Maxi Manual

The Fort Vale Supermaxi Relief ValveMaintenance manual

Chapter 1 Identify Your Valve.

(a) 65mm High Performance Mk3 Supermaxi Highflow March 1997 - Present.(b) 65mm Mk3 Supermaxi Highflow March 1995 - March 1997 .(c) 65mm Mk2 Supermaxi Highflow November 1989 - March 1995.(d) 65mm Maxi Highflow Pre November 1989.

(c) Troubleshooting.

Chapter 3 Refurbishment.

(a) Tool kit.(b) Dismantling Valves.(c) Removing Seals(d) Replacing Seals.(e) Lapping seals.(f) Valve reassembly.

(e) 80mm Hyperflow Supermaxi March 1997 - .(f) Part numbering system.

Chapter 2 Pressure and vacuum leak test.

(a) Pressure test.(b) Vacuum test.

Contents

Chapter 1Identify Your Valve

(a) 65mm High Performance Mk3 Supermaxi Highflow March 1997 - Present.

(b) 65mm Mk3 Supermaxi Highflow March 1995 - March 1997 .

(c) 65mm Mk2 Supermaxi Highflow November 1989 - March 1995.

(d) 65mm Maxi Highflow Pre November 1989.

(e) 80mm Hyperflow Supermaxi March 1997 - .

(f) Part numbering system.

SERVICED BY

SERVICE DATE

65mm High performance Mk3 Supermaxi Highflow 010/series

The simplest way to visually recognize a Mk3super maxi is to look at the outlet ports on thecast body there will be 3 outlet ports with anotch in the centre for the C-spanner

SERVICE EVERY 6 MONTHS1997 FORT VALE ENG. LTD.

MADE IN UK.TEL: 01282 440000FAX: 01282 692554

SEAL TYPE

FORTYT

CONTACT PARTS

316 ST ST

C

FORT VALE

SERIAL NO:

PART NUMBER: 010/16312

FULL FLOW

AT PRESSURE

FED. REG. FLOW (83%)

VACUUM SETTING (-0 +5%)

SET PRESS.(2.5%) 4.40

16036

76.56 5.28

7834 13310

6.2 0.21

2 .5 " MK 3 SU PER MAX I H IG HF LO W REL I E F VALVEL LOYDS REG I S T ER T YPE APP. NO. 95 /00163 ( E2 )

M /HR

BAR

BAR

M /HR

BARVAC

PSIG

SCFM

PSIG

SCFM

63.8

HgVAC

9438 3

3

9700000

2.5" BSP

4.0

4

[102.6

mm

]

3.4

6"

[87.9

mm

]

2.68"Dia [68.0 mm]

Serial Number9708749 or greater

Part Number010/*****

Lloyds registertype app No 95/00163(E2)

Chamfer on boreof inlet.

No lift stop

No holes inface of vacuum

poppet.

4.48" Dia [113.8]

C-spanner notch

Cast body

3 Outlet port

The First step to identifying your valve is to read the text on the top cap.In some cases the text maybe difficult to read in these instances there are somebasic features on the valves which will help you to identify the valves.

(A)

SERVICED BY

SERVICE DATE

65mm Mk3 Supermaxi Highflow 010/series

The simplest way to visually recognize a Mk3super maxi is to look at the outlet ports on thecast body there will be 3 outlet ports with anotch in the centre for the C-spanner


MADE IN UK.TEL: 01282 440000FAX: 01282 692554

SEAL TYPE

FORTYT

CONTACT PARTS

316 ST ST

C

FORT VALE

SERIAL NO:


FULL FLOW

AT PRESSURE



SET PRESS.(2.5%) 4.40

15741

76.56 5.28

7690 13065

6.0 0.203

2 .5 " MK 3 SU PER MAX I H IG HF LO W REL I E F VALVEL LOYDS REG I S T ER T YPE APP. NO. 95 /00163 ( E1 )

M /HR

BAR

BAR

M /HR

BARVAC

PSIG

SCFM

PSIG

SCFM

63.8

HgVAC

9265 3

3

9700000

2.5" BSP

4.0

4

[102.6

mm

]

3.4

6"

[87.9

mm

]

2.66"Dia [67.6 mm]

Serial Number95***** to 9708749


Lloyds registertype app No 95/00163

or 95/00163(E1)

No chamfer onbore of inlet.

Lift stop


poppet.

4.48" Dia [113.8]

C-spanner notch

Cast body

3 Outlet port

The First step to identifying your valve is to read the text on the top cap.In some cases the text maybe difficult to read in these instances there are somebasic features on the valves which will help you to identify the valves.

(B)

In some cases the text maybe difficult to read in these instances there are some basicfeatures on the valves which will help to identify the valves.

65mm Mk2 Supermaxi Highflow 000/series

The simplest way to visually recognize a Mk2super maxi is to look at the support legs on thecast body there will be 2 or 3 0.5 diameterholes drilled through for the C-spanner


MADE IN UK.TEL: 01282 692525FAX: 01282 692554

SEAL TYPE

FORTYT

CONTACT PARTS

316 ST ST

C

FORT VALE

SERIAL NO:


FULL FLOW

AT PRESSURE



SET PRESS.(2.5%) 4.40

14704

76.56 5.28

7183 12204

6.0 0.203

2.5" SUPER MAXI HIGHFLOW RELIEF VALVELLOYDS REGISTER TYPE APP. NO. 91/0020

M /HR

BAR

BAR

M /HR

BARVAC

PSIG

SCFM

PSIG

SCFM

63.8

HgVAC

8654 3

3

9100000

Serial Number91***** to 95*****


Lloyds registertype app No 91/00020

Lift stop

2 holes inface of vacuum

poppet.

SER

VICE EVERY 6 MON

THS

TEL: 0282 692525 TELEX 63520

3

FO

RT VALE ENG. LTD. 1982 NELSON

LANC

S

21/2"MAXIHIGHFLOW RELIEF VALVE

Mat : 316 ST ST SEALFORTYT

C

SER No:PART No

FULL FLOWAT PRES

FED. REG. FLOW (83%)VACUUM SETTING (-0 +5%)

SET PRES.2.5%4.40

14704

76.56

76.56

5.28

7183

6.0

0.203

M /HR

BAR

BAR

BARVAC

PSIG

SCFM

PSIGPSIGSCFM

63.8

HgVAC

86543

9100000000/16312

The First step to identifying your valve is to read the text on the top cap.

SERVICED BY

SERVICE DATE

Cast body

3 Outlet ports

Some older valves may havepressed text on the top cap

C-spanner drive hole.

2.66" Dia [67.6]2.5" BSP

4.0

4"

[102.6

]

3.4

6"

[87.9

]

( C)

In some cases the text maybe difficult to read in these instances there are some basicfeatures on the valves to identify the valves.which will help

65mm Maxi Highflow 00/series

The simplest way to visually recognize a Mk1Maxi is to look at the body it is a fabricated bodywith 4 outlet ports and on the support legs therewill be 2 or 3 0.5 diameter holes drilled throughfor the C-spanner.On top cap there will be a hexagon nut which isthe vacuum guide, which may have either avacuum vent button, (as shown) or a black plasticcap fitted.


C-spanner drive hole.

SERVICE EVERY 6 M

ON

THS

TEL: 0282 692525 TELEX 63520

3F

O

RT VALE ENG. LTD. 1982 NELSO

N LAN

CS

21/2"MAXIHIGHFLOW RELIEF VALVE

Mat : 316 ST ST SEALFORTYT

C

SER No:PART No

FULL FLOWAT PRES

FED. REG. FLOW (83%)VACUUM SETTING (-0 +5%)

SET PRES.2.5%4.40

13529

76.56

76.56

5.28

6610

6.0

0.203

M /HR

BAR

BAR

BARVAC

PSIG

SCFM

PSIGPSIGSCFM

63.8

HgVAC

79633

910000000/16312

2.5" BSP

4.0

3"

[102]

3.4

5"[

87.6

]

2.66" Dia [67.6]

Serial No Pre 91*****

Part No00/*****

Stamped text

Poppet guidenut

2 Holes inface of vacuum

poppet.

Stepped profileon pressure plate

4 outlet ports.

Fabricated body.

Guide Nut on top cap

(D)

SERVICED BY

SERVICE DATE

FO

RT

VA

LE

31

6ST

ST

MA

DE

INU

K


MADE IN UK.TEL: 01282 440000FAX: 01282 692554

SEAL TYPE

FORTYT

CONTACT PARTS

316 ST ST

C

FORT VALE

SERIAL NO:


FULL FLOW

AT PRESSURE



SET PRESS.(2.5%) 4.40

16036

76.56 5.28

7834 13310

6.2 0.21

2 .5 " MK3 SUPER MAX I H IGHFLOW REL I E F VALVEL LOYDS REG I S T ER T YPE APP. NO. 97 /00072 )

M /HR

BAR

BAR

M /HR

BARVAC

PSIG

SCFM

PSIG

SCFM

63.8

HgVAC

9438 3

3

9700000

In some cases the text maybe difficult to read in these instances there are some basicfeatures on the valves to identify the valves.which will help

80mm Mk3 Hyper Flow Supermaxi 023/*****8**


(E)

3.25" Dia [82.5]

4.3

4"

[110.2

]

0.6

4"[

16.3

]

4.48" Dia [113.8]

Serial number 97*****or greater

Part number023/*****8**

Lloyds register typeapp No 97/00072

No lift stop


poppet.

Triple springset

1/4 BSP gauge hole

Cast body

3 outlet ports

Part Numbeing System..

Each relief valve part number describes the valve type, seal material and pressure and vacuum settings,bore and flange styles as follows:-

*** / * ** ** ** *

VALVE CODE

SEAL CODEVACUUM CODE

BORE STYLE

FLANGE STYLE

NOTE: bore style and flange style are omitted from the part no. when the valve is a screwed standard type.

00 = 2 in BSP Maxi relief valve.000 = 2 in BSP Mk2 Super Maxi relief valve.010 = 2 in BSP Mk3 Super Maxi relief valve & high performance MK3 .0*2 = 2 in BSP standard valve complete with flame gauze.

03 = Fabricated Flanged - Maxi relief valve standard body length003 = Fabricated Flanged - Mk2 Super Maxi relief valve standard body length.013 = Cast Flanged - Mk3 Super Maxi relief valve standard body length.

08 = 2 in BSP Maxi relief valve extended body length.008 = 2 in BSP Mk2 Super Maxi relief valve extended body length.018 = 2 in BSP Mk3 Super Maxi relief valve extended body length.

09 = Fabricated Flanged - Maxi relief valve extended body length009 = Fabricated Flanged - Mk2 Super Maxi relief valve extended body length.019 = Cast Flanged - Mk3 Super Maxi relief valve extended body length.

023 = Cast Flanged - Hyper flow Super Maxi relief valve standard body length.0*B = 2 BSP valve with vent button..

Valve Code.

(F)

PRESSURE CODE

Seal Material.

Pressure code.

Vacuum code.

Bore Styles.

Flange Styles.

0 = Viton A - pressure and vacuum.1 = Fortyte -pressure; PTFE - vacuum.2 = PTFE - pressure and vacuum.3 = Kalrez - pressure.4 = Nitrile - pressure and vacuum.5 = Fortyte - pressure; EPDM - vacuum.6 = Tytan - pressure and vacuum.7 = Perfluoroelastomer - pressure and vacuum.

Pressure setting codes represent approximate set pressure in PSI.

Vacuum setting codes represent approximate vacuum setting in inches of mercury multiplied by two.

65 = 65mm parallel bore.66 = 65-80 tapered bore to suit 80mm bursting disc.80 = 80mm parallel bore.

0 = DIN 651 = DIN 802 = 2 in Table D.3 = 3 in. Table D4 = 2 in ASA 150.5 = 3 in. ASA 150

fi

fi

fi Kalrez, fi Viton : Du Pont registered trademarks

Chapter 2Pressure and vacuum

leak test.

(a) Tool list.

(b) Testing.

(c) Performance criteria.

(d) Troubleshooting.

Compressed air Supply.

1) Clean Air : The air supply must be free of oil from the compressor (the de-oiler must be kept in goodcondition), and free from foreign bodies (clean filters and plastic or stainless steel piping downstreamfrom filters). All supply pipes must have an internal diameter of 6mm minimum.

2) The air supply to the test bench must be a minimum of 20% greater than the test pressure of theValve.

Tool list(A)

Pressure gauges.

1) Must be calibrated control gauge.Scale = 0 - 100 Psig or 0-7 Bars.Scale divisions = 0.5 Psig or 0.025 BarsDial Diameter = 150mm minimum.

2) The gauge must be calibrated by a certified authority and must be re-calibrated every 6 months.

3) The gauge Must never be submitted to a greater pressure than their maximum reading pressureor to a vacuum.

4) The gauge point must not be more than 250mm from the valve and the pipework must have aninternal diameter of 6mm minimum.

Tolerance = 0.25%.

Test Rig P/ N 400/9100 C-spanner P/ N 400/3000Water retaining bandP/N 400/8540

Pressure plate liftingTool pressure / vacuumvalves P/N 400/8530

Pressure plate liftingTool pressure onlyvalves P/N 400/8730

Bottle of soapy water

3/32 Allen Key Knife or smallscrew driver

13mm A/F Spanner

Adaptor Flange

Testing(B)All testing should be carried out in a closed clean room on a dedicated test rig.New valves should be taken from their plastic bags directly prior to testing.Old valves MUST be cleaned throughly prior to testing

Ensure test pot is clean and free from foreign bodes

(Fig 1)

(Fig 2)

(Fig 4)

Remove valve -tank gasket

Wet rubber seal to reduce frictionand screw valve into 2.5 BSP

(Fig 6)

(Fig 5)

(Fig 3)

Tighten valve with a C-Spanner

If you are testing a flanged valveyou will need a adaptor flange.

Once the valve has been attached to the test rig open and close the valve 2 or 3 times by opening the airsupply to full pressure and shutting it off as quickly a possible before the pressure tests is carried out.

Soapy water to detect leak

Rubber band to retain water.

On screwed maxis pull the rubber band over the bottom edge of thevalve creating 3 small pockets fill these pockets with soapy water

(Fig 8)

(Fig 7)

On Flanged valves apply the soapywater to the gap between the pressureplate and the valve body on all thevalve ports as shown in fig 8

Apply soapy water here

SELECT TEST TYPE

VENT

MAX PRESSURE 100PSI

OFF

ON

OFF

ONSUPPLY

OFF

ON

0 - 100 Psig 0 - 7 Barg

Pressure Gauge

0 - 29.5"hg 0 - 1.013 Barg

Vacuum Gauge

0 - 7 BarGauge

FORT VALE ENG LTDPARKFIELD WORKSBRUNSWICK STNELSON, LANCSBB9 0SGTEL 01282 44000TELEX 635203

WARNINGAPPLYING VACUUM TO PRESSURE GAUGE ORPRESSURE TO VACUUM GAUGE WILL CAUSE DAMAGEENSURE THAT CORRECT GAUGE IS SWITCHED TO ONAND THAT THE OTHER IS OFF

SUPPLYPRESSUREREGULATOR

PRESSUREGAUGE

VACUUMGAUGE

PRESSURETEST

VACUUMTEST

SUPPLYPRESSURE

Test rig settings for pressure test

Once the valve has been attached to the test rig, the test rig should be set as shown below for pressure test.

SUPPLY

SUPPLY

OFF

OFF

ON

ON

SELECT TEST TYPE

VENT

PRESSURETEST

VACUUMTEST

Slowly turn on the supply pressure and allow thepressure in the test chamber to build up gradually untilthe valve shows first signs of leakage this is then the setpressure, this pressure should fall within the criteria setout in the section labeled performance criteria.

Turn off the air supply to the valve and allow the valve toreseal note the pressure at which the valve stops leakingthis is the resealing value which should fall within thecriteria set out in the section labeled performance criteria.

Check for leakage here

If the valve is a pressure vacuum valveOnce the valve has stopped leaking leave the valve pressurized for 5minuets to check the vacuum poppet If there is no pressure drop in thistime the vacuum poppet is sealing on pressure

Vent the pressure from the test rig,

For pressure only valves the test is now complete, if the valve haspassed the test criteria remove the valve from the test rig and placein a clean plastic bag to prevent contamination. Should the valvehave failed please see the chapter on troubleshooting.

(Fig10)

(Fig 11)

(Fig 12)

(Fig 13)

(Fig 9)

SELECT TEST TYPE

VENT

MAX PRESSURE 100PSI

OFF

ON

OFF

ONSUPPLY

OFF

ON

0 - 100 Psig 0 - 7 Barg

Pressure Gauge

0 - 29.5"hg 0 - 1.013 Barg

Vacuum Gauge

0 - 7 BarGauge

FORT VALE ENG LTDPARKFIELD WORKSBRUNSWICK STNELSON, LANCSBB9 0SGTEL 01282 44000TELEX 635203

WARNINGAPPLYING VACUUM TO PRESSURE GAUGE ORPRESSURE TO VACUUM GAUGE WILL CAUSE DAMAGEENSURE THAT CORRECT GAUGE IS SWITCHED TO ONAND THAT THE OTHER IS OFF

SUPPLYPRESSUREREGULATOR

PRESSUREGAUGE

VACUUMGAUGE

PRESSURETEST

VACUUMTEST

SUPPLYPRESSURE

Test rig settings for vacuum test

For pressure vacuum valves the pressure test is now complete, if the valve has passed the test criteriaproceed to the vacuum test should the valve have failed please see the chapter on troubleshooting.

(Fig 14)

(Fig 15)(Fig 16)

Remove plastic cap

Insert screw driver

Push vacuum poppet down

Prior to vacuum testing if the valve is a valvethat has been in service check the vacuumpoppet is working correctly.

If the poppet is found to be stickingcheck for product ingress and cleanas required

The test rig regulator pressure should be reduced to 25 psi and the valve moved to the positionsshown taking care not to pressurize the vacuum gauge as you do so

SUPPLYOFF

ON

(Fig17)

Open supply valve slowly to the fully open position, read the vacuumgauge for the set pressure this pressure should be within the performancecriteria set out in the section labeled performance criteria.

The test is now complete, if the valve has passed the test criteriaremove the valve from the test rig and place in a clean plastic bag toprevent dirt ingress. should the valve have failed please see thechapter on troubleshooting.

When increasing air supply pressure, the safety valve must not leak below this point.Above 85% of set pressure, bubbles will appear at specific points on the pressure platecircumference.

At test pressure the valve opens and bubbles should appear all around the pressure plate.

After valve has been opened and when air supply is shut off, the valve can leak until apressure equal to 90% of test pressure is reached. Below this point, the valve should re-sealand the pressure indicated by the pressure gauge should remain stable. Check this point for1 minute.

Within the tolerance bands (hatched zones) the valve is performing correctlyand should not be reset and/or repaired.

Tolerance:

3

Performance Criteria

Test set pressure TP 2

Re-sealing Pressure 3

(minimum pressure held after closing)

Minimum pressure held without leakage 1

0 : Atmospheric Pressure

Vacuum Test Pressure VP

(For test rigs equipped withVacuum testing facility)

0 Absolute Pressure

T.P+2.5%

T.P-2.5%

T.P

+2.5%

-2.5%

90% of T.P

+2.5%

-2.5%

85% of T.P

VP +5%

VA

CU

UM

PR

ES

SU

RE

ACCEPTABLETOLERANCE

ACCEPTABLETOLERANCE

ACCEPTABLETOLERANCE

ACCEPTABLETOLERANCE

1

2

4

(C),

(D) Troubleshooting

The valve has failed it pressure test due to cracking at a lower pressure than therequired set pressure.

If the valve is a new valve the most frequent fault, is dirt ingress in to the valve seals from thesurrounding environment and or air supply.

Remove the valve from the test rig and ensure there is no dirt in the in the test rig boss and check thatthe airline is clean. Replace the valve on test rig increase the regulator pressure to the maximum and ventthe valve to blow any dirt that may be on the valve seat.

1

2 Dirt may have got trapped under the valve seal. Use the setting tool lift the valve pressure plate as shownbelow then blow any dirt from the valve seal face with an airline .

(Fig 18)

Insert setting tool into top cap

(Fig 19) (Fig 20)

Locate setting tool onto vacuum poppet or in topressure plate threads.

(Fig 21)(Fig 22)

Whilst holding the setting tool stemtighten the adjusting nut to lift pressureplate from the seal face

Hold setting toolstem

Once the pressure plate is 3.0mm clearof the seal face blow compressed airacross the seal face.

Blow compressed air

Lower the pressure plate onto the seal face, ensuring the seal plate does not rotate as you do so removethe setting tool and retest the valve.

Setting tool400/8530

Setting tool400/8730

Seal damage,The seals of the valve may be damaged due to product corrosion or dirt being embedded into the sealor a indent from dirt that has been subsequently dislodged.

Should this be the case replace the seals (see the relevant chapter in this manual).

Seal face damage,The seal faces of the valve may be damaged due to product corrosion, you ca recognize this by thevalves seats appearing dull and mottled.

Should this be the case re-skim the valve seats (see the relevant chapter in this manual).

Spring Failure,It is possible for the spring to fracture or collapse due to corrosive vapour environments.

In these cases a new spring must be acquired from Fort Vale and the valve refurbished as per thismanual

Test Rig malfunction,Check your test rig gauge regularly to ensure accurate and repeatable results.

3

4

5

6

Chapter 3Refurbishment

(a) Tool list.

(b) Striping the valve.

(c) Removing seals.

(d) Replacing seals.

(e) Lapping Seals.

(f) Re-assembly.

(A) Tool List

Description Fort Vale Part No

1) 3mm & 5mm and Allen keys.2) 3/32 Allen key.3) C-Spanner 400/30004) Teflon Round block. 400/85555) 2x 13mm A/F spanner6) Small Sharp Knife7) Press Drill Cap location Tool 400/83308) Vacuum poppet location Tool 400/83209) Pressure seal expander (65mm) 400/851110) Pressure seal pusher (65mm) 400/851211) Pressure seal Flattener (65mm) 400/852212) Pressure seal expander (80mm) 400/871113) Pressure seal pusher (80mm) 400/871214) Pressure seal Flattener (80mm) 400/872215) Press spacer 400/852016) Drill press lapping tool 400/855017) Pressure plate lifting clamp (Pressure/vacuum) 400/853018) Pressure plate lifting clamp (Pressure only) 400/873019) Lapping plate 400/856020) Engineers Blue.21) Vacuum seal expander22) Vacuum seal pusher,23) 3.7mm drill24) 3/16 tap25) Vacuum poppet assembly tool 400/855626) Fortyt seal extraction tool. 400/855727) 600 Grit wet & dry emery paper28) Emery cloth29) Form tool for lathe30) Super Glue.31) Tytan seal pusher

Plant equipment.

1) Pedestal Drill Press.2) Fly press or toggle press.3) Lathe.4) Vice.

(B) Stripping the valves

Spring loadedValve dismantle

with caution.

(Fig 23)

Remove lead seal

Using 3/32mm Allen keyremove 3/16 grub screw

(Fig 24)

(Fig 25)

(Fig 26) (Fig 27)

Place PTFE block on drillpress bed and cap drive toolinto drill arbor

Place valve overPTFE block

Locate cap drive holes onto cap location tool

(Fig 28)

Cap and drive toollocated

(Fig 29)

Compress valve to lift pressureplate clear of seal face

(Fig 30)) (Fig 31)

Pressure plate

Seal face

On 00/series valves remove the Liftadjusting screw to reveal the driveholes

(Fig 32) (Fig 33)

Lock drillpress arbor inplace

Rotate valve body to unscrew valve.NoteThe body may be difficult to rotate due to burrs from the3/16 grub screw tapping, to loosen the body rotate the bodyboth clockwise and anticlockwise to break the burr

(Fig 34)

Unscrew the valve body fully from the cap, itmay be necessary to release the lock on thedrillpress (taking the load with the feed handle asyou do so) to allow the valve body moreclearance.

Spring loadedValve dismantle

with caution.

Release the lock on the drillpress, taking theload with the feed handle as you do so.Slowly rotate the drill feed handle until thespring load is removed.

(Fig 35)

Remove pressure platefrom valve body

Remove cap and springs fromvalve body, label springs withvalve Part Number to assistidentification at assembly.

(Fig 37)

(Fig 38)

(Fig 36)

Dim

ensi

on

A"

Measure the height of the vacuum poppet assembly before stripping thepressure plate this dimension can then be used in assisting the re-assembly

010/series pressure plate stripping.

(Fig 42)

(Fig 43)

(Fig 44)

(Fig 45)

Remove and label springwith valve part number

Remove poppetfrom pressure plate

Once the poppet is free from thepressure plate check the seal fordamage.

Check the pressure seal for damage itmay not be necessary to replace the main

(Fig 39)

(Fig 40)

(Fig 41)

Place Vacuum poppetassembly tool in a vice, pushpressure plate assembly on totool, compressing springs.

Once the spring iscompressed slide tool underM8 nuts

Remove Nuts with2x 13mmA/ Fspanners


Place the poppet location tool ina vice and locate the vacuumpoppet drive holes on to thelocation tool spigots, as perfigure 49.

(Fig 46)

Dim

ensi

on

A"

Measure the height of the vacuum poppetassembly before stripping the pressure plate thisdimension can then be used in assisting the re-assembly


(Fig 48)

(Fig 47)

(Fig 49)

(Fig 50)

Using a 13mm a/fspanner remove the M8nut

(Fig 53)

(Fig 54) (Fig 56)

Remove and label springwith valve part number.

Remove poppet from pressure plate.


Check the pressure seal for damage it maynot be necessary to replace the main seal.

(Fig 51)

(Fig 52)

Unscrew spring pad by hand.

(Fig 55)

If the vale is a tytan sealvalve check the sealing facefor dirt or corrosion.

Seal Face


Place the poppet location tool ina vice and locate the vacuumpoppet drive holes on to thelocation tool spigots, as perfigure 60.

(Fig 57)

Dim

ensi

on

A"

Measure the height of the vacuum poppetassembly before stripping the pressure plate thisdiameter can then be used in assisting the re-assembly

(Fig 59)

(Fig 58)

(Fig 60)


(Fig 61) (Fig 62)

Locate 4mm allen key intoM8 grub screw.

Remove M8 grub screw

(Fig 65)

(Fig 66) (Fig 68)


Remove poppet from pressure plate


Check the pressure seal for damage itmay not be necessary to replace the main

(Fig 63)

(Fig 64)

Unscrew spring pad by hand.

If the vale is a tytan sealvalve check the sealing facefor dirt or corrosion.

(Fig 67)

Twist the knife to snap theseal and remove from poppet.

Using either a thepoppet stem in the chuck taking care not todamage the M8 threads and polish the sealgroove to remove any residue of glue.

pillar drill or a lathe hold

(Fig 69)

Vacuum Poppet seal Removal

Fortyt seal

(Fig 70)

Using seal removing tool pushradius under seal Pull seal up and out of groove

Ptfe Seal

(Fig 71)(Fig 72)

(Fig 73)

Cut Seal with sharp knife though

Take care not damage the poppetseal face in marked red above

(Fig 74)

Using a knife break the bond betweenthe seal and the poppet work round thepoppet groove taking care not to damagethe poppet face

Rubber seals

(Fig 75)

(C),

PTFE Seal

(Fig 78)

Insert a knife in to PTFE seal taking care notto damage the seal groove and prise the sealout of the seal groove

Using seal extraction toolpush tool down the side ofthe seal.

Pull seal up and out of groovewith extraction tool

Fortyt seal

(Fig 76)(Fig 77)

Pressure Plate seal Removal

Rubber Seals

Tytan Seals

(Fig 79) (Fig 80)

(Fig 81)

Place pressure plate into latheand form tool into tool post

Slowly rotate lathe chuck by hand as youadvance the tool onto the seal this will tear thebond between the seal and pressure plate TAKECARE NOT TO DAMAGE THE SEALGROOVE.

Rotate the pressure plate at approximately 1000 rpm andusing a emery cloth remove ALL the seal and glue residuePLEASE TAKE THE USUAL PRECAUTIONS WHENUSING MACHINE TOOLS.

(Fig 82)

Tytan seal in pressure plate

(Fig 83)

Using a knife prise the PTFE seal outeredge.

(Fig 84)

Prise the seal up all around its periphery andpull the seal from the pressure plate by hand.

(Fig 85)

Pressure plate with sealremoved

(D)Replacing seals

Before you start to rebuild the valve it is important to ensure that your work area is clean andfree from dirt and debris.

All valve components must be throughly cleaned any dirt or grime will cause a leak path andprevent the valve from correct operation.

Fortyt Seals

(Fig 86)(Fig 87)

(Fig 88)

(Fig 89)

(Fig 90)

(Fig 91)

(Fig 92)

Seal Pusher

Seal

Expandercone.

Vacuumpoppet

Place expander cone overpoppet stem.

Place seal over expander cone

Push seal down into groove withseal pusher

Once seal is fitted place poppet assembly in asafe place to prevent seal damage and seal

PTFE Seals

There is a difference between PTFE andfortyt/elastomer poppets to aid Identification betweenthe two poppet types an Identification notch has beenadded to the PTFE poppet.

Fitting the seal onto the poppet is the same a for thefortyt seal see figures 93 to 97. However the PTFE sealonce fitted needs to be turned to produce the sealingprofile

(Fig 93))

Place poppet stem into lathe and griplightly taking care not to damage the M8stem threads.

Rotate cross slide to 50

(Fig 94)

Set the cross slide to produce the 1.528diameter.

1.528 dia for0.084

Using the lathe saddle slide touchonto the PTFE seal, turn the

then using the compound slide turn the50 angle.

50

1.5

28"

DIA

RE

F[3

8.8

mm

]

(Fig 95)

0.084"

[2.1mm]

(Fig 96)

Tool steel turning tool details

(Fig 97)

Sealing edge

Once the poppet/seal assembly has been turnedGreat care must be taken not to damage thesealing edge.

Elastomer seals

Before fitting the seal it is important to ensure that all the glue residue isremoved and that the poppet is clean and free from dirt.

(Fig 98) (Fig 99)

Using a cyanoacrylateadhesive such asLoctite 406

Dip a small rod e.g a paper clip onto the adhesiveand run a very small amount of adhesive aroundthe seal groove, ensure the adhesive is completelyaround the seal groove

Fitting the seal onto the poppet isthe same as for the fortyt seal seefigures 86 to 92.

(Fig 100)

(Fig 101)

When the seal is seated in the grooveimmediately remove any excess adhesivewith a cloth.

If the adhesive has already cured place thepoppet in a pillar drill and remove the curedadhesive with 400 grit wet and dry abrasivepaper.

(Fig 102)

Once the seal has been fitted, place the poppet in a clean area until it is required for fitting.

Fitting Pressure plate seals.

Fortyt and PTFE seal

(Fig 103)

Prior to fitting check that you are using a FortVale O ring this will ensure you of thecorrect O ring quality and size.

(Fig 104)

It is important to ensure that you have thecorrect pressure plate.Pressure plates have different groovedimensions depending upon the seal material.Fortyt pressure plates have a small groove asshown in fig 105.

(Fig 105)

Fortyt identificationgroove

Prior to assembly ensure the pressure plateis clean and free from debris, if necessaryplace the pressure plate in a lathe and polishthe sealing face and groove.

(Fig 109) (Fig 111)

(Fig 112)

(Fig113)

Using a fly-press (show above)or toggle press or drill press.

(Fig 106)

(Fig 107)

Locate the pressure plate, O ring spreaderand O ring seal under the press.

Align the O ring spreaderwith the inside edge of the sealgroove.

(Fig 108)

Place the seal pusher over theseal spreader on to the seal andplace the press spacer onto theseal pusher.

Press the seal into the sealgroove using the press.

Once the seal is located in the grooverotate the pressure plate 25Deg, and re-strike the press spacer repeat this 10 times.

Rotate the pressure plate 25Deg and re-strike the press spacer repeat this 10 times.

(Fig 114)

Remove the seal pusher and sealexpander from the pressure plate.Check that the seal radius face isclean.

Radius facekeep clean

Place the seal flattener and thepress spacer on to the pressureplate and strike the press spacerwith the press

(Fig 110)

Press spacer

Seal pusher

Seal spreader

Seal

Pressureplate.

Once the seal has been flattened it is necessary to lap the sealas described in part E of this chapter.

Elastomer seals

(Fig 115)

It is important to ensure that you have thecorrect pressure plate.Pressure plates have different groovesdepending upon the seal material.Elastomer pressure plates have NOidentification groove as shown in fig 74.

(Fig 116)

NO identificationgroove

Prior to assembly ensure the pressureplate is clean and free from debris, ifnecessary place the pressure plate in alathe and polish the sealing faces.

(Fig 117)

Using a cyanoacrylateadhesive such asLoctite 406

Dip a small rod e.g a paper clip into the adhesive and run avery small amount of adhesive around the seal groove,ensure the adhesive is evenly dispersed around the seal

(Fig 118)

Using a fly-press (show above)or toggle press or drill press.

(Fig 119)

(Fig 120)

Locate the pressure plate, O ring spreaderand O ring seal under the press.

Align the O ring spreaderwith the inside edge of the sealgroove.

(Fig 121)

(Fig 122)

(Fig 123)

Press spacer

Seal pusher

Seal

Seal spreader

Pressure plate

Locate the seal pusher over the seal spreader and thepress spacer on to the seal spreader

Press the seal into the seal groove and holdwhilst the adhesive cures.

Once the seal has been fitted it is necessary lap theseal flat as described in part E of this chapter.

Tytan seals

(Fig 124)

(Fig 131)

Prior to assembly ensure the pressureplate is clean and free from debris, ifnecessary place the pressure plate in alathe and polish the sealing faces.

(Fig 133)(Fig 134)

Once the seal has been fitted it is necessary lap theseal flat as described in Fig 84 to Fig 91.

(Fig 125)

Ensure that the tytan seal ando ring are clean and free fromdirt.

Push the o ring in to the sealgroove

(Fig 126)

(Fig 127) (Fig 128) (Fig 129)

Place pressure plate and sealassembly under drill press and thetytan seal pusher in the drill chuck

Locate the seal centrally in thepressure plate and push the sealin to place.

The seal/pressure plateassembly should look likethis.

(Fig 130)

Push seal the fully home into thepressure plate by hand.

Ensure the seal is correctly located inthe seal grooves.

It may be necessary to apply moreforce to the outer edge the seal toensure it is fully located ifnecessary use the drill press.

(Fig 132)

Locate the poppet into the pressureplate

Using the drill press apply pressureto the poppet to bed in the seal.

(Fig 135)

Place the tool into the drill chuck and boltthe lapping plate to the drill pedestal, setthe drill speed to approximately 115 rpm.

(Fig 136) (Fig 137)

(Fig 138) (Fig 139)

(Fig 140) (Fig 141) (Fig 142)

Place 400 grit wet and dry sheetover the lapping plate

Locate the pressure plate upon thelapping pate and switch on spindle.

Whilst holding the wet and dry paper with the palm ofyour hand locate the rotating lapping tool on to thepressure plate,

Apply light pressure for 2 or 3 seconds release thenreapply light pressure for 2 of 3 seconds. Repeatthis procedure with 1000 grit wet and dry paper

Spindle rotating115 rpm approx

Hold wet anddry paper with

palm of hand

Remove the wet and dry paper fromthe lapping plate ensure the plate isclean then smear a small amount ofengineers blue on to the plate

Place the pressure plate on to thelapping plate apply a light pressureand rotate the pate 5 deg in eitherdirection

Lift the pressure plate from the lapping plateand examine the seal, there should be acontiguous blue line around the seal, if not,repeat the lapping process with the 1000 gritpaper taking extreme care (a maximum of0.01(0.20mm) only can be lapped from thefortyt and tytan seals.

(E) Seal lapping.

(F)

8

(Fig 143) (Fig 144)

Seal Face

Cap threads

Inlet threads

Dim

ensi

on

X

2.5 BSP

Remove the burr if necessary from the 3/16 tappedhole on the cap thread, ensure that both thebody andcap threads are clean and free from debris.Inspect the seal face for are any indentations or theseal surface appears dull re-machine the seal face.

The seal face surface finish should be 8 CLA(0.20 Ra) or better, once the dimension X hasreached 0.12 (3.0mm) the valve body can nolonger be used.

(Fig 145)

(Fig 146)

To machine the seal face place the valve bodyin a lathe if possible using a 2.5 BSPthreaded socket to hold the body as shown infig 145.

Skim the seal face at 0.005 (0.10mm) incrementsuntil any indentation or corrosion is remove.

Re-assembly

(Fig 152)

Lock the nuts with 2x13mm spanners

(Fig 38)

(Fig 147) (Fig 148)


Before commencing to rebuild the valve, ensure the vacuumpoppet and pressure plate are free from debris and dirt.

(Fig 153)

Set the spring pad height to theDimension A taken when the valve wasstripped, If this dimension is not availableset the height to 0.98 (25.0mm).

(Fig 154)

Dim

ensi

on

A"

(Fig 149)

Locate the spring into the corresponding groovein the pressure plate mount the spring pad ontothe spring and compress the assembly.

Vacuum spring

Springpad

Pressure Plate

(Fig 150)

Whilst the assembly is compressedpass the vacuum poppet throughthe pressure plate see fig 108. Screw the two M8 nuts onto

poppet stem.

Assembly tool

(Fig 151)

Remove the pressure plateassembly from the assembly tool.

010/Series Pressure plate assembly

(Fig 162) (Fig 163)

00/series Pressure plate assembly

Before starting to rebuild the valve, ensure the vacuum poppetand pressure plate are free from debris. (Fig 164)

Vacuum spring

Springpad

Pressure Plate(Fig 165)

M8 GrubScrew

Locate the poppet onto thevacuum poppet locationtool and pass the pressureplate over the poppet.

Mount the spring pad onto thespring and compress the assembly,screw the pad down to give thespring pad height to theDimension A taken when thevalve was stripped, If thisdimension is not available set theheight to 0.98 (25.0mm).

Dim

ensi

on

A"

Remove the pressure plate assembly fromthe assembly tool. And store in a clean areabefore fitting,.

Once the pressure plate is at the correctvacuum setting apply nut lock to the grubscrew lock the nut in place using a 8mmA/F Allen key.

Test the pressure plateassembly as sown in figures130 to 133 and chapter 2

(Fig 166)

(Fig 167)

(Fig 168)

Locate the spring into thecorresponding groove in thepressure plate

Once the pressure plate is at thecorrect vacuum setting apply nutlock as shown in figure 159 andlock the nut in place using a 10mmA/F spanner.

(Fig 155) (Fig 156)

Locate the vacuum poppetonto the vacuum poppetlocation tool and pass thepressure plate over thepoppet

Before commencing to rebuild the valve, ensure the vacuumpoppet and pressure plate are free from debris and dirt.

(Fig 160)

(Fig 161)

Dim

ensi

on

A"

(Fig 157)

Locate the spring into thecorresponding groove in thepressure plate

Vacuum spring

Springpad

Pressure Plate

(Fig 158)

(Fig 159)

Remove the pressure plate assembly fromthe assembly tool. And store in a clean areabefore fitting,.

M8 Nut

Mount the spring pad onto the spring and compress theassembly, screw the pad down to give the spring pad heightto the Dimension A taken when the valve was stripped, Ifthis dimension is not available set the height to 0.98(25.0mm).

Add Nut lockhere

Test the pressure plateassembly as sown infigures 130 to 133 andchapter 2

000/series Pressure plate assembly

Once the pressure plate is inposition, test the vacuum settingas per Chapter 2

(Fig 169)

(Fig 170) (Fig 171)

Ensure the valve body is cleanand screw onto the test rig

Place the pressure plate assemblyinto the valve bodyTake care not to damage thepressure seal on the body wall.

(Fig 172) (Fig 173)

Place the PTFE block in the center of thedrill press table and place the valve bodyover the block.

(Fig 174)Sit the pressure plate assemblyonto the PTFE block inside thevalve body Locate the springs into the

pressure plate spring grooves andlocate the cap on to the spring.

(Fig 175)

(Fig 176) (Fig 177) (Fig 178)

Locate drill press captool onto top cap.

Compress spring until cap almost touches the body.

Spring loadedValve re-assemble

with caution.

Once the spring has beencompressed lock the spindle inposition.

(Fig 179) (Fig 180) (Fig 181)

Apply a small amount of lubricante.g. Petroleum jelly on to the bodythreads, align the body threads withthe cap (it may be necessary torelease the spring load ane re-positionthe ptfe block)

Take care not to rotate the seal on thepressure plate, if necessary when the sealapproaches the seal face increase thecompression on the spring.

Lift the valve body and rotateinto the cap threads,

(Fig 182)

Re-algin the 3/16 grub screw holeand recheck the seal face to ensure itis clean.

(Fig 183) (Fig 184)

Remove the load from the spring with the drill feed handle, releasethe drill spindle lock and slowly allow the pressure plate to seat ontothe seal face.

Test the valve and adjust if required as per chapter 2.

(Fig 185)

Once the valve set position hasbeen established, re-drill and tapthe 3/16 BSW hole

Replace the 3/16 BSW grubscrew.

(Fig 186)

3.70mmDrill

(Fig 187)

On 00/Series maxis Replace the liftadjusting screw and the plastic cap

Please note that this binder and the contents herein remain the property of FortVale Engineering Limited.

This binder may not be copied or reproduced, or the information containedherein divulged to any third party without the prior written permission of FortVale Engineering Limited.

Repair/refurbishment may be only carried outby trained and authorised personnel. Fort Vale Engineering Limited shall not,in any circumstances, be liable for injuries, losses, expenses or damage, director consequential, sustained by the buyer or any person which may in anydegree be attributable to the adoption, either by the buyer or any third party, oftechnical or any other information, data or advice given on behalf of Fort ValeEngineering Limited or however otherwise caused in relation to the use of itsproducts in accordance with Fort Vale Engineering Limitedsrecommendation.

' Fort Vale Engineering Limited, 1998.

/resetting of Maxi Relief Valves

Copyright Notice

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Directors: E. S. Fort O.B.E. (Chairman), I. Wilson (Managing), W. B. Robinson (Sales), M. Dury F.C.A. (Financial), D.F.H. Smith (Technical), J.OGara (Works), J. F. Frot (Commercial).

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Documents

Maxi Manual