Flowserve F39 User Manual

Series F39 Pneumatic Actuator - WCENIM2036-00 05/15

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USER INSTRUCTIONS

Worcester Controls/McCANNA Series F39 Pneumatic Actuator

FCD WCENIM2036-00 05/15

Installation

Operation

Maintenance

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Series F39 Pneumatic Actuator - WCENIM2036-00 05/15

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STOP!

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Contents

Page
1 Safety 2
2 Description 2
3 Installation 3
4 Air supply and electrical installation 5
5 Air Consumption 5
6 Electrical Supply (models with integral solenoid only) 6
7 Installation of accessories 6
8 Operation 6

8.1 Basic Actuator – (N Model) 6

8.2 Actuator With Factory-Supplied Solenoid 6

8.3 Standard Stroke Times 7

8.4 Manual Operation 7
9 Maintenance 8
10 Spare Parts 8
11 Troubleshooting 8

12 Rebuilding instructions 9

12.1 Actuator disassembly 9

12.2 Actuator reassembly 11
13 Spring-return actuator 13

14 Size 05 Exploded view/parts/materials 14

15 Size 10-50 Exploded view/parts/materials 15

1

SAFETY

The safety terms DANGER, WARNING, CAUTION and

NOTE are used in these instructions to highlight partic­ular dangers and/or to provide additional information on
aspects that may not be readily apparent.

DANGER: indicates that death, severe personal injury and / or

substantial property damage will occur if proper precautions
are not taken.

WARNING: indicates that death, severe personal injury

and / or substantial property damage can occur if proper
precautions are not taken.

CAUTION: indicates that minor personal injury and / or

property damage can occur if proper precautions are not
taken.

NOTE: indicates and provides additional technical infor-

mation, which may not be very obvious even to qualified
personnel. Compliance with other, not particularly empha­sised notes, with regard to transport, assembly, operation
and maintenance and with regard to technical documentation
(e.g. in the operating instruction, product documentation or
on the product itself) is essential, in order to avoid mistakes,
which, in themselves, might directly or indirectly cause
severe personal injury or property damage.

2

2 DESCRIPTION

Worcester Controls/McCANNA Series F39 actuators

are pneumatic quarter-turn valve actuators. The design
utilizes a double-rack, single pinion concept, with each
rack integrally cast to a piston. On sizes 10-50, both
pistons are supported and centered by large, stainless
steel guide rods that are also used to control the rotation
of actuator via externally mounted stroke adjustment
screws. In double-acting units, both pistons are pressur­ized on both strokes of the actuator.

Standard units feature an extended top shaft for manual

override capabilities and a completely modular design
which allows simple attachment of a variety of accesso­ries. All units allow the direct mounting a solenoid control
block which properly directs supply air to the actuator.
On double-acting actuators, the solenoid control block
provides independently adjustable speed control for both
opening and closing strokes of the actuator. On spring-re­turn actuators only the spring stroke is adjustable.

WARNING:

devices subject to normal wear and tear. Actuator life is
dependent upon application and environmental condi­tions. If applied in hazardous services such as, but not
limited to, media temperature extremes, toxins, flamma-

series F39 actuators are electro-mechanical

Series F39 Pneumatic Actuator - WCENIM2036-00 05/15

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bles, or other services where improper or incomplete
operation could produce a safety hazard, it is incumbent
upon the system designer and the user to provide proper
warning devices such as temperature sensors, oxygen
sensors and flow sensors. Flowserve also recommends
that the optional auxiliary limit switches be used for
monitoring and/or electrical interlock.

CAUTION: When actuator is installed in outdoor
conditions, water can enter the exhaust holes of the
double-acting solenoid block, and then freeze. Flowserve
suggests a cover be used, or mount the actuator such
that the solenoid block is upside down.

Do not install F39S (spring-return) models with air

connection in end cap or with integral solenoid vertical,
without proper precautions to eliminate the ingress of
water spray or rainfall. Exposed end cap or solenoid vent
port will allow water to accumulate in spring chambers.

Flowserve recommends that all products which must

be stored prior to installation be stored indoors, in an
environment suitable for human occupancy. Do not store
product in areas where exposure to relative humidity
above 85%, acid or alkali fumes, radiation above normal
background, ultraviolet light, or temperatures above 120
°F or below 40 °F may occur. Do not store within 50 feet
of any source of ozone.

3.3 Attach mounting bracket to actuator using four (4) cap
screws and lock washers provided in mounting kit. To
avoid any damage to the Series F39 actuator body, ONLY
the proper length screws supplied with the mounting kit
should be used. For small size top mount style valves,
attach bracket such that bracket nameplate will be to side
of valve.

3.4 For mounting to 818/828 Series valves, insert ISO locating
ring into groove on bottom of actuator before attaching
to bracket. Ring can be permanently held in groove by
applying Loctite® 638 to ring before inserting in groove.

NOTE:

Size 05F39, if furnished with factory solenoid, shall
be “cross-line” mounted (i.e. at 90 degrees to the pipe
run) to ensure adequate clearance for air connections.

3.5 Prepare valve for actuation:

CAUTION: Ball valves can trap pressurized media in the

cavity. If it is necessary to remove any valve body bolts,
stem nuts, or remove valve from the line, and if the valve
is or has been in operation, make sure there is NO pres­sure to or in the valve and operate valve one full cycle.

3.5.1 Valve models 45 (2½”–6”), 59 (2”–4”), 51/52 (½”–10”),
151/301 (3”–6”), 82/83 (½”–10”), 818/828 (2”–8”), 94
(½”–6”), 44 (¼”–2”), 59 (¼”–1½”), WK70/WK74 and
H71 (½”–2”):

NOTE:

included in all F39 actuator accessory and Repair
kits is a rebuild/accessory addition label, which is to be
marked with a permanent marker and then applied to the
actuator after an accessory kit has been installed or an
actuator has been repaired.

3 INSTALLATION

NOTE:

Sizes 10-35 Rev. R7 actuators may come with an ISO

Size 40-50 Rev. R7 actuators have an integral ISO loca-

3.1 Determine mode of operation desired (normally open or

3.2 Determine desired quadrant for bracket attachment and

The Series F39 actuator is normally installed with
its major axis parallel to the pipe line (this is mandatory
when mounting actuator to 90° V1 Diverter/Three-Way
(D44 and T44) valves and CPT valves. The actuator can
be oriented above, beside or beneath the valve without
affecting its operation.

locating ring, used for optional ISO mounting.

tion ring.

normally closed) of the valve.

direction of mounting of actuator (in-line or cross-line).

NOTE:

For above listed valves, it is not necessary to
remove any valve body bolts or remove valve from line in
order to mount actuator.

3.5.2 Rotate valve ball and stem to position necessary to
achieve desired operation. If any valve information is
marked on stop plate or handle, it will be necessary to
transfer this information to the bracket nameplate.

3.5.3 For ¼”–2” 44, ½”–2” WK70/WK74, ¼”–1½” 59, and
½”–1½” H71 series top-mount style valves, and ½”–2”
51/52, ½”–1½” 82/83 series valves with high-cycle stem
packing as standard, remove handle nut, lockwasher,
handle, separate stop plate (if any), retaining nut and
stop pin(s). Add the two additional Belleville washers with
their larger diameter sides touching each other. Add the
self-locking nut to the stem and tighten while holding the
stem flats with wrench. Tighten until Belleville washers
are flat — the nut will “bottom” — and then back nut off
1/3 of a turn. The two additional Belleville washers and
the self-locking nut are included in the mounting kit.

CAUTION: Due to the design of the self-locking stem

nut, resistance will be felt as it threads onto the stem
assembly. Ensure the Belleville washers are fully flattened
before backing off.

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3.5.4 For 2” 59, H71, 82/83, and 2½” 45, 82/83 valves, and
valves 3” and larger with square stem, remove handle
assembly, retaining nut, stop and stop screws. Replace
with valve stem spacer or, if valve has graphite stem
packing, with two Belleville washers (except 8”,10” 82/83
and 10” 51/52), and replace retaining nut.

NOTE:

Belleville washers are installed with their larger
diameter sides touching each other. Do not use stem
spacer when Belleville washers are used. Using a wrench
to prevent stem from turning, tighten retaining nut until
stem packing is fully compressed or Bellevilles, if used,
are fully flattened, then back off nut 1/6 turn. Excessive
tightening causes higher torque and shorter seal life.

NOTE:

Large valves with V51 high-cycle stem packing
option installed, identified by two Belleville washers
installed and handle assembly, stop and stop screws
removed, and 818/828 series valves, do not require stem
area disassembly.

3.5.5 For 2”–8” 818/828 valves, remove handle assembly,
locking plates and hardware, and stop screw (if any). Do
not remove stop plate (2”–6” sizes) or spacer (8” size).

3.5.6 For ½”–2” 94 valves, remove handle (if any). Do not
remove gland plate or gland bolts.

3.5.7 For 3”–6” 94 and 2”–8” E818/828 valves, remove handle
assembly, stop, and spacer (if any). Do not remove gland
plate or gland bolts.

• Fail Open or Fail Close - The normal method of mounting
is to have the actuator in line with the pipe line and the
valve and actuator in the “FAIL-CLOSED” (Clockwise to
close) position. “FAIL-OPEN” can be achieved using
the method above but the actuator will then work
as Clockwise to open).

• For “FAIL-OPEN” but with Clockwise to close opera­ tion, the pistons in the actuator will need to be removed
and reassembled from the opposite ends of the
actuator (keeping the guide rods the same sides
relative to the body). This will result in a slight offset
of pinion position on some sizes. See below:

Position of pinion

Inlet support rod
(with cross hole)

Label

Label

flats and groove
(60º approx.)

Foolproof pin

location holes

Bores containing

bearings only

Label

Blank support rod

(without cross hole)

3.6 Attach bracket/actuator assembly to valve as follows:

3.6.1 Center coupling on valve stem.

3.6.2 Lower mounting bracket/actuator assembly over coupling
and onto valve, making sure that female star drive actu­ator shaft engages in the correct orientation with the
coupling.

3.6.3 Secure bracket to valve using cap screws and lock­washers, or bolts and nuts provided in mounting kit.
Tighten securely. For small size top-mount style valves,
bracket nameplate will be to side of valve.

3.6.4 Install set screws (if any) in coupling and tighten securely.

3.6.5 Determine if mode of operation (air to open or close/fail
open or closed) is as desired; if not:

• Air to Open or Close - On all sizes of F39 double-acting
and spring-return actuators, the female drive shaft
is a star drive. This allows selection of either mode of
operation by indexing the coupling (including valve ball
and stem) 90° to the actuator shaft, while keeping the
actuator in an in-line orientation.

Actuator

Size

#

Bores containing

bearings and

0-rings

Foolproof pin

Pinion Offset

Angle #

Inlet

End Cap End Cap

Inlet port

Foolproof pin

Limit Stop

05 0°
10 10°
15 2°
20 2°
25 2°
30 2°
33 2°
35 2°
40 0°
42 0°
45 0°
50 12°

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3.6.6 Determine position indication. Buttons on position indi­cator are set up to show valve closed on in-line mounting,
i.e., pistons together on actuator. If different indication is
required:

• Check which visual indication is required.

• Check that indicator, when located on actuator shaft,
will show correct indication.

• To change indication, on size 10 to 20 push out
(remove) red and white buttons and reassemble in
opposite positions. For sizes 25 and above remove the

complete indicator and orientate to the correct position.

• Locate indicator on actuator shaft flats. Press firmly
until location nibs snap into recess on actuator shaft.

4 AIR SUPPLY AND ELECTRICAL

INSTALLATION

4.1 Air Supply:

The Series F39 Actuator is factory lubricated. For optimum

operation, the use of filtered and lubricated air is recom­mended.

4.2 Air Supply Pressure:

Standard double-acting actuators require 40–120 psig

supply air. Spring-return actuators require 80–120 psig
supply air. Spring-return actuators can also be set up
to operate on supply air pressures ranging from 40–80
psig by using fewer springs. See “Rebuilding Instruc­tions”, Spring-Return Actuator, paragraph 1 on page 13
for proper number and location of springs for reduced
supply air pressures.

WARNING: Air pressure greater than 120 psi must not be

applied.

4.3 Air Supply Connections:

4.3.1 No Integral Solenoid:

Double-Acting (N Models) – Connect air supply lines to

both NPT (1/8” on size 05, ¼” on sizes 10–50) ports.

Spring-Return (SN Models) – Connect air supply line to

the outboard NPT (1/8” on size 05, ¼” on sizes 10–50)
port.

For sizes 10–50, the ports are on the solenoid end cap.

The solenoid end cap is the one on the right end of the
actuator when looking at the nameplate. For 05 size only,
the ports are on the solenoid block interface plate on back
of actuator when looking at the nameplate. For size 05
spring-return it is on the back and near center of actuator.

4.3.2 With Integral Solenoid:

Connect air supply line to the NPT (1/8” on four-way

double-acting blocks, ½” on threeway spring-return
blocks) port on the solenoid block.

4.4 Recommended Tubing Sizes:

In order to provide sufficient flow of supply air to the

Series F39 actuator, the following tubing sizes are recom­mended:

Actuator Size

Runs Up To

4 Ft. Long

05, 10, 15, 20, 25

30, 33, 35, 40, 42, 45 ¼

1

8

/

Runs Over
4 Ft. Long

¼

3

8

/

50 ¼ ½

5. Air Consumption

The following chart shows the amount of pressurized (80

psig) air consumed per stroke in cubic feet. To determine
the total amount of air consumed per complete cycle
for double-acting actuators, simply add the volumes for
both the opening and closing strokes together; for spring
return units, the total volume of air consumed is the
volume shown for the opening stroke.

Actuator Size

05F39 .01 .01

10F39 .04 .05

15F39 .08 .09

20F39 .16 .17

25F39 .28 .30

30F39 .43 .47

33F39 .65 1.1

35F39 .90 1.3

40F39 1.3 1.4

42F39 1.7 3.3

45F39 3.1 4.6

50F39 5.5 7.0

Air consumption cu. ft.

Opening Stroke Closing Stroke

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Series F39 Pneumatic Actuator - WCENIM2036-00 05/15

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6. Electrical Supply

(models with integral solenoid only)

The solenoid coil wattage and required amperage are as

follows:

Watertight and Hazardous Location Solenoids

Voltage

24 VAC 50/60 Hz .71 1.13 11

120 VAC 50/60 Hz .14 .23 10

240 VAC 50/60 Hz .07 .11 10

12 VDC .81 — 10

24 VDC .41 — 10

7

For details of installation of accessories refer to the instal-

INSTALLATION OF ACCESSORIES

lation instructions contained in respective accessory kit

Holding

Amps

Inrush

Amps

Watts

the lock nut will need to be backed off, the adjustment
screw rotated to provide correct positioning and the lock
nut retightened. For size 10 to 35 turn screw clockwise
to decrease rotation and counterclockwise to increase
rotation. For size 40 to 50 the reverse applies. It is critical
to retighten to ensure an effective seal of the washer.

Care should be taken to secure travel stop setting when

tightening lock nut.

8 OPERATION

8.1 Basic Actuator – (N Model)

The Series F39 actuator drive shaft rotates through a full

90° segment with approximately 3° overtravel at each
end of travel. Rotation is accomplished by feeding supply
air into the center chamber, forcing the two opposing
pistons apart, resulting in a counter-clockwise rotation of
the drive shaft to the “open” position. For double-acting
actuators, closure is obtained by feeding supply air into
the end cap chambers, which forces the pistons together,
resulting in a clockwise rotation of the drive pinion. For
spring-return actuators, closure is accomplished by
means of springs contained within the end caps which
force the pistons together when the supply air to the
center chamber has been interrupted.

If rotation opposite to that described above is required,

refer to the section on Installation for the proper proce­dure to reverse the rotation.

The accurate rotation of the actuator pinion is controlled

through the adjustment of two hexagon headed bolts
on the end cap. Each bolt will control either the open
or closing stroke (based on how the actuator has been
orientated on the valve). The adjustment of each bolt
is shown on the end cap. Actuators are factory set to
provide a 90˚ operation. If adjustment needs to be made

8.2 Actuator With Factory-Supplied Solenoid

Double-Acting – Air is supplied to the one NPT port on the

bottom of the block. When the solenoid is energized, the
spring-loaded plunger is withdrawn, allowing the supply
air to shift the spool within the block, which opens the
supply path to the center chamber of the actuator. Air
from the end chambers of the actuator is allowed to pass
through the block and exhaust to atmosphere.

When the solenoid is de-energized, the spring-loaded

plunger blocks the flow of air to the center chamber of the
actuator. The supply air now shifts the spool within the

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block to a position which opens the supply path to the end
chambers of the actuator. Air from the center chamber
of the actuator is allowed to pass through the block and
exhaust to atmosphere.

The double-acting solenoid assembly is electrically fail-

safe. That is, it will return to its de-energized position
upon electrical failure and cycle the actuator to the closed
position provided the air supply is not interrupted.

Double-acting solenoid assemblies have two inde-

pendently adjustable speed control screws which can be
used to adjust the speed of operation for the opening and/
or closing stroke. If the speed control screws are too tight,
the unit will fail to operate. NOTE: Speed control screws
are shipped from the factory in the full open position.

Spring-Return – Air is supplied to the one NPT port on

the bottom of the block. When the solenoid is energized,
the spring-loaded plunger is withdrawn, which opens the
supply path to the center chamber of the actuator. Air
from the end chambers of the actuator is allowed to pass
directly through the block and exhaust to atmosphere.

When the solenoid is de-energized, the spring-loaded

plunger blocks the flow of air to the center chamber of
the actuator. The springs in the end cap of the actuator,
which were compressed on the opening stroke, now
relax, forcing the air contained in the center chamber
of the actuator to exhaust through its supply port in the
solenoid block. The exhaust air passes through the block
and the solenoid where it exhausts to atmosphere.

When using a spring-return solenoid assembly, only

the speed of the spring stroke is adjustable. This is
accomplished by tightening the set screw contained in
the exhaust nut (shipped separately in envelope) which
mounts directly to the end of the solenoid.

8.3 Standard Stroke Times

Series F39 Pneumatic Actuator - WCENIM2036-00 05/15

Actuator Size Stroke Time (sec.)

05F39 1

10F39 1

15F39 1

20F39 1

25F39 2–3

30F39 3–4

33F39 4–5

35F39 4–5

40F39 5–6

42F39 6–7

45F39 10–12

50F39 12–14

8.4. Manual Operation

In the event of air failure, the Series F39 actuator can

be cycled manually. This is accomplished by applying
a wrench to the exposed top shaft of the actuator and
turning it in the desired direction.

WARNING: Care must be taken to ensure that the actuator

is not operated automatically while manual operation is
being performed.

If a routine cycle check is to be performed on a double-

acting actuator equipped with the proper Worcester/
McCANNA solenoid control block, the actuator can be
cycled manually by shifting the spool valve within the
block. This can be done by pushing the red momentary
override button located on the coil housing. The actuator
will cycle to its original position as soon as the manually
applied pressure on the red button is released.

Standard stroke times of the Series F39 actuator are

shown in the following table. Times shown are in seconds
and represent average times under 50% load conditions
with an air supply pressure of 80 psig. Times shown are
per stroke for double acting actuators. For spring-return
actuators, the opening stroke times may be slightly
longer; stroke times for the closing (spring) stroke are
dependent upon the number of springs used.

The figures shown below are meant as an indication

of obtainable speeds only. Faster or slower speeds are
obtainable, if required, by using additional control equip­ment.

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9 MAINTENANCE

CAUTION: The actuator must be isolated both pneumat-

ically and electrically before any maintenance activity is
begun.

Periodic checks should be performed to make certain

that all fasteners remain tight.

All actuators are supplied with sufficient lubrication for

Depending upon the conditions under which the actu-

On spring-return actuators, the springs may need replace-

Actuator

size

05F39 M5 4Nm

10F39 M6 9Nm

15F39 M6 9Nm

20F39 M8 19Nm

25F39 M8 19Nm

30F39 M10 35Nm

33F39 M10 35Nm

35F39 M12 49Nm

40F39 M12 49Nm

42F39 M16 98NM

45F39 M16 98Nm

45F39 M20 216Nm

their normal working life. If required, recommended lubri­cation for all standard actuators is a #1 grease. Consult
Flowserve for lubricants used for high or low temperature
applications.

ator must work, such as extended duty, non-compatible
operating media or abnormal operating conditions,
periodic replacement of internal seals is recommended.
Repair kits containing all necessary seals can be obtained
through any authorized Worcester/McCANNA distributor.

ment after extended duty since springs may fatigue and
break. SPRINGS SHOULD ALWAYS BE REPLACED IN
COMPLETE SETS. Spring kits are available through any
authorized Worcester/McCANNA distributor.

Fastening size Torque

11 TROUBLESHOOTING

For solenoid controlled actuators (with Worcester/

11.1 If actuator does not function, check to ascertain:

11.1.1 That valve is free to rotate. This can be done as described

11.1.2 That actuator is the correct size.

11.1 3 That speed control screws are loose (if screws are tight-

11.1.4 That correct voltage is supplied to solenoid.

11.1.5 That sufficient air supply is available at inlet to control

11.2 If proper voltage and air pressure have been verified and

11.2.1 Turn on signal voltage. Check solenoid for clicking sound.

11.2.2 If no sound is detected, remove air pressure and turn off

• Carefully unscrew solenoid and solenoid stem from

• Reapply signal voltage and observe solenoid plunger. If

11.2.3 If solenoid functions, remove solenoid valve block and

WARNING:

ANY REASON, CONSULT REBUILDING INSTRUCTIONS
CONTAINED IN FOLLOWING SECTION.

McCANNA solenoid control block)

above in Manual Operation (Section 8.4).

ened all the way, actuator will not operate).

block. Inlet pressure to control block should be at least 40
psig for double-acting, 80 psig for spring-return (unless a
reduced spring complement is installed (fewer springs)).
When checking supply pressure, place gauge in line at
control block inlet and monitor gauge for unexpected
pressure drops.

valve is free, proceed as follows:

signal voltage.

block.

it does not retract, replace solenoid.

place on bench. Connect to reduced air supply (50 psig)
and correct voltage. Switch signal voltage and check air
flow. Air should flow out only one output port when sole­noid is energized. The flow should occur only at the other
port when de-energized. (Slight back pressure may be
required to shift the valve spool. This may be generated

by obstructing the outlet ports.)

BEFORE DISASSEMBLING ACTUATOR FOR

10 SPARE PARTS

The following are recommended spare parts which should

be kept on hand for Series F39 pneumatic actuators:

Repair Kit(s) – Kits contain all necessary seals, bearings

and instructions.

Spring Kit(s) – For Spring-Return Actuators.

8

11.2.4 If control block and solenoid are operating correctly,
proceed to Section 11 below.

11.3 If the actuator functions but exhibits leakage, or power
loss accompanied by leakage, proceed as follows:

11.3 .1 Check voltage. Voltage must be within 10% of the spec­ified voltage (low voltage will cause leakage out of the
back of the solenoid and burn out the coil).

Series F39 Pneumatic Actuator - WCENIM2036-00 05/15

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11.3.2 Check air supply. Be certain that no sharp air pressure
drops occur as unit is cycled. Loss of air pressure can
cause incomplete shifting of the spool valves used in all
double-acting units, which results in bypass leakage and
substantial actuator torque losses.

11.4 If air supply and voltage are adequate, proceed as follows:

11.4.1 If leak is at solenoid exhaust port, replace the solenoid.

11.4.2 If leak occurs at exhaust ports in the block itself, the
trouble will be in either the spool valves in the block, or
at one of the piston seals of the actuator. A leaking piston
seal will usually leak on either cycle.

On spring-return actuators, piston seal leakage will show

at the breather port of the end cap, or for 05F39, the sole­noid block interface plate.

The recommended procedure in the cases above is to

replace the spool valve O-rings. If the leakage persists,
rebuild the actuator using a factory-supplied repair kit.

11.5 For actuators without the Worcester/McCANNA solenoid
control block, or if block and solenoid are operating
correctly, remove the actuator from the valve, disas­semble (per Rebuilding Instructions) and check the
following:

11.5.1 Make sure that all internal porting is free and clear of any
obstructions. End caps, guide rods and pistons are air
transporting components.

NOTE: The most common problem encountered on F39

actuators is the improper replacement of the piston guide
rod assembly with the hole in it, relative to the nameplate
on the body (see section 12.2.6 on page 11).

11.5.2 Make certain that the actuator has lubrication, and that
there is no solidified grease between the pinion and the
piston racks:

• If actuator has no lubrication, apply generous amount
of a #1 grease. If actuator is prepared for high or low
temperature operation, consult Flowserve for proper
lubricants.

• If solidified grease between the pinion and the piston
racks is present, clean, dry, re-grease and reassemble.

11.5.3 Verify that actuator pinion shaft and/or pistons are not
bound. If bound, reassemble per Rebuilding Instructions.

11.5.4 If unit exhibits excessive amounts of backlash, check
teeth on piston racks for wear. If worn, replace piston
assemblies.

11.5.5 In spring-return actuators, check for misplaced or broken
springs. If springs are broken, check body bore for
scoring:

• If springs are broken, replace springs. SPRINGS
SHOULD ALWAYS BE REPLACED IN COMPLETE SETS.

• If body bore is scored, replace it. Also, replace piston
O rings (contained in repair kit).

11.5.6 If actuator is free, valve is free and control block (if used)
is shifting air properly, reassemble the actuator and
retest. If unit still fails to operate, consult Flowserve.

12 REBUILDING INSTRUCTIONS

NOTE: For identification of all numbered parts discussed

below, consult exploded view of actuator (see pages
14/15)

After actuator has been repaired, mark rebuild label

accordingly and apply to actuator.

12.1 Actuator disassembly

12.1.1 Disconnect the air supply and electrical service to the
actuator.

12.1.2 Remove the actuator and its mounting bracket from the
valve. If the actuator uses a positioner, loosen the set
screws in the coupling between the valve and actuator.
(See Caution note below.)

CAUTION: Ball valves can trap pressurized media in the

cavity. Isolate the piping system in which the actuator/
valve assembly is mounted and relieve any pressure on
the valve. To remove the actuator bracket from a three­piece non-top-mount style “Miser” valve, the two top
valve body bolts must be removed. For all the valves
listed in Section 3.5, the actuator bracket can be removed
without loosening or removing any valve body bolts.

12.1.3 Remove the actuator bracket (and actuator positioner)
from the actuator to begin repair. (Note mounting of
removed bracket and positioner for easy reassembly.)

12.1.4 It is not necessary to remove solenoid control block (7A)
or (7B) (if so equipped) to rebuild actuator. However,
if it becomes necessary to remove the block, begin by
removing the solenoid block bolts (8E). Use care to retain
the solenoid block gasket (9).

For 05 size only, also remove the solenoid block interface

plate (20) and the interface gasket (19) by removing the
three screws (21).

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Series F39 Pneumatic Actuator - WCENIM2036-00 05/15

STOP!

®

For sizes 10 to 35 it is not necessary to remove the limit

stop bolts from the end cap.

CAUTION: For sizes 40 to 50 the limit stop bolts will need

to be removed to facilitate disassembly. On these sizes
remove the air inlet end cap. Then remove the limit stop
lock nuts and unscrew the limit stop bolts through the
guide rods. This should be done in conjunction with the
instructions below.

12.1.5 For sizes 10–50, each end cap (5A and 5B) is aligned onto
the body (1) over a “foolproof pin”. This ensures that the
end caps can only be assembled to their respective end
of the actuator. Remove all four metric screws (5C) from,
and remove, both end caps. For Rev. R2 and R3 through
R7 actuators, remove the two bearings (6A) and O-rings
(15A and 15B) from each end cap. Note that for Rev. R2
models with top-hat style (6C) bearings, the bearings and
particularly the retaining washers (16) in each end cap
should not be disturbed during O-ring seal replacement,
as they are not included in the rebuilding kit. For size 05,
remove all four metric screws (5C) from both end caps
(5). Remove O-ring (15A) from each end cap.

WARNING: Spring return actuators contain energized

springs. The following section must be followed to ensure
safe disassembly of the actuator.

If the actuator is a spring-return model, first remove

two end cap screws diagonally opposite each other,
then lubricate the threads and under the head. Replace
the screws and repeat the procedure for the other two
screws. Do this for each end cap as this will aid reas­sembly. Now uniformly loosen all four end cap screws on
each end cap two to three turns at a time, in sequence,
to relieve preload of the springs. On larger actuators with
springs use caution when removing end caps. End cap
screws are long enough to allow springs to relieve before
disengaging.

After the screws are removed, gently pry off each end

cap, being careful not to damage the end cap O-Rings.

12.1.6 The two piston guide rod (4) assemblies can now be
removed from each end of the body. Do not disassemble
the piston from the guide rod. (To assist reassembly, mark
the body with a line on the side from which the guide rod
using the thru-hole is removed). Remove all O-rings (15B
and 15C) and bearings (6B) from pistons (3). For size 05,
the two pistons (3) can now be removed from each end
of the body. Remove O-rings (15C) from pistons (3).

12.1.7 The shaft (2A) on Rev. R2 and sizes 05–20 Rev. R3
through R7 models can only be removed after the piston

assemblies are taken out. Remove the position indicator
(17) (if any), the shaft clip (15F) (not a reusable part!)
(see Note below) and the stainless steel washer from the
top of shaft. Then remove the shaft through the larger
opening in the bottom of the body. The top bearing (15G)
and the O-ring (15D) can now be removed. Remove the
two stainless steel washers (10–35 sizes only) and thrust
bearing (10) from the top of the shaft, the O-ring (15E),
and the bearing (15H) (10–42 sizes only) from the bottom
end.

NOTE: For sizes 40 and 42 Rev. R3 through R6 models

and sizes 10 to 50 Rev R7, only a single stainless steel
washer is used and thrust bearing (10) is not used.

NOTE: Some actuators may

be using a spiral-ring type
shaft clip as shown at right.

To remove this clip, engage the lower end of the ring

with a flat blade screwdriver. Using another flat blade
screwdriver push the top end of the clip in the opposite
direction. As the clip I.D. expands, lift the clip from the
shaft. The installation of a new clip would be the above
steps in reverse and ensuring that the edges of the clip
are properly seated in the shaft groove.

The Rev. R2 model, all sizes and the Rev. R3 through

R7 models, sizes 25 through 42, have an anti-ejection
ring (15J). The anti-ejection ring on Rev. 1, sizes 45–50
consists of a flat washer with a shaft clip. All others are
a one-piece spiral wound ring. This ring does not have
to be removed and may or may not be included in repair
kits.

For Rev. R2 models, remove shaft clip (15F) (not a

reusable part!) (see Note above) and the stainless steel
washer from the shaft. Then remove the top shaft bearing
(15G) and the bottom shaft bearing (15H) by carefully
prying them away from the body.

CAUTION: Both of these bearings may have a projecting

“nib” which locates the bearings to the actuator body. Be
careful not to break off these nibs inside the body when
removing the top and bottom bearings. Note: Top bearing
is marked “Top”. Bottom bearing has a larger ID than the
top bearing.

Next, slide the shaft out through the bottom of the body

and remove the top O-Ring (15D) and the bottom O-Ring
(15E) from the body.

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Series F39 Pneumatic Actuator - WCENIM2036-00 05/15

®

12.2 Actuator reassembly

12.2.1 Be sure the actuator surfaces are clean and free of grit
and scratches. If the inside walls of the body are scored,
or the guide rod surfaces are scratched, the actuator will
leak after rebuilding. New parts should be obtained from
the factory. Light tracking, barely detectable to touch, is
acceptable.

12.2.2 All rebuilding kit O-Rings and bearings may now be
installed. Lubricate the standard actuator thoroughly with
a #1 grease. Apply a light film of grease to all O-Rings.

12.2.3 If converting over to a “high-temperature” actuator, or
rebuilding an existing one, lubricate thoroughly with Dow
Corning #7 or other equivalent high temperature silicone
or graphite base grease.

12.2.4 Some Rev. R2 actuators, sizes 10–35, use flanged bear­ings in the end caps. They resemble a “top hat” (6C), and
are installed with the brim of the hat facing out, and are
retained by “star washers” (16). These bearings and star
washers should not be removed for O-Ring seal replace­ment. On sizes 10 and 15 only, there is one star washer,
or retainer, per bearing. On sizes 20–35, there are two
star washers per bearing. They are installed one on top
of the other, with the “points” of the “star” overlapping
each other (as opposed to being on top of each other). All
the washers must be pressed in firmly and straight. The
points of the star are bent slightly. When installed, they

bear back, away from the hole.

For Rev. R3 through R7, sizes 25 through 42 actuators,

replace anti-ejection ring (15J) in its groove on the shaft
(2B), if removed.

For Rev. R2 Models:

• Locate the shaft O-Rings into the actuator body. O-ring
(15D) is the top O-ring while (15E) is the bottom O-Ring.

• Replace the top bearing (15G) and bottom bearing

(15H).

• If the anti-ejection ring (15J) was removed, replace

it in its groove on the shaft (2B). Check that the ring is
properly seated in its groove.

• Replace the shaft in the body through the larger opening

in the bottom of the actuator body.

12.2.6 Replace the stainless steel washer over the top shaft

extension.

12.2.7 For sizes 10–50, very carefully align the piston guide rod

assemblies inside the body. Keep the pistons square to
the body. (This is very important in the 30 F39 actuator
where steel set screws can cause internal body damage if
the piston assemblies “cock” inside the actuator body.)

IMPORTANT:

One piston guide rod assembly has a through
hole drilled in it. It can be easily located by looking down
the ends of both guide rods. This piston assembly must
be reassembled, with its respective guide rod, opposite
the nameplate on the body, as it was removed.

For sizes 10–50 Rev. R2 and 10–42 Rev. R3 through R7

actuators, replace the two split-ring style bearings (6A)
and one guide rod O-ring (15B) in each end cap.

Replace the split-ring style bearing (6B) and guide rod

O-ring(s) (15B) into I.D. groove(s) in each piston (3).
Install O-Rings (15C) onto pistons.

For size 05 actuators, install O-rings (15C) onto the

pistons.

12.2.5 Replace O-ring (15E) and bearing (15H) (10–42 sizes
only) on the bottom of shaft. On the top of the shaft add
the two stainless steel washers (10–35 sizes only) with
the thrust bearing (10) between them. NOTE: For sizes
40 and 42 Rev. R3 through R6 and sizes 10 to 50 Rev.
R7, only a single stainless steel washer is used and thrust
bearing (10) is not used. Locate the top bearing (15G)
and O-ring (15D) into the body. NOTE: For sizes 10–35
Rev. R7 and size 05 actuators, top bearing (15G) is flat
and the same as, and interchangeable with, thrust bearing
(10). Insert the shaft through the larger opening in the
bottom of the body.

°

Nameplate

Figure 1

Pistons at End of Body

IMPORTANT: Note the relative location of the shaft teeth

and the piston assembly's rack teeth. The above figure is
viewed when looking at the top of the actuator.

For size 05, align the pistons inside the body. Keep the

pistons square to the body.

12.2.8 Align the shaft so that the teeth on the shaft will “pick­up” the piston assembly’s rack teeth when turning the top
extension of the shaft clockwise (CW). (See Figure 1.)

IMPORTANT: Proper 90°rotation can only be ensured if

the shaft teeth begin to mesh with the piston assembly’s
teeth at the “proper tooth” between these meshing gear
pairs. (See Figure 1.)

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Series F39 Pneumatic Actuator - WCENIM2036-00 05/15

®

12.2.9 To ensure proper meshing of teeth, move the shaft 15
to 20 degrees counter-clockwise (CCW) from its normal
position when the piston assemblies are located at the
body ends. (See Figure 2.) NOTE: The “normal position”

of the shaft on the 05–20 sizes is when the top flats are
parallel to the main axis of the actuator body. On the 25–
50 sizes the teeth of the shaft will be on the left side of
the actuator when viewed from the ends of actuator. (See
Figure 1.)

12.2.10 With the piston assemblies in the body, gently push each
piston into the body. Turn the top shaft extension clock­wise (CW). Do not allow the pistons to “cock”.

At the proper point of engagement between the shaft

and piston assemblies, both piston assemblies will move
toward the center of the body when turning the top shaft
extension of the actuator clockwise (CW).

12.2.11 Once the shaft and pistons are properly engaged, ensure
that smooth movement and 90 degree operation can
occur without moving the pistons out of the actuator
body. This is important!

12.2.12 Install O-Ring (15A) into and replace the actuator end
caps, (5 or 5A and 5B), noting that the “foolproof” pin
between the body and end cap mates properly (10–50
sizes only). For sizes 40 to 50 the limit stop end cap must
be assembled first. Once assembled feed the limit stop
bolts through the guide rod and screw into the end cap.
Add the sealing washer and lock nut and then attach the
air inlet end cap.

12.2.13 VERY IMPORTANT: Install the NEW shaft clip (15F)

into its mating groove on the top shaft extension. (The
removed shaft clip is not to be reused.)

Place the numbered side up on the shaft clip and be

certain the clip is fully seated in its groove. See Note at
bottom of page 10 for installation of spiral-ring type shaft
clip (which newer rebuilding kits will contain).

12.2.14 If solenoid control block was removed:

For size 05 only, place interface gasket (19) onto solenoid

block interface plate (20) and attach securely to body with
three screws (21). Do not apply any grease to gasket.

Place gasket (9) on solenoid control block (7A) or (7B)

(if used) and attach block securely to end cap, or for size
05, the solenoid block interface plate, to obtain a seal at
gasket. NOTE: If fiber gasket is used, work a generous
amount of assembly grease or petroleum jelly into the
gasket prior to assembly (wipe off excess grease). If a
rubber gasket is used, do not apply any grease, it must
be installed dry.

12.2.15 Replace position indicator (17) (if any). See Section 3.6.6.

12.2.16 Mark Rebuild/Accessory Addition Label, if included in
repair kit, and apply to actuator.

NOTE: For spring return actuators, see spring installa-

tion section on page 13 before installing end caps.

NOTE: When installing the end cap O-Rings, use a small

amount of a general purpose lubricant, such as petro­leum jelly, to hold them in place for ease of assembly and
to avoid having them drop down and get pinched.

On Rev. R2 and earlier actuators, be sure O-Ring is

installed in groove on end cap.

15˚ - 20˚

15˚ - 20˚

05 - 20 F39 Actuator 25 - 50 F39 Actuator

Figure 2

Alignment of Shaft at Reassembly

IMPORTANT:

12

Align gear teeth on the shaft as per Figure 1.

Series F39 Pneumatic Actuator - WCENIM2036-00 05/15

®

13 SPRING-RETURN ACTUATOR

13.1 When replacing springs in a spring-return actuator,
ensure that the springs are replaced in their identical
position in the end cap from where they were removed.

IMPORTANT: When less than the standard number of

springs are used in each end cap, these springs should
be positioned according to the air supply figures below.

The values listed below are for standard and less than the

standard air pressure as required per the ordering code.

NOTE: Maximum operating pressure does not change.

Sizes 10–35 Rev. R2 through R7 and Sizes 40 and 42 Rev. R 2

70 psi - 8 springs - 4 per end cap. Remove center spring.

60 psi - 8 springs - 4 per end cap. Remove center spring.

50 psi - 6 springs - 3 per end cap. Use three on a diagonal.

40 psi - 4 springs - 2 per end cap. Use two in opposite corners.

Sizes 10–50 Rev. R2 (Except Size 40 and 42)

70 psi - 20 springs - 10 per end cap.

60 psi - 20 springs - 10 per end cap.

50 psi - 16 springs - 8 per end cap.

40 psi - 12 springs - 6 per end cap.

The size 05 spring-return actuator operating at 80 psi has four springs
(two per end cap). For air supplies of 70, 60 or 50, remove inner spring
of each end cap.

Remove required number of
springs starting in the center.
Remaining springs should be
evenly spaced as possible.

13.2 If a spring-return actuator is being repaired due to a failed
spring, REPLACE all the springs in this actuator, as well
as any other parts which may have been damaged.

13.3 When replacing the springs in a spring-return actuator,
place the springs in the end cap pocket after thoroughly
lubricating each spring. Be generous with lubricant!

13.4 With the springs pointing up and the end cap on a solid
surface, place the actuator body over the springs and the
proper end cap. (Each end cap can only be mounted to
just one end of the actuator body, as there is a “foolproof”
pin in the end cap, which aligns with a hole in the body.)

13.5 Force the body down and begin by engaging two end cap
screws (5C) by hand through the end cap. Take each end
cap screw up in SMALL and EQUAL turns. Once the end
cap is temporarily secured to the body, turn the actuator
over to its normal position and uniformly take up the four
end cap screws. Uniformly load all the springs to prevent
any spring from buckling.

IMPORTANT: Locating nibs are cast into the Rev. R2 (all

sizes) and the Rev. R3 through R7 (sizes 25 through 42)
actuator piston face. The actuator springs must fit over
these locating nibs on the piston face. Care in following
the above instructions will ensure the proper alignment of
the spring in the actuator body — proper contact with the
piston face and end cap.

13.6 In a similar manner, as written in the previous steps,
replace the springs in the other end of the actuator body.

Ordering Code

Supply Pressure (psi)

05 32 32 32 41

Ordering Code 4 5 6 7 ( )
Supply Pressure (psi)
Actuator Size and
Current Rev.

10 R7
15 R7
20 R7
25 R7
30 R7
33 R7
35 R7
40 R7
42 R7
45 R2
50 R2

1 1 1 ( )

50 60 70 80

40 50 60 70 80

End of Spring Torque (in Lbs)

42 63 84 84 104

74 112 149 149 186
135 212 272 272 339
232 348 465 465 581
372 558 744 744 929
804 1204 1611 1611 2009
929 1398 1859 1859 2328

1496 2239 2982 2982 3735
2593 3885 5177 5177 6469
4735 6319 7849 7849 9478
7319 9762 12204 12204 14638

13.7 On sizes 40 to 50 Rev. R7 only encapsulated springs (pre
compressed) can be used with this design.

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Series F39 Pneumatic Actuator - WCENIM2036-00 05/15

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14 Size 05 Exploded view/parts/materials

(Spring return)

(Double acting)

14A

14A

18

17

14A

5

14B

15F

S. S. Washer

15G

20

15C

3

9

19

5

21

5

(Spring return)

5C

5

(Double acting)

15A

Optional "Rebreather" gasket
(spring return actuators only)

7B

5C

15A

15C

1

3

15D
10

2

15E

9

8E

8D

7A

8E

8B

18C

8A

Item Qty. Description Item Qty. Description

1 1 Body 11 1 Nameplate (Not Shown)
2 1 Shaft
3 2 Pistons

4 2 Guide Rods

12 2 Piston Set Screws
13 2 Pipe Plugs

14A 2 Inner Springs (See Table Page 9)

5 2 End Caps 14B 2 Outer Springs (See Table Page 9)

5A 1 Solenoid Block (Inlet) End Cap
5B 1 Limit Switch End Cap

15A 2 End Cap O-Rings

15C 2 Piston O-Rings
5C 8 End Cap Screws (Metric) 15D 1 Top Shaft O-Ring
7A 1 Solenoid Block (Double-Acting) 15E 1 Bottom Shaft O-Ring
7B 1 Solenoid Block (Spring-Return) 15F 1 Shaft Clip
8A 1 Solenoid 15G 1 Top Pinion Bearing
8B 1 Solenoid O-Ring 17 1 Position Indicator
8C 1 Solenoid Plunger 18 1 Indicator Mounting Screw
8D 1 Solenoid Spring 19 1 Interface Gasket
8E 2 Solenoid Block Bolts 20 1 Solenoid Block Interface Plate
9 1 Solenoid Block Gasket 21 3 Plate Mounting Screws (Metric)
10 1 Thrust Bearing

To order proper parts, please specify the actuator size, model and revision number. Use the standard nomenclature listed above.
The rebuilding kits include Items 15A, 15C through 15G, 10, 19 and stainless steel washer. Color of some replacement parts, such
as bearings, may vary from the parts removed.

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Series F39 Pneumatic Actuator - WCENIM2036-00 05/15

®

15 Size 10-50 Exploded view/parts/materials

The rebuilding kit includes items
15A through 15H, 6A and 6B, 10,
and stainless steel washers. Color

of some replacement parts, such as
bearings, may vary from the parts
removed. Item 15J may or may not
be included in repair kits.

Rebuild kit labled R6 is for Rev. R2
through R6 actuators.

Item Qty. Description Item Qty. Description

1 1 Body 8E 2 Solenoid Block Bolts
2A 1 Shaft (10-2039) 9 1 Soleniod Block Gasket
2B 1 Shaft (25-50F39) 10 1 Thrust bearing (R7 RK Only)
3 2 Pistons 11 1 Nameplate
4 2 Guide Rods 12 2 Piston Set Screws
5A 1 Solenoid Block (Inlet) End Cap 13 2 Pipe Plugs
5B 1 Limit Switch End Cap 15A 2 End Cap O-Rings
5C 8 End Cap Screws (Metric) 15B 6 or 12 Guide Rod O-Rings (See Note Below)
*6 - Bearings (Guide Rod) 15C 2 Piston O-Rings
6C 4 End Cap Bearing (Top-Hat Style) 15D 1 Top Shaft O-Ring
6A 4 End Cap Bearing (Split-Ring Style) 15E 1 Bottom Shaft O-Ring
6B 2 Piston Bearing (Split-Ring Style) 15F 1 Shaft Clip
7A 1 Solenoid Block (Double-Acting) 15G 1 Top Pinion Bearing
7B 1 Solenoid Block (Spring-Return) 15H 1 Bottom Pinion Bearing
8A 1 Solenoid 15J 1 Anti-Ejection Ring (R2 and Sizes 25-42 R3-R7)
8B 1 Solenoid O-Ring 16 4 or 8 Bearing Retainer (R2 Only)
8C 1 Solenoid Plunger 17 1 Position Indicator
8D 1 Solenoid Spring

NOTE: Size 15 Rev. R7 rebuilding kits include twelve Guide Rod O-rings. The six larger diameter O-rings are for Rev. R3 through R7 actuators.
*End cap bearings (6C) illustrated are for Rev. R2 actuators only. All other revision end caps use split-ring style (6A), same as piston bearing
(6B). Only split-ring style bearings are included in R7 rebuilding kits, and normally all styles of bearings do not need replacement during a rebuild.
To order proper parts, please specify the actuator size, model and revision number. Use the standard nomenclature listed above.

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Series F39 Pneumatic Actuator - WCENIM2036-00 05/15

®

FLOWSERVE Flow Control
1978 Foreman Drive
Cookeville, Tennessee 38501
USA

Phone: [phone]
Fax: [phone]

FCD WCENIM2036-00-AQ 05/15

To find your local Flowserve representative:

For more information about Flowserve Corporation.

visit www.flowserve.com

© 2015 Flowserve Corporation. Flowserve a trademark of Flowserve Corporation

Due to continuous development of our product range. we reserve the
right to alter the dimensions and information contained in this leaflet as
required. Information given in this leaflet is made in good faith and based
upon specific testing but does not, however, constitute a guarantee

flowserve.com

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