GE mn-36005 Technical Specifications

GE Oil & Gas

36005 Series V-Max

Masoneilan* High Capacity Control Ball Valve
Instruction Manual

*

GE Data Classification : Public

© 2014 General Electric Company. All rights reserved.

b | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE INFORMATION
IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE PROCEDURES. SINCE OPERATION
AND MAINTENANCE PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY AND ITS SUBSIDIARIES AND AFFILIATES) DOES
NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY
THE TYPE OF EQUIPMENT PROVIDED.

THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE REQUIREMENTS
FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS.
THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES
AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT
AT THE SITE.

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR
EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD
FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY
FOR THE CUSTOMER/OPERATOR'S PURPOSES THE MATTER SHOULD BE REFERRED TO GE.

THE RIGHTS, OBLIGATIONS AND LIABILITIES OF GE AND THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO THOSE
EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS
OR WARRANTIES BY GE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE
INSTRUCTIONS.

THESE INSTRUCTIONS CONTAIN PROPRIETARY INFORMATION OF GE, AND ARE FURNISHED TO THE CUSTOMER/OPERATOR
SOLELY TO ASSIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED.
THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART NOR SHALL ITS CONTENTS BE DISCLOSED TO ANY
THIRD PARTY WITHOUT THE WRITTEN APPROVAL OF GE.

Masoneilan 36005 Series High Capacity Control Ball Valves | c

© 2014 General Electric Company. All rights reserved.

Contents

Important : Safety Warning � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �1
1�0 Introduction

Numbering System........................................................................................ 2

2�0 Installation

2.1 General................................................................................................4

2.2 Pipeline Mounting...................................................................................... 4

2.3 Air Piping ..............................................................................................4

2.4 Changing Actuator Position ............................................................................4

2.5 Changing valve ACTION ................................................................................6

3�0 Maintenance

3.1 Bracket Subassembly ..................................................................................8

3.3 Body Subassembly.....................................................................................9

3.3.1 PackinG.............................................................................................10

3.3.2 MN-7 Seal Ring......................................................................................10

3.3.3 Standard Metal Seal Ring ............................................................................10

3.3.4 Heavy Duty Metal Seal Ring .........................................................................11

3.3.5 Ball Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.4 Actuator Subassembly .................................................................................12

3.5 Handwheel Subassembly .............................................................................14

3.6 Diaphragm Replacement...............................................................................15

Figure 1 — Numbering System and Standard

Mounting Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Figure 2 — General Assembly .............................................................................17

Figure 3 — Actuator Sizes B & C Bracket & Linkage.........................................................18

Figure 4 — Handwheel Assembly, Actuator Sizes B & C .....................................................18

Figure 5 — Handwheel Detail, Actuator Sizes B & C.........................................................18

Figure 6 — Handwheel Bracket Detail, Sizes B & C..........................................................18

Figure 7 — Handwheel Lever Detail, Sizes B & C............................................................18

Figure 8 — Handwheel Clevis Detail, Sizes B & C ...........................................................18

Figure 9 — AcTuator General Assembly, Sizes B & C ........................................................19

Figure 10 — Lever Position Air to Open, Sizes B & C .........................................................19

Figure 11 — Lever Position Air to Close, Sizes B & C .........................................................19

Figure 12 — Position Indicator Detail, Sizes B & C...........................................................20

Figure 13 — Size AC Actuator Assembly ...................................................................20

Figure 14 — Size AC Actuator Bottom View ................................................................21

Figure 15 — Size AC Actuator Linkage Detail ...............................................................21

Figure 16 — Size AC Handwheel Detail.....................................................................22

Figure 17 — insulation Detail ..............................................................................22

Table 1 — Body Parts List .................................................................................23

Table 2 — Bracket and Linkage Parts List ..................................................................23

Table 3 — Handwheel Parts List ...........................................................................24

Table 4 — Actuator Parts List .............................................................................24

Table 5 — Line Bolting ....................................................................................25

d | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

Safety Information

WARNING

CAUTION

WARNING

DANGER

WARNING

CAUTION

CAUTION

WARNING

CAUTION

WARNING

Important - Please Read Before Installation

Masoneilan 36005 Series instructions contain DANGER,
WARNING, and CAUTION labels, where necessary, to alert

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

This is the safety alert symbol. It alerts you to potential
personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.

Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.

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 GE’s written
permission.

• Pleasereportanyerrorsorquestionsaboutthe informationin

this manual to your local supplier.

• These instructionsare written specifically for the 36005 Series

control valves, and do not apply for other valves outside of
this product line.

Warranty

Items sold by General Electric 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 GE recommended usages. GE reserves the right
to discontinue manufacture of any product or change product
materials, design or specifications without notice.

This instruction manual applies to the Masoneilan 36005 Series
control valves.

The Control Valve MUST BE:

• Installed, put into service and maintained by qualified

and competent professionals who have undergone
suitable training.

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.

• Under certain operating conditions, the use of damaged
equipment could cause a degradation of the performance
of the system which may lead to personal injury or death.

• Changesto specifications, structure,andcomponentsused

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

• All surrounding pipe lines must be thoroughly flushed to

ensure all entrained debris has been removed from the
system.

Masoneilan 36005 Series High Capacity Control Ball Valves | 1

© 2014 General Electric Company. All rights reserved.

1�0 Introduction

The following instructions are designed to assist
maintenance personnel in performing most of the
maintenance required on the 36005 V-Max* valve and if
followed carefully will reduce maintenance time.

GE Masoneilan has highly skilled Service Engineers
available for start-up, maintenance and repair of our
valves and component parts. In addition, regularly
scheduled training programs are conducted to train
customer service and instrumentation personnel in

Numbering System

the operation, maintenance and application of our
control valves and instruments. Arrangements for these
services can be made through your GE Masoneilan
Representative or District Office. When performing
maintenance use only Masoneilan replacement parts.
Parts are obtainable through your local GE Masoneilan
Representative or District Office. When ordering parts
always include MODEL and SERIAL NUMBER of the unit
being repaired.

1st

Actuator Type

33 Spring Diaphragm. Air to

extend action only.

1st

3

Body Series

36

2nd

6

Actuator Mounting

(See guide on page 4)

0 Undefined
1 Valve closes on stem

extension (Air to Close,
Fail Open)

2 Valve opens on stem

extension (Air to Open,
Fail Closed

3 Valve closes on stem

extension (Air-to-Close,
Fail Open)

4 Valve opens on stem

extension (Air-to-Open,
Fail Closed)

7 Valve closes on stem

extension (Air-to-Close,
Fail Open)

8 Valve opens on stem

extension (Air-to-Open,
Fail Closed)

4th3rd2nd

5th

5

Seal Type

1 MN-7 Seal Ring
2 316 SS Seal

Ring

3 Heavy Duty

Metal Seal Ring

Design Series

5

2 | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

V-Max Valves

Actuator Model 33, Size AC

3 X 3 6 X 0 5

Actuator Position in Relation to Valve Body
Numbering System: 1 to 8

Actuator Model 33, Sizes B and C

Masoneilan 36005 Series High Capacity Control Ball Valves | 3

© 2014 General Electric Company. All rights reserved.

2�0 Installation

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

2�1 General

2�1�1 Unpack valve carefully to avoid damage to valve,

accessories, or tubing.

2�1�2 Record all valve and accessory serial plate data
for future reference. Always provide serial and model
numbers when ordering spare parts.

2�2 Pipeline Mounting

Do not remove button head screw (9) and
washer (10) during installation� The function
of these parts is to hold the retainer (3) and
seal ring (8) in place and should be removed
only when the valve is to be disassembled for
maintenance (Figure 2)�

A. Before installing the valve in the line, clean pipe and

valve of all foreign materials such as welding chips,
scale, oil, grease or dirt. Gasket surfaces must be
thoroughly cleaned to ensure leak free joints.

B. Install valve in a horizontal or vertical line with the flow

tending to push the seal ring (8) against the ball (2) as
indicated by the flow arrow cast into the body. It is
recommended that if adjacent walls and piping permit,
the valve be oriented such that the ball opens upward.
This is especially important when handling slurries. See
Figure 1 for actuator mounting positions and for flow
direction and Table 5 for line flange bolting lengths.
Note: Flange bolt lengths are non-standard on inlet and
standard on outlet side.

C. Tighten bolting evenly and in crisscross fashion so that

the retainer (3) held in place by the line flange will bear
evenly against the seal ring (8).

D. The linkage of the 36005 V-Max valve has been

properly adjusted at the factory and requires no further
adjustment.

E. Where insulation of the valve body is required, do not

insulate the valve bonnet. See Figure 17.

2�3 Air Piping

2�3�1 Air piping must be adequately sized to provide the

regulated supply pressure specified on the nameplate. As
a general guideline, use 1/4" O.D. tubing or equivalent for
all air lines. If supply air line exceeds 25 feet in length, use
3/8" O.D. tubing.

2�3�2 The actuator is furnished with a 1/4" NPT instrument
air port on the upper case.

Before proceeding with changing actuator
position, air action or valve maintenance,
isolate valve, vent process pressure and shut
off air supply and signal air lines or electrical
lines to unit� It is recommended that the
valve be removed from the pipeline prior to
maintenance work� Keep hands and tools away
from the segmental ball, particularly when
disconnecting the actuator stem from shaft
arm as ball may rotate freely to its lowest
position

For each valve action (air to open/air to close) the
actuator may be positioned to either side of the pipe.
Actuator position is usually determined by adjacent
piping, obstacles of various types or air piping
arrangements. To reposition the actuator and/or bracket
follow the disassembly and reassembly instructions
below.

Note: Actuator positioning should be performed
prior to installing the valve in the pipeline. To change
actuator position and/or valve action refer to Figure 1
for desired position.

A. Remove valve from process line after closing isolating

valves and disconnecting all pneumatic tubing and
electrical wiring.

B. If valve is equipped with a handwheel (Figure 4)

disengage handwheel and remove retaining clips (63),
clevis pin (66) and pivot pins (72); remove entire hand­wheel assembly from bracket (62).

C. Remove pivot pin retaining clips (40), pivot pin (39) and

spacer rings (69). Remove actuator hex nuts (75) and
washers (76). Remove actuator.

Note: Spacer rings apply only on handwheel option.

D. Remove shaft cover (42) and screw (43). Loosen lever

cap screw (33). Remove packing flange stud nuts (24),
bracket mounting stud nuts (24) and washers (18).
Loosen ball plug indicator arm (35).

E. If necessary, scribe a witness line on the lever (32)

in relation to the slot on the end of the shaft (5).
Note: Standard lever has arrows stamped into it for
alignment. For handwheel lever use slot for alignment.

F. Slide bracket (31) away from body until it clears bracket

and packing flange studs (26 and 25), allowing lever
(32) lever arm (64) and indicator arm (35) to be removed
from shaft. Total removal of the bracket is not required.

4 | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

Before proceeding determine valve action (air

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

to open/air to close), refer to the appropriate
figure (Figure 10 to open, Figure 11 to close)�
To obtain proper alignment, the lever must be
oriented on the shaft so that the slot in the end
of the shaft and arrows or indicator lines are
aligned as shown; with the ball in the closed
position, the distance between the top of the
bracket and the top of the pivot pin must be as
shown�

G. Slide lever (32) and lever arm (64) back onto shaft in

desired position. Slide indicator arm (35) back onto
shaft. Align bracket and slide back onto bracket
mounting studs (26) and packing flange studs (25).
Replace bracket mounting stud nuts (24) and washers
(18). Slide packing flange (23) back onto packing flange
studs (25) and replace packing flange stud nuts (24).

H. Remount actuator onto bracket and replace actuator

mounting hex nuts (75) and washers (76). Position lever
(32) and lever arm (64) so that rod end bearing (94) lines
up in lever (32). Tighten lever cap screws (34).

I. Rotate ball plug (2) to closed position. If actuator action

is air to open loosen rod end bearing locknut (93) and
adjust position of rod end bearing (94) so that holes in
lever (32) and rod end bearing (94) line up. Insert pivot
pin (39) and replace spacer rings (69) and retaining rings
(40).

When stroking valve keep hands and
equipment clear of ball plug and seal ring
to avoid injury or damage to personnel and
equipment�

J. If action is air to close place ball plug (2) in closed

position and pneumatically stroke actuator fully.

Do not exceed maximum air supply pressure�
Keep hands clear of actuator stem and linkage�

Loosen rod end bearing locknut (93) and adjust rod end
bearing (94) so that holes in lever (32) and rod end bearing
(94) line up. Insert pivot pin (39) and spacers (69) and
replace retaining rings (40).

K. For both air to open and air to close action, stroke valve

fully to ensure proper closure of ball plug and operation
of valve. It may be necessary to readjust rod end

bearing slightly by loosening locknut and rotating stem.

L. Replace handwheel assembly in bracket (62), pivot pins

(72) and retaining clips (63).

M. Replace shaft cover (42) and screw (43).

N. Set and lock indicator arm (35) to indicate plug position.

2�4�2 Changing Actuator Position Model 33, size AC only�

Before proceeding with changing actuator
position, air action or valve maintenance,
isolate valve, vent process pressure and shut
off air supply and signal air lines or electrical
lines to unit� It is recommended that the
valve be removed from the pipeline prior to
maintenance work� Keep hands and tools away
from the segmental ball, particularly when
disconnecting the actuator stem from shaft
arm as ball may rotate freely to its lowest
position�

For each valve action (air to open/air to close) the
actuator may be positioned to either side of the pipe.
Actuator position is usually determined by adjacent
piping, obstacles of various types or air piping
arrangements. To reposition the actuator and/or bracket
follow the disassembly and reassembly instructions
below.

Note: Actuator positioning should be performed
prior to installing the valve in the pipeline. To change
actuator position and/or valve action refer to Figure 1
for desired position.

A. Remove valve from process line after closing isolating

valves and disconnecting all pneumatic tubing and
electrical wiring.

B. If valve is equipped with a handwheel (Figures 13 & 16)

disengage handwheel and remove retaining clip (54-7)
and washer (54-4). Remove entire handwheel assembly
from actuator housing (31).

C. Remove pivot pin retaining clips (40), pivot pin (39).

Remove actuator hex nuts (75) and washers (76).
Remove actuator.

D. Remove shaft cover (42) and screw (43). Loosen lever

cap screw (33). Remove packing flange stud nuts (24),
bracket mounting stud nuts (24) and washers (18).
Loosen ball plug indicator arm (35).

E. If necessary, scribe a witness line on the lever (32) in

relation to the slot on the end of the shaft (5).

F. Slide housing (31) away from body until it clears bracket

and packing flange studs (26 and 25), allowing lever (32)
and indicator arm (35) to be removed from shaft. Total

Masoneilan 36005 Series High Capacity Control Ball Valves | 5

© 2014 General Electric Company. All rights reserved.

removal of the bracket is not required.

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

Before proceeding determine valve action (air
to open/air to close)�

G. Slide lever (32) back onto shaft in desired position.

Slide indicator arm (35) back onto shaft. Align bracket
and slide back onto mounting studs (26) and packing
flange studs (25). Replace mounting stud nuts (24)
and washers (18). Slide packing flange (23) back onto
packing flange studs (25) and replace packing flange
stud nuts (24).

H. Remount actuator onto housing and replace actuator

mounting hex nuts (75) and washers (76). Position lever
(32) so that rod end bearing (94) lines up in lever (32)
and that the pads on the lever will contact the stop
bolts (102). Tighten lever cap screw (33).

I. Rotate ball plug (2) to closed position. Adjust closed

position travel stop (102) until it contacts the pad on
lever (32). Tighten locknut (101).

J. Rotate ball plug (2) to open position. Adjust open

position travel stop until it contacts pad on lever (32).
Tighten locknut (101).

Ensure rotation of AC actuator does not
exceed 90deg� Damage to actuator rod may
result�

K. If actuator action is air to open, rotate ball plug (2) to

open position. Pneumatically stroke actuator to open
position. Loosen rod end bearing locknut (93) and
adjust position of rod end bearing (94) so that holes in
lever (32) and rod end bearing (94) line up. Insert pivot
pin (39) and retaining rings (40).

When stroking valve keep hands and
equipment clear of ball plug and seal ring
to avoid injury or damage to personnel and
equipment�

L. If action is air to close place ball plug (2) in closed

position. The pad on lever should contact the closed
position travel stop (102). If it does not, repeat
adjustment as noted in step I above. Return ball plug (2)
to open position. Pneumatically stroke actuator to open
position.

Do not exceed maximum air supply pressure�
Keep hands clear of actuator stem and linkage�

Loosen rod end bearing locknut (93) and adjust rod end
bearing (94) so that holes in lever (32) and rod end bearing
(94) line up. Insert pivot pin (39) and replace retaining rings
(40).

M. For both air to open and air to close action, stroke

valve fully to ensure proper closure of ball plug and
operation of valve. It may be necessary to readjust rod
end bearing slightly by loosening locknut and rotating
stem.

N. Replace handwheel assembly in housing (31), washer

(54-7) and retaining clip (54-4).

O. Replace shaft cover (42) and screw (43).

P. Set and lock indicator arm (35) to indicate plug position.

2�5 Changing Valve Action

Note: If the valve action is to be changed it should be
done before the valve is installed in the line. This allows
a positive visual check to ensure that the ball plug is
fully closed when the actuator is in the proper position.

2�5�1 Model 33, sizes B & C only� For size AC refer
to section 2�5�2

A. If the valve is equipped with a handwheel disengage

the handwheel and remove retaining clips (63), clevis
pin (66), and pivot pins (39). Remove cap screws (70),
washers (71) and handwheel bracket (62).

B. If necessary, scribe a witness mark on the lever

(32) in relation to the slot on the end of the shaft (5).
Note: Standard lever has arrows stamped into it for
alignment. For handwheel lever use slot for alignment.

C. Remove pivot pin retaining clips (40), pivot pin (39) and

spacer rings (69). Remove shaft cover (42) and screw
(43). Remove actuator hex nuts (75) and washers (76).
Remove actuator.

Note: Spacer rings apply only on handwheel option.

D. Loosen lever cap screw (33). Remove packing flange

stud nuts (24), bracket mounting stud nuts (24) and
washers (18). Loosen ball plug indicator arm (35).

E. Slide bracket (31) away from body until it clears bracket

and packing flange mounting studs. Remove lever (32),
lever arm (64) and indicator arm (35) from shaft.

Before proceeding determine valve action (air
to open/air to close), refer to the appropriate

6 | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

figure (Figure 10 to open, Figure 11 to close)�

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

To obtain proper alignment, the lever must be
oriented on the shaft so that the slot in the end
of the shaft and arrows or indicator lines are
aligned as shown; with the ball in the closed
position, the distance between the top of the
bracket and the top of the pivot pin must be as
shown�

F. Flip lever (32) and lever arm (64) and replace on shaft

90 away from original position. Replace indicator arm
(35). Slide bracket back onto bracket mounting studs
(26), replace washers (18) and nuts (24) and tighten. Slide
packing flange (23) back over packing flange studs (25)
and replace packing flange stud nuts (24) and tighten.

G. Replace actuator on bracket in correct mounting

position for air action. Replace actuator stud nuts (75)
and washers (76). Position lever (32) and lever arm
(64) so that rod end bearing (94) lines up in lever (32).
Tighten lever cap screw (33).

H. Place ball plug (2) in closed position. If actuator action

is air to open, loosen rod end bearing nut (93) and
adjust position of rod end bearing (94) so that holes in
lever (32) and rod end bearing (94) line up. Insert pivot
pin (39) and replace retaining rings (40).

I. If action is air to close, place ball plug (2) in closed

position and pneumatically stroke actuator fully.

the handwheel and remove retaining clip (54-7) and
washer (54-4). Remove handwheel assembly (54) from
housing (31) by rotating counter-clockwise.

B. Remove pivot pin retaining clips (40), pivot pin (39).

Remove actuator hex nuts (75) and washers (76).
Remove actuator.

C. Remove cover (48) from opposite side of bracket (31)

and install on side actuator was just removed from.

Note: Cover (48) is attached to yoke with contact
adhesive that is pre-applied. If a new cover is not
available, it can be re-installed by applying contact
adhesive to the cover and bracket following the
instructions for the specific adhesive used.

D. Install actuator on opposite side of yoke than it was

removed from. Attach using washers (76) and hex nuts
(75).

Before proceeding determine valve action (air
to open/air to close)�

E. Rotate ball plug (2) to closed position. Verify closed

position travel stop (102) contacts the pad on lever (32).
Adjust as necessary. Tighten locknut (101).

Do not exceed maximum air supply pressure�

J. For both air to open and air to close action, stroke valve

fully to ensure proper closure of ball plug and operation
of valve. Tighten rod end bearing locknut (93).

When stroking valve keep hands and
equipment clear of ball plug and seal ring
to avoid injury or damage to personnel or
equipment�

K. Replace handwheel bracket (62), cap screws (70)

and lockwashers (71) on opposite side of actuator
bracket from where originally found. Insert handwheel
assembly in bracket and replace clevis pin (66),
retaining rings (63), lever arm bearing (65) and pivot
pins (72). Replace shaft cover (42) and screw (43).

L. Set and lock indicator (35) to indicate plug position.

2�5�2 Model 33, size AC only� For sizes B & C refer
to section 2�5�1 above�

A. If the valve is equipped with a handwheel disengage

Ensure rotation of AC actuator does not
exceed 90deg� Damage to actuator rod may

result�

F. Rotate ball plug (2) to open position. Verify open

position travel stop contacts pad on lever (32). Adjust as
necessary. Tighten locknut (101).

G. If actuator action is air to open, rotate ball plug (2) to

open position. Pneumatically stroke actuator to open
position. Loosen rod end bearing locknut (93) and
adjust position of rod end bearing (94) so that holes in
lever (32) and rod end bearing (94) line up. Insert pivot

pin (39) and retaining rings (40).

When stroking valve keep hands and
equipment clear of ball plug and seal ring
to avoid injury or damage to personnel and
equipment�

H. If action is air to close place ball plug (2) in closed

position. The pad on lever should contact the closed
position travel stop (102). If it does not, repeat

Masoneilan 36005 Series High Capacity Control Ball Valves | 7

© 2014 General Electric Company. All rights reserved.

adjustment as noted in step I above. Return ball plug (2)

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

to open position.

Do not exceed maximum air supply pressure�
Keep hands clear of actuator stem and linkage�

Loosen rod end bearing locknut (93) and adjust rod end
bearing (94) so that holes in lever (32) and rod end bearing
(94) line up. Insert pivot pin (39) and replace retaining rings
(40).

I. For both air to open and air to close action, stroke valve

fully to ensure proper closure of ball plug and operation
of valve. It may be necessary to readjust rod end
bearing slightly by loosening locknut and rotating stem.

J. Replace handwheel assembly (54) in bracket (31),

washer (54-7) and retaining clip (54-4).

K. Set and lock indicator arm (35) to indicate plug position.

3�0 Maintenance

3�1 Bracket Subassembly – Model 33, sizes B &
C only� Refer to section 3�2 for size AC

3�1�1 Disassembly

When disconnecting actuator rod end bearing
from shaft arm, the ball is likely to rotate
toward the bottom of the valve body� Keep
hands and tools away from the ball�

A. Remove screw (43) and shaft cover (42) or positioner if

so equipped.

B. Remove retaining clips (40), pivot pin (39) and spacer

rings (69).

Note: Spacer rings apply only on handwheel option.

C. Remove actuator mounting nuts (75) and washers (76)

and remove actuator from bracket (31).

D. If valve has handwheel, remove retainer clips (63), clevis

pin (66), pivot pins (72). Remove handwheel assembly
from bracket.

E. Loosen cap screw (33) and indicator arm (35). Remove

packing flange stud nuts (24) and bracket mounting
stud nuts (26) and washers (18).

F. Scribe a witness mark on the lever (32) indicating

relative position to the slot in the end of the shaft (5).

G. Slide bracket (31) off studs and shaft, removing

indicator arm (35), lever (32), lever arm (64) and packing
flange (23).

H. Remove bearing (47) from bracket. Examine all parts for

wear and/or damage. Replace if necessary.

3�1�2 Reassembly

Note: If the valve is equipped with a handwheel the
lever consists of two separate arms which are a
MATCHED PAIR and are not interchangeable with any
other pair. The sequence of assembly is to place one
lever over the shaft then the lever arm (64) insert pin
(68), and then the second lever arm onto the shaft then
slide the shaft into the bracket and bearing.

A. Replace ball bearing (47) in the bracket (31).

B. Place ball plug (2) in closed position. Slide bracket (31)

partially over shaft. Ensure all packing box parts are
in place and then slide packing flange (23) onto shaft.
Slide lever (32) onto shaft on its former position. Slide
handwheel lever arm (64) and second lever (32) onto
shaft if valve has handwheel. Replace indicator arm
(35). Slide bracket fully onto mounting studs (26); ensure
shaft (5) is properly located in bearing (47). Replace lock­washer (18) and bracket mounting stud nuts (24) and
tighten. Replace packing flange stud nuts (24).

C. Pull shaft out to bottom against bearing. Replace

actuator and install washers (76) and nuts (75). Slide
lever (32) on shaft so that it is lined up with rod end
bearing (94). Tighten lever locking screw (33).

D. If valve action is air to open place ball plug (2) in

closed position. Loosen rod end bearing locknut (93)
and adjust rod end bearing until holes in lever (32)
and rod end bearing (94) line up. Install pivot pin (39),
spacers (69) (handwheel only) and retainer rings (40). If
valve action is air to close, place ball plug (2) in closed
position and pneumatically stroke actuator fully.

Do not exceed maximum air supply pressure
specified on the valve nameplate�

E. For both air to open and air to close action, stroke valve

fully to ensure proper closure of ball plug and operation
of valve. Tighten rod end bearing locknut (93).

When stroking valve keep hands and
equipment clear of ball plug and seal ring
to avoid injury or damage to personnel or
equipment� Do not exceed pressure specified
on the valve nameplate�

F. Replace shaft cover (42) and screw (43) (or positioner if

so equipped).

G. Replace handwheel assembly in bracket (62) and

8 | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

replace clevis pin (66), retaining clips (63), and pivot pins

CAUTION

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WARNING

CAUTION

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(72).

H. Set and lock indicator arm (35) to indicate plug position.

I. Check that handwheel operates valve through full range

of travel. There is a 1/2" adjustment available at the end
of the handwheel extension. Retract handwheel, remove
end cap (51) and cap screw (55B). Rearrange stop (55A)
and/or spacer (55C) to obtain desired extension.

3�2 Bracket Subassembly – Model 33, size AC
only� Refer to section 3�1 for sizes B & C

3�2�1 Disassembly

studs (26); ensure shaft (5) is properly located in bearing
(47). Replace lockwasher (18) and bracket mounting
stud nuts (24) and tighten. Replace packing flange stud
nuts (24).

C. Pull shaft out to bottom against bearing. Replace

actuator and install washers (76) and nuts (75). Slide
lever (32) on shaft so that it is lined up with rod end
bearing (94). Tighten lever locking screw (33).

D. Place ball plug (2) in closed position. If valve action is

air to close, pneumatically stroke actuator fully. Loosen
rod end bearing locknut (93) and adjust rod end bearing
until holes in lever (32) and rod end bearing (94) line up.
Install pivot pin (39) and clips (40).

When disconnecting actuator rod end bearing
from shaft arm, the ball is likely to rotate
toward the bottom of the valve body� Keep
hands and tools away from the ball�

A. Remove screw (43) and shaft cover (42) or positioner if

so equipped.

B. Remove retaining clips (40), pivot pin (39).

C. Remove actuator mounting nuts (75) and washers (76)

and remove actuator from bracket (31).

D. If valve has handwheel, remove retainer clip (54-7) and

washer (54-4). Remove handwheel assembly (54) from
bracket.

E. Loosen cap screw (36) and indicator arm (35). Remove

packing flange stud nuts (24) and bracket mounting
stud nuts (26) and washers (18).

F. Scribe a witness mark on the lever (32) indicating

relative position to the slot in the end of the shaft (5).
Loosen cap screw (11).

G. Slide bracket (31) off studs and shaft, removing

indicator arm (35), lever (32) and packing flange (23).

H. Remove bearing (47) and grommet (106) from bracket.

Examine all parts for wear and/or damage. Replace if
necessary.

3�2�2 Reassembly

A. Replace ball bearing (47) and grommet (106) in the

housing (31). Note, the grommet has a recessed area on
one side. It should be installed with that side should be
toward the inside of the bracket.

B. Place ball plug (2) in closed position. Slide bracket (31)

partially over shaft. Ensure all packing box parts are
in place and then slide packing flange (23) onto shaft.
Slide lever (32) onto shaft on its former position. Replace
indicator arm (35). Slide bracket fully onto mounting

Do not exceed maximum air supply pressure
specified on the valve nameplate�

E. For both air to open and air to close action, stroke valve

fully to ensure proper closure of ball plug and operation
of valve. Tighten rod end bearing locknut (93).

When stroking valve keep hands and
equipment clear of ball plug and seal ring
to avoid injury or damage to personnel or
equipment� Do not exceed pressure specified
on the valve nameplate�

F. Replace shaft cover (42) and screw (43) (or positioner if

so equipped).

G. Replace handwheel assembly (54) in housing (31) and

replace washer (54-4) and retaining clip (54-7).

H. Set and lock indicator arm (35) to indicate plug position.

I. Check that handwheel operates valve through full range

of travel.

3�3 Body Subassembly

3�3�1 Packing

Note: The packing follower should be held firmly, but
not too tightly against the packing.

Overtightening of the packing causes excessive friction
and may affect valve operation. The packing in a new
V-Max valve has not been tightened prior to shipment. It
is recommended that further adjustments be made when
the valve is put into service. If necessary to add packing,

proceed as follows:

Masoneilan 36005 Series High Capacity Control Ball Valves | 9

© 2014 General Electric Company. All rights reserved.

When stroking valve keep hands and

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

equipment clear of ball plug and seal ring
to avoid injury or damage to personnel or
equipment� Do not exceed pressure specified
on the valve nameplate�

F. Replace shaft cover (42) and screw (43) (or positioner if

so equipped).

G. Replace handwheel assembly (54) in housing (31) and

replace washer (54-4) and retaining clip (54-7).

H. Set and lock indicator arm (35) to indicate plug position.

I. Check that handwheel operates valve through full range

of travel.

3�3 Body Subassembly

3�3�1 Packing

Note: The packing follower should be held firmly, but
not too tightly against the packing.

Overtightening of the packing causes excessive friction
and may affect valve operation. The packing in a new
V-Max valve has not been tightened prior to shipment. It
is recommended that further adjustments be made when
the valve is put into service. If necessary to add packing,
proceed as follows:

Valve must be isolated and process pressure
vented before performing packing box
maintenance�

3�3�1�1 Disassembly

A. Loosen and remove packing flange nuts (24) and

slide packing flange (23) and packing follower (20)
toward shaft lever (32). Note: The lever (32) may be
disconnected from the actuator stem and pushed up
against the shaft bearing (47) (refer to section 3.1), if
necessary for clearance.

B. Using a packing hook, remove the top pieces of packing

rings.

3�3�1�2 Reassembly

A. Install new packing ring(s), making sure the skive cut in

adjacent packing rings is offset 120° apart.

B. Replace packing follower (20) packing box flange (23)

and packing nuts (24).

C. Evenly tighten packing nuts (24).

10 | GE Oil & Gas

DO NOT overtighten packing nuts�

D. Place valve into service and tighten packing nuts (24)

only as much as necessary to stop any leakage.

3�3�2 Seal Ring – MN-7 Seal

3�3�2�1 Disassembly

Note: Seal ring removal, inspection and reinstallation
must be done with the valve removed from the
pipeline.

A. Remove screws (9) and washers (10), retainer (3), MN-7

seal ring (8) and downstream back-up ring (32).

B. Remove gasket (4) residue from body and retainer

taking care not to damage seal surfaces.

3�3�2�2 Reassembly

A. Move ball to the closed position.

Note: Use a light coating of Dow-Corning 111® or
equal on the ball plug to break in seat.

B. Replace backup ring (32), seal assembly, gasket (4) and

retainer (3). Take care that beveled edges of seal (8) and
backup ring (32) are facing the ball.

C. Replace set screws (9) and washers (10) and tighten.

3�3�3 Seal Ring – Standard Metal Seal

3�3�3�1 Disassembly

Note: Seal ring removal, inspection and reinstallation
must be done with the valve removed from the
pipeline.

A. Remove screws (9) and washers (10).

Note: The flexible metal seal assembly consists of a
seal ring (8), gasket (7), and backup ring (6).

B. Mark flexible metal seal ring (8) so that, if reinstalled,

the same side will be in contact with the ball. Remove
retainer, seal assembly and downstream back-up
ring (32). If difficulty is encountered in removing seal
assembly, rotate the ball to open position and pull out
the seal ring.

C. Remove gasket (4) residue from body and retainer

taking care not to damage seal surfaces.

D. If replacing MN-7 or flat metal seal with HD metal

version, upper and lower guide bushings (16, 17) should
be replaced with satellite material.

3�3�3�2 Reassembly

Note: If retrofitting a valve originally equipped with an
MN-7 seal ring follow steps A through D. If valve was
originally supplied with a metal seal, please proceed to
step C.

© 2014 General Electric Company. All rights reserved.

A. Clean the contact surfaces of the ball plug (2) with

alcohol or other suitable degreaser to facilitate
application of the dry graphite spray lubricant. If
necessary, very mild abrasive pads such as Scotch­Brite™ may be used to remove any oxide layers on the
ball plug (2).

B. Apply the dry graphite lubricant spray (Dow- Corning

321®) in several light coats on the plated seal contact
surfaces of the ball plug (2). Allow the graphite spray to
dry fully – which will produce a dull gray finish on the
coated parts.

C. Move ball to the closed position.

D. Replace downstream back-up ring (32), seal assembly,

gasket (4) and retainer (3). Take care that beveled edge
flexible metal seal (8) and backup rings (6 & 32) are
facing the ball.

E. Replace set screws (9) and washers (10) and tighten.

Silicon grease (or equivalent) and install it over the end
of the Heavy Duty Seal Ring (8).

Note: The open lips of the radial seal (30) must face
AWAY from the seat bevel and ball.

E. Install the Wave Spring (31) over the end of the Heavy

Duty Seal Ring (8).

F. Insert the Seat Retainer (3) over the end of the Seat (8)

and apply even pressure to overcome the resistance
of the radial seal (30) until the wave spring (31) is
compressed.

G. Install the retainer/body gasket (4).

H. Install the seat (8), retainer (3), radial seal (101) and

wave spring (102) assembly into the body counterbore
until contact is made with the ball plug (2).

I. Install retainer screws (9) and washers (1) and tighten to

secure the retainer and seal assembly in the body.

3�3�4 Seal Ring – Heavy Duty Metal Seal

3�3�4�1 Disassembly

Note: Seal ring removal, inspection and reinstallation
must be done with the valve removed from the
pipeline.

A. Remove screws (9) and washers (10).

Note: The Heavy Duty Metal Seal assembly consists of
a seal ring (8), radial seal (30) and wave spring (31).

B. Note the orientation of the radial seal (30) and wave

washer (31) for reassembly.

C. Clean parts of any residue that remains from the

process. Take care not to damage or mark the sealing
surfaces of seal ring (8) or radial seal (30).

3�3�4�2 Reassembly

Note: If retrofitting a valve originally equipped with an
MN-7 seal ring follow steps A through D. If valve was
originally supplied with a metal seal, please proceed to
step C.

A. Clean the contact surfaces of the ball plug (2) with

alcohol or other suitable degreaser to facilitate
application of the dry graphite spray lubricant. If
necessary, very mild abrasive pads such as Scotch­Brite™ may be used to remove any oxide layers on the
ball plug (2).

B. Apply the dry graphite lubricant spray (Dow- Corning

321®) in several light coats on the plated seal contact
surfaces of the ball plug (2). Allow the graphite spray to
dry fully – which will produce a dull gray finish on the
coated parts.

C. Move ball to the closed position

D. Lubricate the Radial Seal (30) with Dow-Corning 111

3�3�5 Ball Plug

3�3�5�1 Ball Plug Disassembly

A. Remove bracket (see section 3.3.2).

B. Remove screws (9) and washers (10). Slide the retainer

(3) out of the valve body. Remove seal assembly (refer to
Para. 3.2.2.1 Seal Ring - Disassembly).

C. Remove safety pin (27). Remove the shaft (5) from the

valve body. The packing (19), packing adaptor (28) and
packing follower (20) will slide out with the shaft. If the
shaft will not move, thread nuts (24) on the packing
studs, then place the packing flange (23) on top of the
nuts. Slide the lever (32) onto the shaft (5) up against
the packing flange (23) and tighten screw (34). By
unscrewing the packing nuts (24) evenly, ample force
is developed to move the shaft (5). Once shaft has
been started, it should be possible to remove the shaft
completely. If not, a suitable size bolt screwed into the
tapped hole on the shaft end can be used as a shaft
“puller”.

D. Remove nuts (13), end flange (14), pin shaft (11) and

gasket (15). If the pin shaft will not move, push it out
with a rod inserted through the bonnet end of the
valve.

E. Remove the ball (2) and separate the lower bushing

(16) from it. Remove the upper bushing (17). If it sticks,
the upper bushing (17) can be pushed out with a rod of
suitable size inserted into the pin shaft end of the body.

F. Examine all parts for damage due to erosion, corrosion,

or wear. Replace the seal ring if damaged, worn or
distorted. Replace all defective parts and all packing
and gaskets. Clean the valve parts thoroughly before

®

reassembly. Remove gasket (4) and (15) residue from

Masoneilan 36005 Series High Capacity Control Ball Valves | 11

© 2014 General Electric Company. All rights reserved.

body and retainer taking care not to score sealing

CAUTION

CAUTION

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CAUTION

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WARNING

CAUTION

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WARNING

areas.

3�3�5�2 BaIl Plug Reassembly

Note: If installing a new ball plug into a valve equipped
with either the standard metal or Heavy Duty metal
seal rings, the ball plug must be first coated with dry
graphite lubricant as described in steps A and B. If
equipped with an MN-7 seal ring, proceed to step C.

A. Clean the contact surfaces of the ball plug (2) with

alcohol or other suitable degreaser to facilitate
application of the dry graphite spray lubricant. If
necessary, very mild abrasive pads such as Scotch­Brite™ may be used to remove any oxide layers on the
ball plug (2).

B. Apply the dry graphite lubricant spray (Dow- Corning

321®) in several light coats on the plated seal contact
surfaces of the ball plug (2). Allow the graphite spray to
dry fully – which will produce a dull gray finish on the
coated parts.

C. Replace lower bushing (16) in the ball and position ball

in the body. Replace gasket (15).

D. Lubricate pin shaft (11) and insert through body and

into the ball. Secure with end flange (14) and end flange
nuts (13). Tighten nuts alternately to assure tight seal
against the gasket. (Recommended lubricant SAF-T-EZE
Anti-Seize or equal.)

E. Replace ring (29), and upper bushing (17)on the shaft (5).

Install shaft in the body andengage the ball such that
when the ball is in the closed position, the machined
slot in the shaft end is vertical (perpendicular to the
body axis). Coat shaft below ring groove and bushing
with lubricant (SAF-T-EZE Anti-Seize or equal).

F. Install packing adaptor (28), bevel side out over the

shaft (5) and into the valve bonnet so that the hole
through the side of the adaptor is aligned with the
tapped hole through the bonnet for the safety pin (27).

G. Apply pipe sealant to the safety pin, install into bonnet

and tighten.

Safety pin must engage hole in packing
adaptor� Test by manually pulling on shaft to
verify pin engagement�

H. Install packing (19) so that skive cut of each piece

of packing is offset approximately 120° from that of
adjacent piece.

I. Install packing follower (22) over shaft and into bonnet

with bevel side out. Install packing box flange (23) and

nuts (24).

J. Install seal ring and retainer assembly as described in

section 3.3.2, 3.3.3 or 3.3.4 depending on seal type.

K. Install mounting bracket (31) and lever (32). Follow

instruction 3.1.2 Bracket Reassembly. L. Evenly tighten
packing flange nuts (24) against packing flange (23)
before placing valve into service.

DO NOT over tighten packing flange nuts� After
valve has been in service, retighten packing
flange nuts evenly until any leaks are stopped�

3�4 Actuator Subassembly�

3�4�1 Model 33, sizes B & C� Refer to section 3�7 for size
AC actuators�

3�4�1�1 Disassembly

The upper diaphragm case (84) is under spring
tension� A warning tag (97) is attached to
each of the three (3) long cap screws (95)� The
tension nuts (96) attached to cap screws (95)
must be evenly removed last� The following
procedure must be followed to avoid injury�

A. Isolate the valve, vent process pressure and shut off all

electrical, signal air and supply air lines to the valve.

B. If equipped with a handwheel, it must be rotated to the

disengaged position.

C. Remove air supply piping to upper diaphragm case (84).

D. Remove side covers (46).

E. Remove retaining clips (40) and remove pivot pin (39)

and spacers (69) (handwheel only) to free rod end
bearing (94).

F. Loosen and remove all short cap screws (86) and hex

nuts (87). Mark upper case (84) and lower case (20) so
that they can be reassembled with the same orientation
of air inlet and mounting bolts.

G. Loosen each tension nut (96) approximately three full

turns.

12 | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

The upper diaphragm case (84) should

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

separate from the lower case (91) as the
tension nuts are loosened the three turns�
If it does not, before proceeding, separate
the upper diaphragm case (84) by tapping
it around the circumference or inserting a
screwdriver between the upper (84) and lower
case (91)� If the cases still do not separate,
check that the actuator stem is not hung
up inside the bracket� DO NOT PROCEED
WITH DISASSEMBLY UNLESS THE CASES CAN
SEPARATE FREELY�

H. Continue loosening the tension nuts (96) evenly

approximately three turns each time ensuring that
the upper diaphragm case (84) and diaphragm (85)
continue to separate.

Note: Continue Step H until the tension nuts (96)
can be easily removed by hand indicating the upper
diaphragm case (84) is not under spring tension.

I. Remove tension bolts (95) and upper diaphragm case

(84).

J. Remove diaphragm (85) and diaphragm plate

subassembly from the actuator.

K. Remove retaining clip (78). Remove clevis pivot pin (79).

Inspect for damage and/or wear in clevis (80), lever (32),
clevis pins (79, 39) and rod end bearings (94). Replace if
necessary.

L. Clean all mating/sealing surfaces which will come in

contact with the diaphragm (85).

3�4�1�2 Reassembly

A. Connect rod end bearing (94) to diaphragm plate

clevis (80) by installing clevis pin (79) and retaining
clips (78). Ensure that the stem (77) is installed such
that the wrench flats are at the end furthest from the
diaphragm plate (88).

B. Ensure spring (90) and spring guide (89) are properly

aligned in lower case (91) and install the diaphragm
plate and stem subassembly. Replace diaphragm (85).

C. Align marks for correct orientation of upper case (84)

and lower case (91). Replace upper diaphragm case (84)
and install long cap screws (95), warning plate (97) and
tension nuts (96).

Note: These bolts must be equally spaced at 120°
intervals.

D. Take up tension nuts (96) evenly and sufficiently to

allow installation of short cap screws (83) and hex nuts
(87).

E. Tighten tension nuts (96) and then tighten all hex nuts

(87) using a criss-cross tightening pattern.

Note: Nuts should be tightened only enough to seal
the diaphragm between the upper and lower case. Do
not overtighten.

F. Connect rod end bearing (94) to lever (32) by installing

pivot pin (39), spacers (69) (handwheel only), and
retaining clips (40).

G. Replace side covers (46) and reconnect signal and

supply lines.

H. Place back in service and, if so equipped, rotate

handwheel to desired position.

3�4�2 Actuator Subassembly – Model 33, size AC� Refer
to section 3�4�1 for sizes B & C� Figures 13, 14, 15 & 16�

3�4�2�1 Disassembly

The upper diaphragm case (84) is under spring
tension� A warning tag (97) is attached to
each of the three (3) long cap screws (95)� The
tension nuts (96) attached to cap screws (95)
must be evenly removed last� The following
procedure must be followed to avoid injury�

A. Isolate the valve, vent process pressure and shut off all

electrical, signal air and supply air lines to the valve.

B. If equipped with a handwheel, it must be rotated to the

disengaged position.

C. Remove air supply piping to upper diaphragm case (84).

D. Remove covers (44 & 46).

E. Remove retaining clips (40) and remove pivot pin (39) to

free rod end bearing (94).

F. Loosen and remove all short cap screws (86) and hex

nuts (87). Mark upper case (84) and lower case (91) so
that they can be reassembled with the same orientation
of air inlet and mounting bolts.

G. Loosen each tension nut (95) approximately three full

turns.

Masoneilan 36005 Series High Capacity Control Ball Valves | 13

© 2014 General Electric Company. All rights reserved.

The upper diaphragm case (84) should

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

separate from the lower case (91) as the
tension nuts are loosened the three turns�
If it does not, before proceeding, separate
the upper diaphragm case (84) by tapping
it around the circumference or inserting a
screwdriver between the upper (84) and lower
case (91)� If the cases still do not separate,
check that the actuator stem is not hung
up inside the bracket� DO NOT PROCEED
WITH DISASSEMBLY UNLESS THE CASES CAN
SEPARATE FREELY�

H. Continue loosening the tension nuts (95) evenly

approximately three turns each time ensuring that
the upper diaphragm case (84) and diaphragm (85)
continue to separate.

Note: Continue Step H until the tension nuts (95)
can be easily removed by hand indicating the upper
diaphragm case (84) is not under spring tension.

I. Remove tension bolts (95) and upper diaphragm case

(84).

J. Remove diaphragm (85) and diaphragm plate

subassembly from the actuator.

K. Remove retaining clip (78). Remove clevis pivot pin (79).

Inspect for damage and/or wear in clevis (80), lever (32),
clevis pins (79, 39) and rod end bearings (94). Replace if
necessary.

L. Clean all mating/sealing surfaces which will come in

contact with the diaphragm (85).

3�4�2�2 Reassembly

A. Connect rod end bearing (94) to diaphragm plate clevis

(80) by installing clevis pin (79) and retaining clips (78).
Ensure that the stem is installed such that the wrench
flats are at the end furthest from the diaphragm plate
(88).

B. Ensure spring (90) and spring guide (98) are properly

aligned in lower case (91) and install the diaphragm
plate and stem subassembly. Replace diaphragm (85).

C. Align marks for correct orientation of upper case (84)

and lower case (91). Replace upper diaphragm case (84)
and install long cap screws (95), warning plate (97) and
tension nuts (96).

Note: These bolts must be spaced as equally as
possible.

D. Take up tension nuts (96) evenly and sufficiently to

allow installation of short cap screws (86) and hex nuts
(87).

E. Tighten tension nuts (96) and then tighten all hex nuts

(87) using a criss-cross tightening pattern.

Note: Nuts should be tightened only enough to seal
the diaphragm between the upper and lower case. Do
not overtighten.

F. Connect rod end bearing (94) to lever (32) by installing

pivot pin (39), and retaining clips (40).

G. Replace covers (44 & 46) and reconnect signal and

supply lines.

H. Place back in service and, if so equipped, rotate

handwheel to desired position.

3�5 Handwheel Subassembly

3�5�1 Model 33 sizes B & C only� Refer to section 3�5�2 for
size AC actuators�

3�5�1�1 Disassembly

Turn handwheel to disengage position before
proceeding with handwheel maintenance�
Refer to Figures 13 through 16�

A. Remove retaining clips (63) and push out pin (66). Make

sure bushing (65) remains in the arm (64).

B. Remove the pivot pins (72) and remove handwheel

subassembly.

C. Remove handwheel shaft subassembly (55) retaining

ring (59) and unscrew nut (58). Remove needle bearing
and race (60). Clean and check needle bearing and race
for signs of wear. Replace if necessary.

D. Remove handwheel pivot (56) and thrust washer (61).

Check washer and replace if necessary. Check 0-ring
(57) and replace if necessary.

E. Clean ACME threads on handwheel (54) and shaft S/A

(55) and grease with Molykote G.

3�5�1�2 Reassembly (Figure 5)

A. Install thrust washer (61) and 0-ring (57). Apply silicone

lubricant sparingly to 0-ring.

B. Slide handwheel pivot (56) onto the handwheel

subassembly. Lubricate and install bearing race, needle
bearing and outer race.

C. Install nut (58) bevel side toward bearing race and

screw down tight. DO NOT OVERTIGHTEN. Replace
retaining ring (59). Correct assembly should have the
nut (58) touching the retaining ring (47).

14 | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

Do not rotate handwheel prior to replacing

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

WARNING

WARNING

WARNING

CAUTION

CAUTION

WARNING

pivot pins (72) into the handwheel mounting
bracket (62)�

D. Install assembly into handwheel mounting bracket (62)

and replace pivot pins (72).

E. Connect handwheel shaft S/A (55) to handwheel (54)

and to the lever arm with pin (66) and replace clip (63).

cross pattern.

D. Verify actuator stem (77) and rod end (94) are securely

connected to lever (32) through pivot pin (39) and that
retaining clips (40) are in place.

E. Loosen tension nuts (96) evenly in sequence. Do

not exceed three turns of any one nut (96) before
proceeding to the next one. Do not vary the sequence.

3�5�2 Handwheel Subassembly – Model 33, Size AC�
Refer to section 3�5�1 for sizes B & C� Refer to Figures
13, 14 & 16�

3�5�2�1 Disassembly

Turn handwheel to disengage position before
proceeding with handwheel maintenance�

A. Remove retaining ring (54-7) and shaft washer (54-4).

B. Rotate Handwheel (54) counterclockwise until it is

removed from housing (31).

C. Clean ACME threads on handwheel shaft (54-3) and

grease with Molykote G.

3�5�2�2 Reassembly� Refer to Figures 13, 14 & 16�

A. Thread handwheel assembly (54) into housing (31) until

it extends through the housing and the groove in the
stem (54-3) is visible.

B. Place shaft washer (54-4) over stem (54-3).

C. Install retaining ring (54-7) into groove on stem (54-3).

3�6 Diaphragm Replacement

Failure to evenly unload tension nuts may
result in personal injury!

F. Continue loosening tension nuts (96) until further

loosening of the tension nuts (96) is no longer
accompanied by an increase in separation of the upper
diaphragm case (84) from the lower case (91). At this
point the tension nuts (96), bolts (95) and warning plates
(97) can be removed.

G. Remove the upper diaphragm case (84) and diaphragm

(85).

The diaphragm plate (88) remains under spring
load�

3�6�1�2 Reassembly

A. Ensure that sealing surfaces of diaphragm cases (84)

and (91) are clean and free of any dirt or debris. Check
that there are no foreign objects that may interfere
with travel or damage diaphragm.

B. Install diaphragm (85) on diaphragm plate (88). Align

bolt holes with holes in lower case (91).

Spring diaphragm actuators contain large
forces due to their preloaded powerful springs�
Failure to carefully follow this procedure can
result in personal injury!�

3�6�1 Model 33 sizes B & C only� Refer to section

3�6�1�1 Disassembly

A. Relieve actuator pressure and disconnect air supply. Do

not remove pivot pin (39).

B. Verify that all three tension bolts (95) and nuts (96) are

in place and secure.

C. Remove nuts (87) and cap screws (86) following a criss-

C. Install three tension bolts (95) with warning plates (97)

into upper case (84). Ensure bolts are equally spaced at
120° to each other.

D. Mount upper case (84) onto diaphragm plate (88) such

that the tension bolts pass through holes in diaphragm
(85) and lower case (91).

E. Install tension nuts (96) finger tight onto tension bolts

(95).

F. Tighten each tension nut (96) three turns before

proceeding to the next to ensure actuator spring (90)
is evenly loaded. Continue until the diaphragm is firmly
sandwiched between the flanges of the upper and
lower diaphragm cases. Torque tighten tension bolts to
50 in. lbs.

Masoneilan 36005 Series High Capacity Control Ball Valves | 15

© 2014 General Electric Company. All rights reserved.

G. Install cap screws (86) and nuts (87). Torque tighten to

WARNING

50 in. lbs. in a criss-cross pattern. As this will tend to
unload the tension bolts (96) repeat torque tightening
of tension bolts and cap screws (86) to 50 in. lbs. in
a criss-cross pattern until joint is evenly loaded to
specified torque values.

H. Reconnect air supply.

I. Stroke actuator to confirm operation. 3.6.2 Model 33 size

AC actuators only. Refer to section 3.6.1 for sizes B & C.

3�6�2 for size AC actuators�

3�6�2�1 Disassembly

A. Relieve actuator pressure and disconnect air supply. Do

not remove pivot pin (39).

G. Remove the upper diaphragm case (84) and diaphragm

(85).

The diaphragm plate (88) remains under spring load.

3�6�2�2 Reassembly

A. Ensure that sealing surfaces of diaphragm cases (84)

and (91) are clean and free of any dirt or debris. Check
that there are no foreign objects that may interfere
with travel or damage diaphragm.

B. Install diaphragm (85) on diaphragm plate (88). Align

bolt holes with holes in lower case (91).

C. Install three tension bolts (95) with warning plates (97)

into upper case (84). Ensure bolts are equally spaced
around the circumference of the case.

B. Verify that all three tension bolts (95) and nuts (96) are

in place and secure.

C. Remove nuts (87) and cap screws (86) following a criss-

cross pattern.

D. Verify actuator stem (15) and rod end (94) are securely

connected to lever (32) through pivot pin (39) and that
retaining clips (40) are in place.

E. Loosen tension nuts (96) evenly in sequence. Do

not exceed three turns of any one nut (96) before
proceeding to the next one. Do not vary the sequence.

Failure to evenly unload tension nuts may
result in personal injury!

F. Continue loosening tension nuts (96) until further

loosening of the tension nuts (96) is no longer
accompanied by an increase in separation of the upper
diaphragm case (84) from the lower case (91). At this
point the tension nuts (96), bolts (95) and warning plates
(97) can be removed.

D. Mount upper case (84) onto diaphragm plate (88) such

that the tension bolts pass through holes in diaphragm
(85) and lower case (91).

E. Install tension nuts (96) finger tight onto tension bolts

(95).

F. Tighten each tension nut (86) three turns before

proceeding to the next to ensure actuator spring (90)
is evenly loaded. Continue until the diaphragm is firmly
sandwiched between the flanges of the upper and
lower diaphragm cases. Torque tighten tension bolts to
50 in. lbs.

G. Install cap screws (86) and nuts (87). Torque tighten to

50 in. lbs. in a criss-cross pattern. As this will tend to
unload the tension bolts (95) repeat torque tightening
of tension bolts and cap screws (86) to 50 in. lbs. in
a criss-cross pattern until joint is evenly loaded to
specified torque values.

H. Reconnect air supply.

I. Stroke actuator to confirm operation.

16 | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

Masoneilan 36005 Series High Capacity Control Ball Valves | 17

© 2014 General Electric Company. All rights reserved.

18 | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

Masoneilan 36005 Series High Capacity Control Ball Valves | 19

© 2014 General Electric Company. All rights reserved.

20 | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

Masoneilan 36005 Series High Capacity Control Ball Valves | 21

© 2014 General Electric Company. All rights reserved.

22 | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

Table 1 - Body Parts List Table 2 - Bracket and Linkage Parts List

Ref� No� Description

1

2

3

Body
Ball Plug
Retainer (ISA S75.04)
Retainer (ANSI B16.10)

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

Gasket (Retainer/Body)
Shaft
Backup Ring (Std. Metal Seal)
Gasket (Std. Metal Seal)
Seal Ring
Slot Button Head Screw
Flat Washer
Pin Shaft
Stud, End Flange
Nut, End Flange
End Flange
Gasket, Pin Shaft
Lower Bushing
Upper Bushing
Lockwasher
Packing
Packing Follower
O-Ring
O-Ring
Packing Box Flange
Nut, End Flange
Stud, Packing Flange
Stud, Bonnet
Safety Pin
Packing Adapter
Shaft Ring
Radial Seal
Wave Spring
Backup Ring

Ref� No� Description

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

99

100

101

102

103

104

105

Cap Screw
Lockwasher
Indicator Arm
Machine Screw
Hex Nut
Indicator Dot
Pivot Pin
Retaining Clip
Front Cover S/A
Shaft Cover
Machine Screw
Bottom Cover
Boss Cover
Side Cover
Bearing
Hole Cover
Yoke
Lever
Lockwasher
Screw
Hex Nut
Adjusting Screw
Pin
Roller
Thread Plug

Masoneilan 36005 Series High Capacity Control Ball Valves | 23

© 2014 General Electric Company. All rights reserved.

Table 3 - Handwheel Parts List Table 4 - Actuator Parts List

Ref� No� Description

32

33

34

51

52

53

54

51-1*

54-2*

54-3*

54-4*

54-5*

54-6*

54 -7*

54-8*

54-9*

55

55A

55B

55C

56

57

58

59

60

60A

61

62

63

64

65

66

67

68

69

70

71

72

Lever Set
Lockwasher
Cap Screw
End Cap
Plate
Screw
Handwheel S/A
Handwheel
Lock, Handwheel
Handwheel Shaft
Washer
Key
Screw
Retaining Ring
Handwheel Plate
Screw
Handwheel Shaft S/A
Handwheel Stop
Cap Screw
Spacer
Handwheel Pivot
O-Ring
Locknut
Retianing Ring
Needle Bearing
Bearing Race
Thrust Washer
Handwheel Bracket
Retaining Clip
Lever Arm
Lever Arm Bearing
Clevis Pin
Guide
Lever Arm PIn
Spacer
Cap Screw
Lockwasher
Pivot PIn

*Size AC Actuator Only

Ref� No� Description

75

76

77

78

79

80

83

84

85

86

87

88

89

90

91

92

92

94

95

95

97

98

Hex Nut
Lockwasher
Stem
Clip
Clevis Pin
Clevis
Button Head Cap Screw
Upper Diaphragm Case
Diaphragm
Cap Screw
Nut
Diaphragm Plate
Spring Guide
Spring
Lower Diaphragm Case
Stop
Nut
Rod End Bearing
Tension Bolt
Tension Nut
Warning Plate
Spring Button

24 | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

Table 5 - Line Bolting (Inlet Side)

Size ANSI

in DN in mm in mm

1 25

1-1/2 40

2 50

3 80

4 100

6 150

8 200

10 250

12 300

150 2 1/2" 64 3 1/2" 89

300 3" 76 - -

150 3" 76 5" 140

300 3 1/2" 89 - -

150 3 3/4" 95 5 1/2" 140

300 4" 100 - -

150 4" 100 5 1/4" 134

300 4 3/4" 121 - -

150 4" 100 5 1/4" 134

300 5" 130 - -

150 4 1/2" 114 6" 153

300 6" 153 - -

150 4 3/4" 121 6 3/4" 172

300 6" 153 - -

150 5 1/4" 134 6 1/2" 165

300 7" 178 - -

150 5 1/2" 140 6" 153

300 7 1/2" 191 - -

ISA S75�04 Face

to Face

ANSI B6�10

Short Pattern

Face to Face

Masoneilan 36005 Series High Capacity Control Ball Valves | 25

© 2014 General Electric Company. All rights reserved.

NOTES

26 | GE Oil & Gas

© 2014 General Electric Company. All rights reserved.

NOTES

Masoneilan 36005 Series High Capacity Control Ball Valves | 27

DIRECT SALES OFFICE LOCATIONS

AUSTRALIA
Brisbane:
Phone: [phone]
Fax: [phone]

Perth:
Phone: [phone]
Fax: [phone]

Melbourne:
Phone: [phone]
Fax : [phone]

BELGIUM
Phone: [phone]
Fax: [phone]

BRAZIL
Phone: [phone]
Fax: [phone]

CHINA
Phone: [phone]
Fax: [phone]

FRANCE
Courbevoie
Phone: [phone]
Fax: [phone]

GERMANY
Ratingen
Phone: [phone]
Fax: [phone]

INDIA
Mumbai
Phone: [phone]
Fax: [phone]

New Delhi
Phone: [phone]
Fax: [phone]

ITALY
Phone: [phone]
Fax: [phone]

JAPAN
Chiba
Phone: [phone]
Fax: [phone]

KOREA
Phone: [phone]
Fax: [phone]

MALAYSIA
Phone: [phone]
Fax: [phone]

MEXICO
Phone: [phone]

.

THE NETHERLANDS
Phone: [phone]
Fax: [phone]

RUSSIA
Veliky Novgorod
Phone: [phone]
Fax: [phone]

Moscow
Phone: [phone]
Fax: [phone]

SAUDI ARABIA
Phone: [phone]
Fax: [phone]

SINGAPORE
Phone: [phone]
Fax: [phone]

SOUTH AFRICA
Phone: [phone]
Fax: [phone]

SOUTH & CENTRAL
AMERICA AND THE CARIBBEAN
Phone: [phone]
Fax: [phone]

SPAIN
Phone: [phone]
Fax: [phone]

UNITED ARAB EMIRATES
Phone: [phone]
Fax: [phone]

UNITED KINGDOM
Wooburn Green
Phone: [phone]
Fax: [phone]

UNITED STATES
Massachusetts
Phone: [phone]
Fax: [phone]

Corpus Christi, Texas
Phone: [phone]
Fax: [phone]

Deer Park, Texas
Phone: [phone]
Fax: [phone]

Houston, Texas
Phone: [phone]
Fax: [phone]

* Masoneilan and V-Max are registered trademarks of the General Electric Company.
Other company names and product names used in this document are the registered trademarks
or trademarks of their respective owners.

© 2014 General Elec tric Compa ny. All rights res erved.

GEA30562A 05/2014