal (30) and
wave washer (31) for reassembly.
C. Clean parts of any residue that remains from the
process. Take care not to damage or mark the
sealing surfaces of seal ring (8) or radial seal (30).
3.3.4.2 Reassembly
Note: If retrofitting a valve originally equipped with
an MN-7 seal ring follow steps A through D. If valve
was originally supplied with a metal seal, please
proceed to step C.
A. Clean the contact surfaces of the ball plug (2) with
alcohol or other suitable degreaser to facilitate
application of the dry graphite spray lubricant.
If necessary, very mild abrasive pads such as
Scotch-Brite™ may be used to remove any oxide
layers on the ball plug (2).
B. Apply the dry graphite lubricant spray (Dow-
Corning 321®) in several light coats on the
plated seal contact surfaces of the ball plug (2).
Allow the graphite spray to dry fully – which will
produce a dull gray finish on the coated parts.
C. Move ball to the closed position
D. Lubricate the Radial Seal (30) with Dow-Corning
111® Silicon grease (or equivalent) and install it
over the end of the Heavy Duty Seal Ring (8).
Note: The open lips of the radial seal (30) must
face AWAY from the seat bevel and ball.
E. Install the Wave Spring (31) over the end of the
Heavy Duty Seal Ring (8).
F. Insert the Seat Retainer (3) over the end of the
Seat (8) and apply even pressure to overcome
the resistance of the radial seal (30) until the
wave spring (31) is compressed.
G. Install the retainer/body gasket (4).
H. Install the seat (8), retainer (3), radial seal (101) and
wave spring (102) assembly into the body counter-
bore until contact is made with the ball plug (2).
I. Install retainer screws (9) and washers (1) and
tighten to secure the retainer and seal assembly
in the body.
3.3.5 Ball Plug
3.3.5.1 Ball Plug Disassembly
A. Remove bracket (see section 3.3.2).
B. Remove screws (9) and washers (10). Slide
the retainer (3) out of the valve body. Remove
seal assembly (refer to Para. 3.2.2.1 Seal Ring -
Disassembly).
C. Remove safety pin (27). Remove the shaft (5) from
the valve body. The packing (19), packing adaptor
(28) and packing follower (20) will slide out with the
shaft. If the shaft will not move, thread nuts (24) on
the packing studs, then place the packing flange
(23) on top of the nuts. Slide the lever (32) onto the
shaft (5) up against the packing flange (23) and
tighten screw (34). By unscrewing the packing nuts
(24) evenly, ample force is developed to move the
shaft (5). Once shaft has been started, it should be
possible to remove the shaft completely. If not, a
suitable size bolt screwed into the tapped hole on
the shaft end can be used as a shaft “puller”.
D. Remove nuts (13), end flange (14), pin shaft
(11) and gasket (15). If the pin shaft will not
move, push it out with a rod inserted through the
bonnet end of the valve.
E. Remove the ball (2) and separate the lower
bushing (16) from it. Remove the upper bushing
(17). If it sticks, the upper bushing (17) can be
pushed out with a rod of suitable size inserted
into the pin shaft end of the body.
F. Examine all parts for damage due to erosion,
corrosion, or wear. Replace the seal ring if
damaged, worn or distorted. Replace all defective
parts and all packing and gaskets. Clean the valve
parts thoroughly before reassembly. Remove
gasket (4) and (15) residue from body and
retainer taking care not to score sealing areas.
3.3.5.2 BaIl Plug Reassembly
Note: If installing a new ball plug into a valve equipped
with either the standard metal or Heavy Duty metal
seal rings, the ball plug must be first coated with dry
graphite lubricant as described in steps A and B. If
equipped with an MN-7 seal ring, proceed to step C.
A. Clean the contact surfaces of the ball plug
(2) with alcohol or other suitable degreaser to
facilitate application of the dry graphite spray
lubricant. If necessary, very mild abrasive pads
such as Scotch-Brite™ may be used to remove
any oxide layers on the ball plug (2).
B. Apply the dry graphite lubricant spray (Dow-
Corning 321®) in several light coats on the
plated seal contact surfaces of the ball plug (2).
Allow the graphite spray to dry fully – which will
produce a dull gray finish on the coated parts.
C. Replace lower bushing (16) in the ball and
position ball in the body. Replace gasket (15).
D. Lubricate pin shaft (11) and insert through body and
into the ball. Secure with end flange (14) and end
flange nuts (13). Tighten nuts alternately to assure

11
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
tight seal against the gasket. (Recommended
lubricant SAF-T-EZE Anti-Seize or equal.)
E. Replace ring (29), and upper bushing (17)
on the shaft (5). Install shaft in the body and
engage the ball such that when the ball is in the
closed position, the machined slot in the shaft
end is vertical (perpendicular to the body axis).
Coat shaft below ring groove and bushing with
lubricant (SAF-T-EZE Anti-Seize or equal).
F. Install packing adaptor (28), bevel side out over
the shaft (5) and into the valve bonnet so that the
hole through the side of the adaptor is aligned
with the tapped hole through the bonnet for the
safety pin (27).
G. Apply pipe sealant to the safety pin, install into
bonnet and tighten.
Safety pin must engage hole in packing adaptor.
Test by manually pulling on shaft to verify pin
engagement.
H. Install packing (19) so that skive cut of each
piece of packing is offset approximately 120°
from that of adjacent piece.
I. Install packing follower (22) over shaft and into
bonnet with bevel side out. Install packing box
flange (23) and nuts (24).
J. Install seal ring and retainer assembly as
described in section 3.3.2, 3.3.3 or 3.3.4
depending on seal type.
K. Install mounting bracket (31) and lever (32).
Follow instruction 3.1.2 Bracket Reassembly.
L. Evenly tighten packing flange nuts (24) against
packing flange (23) before placing valve into
service.
DO NOT over tighten packing flange nuts. After
valve has been in service, retighten packing
flange nuts evenly until any leaks are stopped.
3.4 Actuator Subassembly.
3.4.1 Model 33, sizes B & C. Refer to section 3.7
for size AC actuators.
3.4.1.1 Disassembly
The upper diaphragm case (84) is under spring
tension. A warning tag (97) is attached to each of
the three (3) long cap screws (95). The tension nuts
(96) attached to cap screws (95) must be evenly
removed last. The following procedure must be
followed to avoid injury.
A. Isolate the valve, vent process pressure and
shut off all electrical, signal air and supply air
lines to the valve.
B. If equipped with a handwheel, it must be rotated
to the disengaged position.
C. Remove air supply piping to upper diaphragm
case (84).
D. Remove side covers (46).
E. Remove retaining clips (40) and remove pivot
pin (39) and spacers (69) (handwheel only) to
free rod end bearing (94).
F. Loosen and remove all short cap screws (86) and
hex nuts (87). Mark upper case (84) and lower
case (20) so that they can be reassembled with
the same orientation of air inlet and mounting bolts.
G. Loosen each tension nut (96) approximately
three full turns.
The upper diaphragm case (84) should separate
from the lower case (91) as the tension nuts are
loosened the three turns. If it does not, before
proceeding, separate the upper diaphragm case
(84) by tapping it around the circumference or
inserting a screwdriver between the upper (84)
and lower case (91). If the cases still do not
separate, check that the actuator stem is not
hung up inside the bracket. DO NOT PROCEED
WITH DISASSEMBLY UNLESS THE CASES
CAN SEPARATE FREELY.
H. Continue loosening the tension nuts (96) evenly
approximately three turns each time ensuring
that the upper diaphragm case (84) and
diaphragm (85) continue to separate.
Note: Continue Step H until the tension nuts (96)
can be easily removed by hand indicating the
upper diaphragm case (84) is not under spring
tension.
I. Remove tension bolts (95) and upper diaphragm
case (84).
J. Remove diaphragm (85) and diaphragm plate
subassembly from the actuator.
K. Remove retaining clip (78). Remove clevis pivot
pin (79). Inspect for damage and/or wear in
clevis (80), lever (32), clevis pins (79, 39) and
rod end bearings (94). Replace if necessary.
L. Clean all mating/sealing surfaces which will
come in contact with the diaphragm (85).
3.4.1.2 Reassembly
A. Connect rod end bearing (94) to diaphragm
plate clevis (80) by installing clevis pin (79) and
retaining clips (78). Ensure that the stem (77)
is installed such that the wrench flats are at the
end furthest from the diaphragm plate (88).

12
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
B. Ensure spring (90) and spring guide (89) are
properly aligned in lower case (91) and install
the diaphragm plate and stem subassembly.
Replace diaphragm (85).
C. Align marks for correct orientation of upper
case (84) and lower case (91). Replace upper
diaphragm case (84) and install long cap screws
(95), warning plate (97) and tension nuts (96).
Note: These bolts must be equally spaced at
120° intervals.
D. Take up tension nuts (96) evenly and sufficiently
to allow installation of short cap screws (83) and
hex nuts (87).
E. Tighten tension nuts (96) and then tighten all hex
nuts (87) using a criss-cross tightening pattern.
Note: Nuts should be tightened only enough to
seal the diaphragm between the upper and lower
case. Do not overtighten.
F. Connect rod end bearing (94) to lever (32) by
installing pivot pin (39), spacers (69) (handwheel
only), and retaining clips (40).
G. Replace side covers (46) and reconnect signal
and supply lines.
H. Place back in service and, if so equipped, rotate
handwheel to desired position.
3.4.2 Actuator Subassembly – Model 33, size AC.
Refer to section 3.4.1 for sizes B & C. Figures 13,
14, 15 & 16.
3.4.2.1 Disassembly
The upper diaphragm case (84) is under spring
tension. A warning tag (97) is attached to each of
the three (3) long cap screws (95). The tension nuts
(96) attached to cap screws (95) must be evenly
removed last. The following procedure must be
followed to avoid injury.
A. Isolate the valve, vent process pressure and
shut off all electrical, signal air and supply air
lines to the valve.
B. If equipped with a handwheel, it must be rotated
to the disengaged position.
C. Remove air supply piping to upper diaphragm
case (84).
D. Remove covers (44 & 46).
E. Remove retaining clips (40) and remove pivot
pin (39) to free rod end bearing (94).
F. Loosen and remove all short cap screws (86) and
hex nuts (87). Mark upper case (84) and lower
case (91) so that they can be reassembled with
the same orientation of air inlet and mounting bolts.
G. Loosen each tension nut (95) approximately
three full turns.
The upper diaphragm case (84) should separate
from the lower case (91) as the tension nuts are
loosened the three turns. If it does not, before
proceeding, separate the upper diaphragm case
(84) by tapping it around the circumference or
inserting a screwdriver between the upper (84)
and lower case (91). If the cases still do not
separate, check that the actuator stem is not
hung up inside the bracket. DO NOT PROCEED
WITH DISASSEMBLY UNLESS THE CASES
CAN SEPARATE FREELY.
H. Continue loosening the tension nuts (95) evenly
approximately three turns each time ensuring
that the upper diaphragm case (84) and
diaphragm (85) continue to separate.
Note: Continue Step H until the tension nuts (95)
can be easily removed by hand indicating the upper
diaphragm case (84) is not under spring tension.
I. Remove tension bolts (95) and upper diaphragm
case (84).
J. Remove diaphragm (85) and diaphragm plate
subassembly from the actuator.
K. Remove retaining clip (78). Remove clevis pivot
pin (79). Inspect for damage and/or wear in
clevis (80), lever (32), clevis pins (79, 39) and
rod end bearings (94). Replace if necessary.
L. Clean all mating/sealing surfaces which will
come in contact with the diaphragm (85).
3.4.2.2 Reassembly
A. Connect rod end bearing (94) to diaphragm plate
clevis (80) by installing clevis pin (79) and retaining
clips (78). Ensure that the stem is installed such
that the wrench flats are at the end furthest from
the diaphragm plate (88).
B. Ensure spring (90) and spring guide (98) are
properly aligned in lower case (91) and install
the diaphragm plate and stem subassembly.
Replace diaphragm (85).
C. Align marks for correct orientation of upper
case (84) and lower case (91). Replace upper
diaphragm case (84) and install long cap screws
(95), warning plate (97) and tension nuts (96).
Note: These bolts must be spaced as equally as
possible.
D. Take up tension nuts (96) evenly and sufficiently
to allow installation of short cap screws (86) and
hex nuts (87).
E. Tighten tension nuts (96) and then tighten all hex
nuts (87) using a criss-cross tightening pattern.
Note: Nuts should be tightened only enough to seal
the diaphragm between the upper and lower case.
Do not overtighten.
F. Connect rod end bearing (94) to lever (32) by
installing pivot pin (39), and retaining clips (40).

13
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
G. Replace covers (44 & 46) and reconnect signal
and supply lines.
H. Place back in service and, if so equipped, rotate
handwheel to desired position.
3.5 Handwheel Subassembly
3.5.1 Model 33 sizes B & C only. Refer to section
3.5.2 for size AC actuators.
3.5.1.1 Disassembly
Turn handwheel to disengage position before
proceeding with handwheel maintenance. Refer to
Figures 13 through 16.
A. Remove retaining clips (63) and push out pin (66).
Make sure bushing (65) remains in the arm (64).
B. Remove the pivot pins (72) and remove
handwheel subassembly.
C. Remove handwheel shaft subassembly (55)
retaining ring (59) and unscrew nut (58).
Remove needle bearing and race (60). Clean
and check needle bearing and race for signs of
wear. Replace if necessary.
D. Remove handwheel pivot (56) and thrust washer
(61). Check washer and replace if necessary.
Check 0-ring (57) and replace if necessary.
E. Clean ACME threads on handwheel (54) and
shaft S/A (55) and grease with Molykote G.
3.5.1.2 Reassembly (Figure 5)
A. Install thrust washer (61) and 0-ring (57). Apply
silicone lubricant sparingly to 0-ring.
B. Slide handwheel pivot (56) onto the handwheel
subassembly. Lubricate and install bearing race,
needle bearing and outer race.
C. Install nut (58) bevel side toward bearing race
and screw down tight. DO NOT OVERTIGHTEN.
Replace retaining ring (59). Correct assembly
should have the nut (58) touching the retaining
ring (47).
Do not rotate handwheel prior to replacing pivot
pins (72) into the handwheel mounting bracket (62).
D. Install assembly into handwheel mounting
bracket (62) and replace pivot pins (72).
E. Connect handwheel shaft S/A (55) to handwheel
(54) and to the lever arm with pin (66) and
replace clip (63).
3.5.2 Handwheel Subassembly – Model 33, Size
AC. Refer to section 3.5.1 for sizes B & C. Refer to
Figures 13, 14 & 16.
3.5.2.1 Disassembly
Turn handwheel to disengage position before
proceeding with handwheel maintenance.
A. Remove retaining ring (54-7) and shaft washer
(54-4).
B. Rotate Handwheel (54) counterclockwise until it
is removed from housing (31).
C. Clean ACME threads on handwheel shaft (54-3)
and grease with Molykote G.
3.5.2.2 Reassembly. Refer to Figures 13, 14 & 16.
A. Thread handwheel assembly (54) into housing
(31) until it extends through the housing and the
groove in the stem (54-3) is visible.
B. Place shaft washer (54-4) over stem (54-3).
C. Install retaining ring (54-7) into groove on stem
(54-3).
3.6 Diaphragm Replacement
Spring diaphragm actuators contain large forces due to
their preloaded powerful springs. Failure to carefully follow
this procedure can result in personal injury!
3.6.1 Model 33 sizes B & C only. Refer to section
3.6.2 for size AC actuators.
3.6.1.1 Disassembly
A. Relieve actuator pressure and disconnect air
supply. Do not remove pivot pin (39).
B. Verify that all three tension bolts (95) and nuts
(96) are in place and secure.
C. Remove nuts (87) and cap screws (86) following
a criss-cross pattern.
D. Verify actuator stem (77) and rod end (94) are
securely connected to lever (32) through pivot
pin (39) and that retaining clips (40) are in place.
E. Loosen tension nuts (96) evenly in sequence.
Do not exceed three turns of any one nut (96)
before proceeding to the next one. Do not vary
the sequence.
Failure to evenly unload tension nuts may result
in personal injury!
F. Continue loosening tension nuts (96) until further
loosening of the tension nuts (96) is no longer
accompanied by an increase in separation of the
upper diaphragm case (84) from the lower case
(91). At this point the tension nuts (96), bolts (95)
and warning plates (97) can be removed.

14
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
G. Remove the upper diaphragm case (84) and
diaphragm (85).
The diaphragm plate (88) remains under spring
load.
3.6.1.2 Reassembly
A. Ensure that sealing surfaces of diaphragm cases
(84) and (91) are clean and free of any dirt or
debris. Check that there are no foreign objects that
may interfere with travel or damage diaphragm.
B. Install diaphragm (85) on diaphragm plate (88).
Align bolt holes with holes in lower case (91).
C. Install three tension bolts (95) with warning
plates (97) into upper case (84). Ensure bolts
are equally spaced at 120° to each other.
D. Mount upper case (84) onto diaphragm plate
(88) such that the tension bolts pass through
holes in diaphragm (85) and lower case (91).
E. Install tension nuts (96) finger tight onto tension
bolts (95).
F. Tighten each tension nut (96) three turns before
proceeding to the next to ensure actuator spring
(90) is evenly loaded. Continue until the diaphragm
is firmly sandwiched between the flanges of the
upper and lower diaphragm cases. Torque tighten
tension bolts to 50 in. lbs.
G. Install cap screws (86) and nuts (87). Torque
tighten to 50 in. lbs. in a criss-cross pattern. As this
will tend to unload the tension bolts (96) repeat
torque tightening of tension bolts and cap screws
(86) to 50 in. lbs. in a criss-cross pattern until joint
is evenly loaded to specified torque values.
H. Reconnect air supply.
I. Stroke actuator to confirm operation.
3.6.2 Model 33 size AC actuators only. Refer to
section 3.6.1 for sizes B & C.
3.6.2.1 Disassembly
A. Relieve actuator pressure and disconnect air
supply. Do not remove pivot pin (39).
B. Verify that all three tension bolts (95) and nuts
(96) are in place and secure.
C. Remove nuts (87) and cap screws (86) following
a criss-cross pattern.
D. Verify actuator stem (15) and rod end (94) are
securely connected to lever (32) through pivot
pin (39) and that retaining clips (40) are in place.
E. Loosen tension nuts (96) evenly in sequence.
Do not exceed three turns of any one nut (96)
before proceeding to the next one. Do not vary
the sequence.
Failure to evenly unload tension nuts may result
in personal injury!
F. Continue loosening tension nuts (96) until further
loosening of the tension nuts (96) is no longer
accompanied by an increase in separation of the
upper diaphragm case (84) from the lower case
(91). At this point the tension nuts (96), bolts (95)
and warning plates (97) can be removed.
G. Remove the upper diaphragm case (84) and
diaphragm (85).
The diaphragm plate (88) remains under spring
load.
3.6.2.2 Reassembly
A. Ensure that sealing surfaces of diaphragm cases
(84) and (91) are clean and free of any dirt or
debris. Check that there are no foreign objects that
may interfere with travel or damage diaphragm.
B. Install diaphragm (85) on diaphragm plate (88).
Align bolt holes with holes in lower case (91).
C. Install three tension bolts (95) with warning plates
(97) into upper case (84). Ensure bolts are equally
spaced around the circumference of the case.
D. Mount upper case (84) onto diaphragm plate
(88) such that the tension bolts pass through
holes in diaphragm (85) and lower case (91).
E. Install tension nuts (96) finger tight onto tension
bolts (95).
F. Tighten each tension nut (86) three turns before
proceeding to the next to ensure actuator spring
(90) is evenly loaded. Continue until the diaphragm
is firmly sandwiched between the flanges of the
upper and lower diaphragm cases. Torque tighten
tension bolts to 50 in. lbs.
G. Install cap screws (86) and nuts (87). Torque
tighten to 50 in. lbs. in a criss-cross pattern. As this
will tend to unload the tension bolts (95) repeat
torque tightening of tension bolts and cap screws
(86) to 50 in. lbs. in a criss-cross pattern until joint
is evenly loaded to specified torque values.
H. Reconnect air supply.
I. Stroke actuator to confirm operation.

15
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
Figure 2 - General Assembly
DETAIL B
SCALE 2 : 1
SECTION A-A
DETAIL C
SCALE 2 : 1
ALTERNATE VIEW C
SCALE 2 : 1
ALTERNATE VIEW C
SCALE 2 : 1

16
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
Figure 4 - Handwheel General Assembly,
Actuator Sizes B & C
Figure 3 - Sizes B & C Bracket and Linkage
Figure 5 - Handwheel Detail, Actuator Sizes B & C
Figure 6 - Handwheel Bracket Detail,
Actuator Sizes B & C
Figure 7 - Handwheel Lever Detail,
Actuator Sizes B & C
Figure 8 - Handwheel Clevis Detail,
Actuator Sizes B & C

17
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
Figure 9 - Actuator General Assembly,
Actuator Sizes B & C
Figure 10 - Lever Position Air to Open,
Actuator Sizes B & C Figure 11 - Lever Position Air to Close,
Actuator Sizes B & C

18
Instructions EM36005 – 07/10
36005 Series V-Max® Control Ball Valve
Figure 13 - Size AC Actuator
Figure 12 - Position Indicator Detail,
Actuator Sizes B & C