Masoneilan 39003 Series User manual

Instruction Manual
EM39003
05/10
39003 Series
High Performance
Butterfly Valves
Putting You In Control

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.
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.
Table of Contents Page
1. INTRODUCTION
1.1 VALVE DESCRIPTION ..........................................................................................2
1.2 VALVE DESIGN FEATURES .................................................................................2
1.3 FLANGE COMPATIBILITY ....................................................................................2
1.4 GASKET COMPATIBILITY ....................................................................................2
1.5 PIPE SCHEDULE COMPATIBILITY ......................................................................2
1.6 NUMBERING SYSTEM ........................................................................................3
1.7 OPERATING PRESSURES ...................................................................................5
1.8 SEAT ALTERNATIVES ..........................................................................................5
1.9 OFFSET DISC DESIGN ........................................................................................5
1.10 SEAT RETAINER ALTERNATIVES ........................................................................6
2. INSTALLATION RECOMMENDATIONS
2.1 VALVE RATINGS ..................................................................................................6
2.2 SEAT UPSTREAM vs. SEAT DOWNSTREAM .......................................................6
2.3 DISC CLEARANCES ............................................................................................7
2.4 OPENING ROTATION ..........................................................................................7
2.5 INSTALLATION POSITION ...................................................................................7
2.6 VALVE AND FLANGE PREPARATION ..................................................................7
2.7 INSTALLATION TOOLS ........................................................................................7
2.8 REQUIRED BOLTING ...........................................................................................7
2.9 UNPACKING AND STORAGE INSTRUCTIONS ....................................................7
2.10 PRE-INSTALLATION PROCEDURE ......................................................................7
2.11 VALVE INSTALLATION PROCEDURE ..................................................................7
2.12 ACTUATOR INSTALLATION .................................................................................8
2.13 BOLTING DIMENSIONS .......................................................................................9
3. MAINTENANCE INSTRUCTIONS
3.1 SAFETY PRECAUTIONS ....................................................................................11
3.2 GENERAL MAINTENANCE ................................................................................11
3.3 PACKING REPLACEMENT ................................................................................11
3.4 END CAP SEAL REPLACEMENT .......................................................................11
3.5 STANDARD SOFT SEAT REPLACEMENT .........................................................11
3.6 FIRE-SAFE AND METAL SEAT REPLACEMENT ................................................12
3.7 DISC, SHAFT AND BEARING REPLACEMENT ..................................................13
3.8 VALVE PARTS LIST ...........................................................................................14
3.9 REMOTE ACTUATOR (MALE DRIVE) MOUNTING PROCEDURE .......................15
3.10 REMOTE ACTUATOR (FEMALE DRIVE) MOUNTING PROCEDURE ...................15
3.11 33 ACTUATOR DISASSEMBLY .........................................................................16
3.12 ACTUATOR DIAPHRAGM REPLACEMENT .......................................................17
3.13 33 ACTUATOR REASSEMBLY ..........................................................................18
3.14 ACTUATOR PARTS LIST ...................................................................................20

Safety Information
Important -
Please Read Before Installation
Masoneilan 39003 Series High Performance Butterfly 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.
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 39003 Series
High Performance Butterfly 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 39003 Series
High Performance Butterfly Valves.
The Control Valve and Actuator 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 air supply to the actuator must be turned off.
• All surrounding pipe lines must be thoroughly flushed
to ensure all entrained debris has been removed from
the system.
Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 1

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 2
1. Introduction
1.1 Valve Description
The Masoneilan 39003 Series High Performance Butterfly Valve
(HPBV) is designed for ANSI Class 150, 300 and 600 piping
systems and is available in both Wafer and Lug style body
designs. The standard size range available is as follows:
ANSI Class 150 ........................ 2" through 48"
ANSI Class 300 ........................ 2" through 30"
ANSI Class 600 ........................ 2" through 16"
1.2 Valve Design Features
• Masoneilan’s HPBVs feature a double offset (or double
eccentric) shaft design to minimize seat abrasion and lower
torque. This double offset design allows the disc to lift off and
“cam” away from the seat as it rotates open.
• The 39003 Series valve always rotates clockwise to close
(when viewed from above) and counterclockwise to open.
• The valve body has an overtravel stop which prevents the disc
from over rotating into the wrong quadrant. This stop is not
to be used as a disc position stop; if the disc contacts the
overtravel stop, this means it has rotated beyond the seat.
• The 39003 Series valve is bi-directional, but the preferred
installation position is with the seat in the upstream position
(SUS). Note the arrow on the metal tag attached to the valve
body for preferred direction of flow.
1.3 Flange Compatibility
The 39003 Series valve is designed to fit between flanges as
follows:
ANSI Class 150 ........................ 2" through 24"
MSS SP-44 Class 150 ............. 30" through 48"
ANSI Class 300 ........................ 2" through 24"
MSS SP-44 Class 300 ............. 30"
ANSI Class 600 ........................ 2" through 16"
1.4 Gasket Compatibility
The 39003 Series valve is designed to accommodate the use of
standard fiber gaskets (such as non-asbestos, flexible graphite,
asbestos or equivalent gasket materials) of 1/16" or less,
meeting the dimensional requirements of ANSI/ASME B16.21.
Thick elastomeric gaskets are not recommended. Metallic
wound (Flexitallic) gaskets may be used with the wedge ring
retainer configuration.
1.5 Pipe Schedule Compatibility
The 39003 Series valve is designed to allow the disc edge to
rotate into the open position without interference with pipe of a
schedule equal to or lighter to those shown below:
Size ANSI 150 ANSI 300 ANSI 600
2" – 12" SCH 80 SCH 80 SCH 120
14" – 24" SCH 40 SCH 80 SCH 120
30" SCH 30 SCH 80
36" – 42" STD WT
48" XS

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 3
2nd
3
Body Series
39
2nd
9
5th
3
4th
3rd
33 Spring Diaphragm
(Air to extend action only
with or without auxilliary
handwheel)
1st
3
1st
3
Actuator Type Design
Series
3
*Standard Actuator Mounting
Arrangement
Note 1: Looking at valve from
actuator and bracket end, valve
would not be visible.
Note 2: Positions 1, 2, 5 and 6
shown dotted and obtained by
rotating the valve 180° about its
shaft axis.
Caution: The valve must not be installed with
the actuator mounted vertically below center.
Figure 1
ATC
FTO
ATO
FTO
ATO
FTO
Actuator Mounting
0. Undefined
1. Horizontal above center.
Valve opens on stem extension
(air-to-open action)
2. Horizontal above center.
Valve closes on stem extension
(air-to-close action)
*3. Vertical above center.
Valve opens on stem extension
(air-to-open action)
*4. Vertical above center.
Valve closes on stem extension
(air-to-close action)
5. Horizontal below center.
Valve opens on stem extension
(air-to-open action)
6. Horizontal below center.
Valve closes on stem extension
(air-to-close action)
7. Vertical above center.
Valve opens on stem extension
(air-to-open action)
8. Vertical above center.
Valve closes on stem extension
(air-to-close action)
1.6 Numbering System
Seal Type
1. PTFE or
RTFE Seal
Ring
2. Inconel Seal
Ring
3. Fire-Safe
Seal Ring
ATC
FTO

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 4
2nd
4
2nd
9
5th
3
4th
3rd
1st
3
1st
3
Figure 2
Seal Type
1. PTFE or
RTFE Seal
Ring
2. Inconel Seal
Ring
3. Fire-Safe
Seal Ring
Body Series
39
34 Double acting or spring
return piston actuator
Actuator Type Design
Series
3
Actuator Mounting
0. Undefined
*1. Parallel to pipe.
Air to open action.
*2. Parallel to pipe.
Air to close action.
3. Perpendicular to pipe.
Air to open action.
4. Perpendicular to pipe.
Air to close action.
5. Parallel to pipe.
Air to open action.
6. Parallel to pipe.
Air to close action.
7. Perpendicular to pipe.
Air to open action.
8. Perpendicular to pipe.
Air to close action.
* Standard Actuator
Mounting Arrangement

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 5
1.7 Operating Pressures
All Masoneilan HPBVs may be applied to full ANSI ratings.
However, different materials of construction may affect the
rated pressure. The shut-off pressure rating is determined by
the valve shaft and disc materials as well as the seat design,
and is reflected on the metal identification tag attached to the
valve.
1.8 Seat Alternatives
Masoneilan HPBVs have three alternatives, all of which are
bi-directional.
Soft Seats provide tight shut-off to zero leakage specifications.
Standard Soft Seat material includes virgin TFE or reinforced
TFE (RTFE).
Fire-Safe Seats are designed for critical piping applications
in installations such as Refinery and Petrochemical Plants.
These seats are a combination of both metal and soft seats
with the metal seat being designed to function during and after
a fire. Valves of this type are referred to as “Fire-Safe” and are
tested to meet API 607 “Fire-Safe” specifications and operation
criteria.
Metal Seats are well suited for higher temperature applications
and provide shut-off to ANSI B16.104 Class IV.
1.9 Offset Disc Design
All Masoneilan HPBVs have both off-set discs and eccentric
shafts. The off-set is applicable to the disc edge seating surface
relative to the shaft center line. By off-setting the seating
surface from the rotational center line, a contact with the seat
is possible throughout the 360° circumference. The shaft is
eccentric in the body by 0.060 inches and this enhances seat
life by imparting a camming action to the disc as it rotates both
in and out of the seat. Seat wear points are eliminated at the
top and bottom of the disc and operating torque is reduced.
Soft Seat
Profile
Fire-Safe
Seat Profile
Metal Seat
Profile
Figure 3
Figure 4
Figure 5
Figure 6

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 6
1.10 Seat Retainer Alternatives
Masoneilan HPBVs are designed to be easily maintained and,
in particular, to allow rapid and simple replacement of the seat.
The seat is held in the valve body by a seat retainer which,
Cap Screw Retainer
(The retainer is held to the valve body by cap screws recessed in the retainer face.)
Wedge Ring Retainer
(A wedge ring is forced outward into a groove machined in the body by the insertion of set screws in the face of the retainer.)
Figure 7
Figure 8
when assembled, becomes part of the raised face flange mating
surface. Two types of seat retainer fastening designs are used
in Masoneilan HPBVs.
Installation Recommendations
2.1 Valve Ratings
Masoneilan HPBVs are intended for use at the pressure and
temperatures indicated on the metal nameplate attached to
each individual valve. Check the valve operating temperature
and pressure ratings on the valve nameplate before proceeding
with installation.
2.2 Seat Upstream vs. Seat Downstream
Although all Masoneilan seat designs are completely
bi-directional, every effort should be made to install the valve
with pressure and flow from the seat side of the valve (seat
upstream). Positive shutoff will be achieved with the valve in
either orientation. However, installation with the seat in the
upstream position will result in longer service life and lower
torque values.

7
Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 7
2.3 Disc Clearances
Prior to installing the valve, it is important to make sure the ID of
the pipe and pipe flanges is large enough to allow the disc edge
to swing into the opening without interference. Damage to the
disc edge can severely affect the performance of the valve. Pipe
schedule compatibility for Masoneilan valves is shown in Section
1.5 of this manual.
2.4 Opening Rotation
The Masoneilan valve is designed to open with counterclockwise
rotation of the shaft, and to close with clockwise rotation of the
shaft when viewed from above with the shaft in the vertical
position. An overtravel stop is provided in the body to prevent
overtravel of the disc in the wrong direction. This stop is not to
be used as a disc position stop. Contact with this stop means
the disc has travelled past the seat.
2.5 Installation Position
To prevent damage during installation, the valve disc must be
fully closed before installing the valve in the line. It is preferable
to install HPBVs with the shaft horizontal. This is important for
valves applied to fluids which contain particulates. For HPBVs
16" and larger, installation should always be made with the shaft
in the horizontal position.
2.6 Valve and Flange Preparation
If the valve and mating pipe are properly prepared
for installation, future problems can be avoided. All valve and
pipe flange faces should be free of dirt, grit, indentations, or
surface irregularities which may disrupt flange sealing and cause
external leakage. The valve seat and disc sealing surface should
also be inspected to eliminate any dirt or foreign material that will
adversely affect the operation of the valve.
2.7 Installation Tools
The only tool required in the installation of a Masoneilan HPBV
is a wrench suitable for tightening the flange bolts and/or nuts
required to secure the valve in-line. A hoist may be required
for handling valves 10" and larger. Smaller sized valves can
usually be installed by hand. Temporary pipe supports may be
used to keep mating flange faces parallel in order to aid in valve
installation.
2.8 Required Bolting
The tables outlined on the following pages are furnished to
provide information regarding the size, type, and quantity
of bolting recommended for the installation of Masoneilan
HPBVs. These tables are intended for use as a planning and
procurement guide. All recommendations are based on pipe
flanges in accordance with ANSI B16.5 for 2" through 24" valves
and ANSI B16.47 Class A for valves 30" and larger. Flange
bolting is not included with the valve shipment.
2.9 Unpacking and Storage Instructions
1. Check the packing list against the valve received to verify
that the size, material, and trim are correct.
2. Check to make sure that the valve and operator were not
damaged during shipment.
3. When lifting the valve, take care to avoid damage to the
flange faces, disc sealing edge, or operator. On larger
valves, lifting holes are provided on the periphery of the
valve body to aid in valve handling.
4. If the valve is to be stored before being installed, it should
be protected from harsh environmental conditions.
5. Store the valve with the disc in the closed position to
protect the sealing edge and the seat.
6. Keep the valve in a clean location, away from dirt, debris
and corrosive materials.
7. Keep the valve in a dry area with the flange protectors
attached and on a suitable skid or pallet.
8. Keep the valve in a cool location if possible, out of direct
sunlight.
2.10 Pre-Installation Procedure
1. Remove the protective flange covers from the valve.
2. Inspect the valve to be certain the waterway is free from
dirt and foreign matter. Be certain the adjoining pipeline is
free from any foreign material such as rust and pipe scale or
welding slag that could damage the seat and disc sealing
surfaces.
3. Actuators should be mounted on the valve prior to
installation to facilitate proper alignment of the disc in the
valve seat.
4. The valve should be in the closed position. Make sure
the open and closed positions of the actuator correspond
to the counterclockwise to open direction of rotation of the
valve.
5. Cycle the valve to the fully open position, then back to
the fully closed position, checking the actuator travel stop
settings for proper disc alignment.
6. Check the valve identification tag for valve class, materials,
and operating pressure to be sure they are correct for the
application.
Personal injury or property damage may result if the valve
is installed where service conditions could exceed the valve
ratings.
7. Check the flange bolts or studs for proper size, threading
and length.
2.11 Valve Installation Procedure
The Masoneilan 39003 Series High Performance Butterfly Valve
can be installed in the pipeline with the shaft in the vertical,
horizontal, or other intermediate position. Based on applications
experience, however, in media with concentrations of solid or
abrasive particles or media subject to solidification buildup,
valve performance and service life will be enhanced by mounting
the valve with the shaft in the horizontal position.
All Masoneilan valves are bi-directional and can be mounted in
the pipeline in either flow direction; however, the preferred flow
direction for all seat styles and materials is with the seat retainer
ring located upstream to provide maximum seat protection.

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 8
1. For Wafer Style Valves:
A. Loosely install the lower flange bolts to form a cradle
between the flanges. (See Figure 9.)
B. Noting the flow direction arrow on the tag, place the valve
and flange gaskets between the flanges, making sure the
arrow on the tag points in the direction of the flow.
C. Install the remaining flange bolts, shifting the valves as
necessary to permit the bolts to pass by or through the
valve body.
Figure 9
For Lug Style Valves:
A. Noting the flow direction arrow on the tag, place the valve
between the flanges, making sure the arrow on the tag
points in the direction of the flow.
B. Install the lower flange bolts loosely, leaving space for the
flange gaskets.
C. After inserting the flange gaskets, install the remaining
bolts.
2. Using the sequence shown in Figure 10 tighten the flange
bolts evenly to assure uniform gasket compression.
The valve should be centered between the flanges and gaskets
to prevent damage to the disc edge and shaft as a result of the
disc striking the flange, gasket, or pipe.
Figure 10
3. If an actuator is to be used, air hoses or electricity should
be connected to the unit as specified.
4. The valve is now ready for operation.
Remember: Install the valve with the disc in the FULL
CLOSED POSITION.
2.12 Actuator Installation
1. Actuator Air Piping
The Model 33 actuator used with the High Performance Butterfly
Valve is designed to accept 1/4" NPT air supply piping. Use 1/4"
OD tubing or equivalent for all air lines. If the air line exceeds
25 ft. in length, or the valve is equipped with volume boosters,
3/8" tubing is preferred. All connections must be free of leaks.
Do not exceed loading pressure indicated on a warning tag
located on the upper diaphragm case.
2. Changing Actuator Position
For each valve action, air to open or air to close, the actuator
and bracket may be mounted in any one of four recommended
positions (see Figure 1). Actuator position is usually determined
by adjacent piping, obstacles of various types or piping
arrangements. Valves may be rotated 180° around the axis
of the shaft, if necessary. In such a case, no disassembly is
required, other than repositioning gauges so they are not upside
down. (However, note caution in Figure 1). Note also that the
preferred flow direction is reversed. If it becomes necessary to
rotate the actuator position 90°, partial disassembly is required.
Depending on whether the valve is or is not equipped with a
handwheel, select the appropriate section in this instruction and
proceed.
3. Changing Actuator Action
For the positions shown in Figure 1, the valve action is air to
open or air to close. In both cases the actuator stem extends
with admission of air to the actuator. Changing valve action
requires partial disassembly in repositioning the actuator to the
other hole in the bracket and reorientation of linkage. Refer to
Figures 19 and 20. If the valve is equipped with a handwheel, it
must be repositioned to the opposite side of the bracket.
Note: The handwheel is always installed so it operates
against the actuator spring force. The handwheel is
always located on the same side of the bracket as the
actuator (see Figures 19 and 20). Depending on whether
the valve is or is not equipped with a handwheel, select
the appropriate section on disassembly and proceed.

2.13 Bolting Dimensions
9
Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves
Class 150 2" – 24"
Class 150 30" – 48"
Lug Valves Wafer Valves
Studs & Nuts Machine Bolts Studs & Nuts
Valve
Size
Valve
Series
Thread
Size
Qty
C
Length
C
Qty
D
Length
D
Qty
F
Length
F
Qty
G
Length
G
Qty
E
Length
E
2" G 5
/8-11 4 2.50 4 2.50 4 1.63 4 1.63 4 5.50
3" G 5
/8-11 4 3.25 4 2.50 4 2.25 4 1.63 4 6.00
4" G 5
/8-11 8 3.00 8 2.75 8 2.12 8 1.88 8 6.00
6" G ¾-10 8 3.50 8 3.00 8 2.50 8 1.88 8 6.50
8" G ¾-10 8 3.75 8 3.25 8 2.70 8 2.13 8 7.00
10" G 7
/8-9 12 4.25 12 3.50 12 3.00 12 2.25 12 7.50
12" G 7
/8-9 12 4.75 12 3.50 12 3.45 12 2.35 12 8.50
14" G 1-8 12 5.00 12 4.00 12 3.75 12 2.70 12 9.50
16" G 1-8 16 5.50 16 4.25 16 4.12 16 2.75 16 10.00
18" G 11
/8-8 16 5.75 16 4.75 16 4.38 16 3.25 16 11.00
20"
G 11
/8-8 16 6.75 16 4.75 16 5.12 16 3.25 16 11.50
G 11
/8-8 4** 5.50 4** 4.75 4** 4.12 4** 3.25 4** 5.50
24" G 11
/8-8 20 7.25 20 5.75 20 5.63 20 4.25 20 13.00
30"
H 1¼-8 24 7.75 24 7.75 24 6.25 24 6.25 24 16.00
H 1¼-8 4** 6.50 4** 6.25 4** 5.00 4** 4.63 4** 6.50
36"
H 1½-8 28 9.50 28 9.50 28 7.75 28 7.75 28 19.50
H 1½-8 4** 7.50 4** 7.25 4** 5.75 4** 5.50 4** 7.50
42"
H 1½-8 32 10.00 32 10.00 32 8.50 32 8.25 32 20.50
H 1½-8 4** 8.25 4** 7.50 4** 6.50 4** 5.75 4** 8.25
48"
H 1½-8 40 11.75 40 11.00 40 9.88 40 9.25 40 23.00
H 1½-8 4** 9.00 4** 8.25 4** 7.12 4** 6.50 4** 9.00
Length of machine bolts based on:
1. Gasket thickness of 0.06 inches.
2. Minimum flange thickness of weld neck flanges per ANSI B16.5 and B16.47 Series A.
**Variation to specified bolting length may result in improper installation.
Every effort is made to provide accurate information, but no liability for claims arising from erroneous data will be accepted
by Dresser.

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 1010
ANSI Class 300 2" – 24"
MSS SP-44 Class 300 30"
Lug Valves Wafer
Valves
Bolt Engagement in Valve* Studs & Nuts Machine Bolts
Studs & Nuts
Valve
Size
Valve
Series
Thread
Size
Qty
A
Length
A
Qty
B
Length
B
Qty
C
Length
C
Qty
D
Length
D
Qty
F
Length
F
Qty
G
Length
G
Qty
E
Length
E
2" G
5
/8-11
8 .940 8 .570 8 2.25 8 2.62 8 1.50 8 2.00 8 5.25
3" G ¾-10 8 1.034 8 .826 8 3.00 8 3.00 8 2.12 81 2.00 8 6.00
4" G ¾-10 8 1.196 8 .870 8 3.50 8 3.25 8 2.50 8 2.00 8 6.50
6" G ¾-10 12 1.301 12 .929 12 3.75 12 3.50 12 2.75 12 2.25 12 7.00
8" G
7
/8-9
12 1.702 12 1.128 12 4.50 12 4.00 12 3.25 12 2.75 12 8.25
10" G 1-8 16 1.867 16 1.300 16 5.00 16 4.50 16 3.25 16 3.12 14 9.25
G 1-8 - - - - - - - - - - - - 4** 5.00
12" G
11
/8-8
16 2.057 16 1.475 16 5.50 16 5.00 16 4.00 16 3.38 12 10.00
G 11
/8-8
- - - - - - - - - - - - 8** 5.25
14" H
11
/8-8
16 2.442 16 2.118 16 6.00 16 5.75 16 4.62 16 4.25 16 11.50
H 11
/8-8
4** 1.608 4** 1.267 4** 5.25 4** 4.75 4** 3.75 4** 3.44 8** 5.25
16" H
1¼-8 16 2.562 16 2.628 16 6.50 16 6.50 16 4.88 16 4.88 16 13.00
H 1¼-8 4** 1.538 4** 1.588 4** 5.25 4** 5.25 4** 3.88 4** 4.25 8** 5.25
18" H
1¼-8 20 2.875 20 2.890 20 7.00 20 7.00 20 5.25 20 5.25 20 14.00
H 1¼-8 4** 1.675 4** 1.437 4** 5.50 4** 5.50 4** 4.00 4** 3.88 8** 5.50
20" H
1¼-8 20 3.184 20 3.006 20 7.50 20 7.25 20 5.69 20 5.69 20 14.50
H 1¼-8 4** 1.681 4** 1.750 4** 5.75 4** 5.50 4** 4.19 4** 4.00 8** 5.75
24" H
1½-8 20 3.560 20 3.510 20 8.25 20 8.25 20 6.31 20 6.25 20 16.50
H 1½-8 4** 1.800 4** 1.750 4** 6.25 4** 6.25 4** 4.56 4** 4.50 8** 6.25
30" H
1¾-8 24 4.331 24 4.429 24 10.25 24 10.50 24 7.88 24 7.88 24 20.50
H 1¾-8 4** 2.039 4** 2.071 4** 8.00 4** 8.00 4** 5.44 4** 5.47 8** 8.00
ANSI Class 600 3" – 14"
Lug Valves Wafer
Valves
Bolt Engagement in Valve* Studs & Nuts Machine Bolts
Studs & Nuts
Valve
Size
Valve
Series
Thread
Size
Qty
A
Length
A
Qty
B
Length
B
Qty
C
Length
C
Qty
D
Length
D
Qty
F
Length
F
Qty
G
Length
G
Qty
E
Length
E
3" G
¾-10 8 1.034 8 1.026 8 3.50 8 3.50 8 2.25 8 2.38 8 7.00
4" G
7
/8-9
8 1.274 8 1.165 8 3.50 8 3.25 8 2.75 8 2.75 8 7.75
6" G 1-8 12 1.274 12 1.306 12 4.75 12 4.75 12 3.25 12 3.25 12 9.50
8" G 11
/8-8
12 1.794 12 1.795 12 5.75 12 5.75 12 4.12 12 4.12 12 11.50
10" H
1¼-8 12 2.495 12 2.000 12 6.75 12 6.25 12 5.00 12 4.50 12 13.00
H 1¼-8 4** 1.375 4** 2.000 4** 5.50 4** 6.25 4** 3.88 4** 4.50 8** 6.25
12" H
1¼-8 16 2.683 16 2.697 16 7.00 16 7.00 16 5.38 16 5.38 16 14.00
H 1¼-8 4** 1.325 4** 1.765 4** 5.25 4** 6.00 4** 4.00 4** 4.38 8** 6.00
14" H
13
/8-8
16 2.994 16 2.996 16 7.50 16 7.50 16 CF 16 CF 16 15.00
H 13
/8-8
4** 1.506 4** 1.869 4** 6.00 4** 6.50 4** CF 4** CF 8** 6.50
*Bolt lengths “A” & “B” are from face of valve body to minimum depth in lug. Flange & gasket thickness must be added to calculate minimum bolt length.
**Special length required for tapped blind holes on either side of the valve shaft at the top and bottom ends of the valve body.
2.13 Bolting Dimensions (cont.)

1111
Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves
ANSI Class 600 3" – 14"
Lug Valves Wafer
Valves
Bolt Engagement in Valve* Studs & Nuts Machine Bolts
Studs & Nuts
Valve
Size
Valve
Series
Thread
Size
Qty
A
Length
A
Qty
B
Length
B
Qty
C
Length
C
Qty
D
Length
D
Qty
F
Length
F
Qty
G
Length
G
Qty
E
Length
E
3" G
¾-10 8 1.034 8 1.026 8 3.50 8 3.50 8 2.25 8 2.38 8 7.00
4" G
7
/8-9
8 1.274 8 1.165 8 3.50 8 3.25 8 2.75 8 2.75 8 7.75
6" G 1-8 12 1.274 12 1.306 12 4.75 12 4.75 12 3.25 12 3.25 12 9.50
8" G 11
/8-8
12 1.794 12 1.795 12 5.75 12 5.75 12 4.12 12 4.12 12 11.50
10" H
1¼-8 12 2.495 12 2.000 12 6.75 12 6.25 12 5.00 12 4.50 12 13.00
H 1¼-8 4** 1.375 4** 2.000 4** 5.50 4** 6.25 4** 3.88 4** 4.50 8** 6.25
12" H
1¼-8 16 2.683 16 2.697 16 7.00 16 7.00 16 5.38 16 5.38 16 14.00
H 1¼-8 4** 1.325 4** 1.765 4** 5.25 4** 6.00 4** 4.00 4** 4.38 8** 6.00
14" H
13
/8-8
16 2.994 16 2.996 16 7.50 16 7.50 16 CF 16 CF 16 15.00
H 13
/8-8
4** 1.506 4** 1.869 4** 6.00 4** 6.50 4** CF 4** CF 8** 6.50
Maintenance Instructions
3.1 Safety Precautions
Before removing the valve from the line or loosening any bolts,
it is important to verify the following conditions:
1. Be sure the line is depressurized and drained.
2. Be sure of the pipeline media. Proper care should be taken
for protection against toxic and/or flammable fluids.
3. Never install the valve without an Operator (Manual or
Automatic) already attached to the valve shaft.
4. Never remove the Operator from the valve while the valve is in
the pipeline under pressure. The eccentric valve design may
allow line pressure to open the valve if the handle/actuator is
not in place while the valve is under pressure.
5. Always be sure that the disc is in the full closed position
before removing or installing the valve.
6. Take care in handling the valve. Personal injury or property
damage may result if the valve is damaged or mishandled
during maintenance operations.
3.2 General Maintenance
Normal maintenance for a Masoneilan HPBV is limited to
adjustment of the shaft packing by tightening down evenly
on the gland flange using the gland flange studs and nuts.
Overtightening of the gland should be avoided since this will
shorten the life of the packing. During commissioning, it is
common for dirt and foreign objects to be left in the pipeline
during construction. This debris can damage the HPBV seat or
disc edge which will prevent the valve from providing tight shut-
off. In such cases seat replacement may be necessary.
3.3 Packing Replacement
1. Remove the handle or actuator and the mounting hardware
from the valve.
2. Remove the gland flange nuts and lockwashers.
3. Remove the gland flange and gland.
4. Replace the old packing with new packing. Correct
packing selection is important. On larger valves it may be
necessary to compress each stem seal into the stuffing box
before adding the next one.
5. Reinstall gland, gland flange, lockwashers and nuts.
6. Tighten the gland flange nuts evenly to torque specified in
Table 1.
7. Operate the disc several times.
8. Reinstall the handle or actuator and mounting hardware.
9. Set the actuator stops.
Table 1
Valve Size (in.) Torque (in.-lb.)
2 to 8 25
10 to 12 35
14 to 20 50
24 to 30 75
36 to 48 100
3.4 End Cap Seal Replacement
(where applicable)
1. Remove the end cap bolts and lockwashers.
2. Rotate the end cap to break the seal, then pull the cap out.
3. Remove the old seal.
4. Clean the body and end cap prior to installing the new seal.
5. Slide the new seal into place, then guide the end cap into
the body.
6. Align the bolt holes and reinstall the lockwashers and bolts.
7. Tighten the bolts evenly to the torque specified in Table 2.
Table 2
Valve Size (in.) Torque (in.-lb.)
2 to 8 50
10 to 12 80
14 to 30 100
3.5 Standard Soft Seat Replacement
1. Place the valve on a bench with the seat retainer facing up.
Use blocks to elevate the valve above the work surface to
provide enough clearance to prevent the disc from being
damaged when the valve is opened.
2. A. Cap Screw Retainer:
Remove the cap screws and lift the seat retainer out of
the valve.
B. Wedge Ring Retainer:
Unlock the retainer by removing the set screws. If
difficulty is experienced in removing the retainer, open
the disc approximately 20 degrees and then tap the
retainer with a non metallic hammer. Lift the retainer
from the body.
3. Remove the old seat from the seat retainer and discard.
4. Thoroughly clean the seat cavity in the body and the seat
retainer prior to installing a new seat.
5. Carefully clean and polish the disc sealing surface with a
soft cloth. The disc sealing surface should be free of all
grooves and scratches.
6. Place the seat retainer on a flat surface with the seat
locating area facing up.
7. Place the new preformed seat assembly (Seat and O-ring)
on the seat retainer with the marked (tape) side facing
down.
8. Using the balls of each thumb, press down on the seat
engaging the shoulder of the seat behind the lip in the
seat retainer. Stretch the seat into place by sliding each
thumb around the circumference of the seat maintaining
downward pressure and forcing the seat shoulder over the
seat retainer lip.

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 1212
9. With the disc in the closed position place the seat retainer
with seat into the counterbore of the body.
A. Cap Screw Retainer:
Apply lubricant to the cap screw threads and tighten
them down uniformly.
B. Wedge Ring Retainer:
Place the wedge ring in the groove on the outside
edge of the retainer taking care to position the wedge
ring gap away from any set screw. Using opposing
C-clamps, pull the retainer into a position flush with
body face. (The C-clamps should not block access to
the set screw holes.)
10. Open the disc and relax the retainer pressure slightly to
permit the seat to expand fully inward against the seat
retaining lip machined in the retainer and body seat
cavities. A positive “snap” action will be observed.
A. Cap Screw Retainer:
Leaving the valve disc open, retighten the cap screws
to the torques specified in Table 3.
B. Wedge Ring Retainer:
Leaving the valve disc open, retighten the C-clamps
and install the set screws. Remove the C-clamps after
all screws have been tightened.
11. Operate the disc several times and inspect the seat for
damage before reinstalling the valve in the pipeline.
12. Inspect the position of the disc in the closed position
to determine whether the actuator stops are adjusted
properly. The face of the disc should be parallel to the seat
retainer face when the valve is in the fully closed position.
Table 3
Valve Size (in.) Torque (in.-lb.)
2 to 12 50
14 to 20 75
24 to 48 100
3.6 Fire-Safe and Metal Seat Replacement
1. Follow Steps 1 and 2 of Soft Seat Replacement instructions.
2. Remove old soft seat and graphite gaskets and discard.
Clean and inspect the metal seat.
3. If metal seat is scored, bent or otherwise damaged it will
require replacement.
4. Thoroughly clean the seat cavity in the body and the seat
retainer prior to installing the new seat.
5. Carefully clean and polish the disc edge sealing surface
with a soft cloth. The disc sealing surface should be free of
all grooves and scratches.
6. A graphite gasket is required on both sides of the metal
seat. Gaskets can be made from self-adhesive graphite
tape as follows:
A. Suggested graphite tape size:
2" – 12" valves – 1/2" wide
14" – 48" valves – 1" wide
B. To install the tape, peel off 6" of backing paper at a
time. Apply the tape to the metal seat covering the flat
outer edge area on both sides. Overlap the two ends
of the tape a minimum of 1/8 inch.
Note: It is important that both sides have gaskets.
C. Smooth tape as much as possible by hand. Slight
roughness is acceptable and will be pressed flat
during final assembly. Avoid tearing tape. If a tear
occurs, tape should be overlapped a minimum of 1/8
inch. Trim excess tape from outside diameter of the
seat.
D. If cap screw retainer design, bolt holes in metal seat
should be opened by slitting an “X” in the hole. Do not
attempt to cut round holes.
7. For Fire-Safe valves, place the preformed seat assembly
in the body seat cavity with the marked (tape) side up. For
metal seated valves, place the 316SS back-up ring in the
body seat cavity.
8. Place the metal seat with the graphite gaskets on the TFE
Figure 11

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 13
seat or 316SS back-up ring already in the body. The metal
seat should be installed with the rounded edge down
against the TFE seat or the 316SS back-up ring.
9. Follow steps 9 thru 12 of Soft Seat Replacement
instructions.
3.7 Disc, Shaft and Bearing Replacement
Figure 12
Masoneilan uses a wedge pin method of disc/shaft pinning. This
method permits the replacement of either a disc or a shaft since
they are not required to be matched sets.
1. Remove any actuator and mounting bracket from top of
valve.
2. Remove all top and bottom packing and/or end seals as
required.
3. To prepare for removal of existing wedge pins, grind away
any disc material that has been peened over pin heads.
4. A. For Through Shaft Design:
Using a punch approximately the same size as the
wedge pins, drive each pin out of the disc hub from
the non-peened side of the disc to the peened side of
the disc.
B. For Split Shaft Design:
Pull the wedge pins out of the disc hub using the
threaded holes on top of each pin and a jack screw.
5. Support the valve body and disc on a flat surface in
the horizontal position. Slowly remove shaft(s).
6. Remove the disc from the body.
7. To remove bearings, cut or grind a slot lengthwise in
each bearing in order to be able to collapse bearing
prior to removal. Be careful not to damage bearing
seating bore within the body.
8. Clean all components thoroughly.
9. Inspect all parts for damage prior to reassembly. Damaged
parts should be repaired or replaced with new parts.
10. Carefully clean and polish the disc sealing surface with a
soft cloth. The disc sealing surface should be free of all
grooves and scratches.
11. Install the new bearings by gently tapping them into the
body with a soft rod and hammer. The bearings should be
installed into the shaft bore firmly against the counterbore
or bottom of shaft hole.
A. Valves 2" thru 12":
With the valve body on edge on the bench, shaft
horizontal, and the body overtravel stop nearest to the
bench, position the disc in the open position with the flat
face upward. Present the disc to the valve body from
the side opposite the seat retainer cavity.
B. Valves 14" and larger:
Support the disc on a bench, flat side down and elevated
above the bench top to a height of approximately 4
inches. Lower the valve body over the disc, seat retainer
side facing upward, until the bearing bore and disc hole
are aligned. Install the shaft into the body and disc.
13. The shaft keyway when viewed from the top of the valve
should be to the right, which is also the direction from
which the pins are installed.
14. Line up the shaft flat to permit the insertion of the wedge
pins. Install the first wedge pin in the disc hole closest to
the top of the valve. Fingertight installation is appropriate.
15. Move the shaft fully into the valve and against this first
installed pin. Insert the second pin. Tap both wedge pins
in equal amounts until all play between shaft and disc is
removed. Care should be taken not to attempt to over seat
the wedge pins. If the pin is flush or protruding after tapping
in, tack weld on the opposite side for security. Otherwise,
peening of the installing side is recommended.
16. Install a new end seal if applicable with the end cap as
described in Steps 4 through 7 of the End Cap Seal
Replacement procedure.
17. Install new packing box components as described in Steps
4 through 10 of the Packing Replacement procedure.
18. Install new seat as described in the Seat Replacement
procedure.
19. Cycle the valve several times to ensure the disc is pinned
tightly to the shaft and there is no shaft binding or seat
damage before reinstalling the valve in the pipeline.
20. Reinstall the actuator mounting hardware and actuator.
21. Set the actuator stops.

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 14
3.8 Valve Parts List
• Recommended Spare Parts
Item Description
1 Body
2 Seat Retainer
•3 Disc
•4 Shaft
•5 Seat
•6 Seat O-ring
•7 Bearing
•8 Packing
9 Gland
10 Gland Follower
11 End Cap
12 End Cap Bolts
13 Set Screws
14 Wedge Pins
15 Gland Flange Stud
16 Gland Flange Nut
17 Lockwasher
18 Wedge Ring
• 19 End Cap Seal
Through Shaft Design
Item Description
1 Body
2 Seat Retainer
•3 Disc
•4 Shaft
•5 Seat
•6 Seat O-ring
•7 Bearing
•8 Packing
9 Gland
10 Gland Follower
11 Disc Thrust Spacer
(2"-5")
12 Set Screws
13 Wedge Pins
14 Gland Flange Stud
15 Gland Flange Nut
16 Lockwasher
17 Wedge Ring
Split Shaft Design

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 15
3.9 Remote Actuator (Male Drive) Mounting
Procedure
1. Position the disc in the closed position.
2. Install the actuator mounting bracket on the valve body
with the actuator mounting holes facing upward. Fasten
the bracket securely in place with the appropriate machine
bolts and lockwashers. Tighten to torque specified in Table
4.
3. Install the drivekey in the keyway of the shaft. Tap the key
in place to ensure it is fully seated.
4. Install the drive coupling on the shaft by lining up the proper
keyway in the coupling with the key in the shaft.
5. Rotate the actuator shaft to the full clockwise position. Align
the drive coupling with the actuator shaft and install the
actuator on the mounting bracket.
6. Fasten the actuator to the mounting bracket with the
appropriate machine bolts and lockwashers. Tighten to
torque specified in Table 4. It may be necessary to slightly
rotate the actuator shaft to align the mounting holes in the
actuator with the mounting bracket.
7. Adjust the stops in the actuator to position the face of the
disc parallel with the face of the valve body in the closed
position and perpendicular to the face of the valve body in
the open position.
The overtravel stop in the valve body is not to be used as an
actuator stop.
Changing the Quadrant:
If it is necessary to rotate the actuator 90° from standard
position, complete the following steps:
1. Close the valve.
2. Remove the bolts and lockwashers holding the actuator
to the mounting bracket. Lift the actuator off the mounting
bracket.
3. Remove the drive coupling from the valve shaft and rotate
it 90° to the adjacent keyway.
4. Reinstall the drive coupling on the valve shaft.
5. Align the drive coupling with the actuator shaft and install
the actuator on the mounting bracket.
6. Reinstall the bolts and lockwashers to fasten the actuator
to the mounting bracket. Tighten to torque specified in
Table 4.
7. Adjust the actuator stops as described above.
If it is necessary to rotate the actuator 180° from standard
position, complete the following steps:
1. Close the valve.
2. Remove the bolts and lockwashers holding the actuator to
the mounting bracket.
3. Lift the actuator off the mounting bracket. Rotate the
actuator 180°.
4. Align the drive coupling with the actuator shaft and install
the actuator on the mounting bracket.
5. Reinstall the bolts and lockwashers to fasten the actuator
to the mounting bracket. Tighten to torque specified in
Table 4.
6. Adjust the actuator stops as described previously.
3.10 Remote Actuator (Female Drive) Mounting
Procedure
1. Position the disc in the closed position.
2. Install the actuator mounting bracket on the valve body with
the actuator mounting holes facing up. Fasten the bracket
securely in place with the appropriate machine bolts and
lockwashers.
3. Install the drive key in the shaft. Tap the key in place to
ensure it is fully seated.
4. Install the drive coupling on the shaft by lining up the proper
coupling keyway with the key in the shaft.
5. Install the drive key in the drive coupling. Tap the key in
place to ensure it is properly seated.
6. Rotate the actuator to the full clockwise position. Align
the keyway in the actuator bore with the key in the drive
coupling and slide the actuator on the drive coupling.
7. Fasten the actuator to the mounting bracket with the
appropriate machine bolts and lockwashers. It may be
necessary to rotate the actuator slightly to align the
actuator with the mounting bracket. Tighten to torque
specified in Table 4.
8. Adjust the stops in the actuator to position the face of the
disc parallel with the face of the valve body in the closed
position and perpendicular to the face of the valve body in
the open position.
The overtravel stop in the valve body is not to be used as an
actuator stop.
Changing the Quadrant:
If it is necessary to rotate the actuator 90° from standard
position complete the following steps:
1. Close the valve.
2. Remove the bolts and lockwashers holding the actuator to
the mounting bracket.
3. Lift the actuator off the mounting bracket.
4. Remove the key from the drive coupling and reinstall in the
adjacent keyway 90° away. Tap the key in place to ensure
it is fully seated.
5. Align the keyway in the actuator bore with the key in
the drive coupling and slide the actuator onto the drive
coupling.
6. Reinstall the bolts and lockwashers to fasten the actuator
to the mounting bracket. Tighten to torque specified in
Table 4.
7. Adjust the actuator stops as described previously.

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 16
If it is necessary to rotate the actuator 180° from its standard
position, complete the following steps:
1. Close the valve.
2. Remove the bolts and lockwashers holding the actuator to
the mounting bracket.
3. Lift the actuator off the mounting bracket.
4. Remove the drive coupling from the valve shaft and rotate
it 90°.
5. Reinstall the drive coupling on the valve shaft.
6. Remove the key from the drive coupling and reinstall the
key in the adjacent keyway 90° away. Tap the key in place
to ensure it is fully seated.
7. Align the keyway in the actuator bore with the key in
the drive coupling and slide the actuator onto the drive
coupling.
8. Reinstall the bolts and lockwashers to fasten the actuator
to the mounting bracket. Tighten to torque specified in
Table 4.
9. Adjust the actuator stops as described previously.
Actuator Maintenance
Refer to Section 3.11 for Model 33 installation and maintenance
instructions. For other actuators, refer to specific manufacturers
installation and maintenance manuals.
Table 4
Fastener Tightening Torque
Fastener
Thread Size
Required
Torque (ft.-lb.)
¼"-20 UNC 3
5/16"-18 UNC 5.5
3/8"-16 UNC 10
½"-13 UNC 24
9/16"-12 UNC 35
5
/8"-11 UNC 48.5
¾"-10 UNC 87
7
/8"-9 UNC 140.5
1"-8 UNC 211
11
/8"-8 UN 276
1¼"-8 UN 392
13
/8"-8 UN 536
1½"-8 UN 734
3.11 33 Actuator Maintenance
This section addresses the complete disassembly of the Model
33 Spring Diaphragm Actuator in order to gain access for repair
or replacement of components. If only partial disassembly is
required, such as when changing valve action, refer only to the
appropriate section. It is highly recommended that the unit be
removed from the line to perform maintenance.
1. Actuator Removal
When working on air to close units, be certain that the disc is not
jammed in the closed position with the actuator spring exerting
force to open the valve. In such a case, while disassembling, the
disc could suddenly snap open possibly causing injury. When
the actuator stem is fully extended, the spring is exerting force
in the opposite direction. If the disc is jammed closed, on an
air to close unit, use external air pressure to hold the actuator
in a closed position and complete the necessary steps in this
section to disconnect the pivot pin (5), then release air pressure
from the actuator, ensuring rod and bearing (71) separates from
lever (14) and actuator stem (54) fully retracts.
A. If equipped with a handwheel, it must be rotated to the
disengaged position.
B. Remove positioner and air piping to upper diaphragm
case (61).
C. Remove side covers (38), front cover (6) and bottom
cover (41).
D. Ensure actuator stem is fully retracted (see caution
above).
E. Remove retaining rings (4), pivot pin (5) and spacers (3).
Note: The spacers (3) are only used on units equipped
with the handwheel.
F. Remove the hex nuts (52) and lock washers (53) and lift
actuator from bracket.
2. Actuator Disassembly
The upper diaphragm case (61) is under spring tension. A
warning tag (74) is attached to each of three long tension
bolts (72). The tension nuts (73) attached to the tension bolts
(72) must be removed evenly, and must also be the last items
disassembled. The following procedure must be followed to
avoid injury.
A. Loosen and remove all short cap screws (63) and hex
nuts (64).
B. Loosen each tension nut (73) approximately three full
turns.
The upper diaphragm case (61) should separate as the
tension nuts are loosened the three turns. If it does not,
before proceeding, separate the upper diaphragm case
(61) by tapping around the circumference or inserting a
screwdriver between the upper and lower case (61) and
(68).
C. Continue loosening the tension nuts (73) evenly
(approximately three turns each time) ensuring that
the upper diaphragm case (61) and diaphragm (62)
continue to separate.
Note: Continue Step C until the tension nuts (73)
can be easily removed by hand indicating the upper
diaphragm case (61) is not under spring tension.

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 17
D. Remove tension bolts (72) and upper diaphragm case
(61).
E. Remove diaphragm/diaphragm plate subassembly from
the actuator.
F. Remove retaining clips (57) and push out pin (56).
Inspect for damage and/or wear in clevis (55), lever (14),
clevis pins (56, 5) and rod end bearing (71). Replace if
necessary.
3. Handwheel Removal
A. Rotate handwheel to the disengaged position.
B. Remove bottom cover (41).
C. Remove retaining clips (21) and clevis pin (20).
D. Loosen and remove cap screws (24), lock washers (25)
and remove handwheel and bracket subassembly.
4. Handwheel Disassembly
A. Remove pivot pin (26) and remove bracket (23).
B. Remove handwheel subassembly from shaft (22).
C. Remove handwheel shaft subassembly (59). Remove
retaining ring (28) then loosen and remove locknut (51).
D. Remove bearing brace (31) and bearing (30).
E. Remove handwheel pivot (27), O-ring (32) and thrust
washer (29).
F. Refer to Section 3.13 for reassembly.
5. Body Removal
A. Refer to Section 1 (Actuator Removal) and complete
Steps A through E.
B. If the unit is equipped with a handwheel, refer to Section
3 (Handwheel Removal) and complete Steps A through
D.
C. Loosen indicator arm (2) by loosening clamp screw (13)
and nut (50).
Note: At this time, using ink or a small dab of paint,
mark the relative position of the shaft to the lever (14)
or mark a line on the lever in line with the slot in the
end of the shaft. During reassembly these marks will
be used to simplify alignment of the lever on the shaft.
D. Loosen lever cap screw (15).
E. Remove nuts (46), washers (45) and bracket bolts (44),
then remove bolts (43).
F. Remove set screw (81) from coupling (79).
G. Separate body subassembly and yoke (10) from bracket
(1).
Slide shaft (77) out of yoke.
3.12 Actuator Diaphragm Replacement
The upper diaphragm case (61) is under spring tension. A
warning tag (74) is attached to each of three long tension
bolts (72). The tension nuts (73) attached to the tension bolts
(72) must be removed evenly, and must also be the last items
disassembled. The following procedure must be followed to
avoid injury.
1. Isolate the valve, vent process pressure and shut off all
electrical signal air and supply lines to the valve.
2. If equipped with a handwheel it must be rotated to the
disengaged position.
3. Remove air supply piping to upper diaphragm case (61).
4. Remove side covers (38).
5. Verify actuator stem (54) and rod end (71) are securely
connected to lever (14) through pivot pin (5) and retaining
clips (4) are in place.
6. Loosen and remove all short cap screws (63) and hex nuts
(64) in a criss-cross pattern.
7. Loosen each tension nut (73) approximately three full turns.
The upper diaphragm case (61) should separate as the
tension nuts are loosened the three turns. If it does not,
before proceeding, separate the upper diaphragm case
(61) by tapping it around the circumference or inserting a
screwdriver between the upper and lower case (61-68).
8. Continue loosening the tension nuts (73) evenly,
approximately three turns each time and ensuring the
upper diaphragm case (61) and diaphragm (62) continue
to separate.
Note: Continue Step 8 until the tension nuts (73) can be
easily removed by hand, which indicates that the upper
diaphragm case (61) is no longer under spring tension.
8. Remove tension bolts (72) and upper diaphragm case (61).
9. Remove diaphragm.
10. Clean all mating/sealing surfaces which will come in
contact, diaphragm (62), and diaphragm plate (65).
11. Install diaphragm (62) on diaphragm plate (65). Align bolt
holes with holes in lower case (68).
12. Determine correct orientation for air inlet and replace upper
diaphragm case (61).
13. Install three tension bolts (72) with warning plates (74) into
upper case (61). Ensure bolts are spaced at 120° to each
other.
14. Mount upper case (61) on diaphragm plate (65) such that
tension bolts pass through holes in diaphragm (62) and
lower case (68).
15. Install tension nuts (73) finger tight onto tension bolts (72).
16. Tighten each tension nut (73) three turns before proceeding

Instructions EM39003 - 05/10
39003 Series High Performance Butterfly Valves 18
to the next to ensure actuator spring (67) 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. lb.
17. Install cap screws (63) and nuts (64). Torque tighten to 50
in. lb. in a criss-cross pattern. As this will tend to unload the
tension bolts (72) repeat torque tightening of tension bolts
and cap screws (63) to 50 in. lb. in a criss-cross pattern
until joint is evenly loaded to specified torque values.
18. Reconnect air supply.
19. Stroke actuator to confirm operation.
3.13 33 Actuator Reassembly
1. Actuator Reassembly
A. Replace spring (67) into lower diaphragm case (68).
B. Replace locknut (70) on rod end bearing (71) and screw
rod end bearing into actuator stem (54).
C. Replace actuator stem (54) into clevis (55).
D. Replace clevis pin (56) and secure with cap screws (58).
Install clevis pin (56) and clips (57).
E. Refer to Section 3.12 and complete Steps 12 through 20.
2. Reassembly of Yoke and Bracket to Valve
A. Install ball bearing (9) into yoke (10).
B. Mount intermediate bracket (1) to yoke (10) with
bolts (44), nuts (46), and lockwashers (45). Tighten to
appropriate torque value per Table 4.
C. Install bearing (76) into yoke (if applicable).
D. Determine the required actuator action (air to close or
air to open). Refer to the proper figure (Figure 19 to
open, Figure 20 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. The distance between the top of the
yoke and the top of the pivot pin must be as shown. If
the valve is equipped with a handwheel, proceed to step
E. Slide shaft (77) through intermediate bracket (item 1
of Figure 15) and partially into yoke (1). With other hand,
hold lever (14) and align with the shaft (77) in the desired
orientation, slide shaft through lever.
E. If the valve is equipped with a handwheel, the lever
consists of two separate arms that are a matched pair
and the handwheel lever (refer to view c-c of Figure
17). Slide shaft (77) through intermediate bracket (item
1 of Figure 15) and partially into yoke. The sequence
of assembly is to place one lever (item 4 of Figure 17)
over the shaft (77) in the correct orientation (per Step
D). Slide handwheel lever arm (18) onto shaft. Insert pin
(17) and slide second lever arm over shaft in the same
orientation as the first lever.
F. Slide indicator (item 2 as indicated in Figure 15) loosely
over top of shaft (do not tighten clamp screw at this
time). Then continue to slide shaft into yoke until step
on shaft (77) contacts ball bearing (9) (as indicated in
Figure 15).
G. Install woodruff key (80) in shaft (77). Align key (80) in
shaft (77) with keyway in coupling then slide coupling
onto shaft (77).
H. Install key into valve shaft.
I. Move valve to closed position. Rotate valve to required
orientation, slide valve shaft through intermediate
bracket. Aligning keyway in coupling with valve key,
slide valve shaft into coupling (79). Tighten set screw
(81).
J. Connect valve body to bracket using cap screws (43)
and lockwashers. Tighten to appropriate torque value
per Table 4.
3. Reassembly of Actuator to Yoke
With the valve body assembled to the bracket, determine action
desired and proceed as follows:
A. Ensure stop (69) is in place in the actuator.
B. Replace the actuator on the bracket in the appropriate
hole for desired action and ensure that the rod end
bearing (71) is straddled by the lever (14) (or levers if
handwheel is supplied).
C. Replace lock washers (53), hex nuts (52) and tighten
securely per torque value in Table 4.
D. Rotate the disc to the fully closed position.
E. Depending on the valve action (air to close or air to
open), proceed to the appropriate following section for
final adjustment.
4. Air to Close
A. Rotate the disc to fully closed position.
B. Attach a temporary air supply line to the actuator and
apply 20 psi of air pressure ensuring that when the rod
end bearing (71) extends, it is straddled by the lever (14)
(or levers if handwheel is supplied).
C. Align the hole in the rod end bearing (71) with the hole
in the lever (14) by rotating the actuator stem (54) in the
proper direction.
D. Install pivot pin (5) and retaining rings (4).
Note: If the unit is equipped with a handwheel,
spacers (3) must be installed on each side of the rod
end bearing (71).
E. Tighten hex nut (70) against the actuator stem (54).
F. Ensure lever (14) is vertically aligned with the rod end
bearing and stem assembly and tighten lever cap screw
(15).
Note: On units equipped with a handwheel, ensure
both levers are as close together as possible and
in vertical alignment with the rod end bearing and
actuator stem, then tighten cap screws (15).
G. With 20 psi of air pressure still on the actuator, rotate the
actuator stem (54) to back off the disc so that the flat
face of the disc is parallel to the face of the retaining ring.
H. Relieve air pressure and remove temporary air line.
I. Replace front cover (6).
J. Rotate the indicator arm (2) to indicate open position