The Fort Vale Supermaxi Relief Valve

Maintenance manual

Contents
Chapter 1

Identify Your Valve.

(a)
(b)
(c)
(d)
(e)
(f)

Chapter 2

Pressure and vacuum leak test.

(a)
(b)
(c)

Chapter 3

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

65mm Mk3 Supermaxi Highflow March 1995 - March 1997 .
65mm Mk2 Supermaxi Highflow November 1989 - March 1995.
65mm Maxi Highflow Pre November 1989.
80mm Hyperflow Supermaxi March 1997 - .
Part numbering system.

Pressure test.
Vacuum test.
Troubleshooting.

Refurbishment.
(a)
(b)
(c)
(d)
(e)
(f)

Tool kit.
Dismantling Valves.
Removing Seals
Replacing Seals.
Lapping seals.
Valve reassembly.

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.

(e)

80mm Hyperflow Supermaxi March 1997 - .

(f)

Part numbering system.

(A)

65mm High performance Mk3 Supermaxi Highflow 010/series

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 some
basic features on the valves which will help you to identify the valves.
4.48" Dia [113.8]

No lift stop

No holes in
face of vacuum
poppet.

2.68"Dia [68.0 mm]

SERIAL NO:

4.04 [102.6 mm]

3.46" [87.9 mm]

SERVICED BY
SERVICE DATE

2.5" BSP
Serial Number
9708749 or greater

9700000

PART NUMBER: 010/16312

SET PRESS.(2.5%)
FULL FLOW

63.8 PSIG 4.40 BAR

3
9438
SCFM 16036 M /HR
76.56

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

7834

PSIG

5.28 BAR

SCFM

13310 M 3/HR

6.2 HgVAC

CONTACT PARTS
316 ST ST

0.21 BARVAC

Part Number
010/*****

SEAL TYPE
FORTYT

Chamfer on bore
of inlet.

FORT VALE
2 . 5 " M K 3 S U P E R M A X I H I G H F L O W R E L I E F V A LV E
L L O Y D S R E G I S T E R T Y P E A P P. N O. 9 5 / 0 0 1 6 3 ( E 2 )

SERVICE EVERY 6 MONTHS

1997 FORT VALE ENG. LTD.

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

Lloyds register
type app No 95/00163(E2)

The simplest way to visually recognize a Mk3

super maxi is to look at the outlet ports on the
cast body there will be 3 outlet ports with a
notch in the centre for the C-spanner

Cast body

C-spanner notch

3 Outlet port

(B)

65mm Mk3 Supermaxi Highflow 010/series

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 some
basic features on the valves which will help you to identify the valves.

4.48" Dia [113.8]

Lift stop

No holes in
face of vacuum
poppet.

2.66"Dia [67.6 mm]

SERIAL NO:

4.04 [102.6 mm]

3.46" [87.9 mm]

SERVICED BY
SERVICE DATE

2.5" BSP
Serial Number
95***** to 9708749

9700000

PART NUMBER: 010/16312

SET PRESS.(2.5%)
FULL FLOW

63.8 PSIG 4.40 BAR

3
9265
SCFM 15741 M /HR
76.56

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

7690

PSIG

5.28 BAR

SCFM

13065 M 3/HR

6.0 HgVAC 0.203 BARVAC

CONTACT PARTS
316 ST ST

Part Number
010/*****

SEAL TYPE
FORTYT

No chamfer on
bore of inlet.

FORT VALE
2 . 5 " M K 3 S U P E R M A X I H I G H F L O W R E L I E F V A LV E
L L O Y D S R E G I S T E R T Y P E A P P. N O. 9 5 / 0 0 1 6 3 ( E 1 )

SERVICE EVERY 6 MONTHS

1997 FORT VALE ENG. LTD.

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

Lloyds register
type app No 95/00163(E1)
or 95/00163

The simplest way to visually recognize a Mk3

super maxi is to look at the outlet ports on the
cast body there will be 3 outlet ports with a
notch in the centre for the C-spanner

Cast body

C-spanner notch

3 Outlet port

( C)

65mm Mk2 Supermaxi Highflow 000/series

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 some basic
features on the valves which will help to identify the valves.

Lift stop

2.66" Dia [67.6]

Serial Number
91***** to 95*****

21/2"MAXI
HIGHFLOW RELIEF VALVE

PART No 000/16312 SER No: 9100000

63.8 PSIG 4.40 BAR
SET PRES.2.5%
8654 SCFM 14704 M /HR
FULL FLOW
76.56 PSIG 5.28 BAR
AT PRES
FED. REG. FLOW (83%)
7183 SCFM 76.56 PSIG
VACUUM SETTING (-0 +5%)
6.0 HgVAC

PART NUMBER: 000/16312

SET PRESS.(2.5%)

63.8
8654

FULL FLOW

76.56

AT PRESSURE

7183

FED. REG. FLOW (83%)

4.40 BAR
14704 M 3/HR

PSIG

5.28 BAR

SCFM

12204 M 3/HR

6.0 HgVAC 0.203 BARVAC

Part Number
000/*****

VI

SEAL

CE
EV

6M

ON

ERY
LA
ALE
E
S ON
TEL NG. LTD. 1982 N EL 0 3
2
: 0282
6925 TELEX 635

25

FORT VALE
2.5" SUPER MAXI HIGHFLOW RELIEF VALVE
LLOYDS REGISTER TYPE APP NO. 91/0020
.

SERVICE EVERY 6 MONTHS

Some older valves may have

pressed text on the top cap

1996 FORT VALE ENG. LTD.

MADE IN UK.

FORTYT

SE

RT
V

SEAL TYPE
FORTYT

CONTACT PARTS
316 ST ST

0.203 BARVAC

Mat : 316 ST ST

C FO

VACUUM SETTING (-0 +5%)

PSIG
SCFM

9100000

TH

SERIAL NO:

2.5" BSP

CS

2 holes in
face of vacuum
poppet.

TEL: 01282 692525

FAX: 01282 692554

Lloyds register
type app No 91/00020
The simplest way to visually recognize a Mk2
super maxi is to look at the support legs on the
cast body there will be 2 or 3 0.5 diameter
holes drilled through for the C-spanner

C-spanner drive hole.

Cast body

3 Outlet ports

4.04" [102.6]

3.46" [87.9]

SERVICED BY
SERVICE DATE

(D)

65mm Maxi Highflow 00/series

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 some basic
features on the valves which will help to identify the valves.

Stepped profile
on pressure plate

2 Holes in
face of vacuum
poppet.

2.66" Dia [67.6]

21/2"MAXI
HIGHFLOW RELIEF VALVE

PART No 00/16312
SET PRES.2.5%
FULL FLOW
AT PRES
FED. REG. FLOW (83%)
VACUUM SETTING (-0 +5%)
Mat : 316 ST ST

SER No: 9100000

63.8 PSIG 4.40 BAR
3
7963 SCFM 13529 M /HR
76.56 PSIG 5.28 BAR
6610 SCFM 76.56 PSIG
6.0 HgVAC
0.203 BARVAC
FORTYT

ERY 6 M

ON

CS

CE
EV

TH

VI

SEAL

Serial No Pre 91*****

Stamped text

SE

C FO

RT
V

2.5" BSP

Part No
00/*****

LA
ALE
ON
E NG .
LTD. 1982 N ELS 03
T EL
2
: 0282
6925 TELEX 635

25

The simplest way to visually recognize a Mk1

Maxi is to look at the body it is a fabricated body
with 4 outlet ports and on the support legs there
will be 2 or 3 0.5 diameter holes drilled through
for the C-spanner.
On top cap there will be a hexagon nut which is
the vacuum guide, which may have either a
vacuum vent button, (as shown) or a black plastic
cap fitted.

Guide Nut on top cap

C-spanner drive hole.

Fabricated body.
4 outlet ports.

4.03" [102]

3.45"[87.6]

Poppet guide
nut

(E)

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

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 some basic
features on the valves which will help to identify the valves.
4.48" Dia [113.8]

No lift stop

3.25" Dia [82.5]

Serial number 97*****
or greater

SERIAL NO:

Part number
023/*****8**

9700000

PART NUMBER: 023/16312800

63.8 PSIG 4.40 BAR

3
9438
SCFM 16036 M /HR
76.56

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

7834

PSIG

5.28 BAR

SCFM

13310 M 3/HR

6.2 HgVAC

0.21 BARVAC

CONTACT PARTS
316 ST ST

SEAL TYPE
FORTYT

FORT VALE
2 . 5 " M K 3 S U P E R M A X I H I G H F L O W R E L I E F V A LV E
L L O Y D S R E G I S T E R T Y P E A P P. N O. 9 7 / 0 0 0 7 2 )

SERVICE EVERY 6 MONTHS

1997 FORT VALE ENG. LTD.

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

Cast body

3 outlet ports

1/4 BSP gauge hole

316 ST ST

FULL FLOW

MADE IN UK

SET PRESS.(2.5%)

FORT VALE

No holes in
face of vacuum
poppet.

Lloyds register type

app No 97/00072

4.34" [110.2]

SERVICED BY
SERVICE DATE

0.64"[16.3]

Triple spring
set

(F)
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:PRESSURE CODE

VACUUM CODE

SEAL CODE

BORE STYLE
VALVE CODE

FLANGE STYLE

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

Valve Code.
00
000
010
0*2

=
=
=
=

2 in BSP Maxi relief valve.

2 in BSP Mk2 Super Maxi relief valve.
2 in BSP Mk3 Super Maxi relief valve & high performance MK3 .
2 in BSP standard valve complete with flame gauze.

03
003
013

=
=
=

Fabricated Flanged - Maxi relief valve standard body length

Fabricated Flanged - Mk2 Super Maxi relief valve standard body length.
Cast Flanged - Mk3 Super Maxi relief valve standard body length.

08
008
018

=
=
=

2 in BSP Maxi relief valve extended body length.

2 in BSP Mk2 Super Maxi relief valve extended body length.
2 in BSP Mk3 Super Maxi relief valve extended body length.

09
009
019

=
=
=

Fabricated Flanged - Maxi relief valve extended body length

Fabricated Flanged - Mk2 Super Maxi relief valve extended body length.
Cast Flanged - Mk3 Super Maxi relief valve extended body length.

023
0*B
.

=
=

Cast Flanged - Hyper flow Super Maxi relief valve standard body length.
2 BSP valve with vent button.

Seal Material.
0
1
2
3
4
5
6
7

=
=
=
=
=
=
=
=

Viton A - pressure and vacuum.

Fortyte -pressure; PTFE - vacuum.
PTFE - pressure and vacuum.
Kalrez - pressure.
Nitrile - pressure and vacuum.
Fortyte - pressure; EPDM - vacuum.
Tytan - pressure and vacuum.
Perfluoroelastomer - pressure and vacuum.

Pressure code.
Pressure setting codes represent approximate set pressure in PSI.

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

Bore Styles.
65
66
80

=
=
=

65mm parallel bore.

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

Flange Styles.
0
1
2
3
4
5

=
=
=
=
=
=

DIN 65
DIN 80
2 in Table D.
3 in. Table D
2 in ASA 150.
3 in. ASA 150

Kalrez, Viton : Du Pont registered trademarks

Chapter 2
Pressure and vacuum
leak test.
(a)

Tool list.

(b)

Testing.

(c)

Performance criteria.

(d)

Troubleshooting.

(A)

Tool list

Test Rig P/ N 400/9100

Pressure plate lifting

Tool pressure / vacuum
valves P/N 400/8530

3/32 Allen Key

C-spanner P/ N 400/3000

Water retaining band

P/N 400/8540

Pressure plate lifting

Tool pressure only
valves P/N 400/8730

Bottle of soapy water

Knife or small
screw driver

13mm A/F Spanner

Adaptor Flange

Compressed air Supply.

1)

Clean Air : The air supply must be free of oil from the compressor (the de-oiler must be kept in good
condition), and free from foreign bodies (clean filters and plastic or stainless steel piping downstream
from 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 the
Valve.

Pressure gauges.
1)

Must be calibrated control gauge.

Scale
= 0 - 100 Psig or 0-7 Bars.
Scale divisions
= 0.5 Psig or 0.025 Bars
Dial Diameter
= 150mm minimum.
Tolerance
= 0.25%.

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 pressure
or to a vacuum.

4)

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

(B)

Testing
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

Remove valve -tank gasket

Wet rubber seal to reduce friction
and screw valve into 2.5 BSP
(Fig 1)

(Fig 2)
Tighten valve with a C-Spanner

(Fig 3)

(Fig 4)
If you are testing a flanged valve
you will need a adaptor flange.

(Fig 5)

(Fig 6)
Once the valve has been attached to the test rig open and close the valve 2 or 3 times by opening the air
supply 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 the
valve creating 3 small pockets fill these pockets with soapy water

On Flanged valves apply the soapy

water to the gap between the pressure
plate and the valve body on all the
valve ports as shown in fig 8
(Fig 7)
Apply soapy water here

(Fig 8)

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

0 - 7 Bar
Gauge
SUPPLY
PRESSURE

0 - 100 Psig 0 - 7 Barg

0 - 29.5"hg 0 - 1.013 Barg

Pressure Gauge

MAX PRESSURE 100PSI

Vacuum Gauge

SUPPLY
PRESSURE
REGULATOR

SELECT TEST TYPE

VENT

PRESSURE
TEST

PRESSURE
GAUGE

ON

VACUUM
TEST

VACUUM
GAUGE

ON
OFF

OFF

SUPPLY

OFF

ON

WARNING
APPLYING VACUUM TO PRESSURE GAUGE OR
PRESSURE TO VACUUM GAUGE WILL CAUSE DAMAGE
ENSURE THAT CORRECT GAUGE IS SWITCHED TO ON
AND THAT THE OTHER IS OFF

FORT VALE ENG LTD

PARKFIELD WORKS
BRUNSWICK ST
NELSON, LANCS
BB9 0SG
TEL 01282 44000
TELEX 635203

(Fig 9)
Slowly turn on the supply pressure and allow the
pressure in the test chamber to build up gradually until
the valve shows first signs of leakage this is then the set
pressure, this pressure should fall within the criteria set
out in the section labeled performance criteria.

SUPPLY

OFF

ON

(Fig10)
Check for leakage here

(Fig 11)
SUPPLY

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

OFF

ON

(Fig 12)
If the valve is a pressure vacuum valve
Once the valve has stopped leaking leave the valve pressurized for 5
minuets to check the vacuum poppet If there is no pressure drop in this
time the vacuum poppet is sealing on pressure

SELECT TEST TYPE

VENT

Vent the pressure from the test rig,

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

PRESSURE
TEST

(Fig 13)

VACUUM
TEST

For pressure vacuum valves the pressure test is now complete, if the valve has passed the test criteria
proceed to the vacuum test should the valve have failed please see the chapter on troubleshooting.
Prior to vacuum testing if the valve is a valve
that has been in service check the vacuum
poppet is working correctly.

(Fig 14)
Remove plastic cap
(Fig 15)
Insert screw driver

(Fig 16)

If the poppet is found to be sticking

check for product ingress and clean
as required

Push vacuum poppet down

Test rig settings for vacuum test

0 - 7 Bar
Gauge
SUPPLY
PRESSURE

0 - 100 Psig 0 - 7 Barg

0 - 29.5"hg 0 - 1.013 Barg

Pressure Gauge

MAX PRESSURE 100PSI

Vacuum Gauge

SUPPLY
PRESSURE
REGULATOR

SELECT TEST TYPE

VENT

PRESSURE
TEST

PRESSURE
GAUGE

ON
OFF

VACUUM
TEST

VACUUM
GAUGE

ON
OFF

WARNING
APPLYING VACUUM TO PRESSURE GAUGE OR
PRESSURE TO VACUUM GAUGE WILL CAUSE DAMAGE
ENSURE THAT CORRECT GAUGE IS SWITCHED TO ON
AND THAT THE OTHER IS OFF

SUPPLY

OFF

ON

FORT VALE ENG LTD

PARKFIELD WORKS
BRUNSWICK ST
NELSON, LANCS
BB9 0SG
TEL 01282 44000
TELEX 635203

The test rig regulator pressure should be reduced to 25 psi and the valve moved to the positions
shown taking care not to pressurize the vacuum gauge as you do so
Open supply valve slowly to the fully open position, read the vacuum
gauge for the set pressure this pressure should be within the performance
criteria set out in the section labeled performance criteria.
The test is now complete, if the valve has passed the test criteria
remove the valve from the test rig and place in a clean plastic bag to
prevent dirt ingress. should the valve have failed please see the
chapter on troubleshooting.

SUPPLY

OFF

ON

(Fig17)

(C),

Performance Criteria

T.P+2.5%
T.P

ACCEPTABLE
TOLERANCE

Test set pressure TP

ACCEPTABLE
TOLERANCE

Re-sealing Pressure
3
(minimum pressure held after closing)

ACCEPTABLE
TOLERANCE

Minimum pressure held without leakage

T.P-2.5%

+2.5%
90% of T.P

PRESSURE

-2.5%
+2.5%
85% of T.P

-2.5%

0 : Atmospheric Pressure

VACUUM

Vacuum Test Pressure VP

VP +5%

ACCEPTABLE
TOLERANCE

(For test rigs equipped with

Vacuum testing facility)
0 Absolute Pressure

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 plate
circumference.

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 a
pressure equal to 90% of test pressure is reached. Below this point, the valve should re-seal
and the pressure indicated by the pressure gauge should remain stable. Check this point for
1 minute.

Tolerance:

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

Troubleshooting

(D)

The valve has failed it pressure test due to cracking at a lower pressure than the
required set pressure.
If the valve is a new valve the most frequent fault, is dirt ingress in to the valve seals from the
surrounding environment and or air supply.
1

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

Dirt may have got trapped under the valve seal. Use the setting tool lift the valve pressure plate as shown
below then blow any dirt from the valve seal face with an airline .
Setting tool
400/8530

(Fig 18)
Insert setting tool into top cap

(Fig 19)

Setting tool
400/8730

(Fig 20)

Locate setting tool onto vacuum poppet or in to

pressure plate threads.
Hold setting tool
stem

Blow compressed air

(Fig 21)
Whilst holding the setting tool stem
tighten the adjusting nut to lift pressure
plate from the seal face

(Fig 22)
Once the pressure plate is 3.0mm clear
of the seal face blow compressed air
across the seal face.

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

Seal damage,
The seals of the valve may be damaged due to product corrosion or dirt being embedded into the seal
or 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 the
valves 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 this
manual

Test Rig malfunction,

Check your test rig gauge regularly to ensure accurate and repeatable results.

Chapter 3
Refurbishment

(a)

Tool list.

(b)

Striping the valve.

(c)

Removing seals.

(d)

Replacing seals.

(e)

Lapping Seals.

(f)

Re-assembly.

(A)

Tool List

Description
1)
2)
3)
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)

3mm & 5mm and Allen keys.

3/32 Allen key.
C-Spanner
Teflon Round block.
2x 13mm A/F spanner
Small Sharp Knife
Press Drill Cap location Tool
Vacuum poppet location Tool
Pressure seal expander
(65mm)
Pressure seal pusher
(65mm)
Pressure seal Flattener
(65mm)
Pressure seal expander
(80mm)
Pressure seal pusher
(80mm)
Pressure seal Flattener
(80mm)
Press spacer
Drill press lapping tool
Pressure plate lifting clamp (Pressure/vacuum)
Pressure plate lifting clamp (Pressure only)
Lapping plate
Engineers Blue.
Vacuum seal expander
Vacuum seal pusher,
3.7mm drill
3/16 tap
Vacuum poppet assembly tool
Fortyt seal extraction tool.
600 Grit wet & dry emery paper
Emery cloth
Form tool for lathe
Super Glue.
Tytan seal pusher

Plant equipment.
1)
2)
3)
4)

Pedestal Drill Press.

Fly press or toggle press.
Lathe.
Vice.

Fort Vale Part No

400/3000
400/8555
400/8330
400/8320
400/8511
400/8512
400/8522
400/8711
400/8712
400/8722
400/8520
400/8550
400/8530
400/8730
400/8560

400/8556
400/8557

Stripping the valves

(B)

(Fig 25)
Using 3/32mm Allen key
remove 3/16 grub screw
(Fig 23)

(Fig 24)

On 00/series valves remove the Lift

adjusting screw to reveal the drive
holes

Remove lead seal

Spring loaded
Valve dismantle
with caution.

(Fig 26)
Place PTFE block on drill
press bed and cap drive tool
into drill arbor

(Fig 27)
Place valve over
PTFE block

(Fig 28)
Locate cap drive holes on
to cap location tool

Pressure plate

(Fig 29)
Cap and drive tool
located

(Fig 30))
Compress valve to lift pressure
plate clear of seal face

(Fig 31)

Seal face

(Fig 32)
Lock drillpress arbor in
place

(Fig 33)
Rotate valve body to unscrew valve.
Note
The body may be difficult to rotate due to burrs from the
3/16 grub screw tapping, to loosen the body rotate the body
both clockwise and anticlockwise to break the burr

(Fig 34)
Unscrew the valve body fully from the cap, it
may be necessary to release the lock on the
drillpress (taking the load with the feed handle as
you do so) to allow the valve body more
clearance.

Spring loaded
Valve dismantle
with caution.

Release the lock on the drillpress, taking the

load with the feed handle as you do so.
Slowly rotate the drill feed handle until the
spring load is removed.

(Fig 35)

010/series pressure plate stripping.

(Fig 37)
Remove pressure plate
from valve body

(Fig 36)

(Fig 38)
Measure the height of the vacuum poppet assembly before stripping the
pressure plate this dimension can then be used in assisting the re-assembly

Dimension A"

Remove cap and springs from

valve body, label springs with
valve Part Number to assist
identification at assembly.

(Fig 39)
(Fig 40)
Place Vacuum poppet
assembly tool in a vice, push
pressure plate assembly on to
tool, compressing springs.

Remove Nuts with

2x 13mmA/ F
spanners

Once the spring is

compressed slide tool under
M8 nuts
(Fig 41)

(Fig 43)
(Fig 42)

Remove poppet
from pressure plate

Remove and label spring

with valve part number

(Fig 44)
Once the poppet is free from the
pressure plate check the seal for
damage.

(Fig 45)
Check the pressure seal for damage it
may not be necessary to replace the main

Dimension A"

000/series pressure plate stripping.

(Fig 47)
Measure the height of the vacuum poppet
assembly before stripping the pressure plate this
dimension can then be used in assisting the reassembly
(Fig 46)
Remove pressure plate
from valve body

(Fig 49)

(Fig 48)

Place the poppet location tool in

a vice and locate the vacuum
poppet drive holes on to the
location tool spigots, as per
figure 49.

Using a 13mm a/f

spanner remove the M8
nut
(Fig 50)

(Fig 51)
Unscrew spring pad by hand.

(Fig 52)
Remove and label spring
with valve part number.

(Fig 53)

Remove poppet from pressure plate.

Seal Face

(Fig 54)
Once the poppet is free from the
pressure plate check the seal for
damage.

(Fig 55)
If the vale is a tytan seal
valve check the sealing face
for dirt or corrosion.

(Fig 56)
Check the pressure seal for damage it may
not be necessary to replace the main seal.

Dimension A"

00/series pressure plate stripping.

(Fig 58)
Measure the height of the vacuum poppet
assembly before stripping the pressure plate this
diameter can then be used in assisting the reassembly

(Fig 57)
Remove pressure plate
from valve body

(Fig 60)

(Fig 59)

Place the poppet location tool in

a vice and locate the vacuum
poppet drive holes on to the
location tool spigots, as per
figure 60.

(Fig 61)
Locate 4mm allen key into
M8 grub screw.

(Fig 62)
Remove M8 grub screw

(Fig 63)
Unscrew spring pad by hand.

(Fig 64)
Remove and label spring
with valve part number
(Fig 65)

Remove poppet from pressure plate

(Fig 66)
Once the poppet is free from the
pressure plate check the seal for
damage.

(Fig 67)
If the vale is a tytan seal
valve check the sealing face
for dirt or corrosion.

(Fig 68)
Check the pressure seal for damage it
may not be necessary to replace the main

(C),

Vacuum Poppet seal Removal

Fortyt seal

(Fig 69)

(Fig 70)

Using seal removing tool push

radius under seal

Pull seal up and out of groove

Ptfe Seal

(Fig 72)
(Fig 71)
Cut Seal with sharp knife
though

Take care not damage the poppet

seal face in marked red above

(Fig 73)
Twist the knife to snap the
seal and remove from poppet.

Rubber seals

(Fig 74)
Using a knife break the bond between
the seal and the poppet work round the
poppet groove taking care not to damage
the poppet face

(Fig 75)
Using either a pillar drill or a lathe hold the
poppet stem in the chuck taking care not to
damage the M8 threads and polish the seal
groove to remove any residue of glue.

Pressure Plate seal Removal

Fortyt seal

(Fig 77)

(Fig 76)

Pull seal up and out of groove

with extraction tool

Using seal extraction tool

push tool down the side of
the seal.

PTFE Seal

Insert a knife in to PTFE seal taking care not

to damage the seal groove and prise the seal
out of the seal groove

(Fig 78)

Rubber Seals

(Fig 80)

(Fig 79)

Slowly rotate lathe chuck by hand as you

advance the tool onto the seal this will tear the
bond between the seal and pressure plate TAKE
CARE NOT TO DAMAGE THE SEAL
GROOVE.

Place pressure plate into lathe

and form tool into tool post

Rotate the pressure plate at approximately 1000 rpm and

using a emery cloth remove ALL the seal and glue residue
PLEASE TAKE THE USUAL PRECAUTIONS WHEN
USING MACHINE TOOLS.

(Fig 81)

Tytan Seals

(Fig 83)
(Fig 82)
Tytan seal in pressure plate

(Fig 84)
Prise the seal up all around its periphery and
pull the seal from the pressure plate by hand.

Using a knife prise the PTFE seal outer

edge.

(Fig 85)
Pressure plate with seal
removed

Replacing seals
(D)

Before you start to rebuild the valve it is important to ensure that your work area is clean and
free from dirt and debris.
All valve components must be throughly cleaned any dirt or grime will cause a leak path and
prevent the valve from correct operation.

Fortyt Seals

Seal Pusher

Seal

Expander
cone.

Vacuum
poppet

(Fig 86)

(Fig 87)
Place expander cone over
poppet stem.

(Fig 88)
Place seal over expander cone

(Fig 90)

(Fig 92)

(Fig 89)
Push seal down into groove with
seal pusher

(Fig 91)

Once seal is fitted place poppet assembly in a

safe place to prevent seal damage and seal

PTFE Seals
There is a difference between PTFE and
fortyt/elastomer poppets to aid Identification between
the two poppet types an Identification notch has been
added to the PTFE poppet.
Fitting the seal onto the poppet is the same a for the
fortyt seal see figures 93 to 97. However the PTFE seal
once fitted needs to be turned to produce the sealing
profile

0.084"
[2.1mm]

1.528" DIA REF

[38.8mm]

50

(Fig 93))

(Fig 94)

Place poppet stem into lathe and grip

lightly taking care not to damage the M8
stem threads.

Rotate cross slide to 50

(Fig 95)
Set the cross slide to produce the 1.528
diameter. Using the lathe saddle slide touch
onto the PTFE seal, turn the 1.528 dia for
0.084 then using the compound slide turn the
50 angle.

(Fig 96)
Tool steel turning tool details

Sealing edge

Once the poppet/seal assembly has been turned

Great care must be taken not to damage the
sealing edge.
(Fig 97)

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

(Fig 98)
Using a cyanoacrylate
adhesive such as
Loctite 406

(Fig 99)

(Fig 100)

Dip a small rod e.g a paper clip onto the adhesive

and run a very small amount of adhesive around
the seal groove, ensure the adhesive is completely
around the seal groove

(Fig 101)
When the seal is seated in the groove
immediately remove any excess adhesive
with a cloth.

Fitting the seal onto the poppet is

the same as for the fortyt seal see
figures 86 to 92.

(Fig 102)
If the adhesive has already cured place the
poppet in a pillar drill and remove the cured
adhesive with 400 grit wet and dry abrasive
paper.

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

Prior to fitting check that you are using a Fort

Vale O ring this will ensure you of the
correct O ring quality and size.

(Fig 103)

(Fig 104)
Prior to assembly ensure the pressure plate
is clean and free from debris, if necessary
place the pressure plate in a lathe and polish
the sealing face and groove.

Fortyt identification
groove
It is important to ensure that you have the
correct pressure plate.
Pressure plates have different groove
dimensions depending upon the seal material.
Fortyt pressure plates have a small groove as
shown in fig 105.

(Fig 105)

(Fig 108)
(Fig 107)
(Fig 106)
Using a fly-press (show above)
or toggle press or drill press.

Align the O ring spreader

with the inside edge of the seal
groove.

Locate the pressure plate, O ring spreader

and O ring seal under the press.
Press spacer

Seal pusher

Seal spreader
Seal

(Fig 109)
Place the seal pusher over the
seal spreader on to the seal and
place the press spacer onto the
seal pusher.

(Fig 110)

Pressure
plate.

Press the seal into the seal

groove using the press.

(Fig 111)
Once the seal is located in the groove
rotate the pressure plate 25Deg, and restrike the press spacer repeat this 10 times.

Radius face
keep clean

(Fig 112)
(Fig113)
(Fig 114)
Remove the seal pusher and seal
expander from the pressure plate.
Check that the seal radius face is
clean.

Place the seal flattener and the

press spacer on to the pressure
plate and strike the press spacer
with the press

Rotate the pressure plate 25Deg and restrike the press spacer repeat this 10 times.

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

Elastomer seals

(Fig 115)
Prior to assembly ensure the pressure
plate is clean and free from debris, if
necessary place the pressure plate in a
lathe and polish the sealing faces.

NO identification
groove
It is important to ensure that you have the
correct pressure plate.
Pressure plates have different grooves
depending upon the seal material.
Elastomer pressure plates have NO
identification groove as shown in fig 74.

(Fig 116)

(Fig 117)
Using a cyanoacrylate
adhesive such as
Loctite 406

(Fig 118)
Dip a small rod e.g a paper clip into the adhesive and run a
very small amount of adhesive around the seal groove,
ensure the adhesive is evenly dispersed around the seal

(Fig 121)
(Fig 120)
(Fig 119)
Using a fly-press (show above)
or toggle press or drill press.

Locate the pressure plate, O ring spreader

and O ring seal under the press.

Align the O ring spreader

with the inside edge of the seal
groove.

Press spacer

Seal pusher

Seal spreader

Seal
Pressure plate

(Fig 122)

Locate the seal pusher over the seal spreader and the
press spacer on to the seal spreader
(Fig 123)
Press the seal into the seal groove and hold
whilst the adhesive cures.

Once the seal has been fitted it is necessary lap the

seal flat as described in part E of this chapter.

Tytan seals

(Fig 124)

(Fig 125)

Prior to assembly ensure the pressure

plate is clean and free from debris, if
necessary place the pressure plate in a
lathe and polish the sealing faces.

Ensure that the tytan seal and

o ring are clean and free from
dirt.

(Fig 127)
Place pressure plate and seal
assembly under drill press and the
tytan seal pusher in the drill chuck

(Fig 130)
Push seal the fully home into the
pressure plate by hand.

(Fig 126)

(Fig 128)

Push the o ring in to the seal

groove

(Fig 129)

Locate the seal centrally in the

pressure plate and push the seal
in to place.

The seal/pressure plate

assembly should look like
this.

(Fig 132)

(Fig 131)
Ensure the seal is correctly located in
the seal grooves.

It may be necessary to apply more

force to the outer edge the seal to
ensure it is fully located if
necessary use the drill press.

Using the drill press apply pressure

to the poppet to bed in the seal.
(Fig 134)
(Fig 133)
Locate the poppet into the pressure
plate

Once the seal has been fitted it is necessary lap the

seal flat as described in Fig 84 to Fig 91.

Seal lapping.

(E)

(Fig 135)
Place the tool into the drill chuck and bolt
the lapping plate to the drill pedestal, set
the drill speed to approximately 115 rpm.

(Fig 137)

(Fig 136)
Place 400 grit wet and dry sheet
over the lapping plate

Locate the pressure plate upon the

lapping pate and switch on spindle.

Spindle rotating
115 rpm approx

Hold wet and

dry paper with
palm of hand
(Fig 138)

(Fig 139)

Whilst holding the wet and dry paper with the palm of
your hand locate the rotating lapping tool on to the
pressure plate,

Apply light pressure for 2 or 3 seconds release then

reapply light pressure for 2 of 3 seconds. Repeat
this procedure with 1000 grit wet and dry paper

(Fig 140)

(Fig 141)

Remove the wet and dry paper from

the lapping plate ensure the plate is
clean then smear a small amount of
engineers blue on to the plate

Place the pressure plate on to the

lapping plate apply a light pressure
and rotate the pate 5 deg in either
direction

(Fig 142)
Lift the pressure plate from the lapping plate
and examine the seal, there should be a
contiguous blue line around the seal, if not,
repeat the lapping process with the 1000 grit
paper taking extreme care (a maximum of
0.01 (0.20mm) only can be lapped from the
fortyt and tytan seals.

(F)

Re-assembly

Dimension X

Cap threads

Seal Face
8

Inlet threads
2.5 BSP
(Fig 143)
Remove the burr if necessary from the 3/16 tapped
hole on the cap thread, ensure that both thebody and
cap threads are clean and free from debris.
Inspect the seal face for are any indentations or the
seal surface appears dull re-machine the seal face.

(Fig 144)

The seal face surface finish should be 8 CLA

(0.20 Ra) or better, once the dimension X has
reached 0.12 (3.0mm) the valve body can no
longer be used.

(Fig 145)
To machine the seal face place the valve body
in a lathe if possible using a 2.5 BSP
threaded socket to hold the body as shown in
fig 145.

(Fig 146)
Skim the seal face at 0.005 (0.10mm) increments
until any indentation or corrosion is remove.

010/Series Pressure plate assembly

Pressure Plate
Vacuum spring
Spring
pad

(Fig 147)

(Fig 149)

(Fig 148)

Before commencing to rebuild the valve, ensure the vacuum

poppet and pressure plate are free from debris and dirt.
Locate the spring into the corresponding groove
in the pressure plate mount the spring pad onto
the spring and compress the assembly.
(Fig 38)
Remove and label spring
with Assembly tool
valve part number

(Fig 150)

(Fig 151)

Screw the two M8 nuts onto

poppet stem.

Dimension A"

Whilst the assembly is compressed

pass the vacuum poppet through
the pressure plate see fig 108.

(Fig 152)
(Fig 153)
Lock the nuts with 2x
13mm spanners

Remove the pressure plate

assembly from the assembly tool.

(Fig 154)

Set the spring pad height to the

Dimension A taken when the valve was
stripped, If this dimension is not available
set the height to 0.98 (25.0mm).

00/series Pressure plate assembly

(Fig 162)

(Fig 163)

Before starting to rebuild the valve, ensure the vacuum poppet

and pressure plate are free from debris.

Spring
pad

Vacuum spring

(Fig 165)

Locate the poppet onto the

vacuum poppet location
tool and pass the pressure
plate over the poppet.

Dimension A"

M8 Grub
Screw

(Fig 164)

Pressure Plate

(Fig 166)

Locate the spring into the

corresponding groove in the
pressure plate

Mount the spring pad onto the

spring and compress the assembly,
screw the pad down to give the
spring pad height to the
Dimension A taken when the
valve was stripped, If this
dimension is not available set the
height to 0.98 (25.0mm).

Test the pressure plate

assembly as sown in figures
130 to 133 and chapter 2

(Fig 167)

(Fig 168)
Once the pressure plate is at the correct
vacuum setting apply nut lock to the grub
screw lock the nut in place using a 8mm
A/F Allen key.

Remove the pressure plate assembly from

the assembly tool. And store in a clean area
before fitting,.

000/series Pressure plate assembly

(Fig 155)

(Fig 156)

Before commencing to rebuild the valve, ensure the vacuum

poppet and pressure plate are free from debris and dirt.

Locate the vacuum poppet

onto the vacuum poppet
location tool and pass the
pressure plate over the
poppet

(Fig 157)

Spring
pad

M8 Nut

Add Nut lock

here

Vacuum spring

(Fig 158)

Dimension A"

Pressure Plate

Locate the spring into the

corresponding groove in the
pressure plate
(Fig 159)
Mount the spring pad onto the spring and compress the
assembly, screw the pad down to give the spring pad height
to the Dimension A taken when the valve was stripped, If
this dimension is not available set the height to 0.98
(25.0mm).

Test the pressure plate

assembly as sown in
figures 130 to 133 and
chapter 2

Once the pressure plate is at the

correct vacuum setting apply nut
lock as shown in figure 159 and
lock the nut in place using a 10mm
A/F spanner.

(Fig 161)

(Fig 160)

Remove the pressure plate assembly from

the assembly tool. And store in a clean area
before fitting,.

Spring loaded
Valve re-assemble
with caution.

(Fig 170)
(Fig 169)

(Fig 171)

Place the pressure plate assembly

into the valve body
Take care not to damage the
pressure seal on the body wall.

Ensure the valve body is clean

and screw onto the test rig

(Fig 172)

Once the pressure plate is in

position, test the vacuum setting
as per Chapter 2

(Fig 173)

Place the PTFE block in the center of the

drill press table and place the valve body
over the block.

Sit the pressure plate assembly

onto the PTFE block inside the
valve body

(Fig 174)
Locate the springs into the
pressure plate spring grooves and
locate the cap on to the spring.

(Fig 175)
Locate drill press cap
tool onto top cap.
(Fig 176)

(Fig 177)

Compress spring until cap almost touches the body.

(Fig 178)
Once the spring has been
compressed lock the spindle in
position.

(Fig 179)
Apply a small amount of lubricant
e.g. Petroleum jelly on to the body
threads, align the body threads with
the cap (it may be necessary to
release the spring load ane re-position
the ptfe block)

(Fig 181)

(Fig 180)
Lift the valve body and rotate
into the cap threads,

Take care not to rotate the seal on the

pressure plate, if necessary when the seal
approaches the seal face increase the
compression on the spring.

(Fig 183)

(Fig 182)
Re-algin the 3/16 grub screw hole
and recheck the seal face to ensure it
is clean.

(Fig 184)

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

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

3.70mm
Drill

Once the valve set position has

been established, re-drill and tap
the 3/16 BSW hole
Replace the 3/16 BSW grub
screw.

(Fig 187)
(Fig 186)
(Fig 185)

On 00/Series maxis Replace the lift

adjusting screw and the plastic cap

England

USA

Netherlands

South Africa

Fort Vale Engineering Limited

Parkfield Works, Brunswick Street, Nelson, Lancs, Bb9 0SG U.K.
Tel. + 44 (0) 1282 440000 Fax. + 44 (0) 1282 440045 Sales. 440046 Admin. 440044 Purchasing.
Email. Sales@fortvale.com
http:/www.fortvale.com

Copyright Notice

Please note that this binder and the contents herein remain the property of Fort
Vale Engineering Limited.
This binder may not be copied or reproduced, or the information contained
herein divulged to any third party without the prior written permission of Fort
Vale Engineering Limited.
Repair/refurbishment/resetting of Maxi Relief Valves may be only carried out
by trained and authorised personnel. Fort Vale Engineering Limited shall not,
in any circumstances, be liable for injuries, losses, expenses or damage, direct
or consequential, sustained by the buyer or any person which may in any
degree be attributable to the adoption, either by the buyer or any third party, of
technical or any other information, data or advice given on behalf of Fort Vale
Engineering Limited or however otherwise caused in relation to the use of its
products in accordance with Fort Vale Engineering Limiteds
recommendation.
' Fort Vale Engineering Limited, 1998.

Fort Vale SA
Postal Address:

P.O. Box 200, Milnerton, 7435 Capetown, South Africa

Facility Address: Longclaw Drive, Montague Gardens, 7441 Capetown South Africa
Tel + 27 21 551 0246/7 Fax. + 27 21 551 0253
Email. Sasales@fortvale.com

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Fort Vale BV.

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Tel. + 31 1804 101 77/103 09 Fax. + 31 1804 107 97
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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.O Gara (Works), J. F. Frot (Commercial).
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