SV Maintenance V1.2 CONE VALE

Maintenance and repair guide V1.
2
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by worldwide patents and deposited trademarks.
By using this document you bindingly agree to maintain the contained information strictly
confidential, to use it exclusively for the purpose that it was made available to you, to expressly
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measures to prevent access to this Information by third parties.
© 2005-2014 Visval AG
D. Zimmermann 11.12.2014
11/12/2014 16:21
D.Zimmermann
Version 1.2
SoliValve® Maintenance guide

1. Tooling and products ....................................................................................................................................................... 2
1.1 Glue and cleaning products ........................................................................................................................................... 2
1.2 Special tools for mounting/dismounting the SoliValve ®................................................................................................ 4
1.3 Torque table ................................................................................................................................................................... 5
2 Dismounting the SoliValve® ............................................................................................................................................ 6
2.1 Dismounting the head of the SoliValve ......................................................................................................................... 6
2.2 Dismounting the pneumatic motor .............................................................................................................................. 10
2.3 Removing the Ball screw unit ...................................................................................................................................... 14
2.4 Dismounting the TC from the housing ........................................................................................................................ 16
3 Mounting the SoliValve® discharging unit .................................................................................................................... 18
3.1 Mounting the complete TC in the housing .................................................................................................................. 18
3.2 Mounting of the ball screw unit in the SoliValve® ...................................................................................................... 20
3.4 Mounting the pneumatic motor ................................................................................................................................... 24
3.5 Mounting the electric connector .................................................................................................................................. 27
3.6 Mounting the Clamp system distributor ...................................................................................................................... 30
3.7 Mounting the clamping system .................................................................................................................................... 33
3.8 Mounting the vibrator unit ........................................................................................................................................... 37
3.9 Mounting a SoliValve® unit without vibrator .............................................................................................................. 38
3.10 Cone and cover mounting .......................................................................................................................................... 39
4 Mounting the SoliValve® Filling Unit ........................................................................................................................... 40
5 Servicing the SoliValve® ............................................................................................................................................... 44
5.1 Replacing the air filter ...................................................................................................................................................... 44
5.2 Receptacle detection servicing ......................................................................................................................................... 45
5.3 Pneumatic detector for locks ............................................................................................................................................ 48
5.4 Cleaning the fluidization seal / Replacing the fluidization ring ....................................................................................... 50
5.5 Replacing the lip seal and clamping seal .......................................................................................................................... 52
5.6 Replacing the bearings in the vibrator .............................................................................................................................. 54
5.7 Replacing the rotation sensor ........................................................................................................................................... 56
5.8 Pneumatic motor .............................................................................................................................................................. 57
5.9 Manual lock opening/closing repair ................................................................................................................................. 59
5.10 Compressed air lines ...................................................................................................................................................... 60
5.11 Test of mechanical functions .......................................................................................................................................... 61
5.12 Part, products and special tools list ................................................................................................................................ 61
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Version 1.2
1. Tooling and products
1.1 Glue and cleaning products

All these products can be order from Visval with the reference number 500xxx.
500188: Loctite 638 (50ml)
High strength, general purpose. Used for fastening of bronze

rings and pins.
500187: Loctite 542 (50ml)
This glue is used on all screws of the SoliValve® (except 2 or

3 that are specified in this document) for air tightness. It
prevent from air leakage. It must be applied again after each
dismounting. Cleaning the screws before using them again.
500185: Loctite 262 (50ml)
This glue is used only on the screw fastening the stopper of

the ball screw.
500189: Loctite 7063 (400ml)
Degreaser for all parts where Loctite 638, 480 and 262 is
being used. Parts must be carefully degreased before using
glue.
500186: Loctite 480 (20g)
Instant glue, used for example to glue the cellastos on the

cellasto sleeve AH 100171.
500136: Klüber Paraliq GTE 703 (60g)
This FDA grease is used for all O-rings and seals except the
O-Rings with PTFE coating and the white flat gaskets.
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Version 1.2
500135: Klüber Klüberpaste UH184-201 (60g)
This mounting paste is used for the clamping system, for the
magnetic cover unit 100131, for the motor shaft and for the 8
M6 nuts holding the clamping seal.
500138: Klüber Klübersynth UH164- 62 (1kg)
This FDA grease is used for the ball screw and the bearing of
the ball screw
Also available as a 50g tube (500137)
500355: Würth industrial cleaner (5l)
This product is used to clean all flat gaskets and for cleaning
all parts of the SoliValve®.
500139: Klüber Summit HySyn FG 32 (3.8l)
Lubrication oil for the pneumatic motor. Must be filled in the

control panel.
500128: Interflon stainless steel dry cleaner
This is used to make the parts in stainless steel look good.
500332: Würth Leak detection spray
This spray is very efficient to detect air leakage.
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Version 1.2
1.2 Special tools for mounting/dismounting the SoliValve®
These special tools are necessary to mount/dismount the SoliValve®. They can be ordered from Visval.
100507 Magnetic key 100046 Ball screw anti-rotation
Used in chapter 2.1.2 , 2.2.2, 3.4.4, 3.10.3 Used in chapter 2.3.1, 2.3.4, 3.2.3
100842 2 M8x80 threads Tube Ø4x180mm, Tube Ø12x120mm
Used in chapter 3.1.1
100840 Plastic stopper 20x20x130 100047 Ball screw nut mounting tool
Used in chapters 2, 3, 4 Used in chapter 2.3.3, 3.2.3

100845 Connector mounting tool 500241 & 500242 Counterpart Multi-coupling
Used in chapter 3.5.5, 5.7

100621 CS distributor tightness plug 501072 Namur sensor tester
Used in chapter 3.6.2 Used in chapters 3.3.2, 3.3.3, 3.5.4, 5.7

100848 elbow for tighness test + 100174 CS 100835 Bearing and cellasto mounting tool
distributor
Used in chapter 3.6.2
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Version 1.2
500xxx Precision gauges 500xxx hydraulic cylinder

Used in chapter 3.3.2, 5.7.2
100044 Vibrator key 100841 TC straitening tool
Used in chapter 5.6

100497 Clipping / Unclipping tool 100842 Mounting tool for ball screw stopper
1.3 Torque table

All screws must be tightened according to torque values of this table. A precise torque wrench
must be used for all operation. Visval recommend using 2 different torque wrenches, one for
torques from 0 to 10Nm and one for torques from 10 to 50Nm.
Designation Torque Visval reference number

M6x5 headless screw 2 Nm
Socket headcap screw A2 M4x12 2.5 Nm 500048
Socket countersunk head screw M5x10 A2 500038
Socket headcap screw A2 M5 5 Nm
Socket headcap screw A4 M6x16, M6x12 9 Nm 500052, 500674
Self-locking nut M6 A4 70 500028
Socket countersunk head screw M8 10.9 15 Nm
Socket headcap screw A4 M8x40 + Socket 21 Nm 500057
countersunk head M8x25 from the CS distributor
Socket countersunk head screw M10x20 A2 500035
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Version 1.2
2 Dismounting the SoliValve®
2.1 Dismounting the head of the SoliValve

2.1.1: Opening the cone
For most maintenance operation, it is necessary to

2 have the cone opened to work. Set the stroke of the
cone until the plastic stopper 100840 can fit as in
the picture (3). The stroke of the motor can be
1 adjusted by putting compressed air (max 4.5 bar) in
C5 (1). To open the cone, put compressed air (min
0.5bar) in C2 (2). If the stroke must be diminished
put air in C6.
Then put the plastic stopper (3) and turn off the
compressed air. The cone will go down and hold in
place with the plastic stopper. Push on the cone to
3 ensure that the plastic stopper holds in place and
that it’s safe to work on the SoliValve®.
Never put pressure in C6 when the plastic stopper is
in place. Otherwise it will damage the SoliValve®.
2.1.2: Removal of the magnetic cover
Remove the magnetic cover unit 100131 (1) with

the magnetic key 100507 (2).
Degrease the cover and the tool. When the tool is
put on the cover a noise must be heard. If not, put
1 pressure on it and try to turn slightly in both
2 directions until the noise is heard.
It means that the washed has been trapped by the
magnet. The cover can now be opened, by turning
anticlockwise the magnetic key.
2.1.3: Removal of the conical cover unit
1 Remove the 3 M8x16 countersunk head screws (1).

Obstruct 3 holes with 3 fingers and put compressed
air (2) in the 4rd one of the conical cover unit
(100657) to make it pop out.
An emergency solution if compressed air is not
2 available: with a flat screwdriver push carefully in
3 the middle (2) but this is not recommended as it
scratches the surface of the vibrator.
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Version 1.2
If the cone vacuum filter 100094 (2) is dirty it must

be replaced. The side with coating (3) must face
5 downwards. The cavity where the filter is mounted
must be cleaned carefully (4). Don’t put liquid in
the little hole (5)!
2 4
1 The O-ring 500751 (1) must be replaced!
3 Remark: the color of the O-Ring can be red or

black.
2.1.4: Removal of the vibrator unit
To dismount the vibrator unit 100095 (1), remove

the 8 M6x16 screws 500052 (2).
1
Remark: On unit produced until December 2013,
M6x25 screws were used. On newer units, these
2 screws are replaced by M6x16.
If the SoliValve® is not fitted with a vibrator, the

removal of the vibrator dummy 100167 (2) is
3 identical.
Be careful not to lose the 3 distance washers

2 100243 (3) on top of the vibrator dummy. They are
only used with the vibrator dummy.
2.1.5: Removal of the CS distributor cover
Remove the M10x20 counter sunk screw 500035

1 4 (1) with a wrench. Remove the distributor cover
100029 (2).
2 Remove the 3 compression springs 500117 (3) and
the 3 O-Rings Ø11x1 500751 (4)
3
Remark: the color of the O-Ring can be red or
black.
If the SoliValve® is not fitted with a vibrator, the

5
distributor cover (100174) is different (5). It has no
holes and no seals.
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Version 1.2
Remark: If the distributor cover is fitted with 2

white flat gaskets 100634 (6) or 2 O-Rings Ø6x1
(7), it’s an older version of the CS distributor and it
needs to be upgraded (part no 100026-05) plus 2x
6 O-Rings Ø8x1.5 (500951) and 1x O-Ring Ø45x1.5
7 (500952).
After removing the distributor cover, remove the 2

white flat gaskets 100634 Ø11/8x1 (6) and one O-
Ring 500004 Ø36x1.5 (8).
Remark: On older version, O-Rings Ø6x1 were

6
used here as well. The CS distributor must be
8 upgraded with the latest version. See 2.1.6.
At this point, there is 2 options:

1) Removing the complete clamp system
2) Opening the clamp system
2.1.6: Removing the complete clamp system (CS)
This option is chosen if nothing needs to be done on

the clamping system. When the ball screw must be
dismounted for example.
To remove the complete clamping system, pull it

with both hands and turn lightly in both directions
until it comes free.
Once the clamping system is removed, the

SoliValve® looks like this (1).
Remark: The CS distributor with Ø6x1 O-Rings

(made before 2012) should be replaced with the
new CS distributor 100388 (1) if the SoliValve® is
1 serviced.
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Version 1.2
2.1.7: Opening the clamp system
This option is chosen when maintenance must be

2 done on the clamp system. For example, changing
1
the clamping seal, the none-return lip seal or the lip
seal.
1 Remove the 8 M6x16 socket head cap screws (1)
(They are already removed in the picture).
3 2
Remark: On units produced until December 2013,
M6x25 screws were used. They must imperatively
be replaced by M6x16 screws as they can bend the
CS disc 5.
Put again 2 M6x16 screws (1) and just screw them a

few turns. Hit on their head with a plastic hammer
until you feel that the inner plate is separated from
the upper plate, and then remove the 2 screws.
Remove the CS disc 5 100185 (3) by pulling it

4 carefully. To make the removal easier, 2 M6x16
screws can be screwed on 2 of the vibrator threads
(2) and can be used to lift the CS disc 5.
Then remove the CS disc 4 100184 (4).
2.1.8 Removing the clamping seal assembly
To remove the clamping seal assembly, remove the

8 M6 nuts (1). If you can’t pull out it out, remove
2 only 2 of the 4 M5x10 socket countersunk screws
(2) and screw 2 M5x20 (or longer) socket head cap
screw instead (4). It will separate the CS disc 2
from CS disc 1 and the clamping seal assembly can
1 be removed. Immediately put back the M5x10
2 3 screws (2) with Loctite 542 and a torque of 2.5Nm.
These 4 M5x10 screws are only dismounted if the

clamping seal 100191 must be replaced. Otherwise
4 the clamping seal stays together with the CS disc 3
and CS disc 2.
4
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Version 1.2
2.1.9 Removing the CS disc 1
The CS disc 1 100181 (1) with the lip seal 100187

(2) can be removed by simply pulling on it.
Be careful not to damage the wiper seal 500344 (3)

and especially the O-Ring (4) on the CS distributor,
because the wiper seal is sharp.
Once the CS disc 1 is remove, the SoliValve® looks

like this.
2.2 Dismounting the pneumatic motor
2.2.1 Removing the clamp system distributor
Remove the 3 socket countersunk M8x25 screws

500044 (1) to remove the CS distributor 100388
2 (2).
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Version 1.2
Remove all the seals (5x 100015 Ø13/9x1, 1x

500006 Ø44x2) and put them in a safe place. The
white seals must always be replaced after
dismounting.
Update 12.07.2013: The newest version of the TC

External Tube 100021-05 (picture on the right) has
5 O-Rings (501052 Ø9x2) instead of the white flat
seals (100015).
2.2.2 Removing the magnetic cover
Turn the SoliValve upside down and remove the

magnetic cover unit 100131 (1) with the magnetic
key 100507 as seen on point 2.1.1.
2.2.3 Removing the protection tube
Use a tool extension (min 170 mm) (1) to remove

1 the 3 M6x30 screws through the holes of the
protective tube. Then remove the air motor
protective tube 100421 (2).
Remark: On older versions the air motor protective

tube is fitted with 3 M6x16 screws. These versions
are recognizable because the motor is different and
has an additional flange (3).
3
2
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Version 1.2
2.2.4 Removing the pneumatic motor
Check that the marking I for Increase and D for

Decrease are present on the back of the motor and
on the SoliValve® housing (1). If they are missing,
write them before dismounting. If the connections
are inverted at the remounting, the motor will turn
in the wrong direction and the SoliValve® will not
2 1
work.
Unplug the 2 tubes on the SoliValve® (2), unscrew

the 2 M6x16 screws 500052 (3) and pull out the air
motor (100415). Remove the 2 Ø8 G1/8 couplings
(4).
3
1 4
Be careful not to lose the compression spring

5 500117 (5) and the key 4x4x20 500517 (6).
This picture shows the 2 different pneumatic

motors. On the left the old one (100396), on the
right the new one (100415).
2.2.5 Removing the pneumatic motor (old

version)
SoliValve® made before 2012 have a different

motor (100396) with an additional flange 100189-
01 (1) screwed on the motor. After removing the 2
4 tubes and the 2 Ø8 G1/8 couplings, remove the 3
M6x16 socket head cap screws (2). If the motor
5 doesn’t come off easily, put 2 screws in these
threads (3) to push the motor out of the housing.
1 3
2
Remark: Flange 100189 (4) made before May 2011
have M6x20 countersunk screws (5) instead of the
M6x16 socket head screws (2). This version must be
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Version 1.2
updated with the new flange 100189-01 (1).
In this version there is no spring, but a machined

key (5), a spring washer (6) and a needle bearing
(7). Be careful to put them on the motor in the
7 correct order.
The needle bearing has a U cavity for grease. It
6 must be positioned correctly, so that the grease
stays in cavity. The U cavity must point upwards
5 (opposite side of the motor) for a discharging unit
and downwards (towards the motor) for a filling
unit.
When a new motor is need for a SoliValve® with

this flange 100189 (1 or 4), it must be specified at
the order: pneumatic motor (100396).
The new pneumatic motors (100415) will not fit in

this version of the SoliValve.
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Version 1.2
2.3 Removing the Ball screw unit
2.3.1 Block the rotation of the screw

2
Fasten the ball screw anti-rotating tool 100046 (1)
with 2 M4x10 screws on the stopper (2). This part
1 4
prevents the screw assembly to turn during
dismounting. The 2 guides (3) must be aligned in
the nuts (4).
3
2.3.2 Removing the safety screw
With one hand push on the other end of the ball

1 screw (where the ball screw mounting tool is) to lift
it up.
2
Localize the safety screw M4x6 500033 (1) on the
special nut 100059 (2) and remove it with an allen
key. Be careful not to damage the screw.
2.3.3 Removing the nut
With the ball screw nut mounting tool 100047 (1)

1 and a wrench remove the special nut 100059 (2).
2.3.4 Removing the ball screw
Once the special nut is removed, the complete ball

screw unit 100656 can be removed from the
1 SoliValve®. Remove the ball screw anti-rotation
tool 100046 (1)
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Version 1.2
2.3.5 Removing the shaft ball screw unit
Remove the shaft ball screw bronze ring 100025 (1)

together with the thrust ball bearing 500264 (2).
1 Then remove the lower cover (3) and put the parts
3 together again, with the ball screw in a safe and
clean place.
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Version 1.2
2.4 Dismounting the TC from the housing
2.4.1 Dismounting the electric plug
Before dismounting the TC cylinder complete, the

1 2 electric plug must be dismounted.
Push on the quick connector (1) and push on the

tube (2), then pull the tube carefully. It must come
out easily.
Now the connector must be opened.
The connector mounting tool 100845 (3) is plugged

on the connector. The tool must be hold by hand or
3
with one plyer and the nut (4) can be opened with a
key. Then, the body can be unscrewed by hand (5).
5
The 4 wires must be removed from the connector

by loosening the 4 small screws (6).
6
Check that the numbers 1,2,3,4 marked on the white
pins (7) are marked on the cable (8) as well. One
cable has 1 and 2, and the second 3 and 4. If not,
mark them.
It will prevent making a mistake when remounting
the connector later.
8
7 Then cut the pins (7), and remove carefully all the
components of the electric plug.
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Version 1.2
2.4.2 Dismounting the complete TC AH
The cable (1) must first be carefully completely

pulled out of the side arm from the inside.
The 3 M8x40 screws 500057 (2) must be loosen
2 and the whole TC AH 100646 will be removed.
Warning: At least one screw must be removed after
turning the SoliValve® upside down; otherwise the
1 TC will fall and rip off the cable.
Remark: On older versions, M8x25 screws were

used here.
Visval recommend removing the TC AH with the

SV head looking up (like in the picture on the left).
3 You need access from under the SV to remove the
screws (2). The advantage of this variant, is that the
TC AH can’t fall. It must be pulled for removal.
When the screws (2) have been removed, lift

carefully the complete TC AH 100646 (3), taking
care that the cable doesn’t get stuck neither gets
4
pulled (4).
Remove the 4 white seals Ø13/9x1 100015 (4) and

the O-Ring Ø 82.22x2.62 500021 (5).
The dismounting is finished. The complete TC AH

4 is out of the housing. Store it with the sensor cable
5
looking upwards, so that the cable is not bent and
damaged by the weight of the TC AH.
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Version 1.2
3 Mounting the SoliValve® discharging unit

The mounting procedure is similar to the dismounting procedure, but there are a few points to check,
measure, test, seals to grease, etc. That’s why Visval recommend always following the mounting
procedure in order not to forget any details. When remounting a SoliValve®, always use new seals and
O-Rings.
3.1 Mounting the complete TC in the housing
3.1.1 Mounting the TC AC in the housing
Always clean all the surfaces with cleaning product

before mounting seals.
Inspect the Ø82.22x2.62 O-Ring 500021 (1). If it’s

not damaged it can be reused. These O-Rings with
PTFE envelope must be mounted without grease.
Important: When remounting a SoliValve® always

1 use new white seals 100015 (2). The 5 white seals
2 100015 (2) must be degreased before mounting, as
well as the surface that they are in contact with.
Put 2 M8x80 threads 100842 (3) in 2 of the 3 holes.

This is needed to help positioning correctly the TC
in the housing during assembly and avoid
misplacement of the gaskets.
3 4 Clean the lower surface (4) to remove all traces of
grease. This surface will be in contact with the seals
and need to be clean and degreased.
Hold the TC AC complete 100646 vertically and

put the blue wire through the left hole (5).
Remark: the Ø88.22x2.62 O-Ring can be red or

black.
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Version 1.2
The TC AC complete is now positioned (6).
Put one M8x40 screw (8) without Loctite 542 in

7 the free hole. Then remove one of the M8x80
threads (7) and replace it with an M8x40 socket
head cap screw without Loctite 542 and do the
same for the third one. Tighten the screws so that
the TC cylinder doesn’t have play, but don’t tighten
them to the correct torque of 21 Nm now, because
6
the TC cylinder must first be centered.
Remark: On older versions use M8x25 screws here.

8
After centering, the screws will be individually
removed and fitted with Loctite and tightened to the
correct torque. Explanations will follow in step
3.2.2.
3.1.2 Mounting the position sensor cable
Turn the SoliValve® upside down.
1 Put the blue cable (1) in the hole and take it out of
the housing (2).
2 In order to do this you need first to put a Ø6mm
0
8 L=180mm pneumatic tube in the housing (3). Then
you can put the cable in the other extremity of the
tube (4) and push on it until it gets out of the
housing (2).
With a permanent marker write the numbers 3 and 4

at the end of the blue cable (1). This will help later
when mounting the electric connector, not to mix
3 4 the wires.
0
The TC cylinder in now assembled to the housing.
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Version 1.2
3.2 Mounting of the ball screw unit in the SoliValve®
3.2.1 Assembling of the trust ball bearing
The Trust ball bearing (500264) comes in 3 parts.

2 First fill the parts with the balls (2) with UH1
grease (500138).
When you put the rings on the bronze shaft 100025

1 (4), one ring (1) has more play that the other (3).
2 3 This is the one that will be put first in the housing.
The bearing (2) must be mounted in the correct

direction. The U shape is made to retain the grease.
So the U shape must always point up.
In a discharging SoliValve® (like in this example) it

means against the housing, and in a filling
SoliValve® the U must point against the bronze
4
shaft (4), because the filling SoliValve® is installed
1 2 3 with the head looking down.
3.2.2 Installing the trust ball bearing
Put the first ring (1) in the housing, then with the
bearing mounting tool 100835 (2) hit the ring with
a hammer until it is perfectly in place. This ring (1)
5 is centering the TC in the housing. Check that there
is no gap under the ring (1) with a 0.05mm feeler
1 gauge (4). If you still have play, loose a little bit the
screws and try again until there is no play. At this
3 2 point remove one of the 3 M8x40 screws (5), put
Loctite 542 on it and tighten it with 21 Nm. Do the
same for the 2 other screws.
Then the bronze shaft can be added, fitted with the
rest of the bearing, as assembled in 3.2.1 (3).
4
The assembled trust ball bearing looks like this (6).
In this picture however, the blue cable is not yet put
in its right position (see point 3.1.2).
6 Remark: On older version of the SoliValve®, there

is an additional washer (100193) to be put before
the first ring (1).
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3.2.3 Installing the ball screw unit
Fasten the ball screw anti-rotation tool 100046 with

1 2 the 2 screws (1) on the assembled and greased ball
screw unit (2).
Put the ball screw unit in the housing from the

other end. Clean the threads (3) of the ball screw
3 with Loctite 7063 and the special nut 100059 (4) as
well.
Put Loctite 542 on the thread of the special nut (4)

and tighten it on the ball screw unit using the ball
screw nut mounting tool 100047 (5). The nut is
5 tightened by hand. It must not be tightened too
much. Don’t use a wrench!
Now the ball screw anti-rotation tool (1) can be

4 removed.
6 To prevent the nut to loosen itself, a M4x6 500033

safety screw (6) is put on the special nut 100059
with Loctite 542. Be careful not to damage the
screw with too much torque while fastening it.
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3.3 Mounting the rotation sensor
3.3.1 Installing the rotation sensor
Put a pneumatic tube Ø 6 L=180 (1) around the

cable of the rotation sensor 500280.
1
Remove the pneumatic plug (2) off the housing to
facilitate the insertion of the sensor.
2
Don’t forget to put it back before doing the
electric connector, otherwise you will need to
dismount the whole connector again!
Put the sensor from the outside of the SoliValve®

with the help of the pneumatic tube (3).
Mark the extremity of the cable with 1 and 2 in

order to recognize it when you need to make the
3 electric connector. The position sensor is marked
with 3 and 4 (see 3.1.2).
Now put the rotation sensor fastening insert

100904 (4) with a plyer in the hole. The black line
must be aligned as in the picture to ensure proper
positioning (5).
Put the headless screw M6x5 501141 (6) with
4 Loctite 542 and don’t tighten it now.
5 Remark: SoliValve® assembled before march 2014
don’t have the sensor fastening insert 100904 and
have a M6x8 screw instead of the M6x5 501141.
If a sensor must be replaced on a SoliValve®
assembled before march 2014, this update should
be made (insert + new screw).
6
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3.3.2 Adjusting the sensor position
The distance between the sensor and the nut must

be precisely adjusted with a 0.1mm feeler gauge.
2
First turn the special nut (1) clockwise by hand
until you can’t anymore. This operation is
important because there is no play only when the
1
nut is blocked. Only then can the sensor be
3 adjusted. Put a 0.10mm feeler gauge (2) between
the nut and the housing, push on the cable of the
rotation sensor to push it against the feeler. Then
tighten the M6x5 screw (3) with Loctite 542 just
6 enough so that the sensor stays in place.
Connect the sensor cables to the Namur sensor

tester 501072 (1=brown on the right and 2=blue in
the middle) (4). Turn the special nut like in the
picture (5).
4
The sensor is a NO “normally open” type. The
green light will turn on and the tester will make a
5 beep signal when no metal part is in proximity
from the head of the sensor.
Now tighten the M6x5 screw with a torque of 2
Nm (6). You should not see any difference in
intensity of the green light, neither variation of the
sound volume after tightening. If there is a
difference, loose the screw, position the sensor
with the gauge correctly and try again. If the
sound and light has variation, or doesn’t stay
constant, change the sensor. The pressure on the
sensor has an influence on its capacity to work,
that’s why the 2 Nm torque must be imperatively
respected.
If the screw is tightened too much, it will break
the sensor.
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3.3.3 Rotation sensor testing

2 The rotation sensor must now be tested with the
Namur sensor tester unit 501072 (1).
Take the cable with the 1 (brown) and 2 (blue)
marked on it (2) (done on point 3.3.1).
Put the brown in the right input and the blue in the
middle input.
3
Turn the special nut with the hand and observe the
5 green led (3) on the sensor tester (1). The green
led must be off when the nut is 0.1mm from the
sensor (5) and must be on when then sensor is
1 facing one of the 4 gaps (4).
4
3.4 Mounting the pneumatic motor
3.4.1 Preparing the pneumatic motor
The pneumatic motor (100415) must be fitted with

2 2x elbow Ø8G1/4 500238 (1) and 2x elbow Ø8Ø8
1
500231 (2), mounted as in the picture, without
3 Loctite.
Make sure the “I” for Increase and “D” for

decrease are marked on the motor (3).
In case the motor is unmarked, put compressed air

inside and observe the sense of rotation of the
motor. Decrease is clockwise and increase is
anticlockwise. The opposite of an automatic
screwdriver.
Remark: The motor can be blue or without

painting.
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Remark for older versions of the pneumatic motor:
Older pneumatic motors (100396) are different. An

additional flange (100189) must be assembled to
the motor before mounting the motor in the
4 housing.
This picture shows an older motor (100396) on the
left (4) and a new motor (100415) on the right.
This picture shows an older motor with its flange

(5).
3.4.2 Installing the pneumatic motor
Put the compression spring 500117 (1) in the ball

bearing hole. Put mounting past Klüber UH1 84-
201 on the shaft and on the key of the pneumatic
motor (2).
1
2 If they are not already made, mark I for increase
(3) and D for decrease (4) like in this picture.
Put the pneumatic motor in the ball screw and use

it like a screwdriver (turn clockwise) to move the
nut of the ball screw towards the motor. When you
start to fell resistance, the nut is in contact with the
4 cellasto (damper). This step is needed to center
3 precisely the motor. Then you must align the motor
in the correct position (like in the picture) and
fasten it with 2 M6x12 head cap screws 500674
with Loctite 542 and a torque of 9 Nm (5).
Remark: until December 2014, M6x16 screws were

used. It was observed in rare occasions that the
screws were touching the bottom of the holes
without the motor being properly fastened.
7 7 Put the 2 strait fittings Ø8 G1/8 500219 (6) without
Loctite.
Connect the pneumatic motor with the strait fittings
6 (6) with 2 Ø8x145mm pneumatic tubes (7). Pay
attention to connect the motor correctly, I with I
5 6 and D with D, otherwise it will not turn in the
correct direction.
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3.4.3 Test the pneumatic motor for leak
Put a plug in C5 (1) and put 6.5 bar compressed air

in C6 (2). Check for any air leak around the
2 pneumatic motor.
1 Check for leak on the back of the motor, especially
around the connectors and where the holes have
been covered with sealant during the production.
Use leak detector spray (3) to be sure.
By removing the plug (1) and using a pressure of

2.5 bars, the sense of rotation of the motor can be
tested (increase C5, decrease C6).
3.4.4 Installing the protective tube
Put the Ø78.97x3.53 O-Ring 500336 (1) without

grease.
Put the air motor protective tube 100421 on the

housing and fasten it with 3 M6x30 screw (500921)
with Loctite 542 and a torque of 9 Nm. There is
only one possible position (check the 2 holes for
3 the tubes) (2). To fasten the screws an extension
tool of min 170mm is needed (3).
Remark: On version of the SoliValve® with the

2
older pneumatic motor, M6x16 screws were used.
Put the same O-Ring 500336 (4) as under the

protective tube (1).
Put mounting past Klüber UH184-201 on the
thread (5) of the Magnetic cover unit 100131 (6)
and assemble it with the Magnetic Key 100507 (7)
on the air motor protective tube.
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5 7
4
6
3.5 Mounting the electric connector
3.5.1 Marking and cutting the cables
Make sure the quick connector (1) is mounted on

1 the housing.
2 3 4 From the quick connector (1) make line on both
5
cables at 200mm (2), 300mm (3), 325mm (4) and
350mm (5). Then cut both cables at 350mm.
Remove 25mm of the protective envelop from both

cables (the 325mm mark) taking care not to damage
6 the wires (6).
1 3.5.2 Preparing the Connector
Put the Seal 100434 (1) on the wires up to the

200mm marking (2). Put then the Insert 100433 (3).
3
2
6
3 Now put a 100mm Ø12 (4) pneumatic tube up to
4 the insert (3). If the tube doesn’t hold well on the
insert, change the tube. On the other end of the tube
you should see the 300mm marking (5).
5
The seal must be inserted on his entire

circumference in the Insert (6). A small screwdriver
can help pushing the seal in the insert. Be careful
not to damage the seal or the cables. If it is not
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properly assembled, the connector will not be air

tight and will need to be redone.
3.5.3 Assembling the connector

1
Put now the components of the male cable
connector 500333 in the same order as in the
picture. First the nut (1), then the plastic ring (2),
then the seal (3) and the body (4).
2
3
Remove the plastic on the extremity of the 4 wires

on approx. 10mm (5).
Now press the pins on the 4 wires and mark them

5 with the number 1,2,3,4 according to the number on
the envelope of the wires. 1 (brown) and 2 (blue)
are for the rotation sensor and 3 (brown) and 4
(blue) are for the lift position sensor. If there is no
marking on the sensor go to next point.
3.5.4 Testing the 2 sensors
At this point both sensors will be tested again. This

test will validate that both sensors are working
correctly. It is needed as well to make sure the wires
2 1 are assembled correctly in the connector.
Put 1 (brown) in the right input (1) and 2 (blue) in

the middle input (2) of the Namur testing device
(501072). Test the rotation by putting compressed
air (2.5 bar) in C5 (increase stroke) and observe if
the green light is blinking.
In case it is not blinking, either the wrong wires
were connected (the ones from the height sensor) or
the motor doesn’t turn because it’s already at its
max stroke. Connect the compressed air to C6 and
try again. If it doesn’t blink, there is a problem with
the rotation sensor. Go back to point 3.3.2 to check
if it is correctly positioned.
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Then connect 3 (brown) and 4 (blue) the same way

as previously and pull the cylinder or put air into
C2.
You should see the green light blink once at 10mm

If both tests are successful, continue to next point.
3.5.5 Connecting the wires
The wires must be connected according to their

numbers. Find the numbers marked in the connector
and connect the wires.
1
To screw the body (1) to the connector (2) the
2 connector mounting tool 100845 (3) must be
connected to the connector, to prevent it from
rotating while the body (1) is screwed. Screw the
body by hand, and then remove the connector
mounting tool.
3
Now you can mount the nut (4) to the body (1).
Hold the body with the hand and tighten the nut (4)
with a 21 key. Don’t tighten too much.
1
4
Put the 2 wires carefully in the housing of the
SoliValve® and then push the pneumatic tube of the
connector in the quick coupling.
5 If you have difficulties inserting the wires inside the
housing, remove the Ø12 push in (5), insert the
wires almost completely, and then screw it back on
and push the tube inside.
Now the assembly of the connector is finished.
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3.6 Mounting the Clamp system distributor
3.6.1 Mounting the Clamp system distributor
Turn the body of the SoliValve® upside down.

2
3 Put the O-Ring, 5x Ø9x2 501052 (1), 1x Ø44x2
500006 (2) with Klüber Paraliq GTE 703 on the TC
External Tube
1 Remark: On SoliValves® produced before the 12 of
July 2013, instead of the 5x Ø9x2 501052 O-Ring,
there is 5x 100015 Ø13/9 white seals (3). Always
use new white seals and degrease them, as well as
4 the parts in contact before mounting them.
5
Now put the CS distributor complete 100388 (4) on
the TC cylinder, and put the 3 Ø8.73x1.78 O-Ring
(5), grease with Klüber Paraglid GTE 703.
Fasten it with 3 socket countersunk M8x25 screws
(6), with Loctite 542 and a torque of 21 Nm.
Put then the Ø36x1.5 500004 (7) and the
7 Ø94.93x2.62 500013 (8) O-Rings greased with
Klüber Paraliq GTE 703.
Before doing the test (point 3.6.2) wait a minimum

6 of 45 minutes that the glue can dry.
Remark: Filling SoliValve® has a different CS

distributor (100614) than Discharge SoliValve® but
8 the procedure is the same.
3.6.2 Testing the CS distributor
Several tests are done to ensure that the CS

distributor is perfectly tight.
1
2 Test 1:
First put plugs in inlet C5 (1) and C6 (2).
Then connect the inlet C2 (3) to compressed air

supply. You may use any connector available that
fits the requirements. A pressure of 8 bar is needed.
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Put 2 white seals Ø11/8x1 100634 (4) and then the

CS distributor cover 100174 (5) and tighten it with
a countersunk head cap screw M10x20 (6) with a
torque of 21 Nm.
6 Put then a pressure of 8 bar in inlet C2 and check

5 carefully on the whole diameter between the CS
disc system and the telescope cylinder (7) for any
leak. Use leak detector spray if necessary.
Check as well for leaks, the electric plug (9), the 3

arms in the housing of the SoliValve® and around
the TC.
8
7
After the test, the CS distributor cover (5) and the
seals (4) can be removed.
Test 2: Cone Cleaning Function
Put compressed air (2.5 bar) in C1 and obstruct the

4 little holes on the CS distributor (10) with the
fingers. Another person should check around the CS
distributor for leaks.
10
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Test 3: Cone Clamping Function
Screw the CS distributor tightness plug 100621 (11)

in the “Cone Clamping hole” (8) to make it tight.
Put compressed air (4.5 bars) in A3 inlet (11) of the
male multi-connector.
12
11 Check again around the CS distributor for any leak
(7). Then remove the CS distributor tightness plug
100621 (11).
If any of these 3 tests fail, the CS distributor must

be dismounted and the seals must be replaced.
At the end of the test, make the TC cylinder go up,

and put the plastic stopper 100840 as in point 2.1.1.
Remove the CS distributor cover 100174.
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3.7 Mounting the clamping system
3.7.1 CS disc 1
1 Degrease the CS disc 1 100181 and the wiper ring

500344 (1) then put the wiper in the CS disc 1 and
finally put a greased O-Ring 45.69x2.62 500012 (2)
in the nut. Put grease on the inner side of the wiper
2 once it’s installed, to make the assembly in the CS
distributor easier.
Mount the CS disc 1 on the CS distributor. Take

care not to damage the wiper ring and neither the O-
Ring of the CS distributor (3). It should be done
slowly, and once the CS disc 1 is engaged like in
the picture, the O-Ring must be pushed sideways in
the nut with the fingers, to allow the passage of the
3 wiper seal without damaging the O-Ring.
Degrease again the surface of the CS disc 1,

degrease both sides of the Lip seal 100187 and
position it on CS disc 1 (4).
4
3.7.2 CS disc 2
Degrease the CS disc 2 100182 (1) and put the non-

return lip seal 100002 (2) in the nut (2) on the
2 whole circumference. It is important that the seal is
correctly positioned in the nut.
It may seem that the seal is too long. You need to
pull delicately on it in both directions in order to
insert the last millimeters in the groove.
Remark: On filling station, the non-return lip seal

has a different diameter. The reference number for
1 filling station is 100619.
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Put the CS disc 2 on the CS disc 1, the side with the

non-return lip seal looking downwards. Be careful
that the seal stays in its place.
3 Pull on the lip seal (3) to center it against the inner

border of the CS disc 2.
Put mounting past Klüber UH184-201 on the 8 M6
threads (4). It is important, to prevent the nut to
seize on the threads when we need to dismount
4 them for servicing.
3.7.3 CS disc 3
3 2 Degrease the CS disc 3 100183 (1) and put it on the
already degreased CS disc 2. The chamfer of CS
disc 3 must look downwards.
Put the 8 M6 nuts 500028 (2), just partially fastened
by hand. Put the 4 countersunk head cap screws
1 M5x10 500038 (3) with Loctite 542, as well
partially fastened (one turn is enough).
Degrease and wipe the clamping seal 100191

several times until it doesn’t make any black
marking anymore on the rag and until it’s shinning.
4 Insert the clamping seal (4) between the CS disc 2

5 and 3, from its outer diameter. Push it to the bottom.
Then with the help of a screwdriver (5), separate
gently the 2 discs to make the insertion of the
clamping seal easier on the whole circumference.
Don’t damage the parts. If you have difficulties,
loose the screws and bolts to allow the CS disc 3 to
move more. It must go without forcing.
Once the clamping seal (4) is installed, push on its

upper edge (6) on the whole circumference to make
sure that the seal is perfectly pressed in it. Check
that it is even on the whole circumference otherwise
you will have to dismount it again
6
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Remove the plastic stopper 100840 and put the TC

cylinder down, to check if the lip seal is correctly
centered in the inner diameter of the housing of the
SoliValve® (7).
If it’s correctly positioned, fasten the 8 M6 nuts (2)
3
in a cross pattern several times, first with smaller
torque and at the end with a torque of 9 Nm...
Then tighten the 4 M5x10 screws with Loctite 542
(3) with a torque of 2.5 Nm.
7 Check with a 0.05mm gauge that there is no play

between CS disc 1 and 2, and between CS disc 2
and 3.
2 In order to make the next steps easier, it is
recommended to lift again the TC cylinder and put
the plastic stopper 100840.
3.7.4 CS disc 4
Put the CS disc 4 100184 with the chamfer looking

upwards (1) and position the holes centered
between the bolts of the CS disc 3 (2).
2
Put the CS disc 4 as high as possible to make the
mounting of the CS disc 5 easier. If it’s not high
1 enough, you will not be able to screw the M6x16
screws because they are too short.
3.7.5 CS disc 5
1 Degrease the CS disc 5 100185 on both sides, then

put the O-Ring Ø 221.92x2.62 500019 (1) without
grease in the groove. The O-Ring can be red or
black. It is normal that the O-Ring need some
tension to be mounted.
Put the CS disc 5 on the SoliValve®. Align the hole

for Cone vacuum (2) with the pin of the CS
4 distributor (3). Important: It must be on the opposite
side of the pin!
Then turn clockwise/anticlockwise the CS disc 5 in
2 order to align the holes (4) with the threads of the
CS disc 4.
3
Choose the position that allows the nearest position
to the original alignment (2/3) of the CS disc 5.
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Now the CS disc 5 can be fastened with 8 head cap

M6x16 screws 500055 (5). After slightly tightening
5 4 screws, hit on the heads to make the CS disc 4 go
down in its correct position. Then add the 4 other
screws.They must all be fastened in cross pattern,
with Loctite 542 and a torque of 9 Nm.
Remark: Until December 2013 M6x25 screws were

used. They must be replaced by M6x16 screws if the
SoliValve® is opened for maintenance.
3.7.6 Mounting the CS assembly
The clamp system is now complete assembly, and

can be removed or mounted on the SoliValve®
without opening it if the seals don’t need
replacement.
To mount the complete clamp system assembly,
follow the step 3.7.1 to put it on the CS distributor
without damaging the O-Ring and the wiper ring.
Then, to position it correctly angularly, follow point
3.7.5.
3.7.7 Mounting the CS distributor cover
Degrease all parts, put 2 white flat gaskets

(previously degreased) Ø11/8x1 100634 (1), and a
greased O-Ring Ø36x1.5 500004 (2). Then put the
CS distributor cover 100029 (3) on the CS
distributor. The hole must be aligned with the pin.
1 Fasten it lightly with an M10x20 500035 counter
3 2
sunk screw (4). It will be fastened definitively
4 during the mounting of the vibrator unit.
Grease and put 2x O-Rings Ø8x1.5 500951 (5) and

5 1x O-Ring Ø45x1.5 500952 (6) on the CS
distributor.
6
If the distributor cover is fitted with 2 white flat
gaskets 100634 (7) or 2 O-Rings Ø6x1 (8), it’s an
older version (100026) and it needs to be upgraded
with the new part 100029 (3). It is easy to recognize
the old part from the new one because it doesn’t
have the nut for the O-Ring (6) on its
circumference.
7 8 Remark: for a SoliValve® unit without vibrator the
CS distributor (3) is different. Check the mounting
procedure at point 3.9.
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3.8 Mounting the vibrator unit
3.8.1 Centering the vibrator unit
The vibrator unit 100095 can only be assembled in

2 one position on the CS cover, because it is centered
with a pin (1) on the CS distributor cover (2).
1 To center the vibrator is it better to remove all the
O-Rings and the springs of the CS disc 5.
Put the vibrator unit (3) on the SoliValve® and
check the holes. The 8 holes of the CS disc 5 must
be aligned with the holes of the vibrator (4).
3 For this reason, in point 3.6.7, the M10x20 counter

5 sunk screw was not tightened. You need to turn the
whole CS assembly (5) clockwise or anticlockwise
in order to align the holes (4).
When the holes are centered, remove the vibrator
unit, remove the M10x20 screw (500035), put
Loctite 542 on the thread and fasten ist with 21 Nm.
Hold the CS while fastening the screw. Put the
vibrator unit again and check if the holes are still
aligned. It needs sometimes more than one try
4
because when you tighten the screw it may move.
2 3.8.2 Mounting vibrator unit
If you removed the O-Rings on the CS distributor

1 cover, put them again back on, like in point 3.6.7
Put then 3 greased O-Ring Ø11x1 (1) and 3 springs

Ø8x1.25x15 500117 (2) on the CS disc 5.
Put the vibrator in place and hold it down while

fastening it with 2 M6x16 head cap screws 500055.
Then add the next 6 screws and tighten always in
cross pattern with a fastening torque of 9 Nm.
Remark: On units produced until December 2013

M6x25 screws were used instead of M6x16 screws.
The vibrator screws have been changed to be the
same as the screws fastening the CS disc 5 in order
to avoid any confusion when remounting the SV. See
point 3.7.5 for more detail about it.
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3.9 Mounting a SoliValve® unit without vibrator
3.9.1 Mounting the CS distributor
The mounting procedure is the same as in 3.7.7

except that the CS distributor cover 100029 (1) is
replaced by the CS distributor cover without
1 2 vibrator 100174 (2). This part has no holes and
doesn’t require the Ø8x1.5 and Ø45x1.5 O-rings.
3.9.2 Mounting the vibrator dummy
The vibrator unit 100095 is replaced by the vibrator

dummy 100167 (1). To mount the vibrator dummy,
no orientation of the clamping system is needed.
2 The step 3.7.1 is not needed here. The vibrator

dummy can be mounted following the instruction of
step 3.7.2.
1 Before mounting the Conical Cover, it is very

important not for forget to put the 3 washers
100243 (2) on top of the vibrator dummy.
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3.10 Cone and cover mounting
3.10.1 Vacuum filter
Degrease the CS disc 5. Then put the vacuum filter

100094 (1) in its hole. The side with coating (2)
3 must face downwards. Then put the greased Ø 11x1
1 O-Ring 500751 (3).
Remark: the color of the O-Rings can be red or

black.
3.10.2 Installing the conical cover
Degrease the CS disc 5 and the Conical cover

100169. Center the 3 holes of the Conical cover (1)
on the CS disc 5 before putting it on. If you have to
move the Conical cover after it is positioned, there
1 is a risk that it will move the O-Ring (3).
2 3 Fasten it with 3 countersunk head cap screw M8x16
500042 (2) with Loctite 542 and a torque of 9 Nm.
Put a Ø78.97x3.53 O-Ring 500336 (3) in the groove
without grease.
Remark: the color of the O-Rings can be red or

black.
3.10.3 Installing the cover
Put some mounting past Klüber UH184-201 on the

thread of the magnetic cover unit 100131 (1) and
screw it on the cone with the magnetic key 100507
(2).
1 The mounting of the SoliValve® is now completed.
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4 Mounting the SoliValve® Filling Unit

This chapter explains how to assemble the SoliValve® Filling Unit. Until chapter 3.6, the mounting of
the filling unit is identical to the discharge unit.
4.1 Mounting the filling clamp system unit
The clamp system unit for the Filling SoliValve

(100614) is different from the discharge unit. It is
3mm thinner. The filling unit will only work with
the correct clam system unit.
1 The mounting procedure is exactly the same as for
the discharge unit. Follow the chapter 3.6 to mount
the filling clamp system unit (1).
4.2 Assembling the wiper seal on the Cone filling
Degrease the wiper seal 100x108x7x4 (500344) and

2 the nut of the cone filling (100613) and assemble
the wiper seal in the cone filling (1).
1
Put Klüber Paraliq GTE 703 grease (500136) on the
inner side of the wiper seal (2) to prevent damaging
the O-Ring during the mounting.
Lift the telescope cylinder to make the assembling

of the head easier. Put the plastic stopper 100840 in
the housing (3) to prevent the telescope cylinder to
fall down. Follow the procedure from chapter 2.1.1.
Put the Cone filling on the telescope cylinder (4),

taking great care not to damage the O-Ring (5). It
goes better when inserting the cone with an angle
first one side and then pushing the O-Ring under
5 the wiper seal with the fingers. Look at the picture
in chapter 3.7.1.
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4.3 Assembling the cone cleaning distributor
Clean the Cone filling 100613 (1), the Cone

3 cleaning distributor filling 100617 (2) and the lip
seal 100187 (3) with degreaser.
Put the lip seal 100187 (3) on the cone cleaning

distributor filling 100617 (2).
2
Turn it upside down and put it on the Cone filling
(4).
Check that the lip seal stayed in place (5) on the

whole circumference. It is important that it sits
correctly in the groove. Otherwise you will need to
dismount it again later.
4
Put the non-return lip seal filling 100619 in the
1 groove (6). It may seem too big, but during
mounting you need to pull delicately on it in both
directing in order to put the last millimeters inside
the groove.
6
Remark: the non-return lip seal for the filling unit
(100619) is different than the discharging unit
5 (100002).
4.4 Mounting the CS disc 1 filling
Degrease the CS disc 1 filling 100615 (1).

Grease a Ø45.69x2.62 NBR 70 O-Ring (500012)
2 with Klüber Paraliq GTE 703 and put it in the
middle nut (2).
1 Remark: On the filling units made before June 2014

the CS disc 1 has a nut for a wiper seal, like on the
discharge version (see 3.7.1). No wiper seal must
be mounted in this nut.
3 Put the CS disc 1 on the cone cleaning distributor

filling.
4 Align the holes and put 8 socket countersunk head
screws M6x20 (500041) with Loctite 542 (3).
Don’t fasten the screws completely now!
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First you need to check if the lip seal (4) is properly

centered.
Remove the plastic stopper (100840) and go down

with the telescope cylinder until the lip seal in in the
housing (4). Check on the whole circumference, the
lip seal must be centered (5). If not, you need to
correct the position by moving it, or by moving the
4 cone cleaning distributor.
When this has been checked, fasten the screws in

cross with a torque of 9 Nm.
It is better to start with a lower torque and tighten

5 all the screw several times in cross and at the end
do it with a 9Nm torque.
4.5 Mounting the CS disc 2 filling
Lift again the SoliValve head and put the stopper as

in chapter 2.1.1.
1 Degrease the CS disc 2 filling 100616 (1) and the

lip seal 100187 and put the lip seal on the CS disc 2
(2).
Turn it upside down and put it on the CS disc 1

filling (3). Be careful that the lip seal is properly
positioned in its groove.
2 Put mounting grease Klüber UH184-201 (500135)

on the 8 M6 threads (4).
Remark: The mounting grease is necessary here to

prevent the nut to seize on the thread, which can
damage the thread or even when dismounting for
4 maintenance un-weld the threads from the plate.
3
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4.6 Final assembly
From here on, the procedure is the same as on the

Discharging SoliValve®.
Follow chapter 3.7.3 to mount the CS disc 3 (1) and

the clamping seal (2).
1 Follow chapter 3.7.4 to mount the CS disc 4 (3).
Follow chapter 3.7.5 to mount the CS disc 5 (4).
Follow chapter 3.7.7 to mount the CS distributor

cover
4 Follow chapter 3.8 if the Filling SoliValve® is fitted
with a vibrator (special version)
Follow chapter 3.9 if the Filling SoliValve® is not

fitted with a vibrator (standard version)
Follow chapter 3.10 for the final assembly of the

Cone and the Cone Cover.
100613: Cone Filling 4.7 Filling SoliValve® Specific part list
100614: Filling Clamp System Unit
100615: CS disc 1 filling This is the list of the specific parts that are only
100616: CS disc 2 filling used on the Filling SoliValve® unit.
100617: Cone cleaning distributor filling
100619: Non-return lip seal filling The filling unit has as well 2 Lip seals (100187)
500028: Self-locking nut M6 A4 70 (8x) instead of one.
500041: Socket countersunk head screw M6x20
A4 70 (8x)
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5 Servicing the SoliValve®

This chapter contains information about the servicing of the SoliValve® and the repairs.
5.1 Replacing the air filter
The vacuum filter must be checked / replaced preventively every 100 working hours or if there is an
error during the cone vacuum check.
If the vacuum filter is obstructed by dirt, the “Cone Vacuum” function check at the beginning of the
cycle will indicate an error and the cycle will not start.
5.1.1 Dismounting the magnetic cover
Follow the procedure described on chapters 2.1.2

and 2.1.3 to remove the magnetic cover and the
cone.
5 5.1.2 Removing / Replacing the filter

2 Be careful not to lose the O-ring Ø11x1 500751 (1)
or the cone vacuum filter 100094 (2).
4 If the filter (2) is dirty it must be replaced and the
1 O-Ring as well (1).
The side with coating (3) must face downwards.
The cavity where the filter is mounted must be
cleaned carefully (4). Don’t put liquid in the little
hole (5)!
3 Follow all the instructions from chapter 3.9 for the

remounting.
Remark: the color of the O-Ring can be red or

black.
5.1.3 Parts references
100094: Vacuum filter

500751: O-Ring Ø11x1
500336: O-Ring Ø 78.97x3.53
5000042: Socket countersunk head M8x16 (3x)
100507: Magnetic key (tool)
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5.2 Receptacle detection servicing
The receptacle detection can have air leak caused by dirt, wear or wrong manipulation from the
operators. No preventive maintenance is needed here. The leak doesn’t prevent it from working. If for
sanitary reason no leak is tolerated, this problem can be easily solved by following the steps below.
5.2.1 Testing the receptacle detection
The first step is to activate the function “receptacle

detection” manually or to launch a cycle and before
the docking push on the metal balls with the finger,
try to roll it. If the receptacle detection stopped to
leak, there was just some dirt. Repeat several times.
5.2.2 Removing the hood
If the “receptacle detection” ball is still leaking, it

needs to be serviced.
Remove all the connection and turn the SoliValve®
1 2 upside down. Remove the 4 M8x16 screws (1)
holding the hood (2).
To remove the hood, put a flat screwdriver under
each of the 4 square fastening plate and push gently
in order to lift the hood a few millimetres.
When you have enough space, put the flat

screwdriver between the housing and the hood and
turn it to lift the hood.
Be careful not to damage the O-Ring.
When the hood passed the first O-Ring, it can be

removed by hand by pulling on it.
Be careful not to damage the electric cable when
removing it.
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5.2.3 Dismounting the receptacle detection

3
Localise the “receptacle detection” that leaks,
remove the pneumatic tube (3), then remove the
elbow 500236 (4), remove carefully the spring
500118 (5) and put them on a safe place.
Remove the metal ball 500276 and clean the inside

of the receptacle 100032. Then put the ball back
inside.
4
Remark: there are 2 different sizes of receptacle
detection housing and pneumatic connector. The
version shown in the picture is the old version. New
5
version is fitted since 2010.
5.2.4 Reshaping the receptacle
Hit on the ball in its receptacle with a drift pin and a

hammer. Beware, don’t hit too hard otherwise you
might deform the receptacle. Repeat 2-4 times.
Put the spring (5) back inside, the little diameter
facing downwards as in the upper picture then put
the pneumatic connector back.
With a 6mm pneumatic tube and a pressure of 2.5
bars, test the receptacle detection. If it is still
leaking, dismount again and repeat the procedure.
In some occasion, the receptacle must be
dismounted to allow a perpendicularly hit on the
ball (6). Dismounting the receptacle is not
recommended, because it is fastened with Loctite.
6 In case of doubt, contact Visval.
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5.2.5 Remounting the hood
Once the receptacle detection has been tested with

2.5 bars without leak, connect again the pneumatic
9 tube (3) to the elbow (4). Make sure that the O-
8 rings on the housing of the SoliValve® are clean and
greased with Klüber Paraglid GTE 703.
Put the hood back, taking care not to bend the
7 electric plug. The hood must be positioned
correctly, the inscription Locks (7) must be aligned
with the manual lock opening nut (8).
Put back the 4 M8x16 screws (9) with Loctite 542

and a torque of 21 Nm.
100453 : Ball switch complete unit (1)

100032 : Ball switch body new version (2)
1000xx : Ball switch body old version (3)
500118 : Compression spring conical
500236 : Elbow Ø6 G1/8
1 2 3
500276 : Ball Ø8
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5.3 Pneumatic detector for locks

The pneumatic detector for locks can fail. If it happens, the locks will close at the beginning of the
cycle and there will be an error message on the panel saying: SoliValve attach: error IBC not clamped
It means that the detector didn’t give the signal that the locks are closed. In this case, the detector
needs to be replaced before continuing to work with the SoliValve®. Follow this procedure to replace
the pneumatic detector.
5.3.1 Removing the hood

Remove the hood following the instruction from the
chapter 5.2.2
5.3.2 Replacing the detector
Remove first the 2 pneumatic tubes (1), then

remove the 2 M4x12 screw (2) and take the detector
2 with its support plate out.
Remark: The washer around the M4x12 screw is not

mounted anymore on new SoliValves®.
1
Remove the 2 M3x16 screws (3) and replace the
3 malfunctioning pneumatic detector (4) with a new
one, screw it on the support plate, and mount it back
in the SoliValve®, following the reverse order of
this procedure.
4
5.3.3 Adjusting the detector
In order to work properly, the pneumatic detector

must be adjusted.
1
Turn the nut (1) with a 19mm spanner (17mm
spanner on older version of the SoliValve®) to close
the locks manually until you can measure a distance
of 13-16mm between the edge where the ring is
machined (2) and the chamfer of the lock (3). This
distance doesn’t need to be very precise.
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The important point to understand is that the

pneumatic detector must be activated when the
locks are already halfway closed/open. This way,
3 we reduce the risk that the sensor gives the signal if
the locks are stuck.
Now, the cam for locking the pneumatic contact

needs to be adjusted in order for the contact to work
2 properly. To do this adjustment, it is necessary that
the SoliValve® is fully connected to the air supply.
No function must be activated.
The M4x6 socket head screw (4) must be loose, so

that the cam can be rotated by hand (without the
locks to move). Turn it until you hear that the
pneumatic detector is activated. At one position you
4 will hear air coming out, and just after a noise and
no air coming out.
This is the point where is must be positioned (5).

When you reach this point, fasten the M4x6 screw
(4) with Loctite 542.
With the spanner open and close the locks (1)

several times to ensure that the detector is working
correctly and activating when the position is 13-
5 16mm (3).
Remount the hood following the instructions from

chapter 5.2.5.
500263: Link switch with low activation force

100178: Plate for locking pneumatic contact
500048: M4x12 socket head cap screw (2x)
500047: M3x16 socket head cap screw (2x)
500058: M3 washer (2x)
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5.4 Cleaning the fluidization seal / Replacing the fluidisation ring

The fluidisation seal must be dismounted for cleaning and greasing on a regular basis to ensure its
proper functioning and to extend its life expectancy. It must be done every time a maintenance is
planned on the SoliValve, at least every month.
If something gets stuck in the SoliValve® during the closing of the valve, the fluidisation ring is likely
to bend and needs to be replaced immediately to ensure confinement. Usually the fluidisation seal must
be replaced as well because it is damaged.
It happens regularly that the customers damage them with incorrect manipulations. Visval recommend
always having a spare ring onsite
5.4.1 Removing and cleaning the fluidization

seal
Activate manually the function fluidisation seal or

put 2.5 bar in the inlet A5 to pop out the
fluidization seal 100198. Pull it out, clean it and
grease it with Klüber Paraliq GTE 703. Grease all
surfaces except the top and the bottom of the seal
(1).
Clean the nut as well and activate manually the

function fluidisation or put 5 bar in C3 and C4 to
check if all the holes are not obstructed by powder.
1 If they are obstructed (2), you need to break the
hardened powder with a screwdriver and blow air
until the fluidisation holes are free. Then put the
fluidisation seal back aligning the holes of the seal
(3) with the head of the screws (4). This
positioning is important, because by doing so, the
holes in the seal are all on an equal distance from
the fluidisation holes in the SoliValve. Otherwise,
2
the air flow will be unequal from one hole to
another.
1 Clean the excess of grease from the top of the seal.
Parts references
100198: Fluidisation seal

1
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5.4.2 Replacing the fluidization ring
If the fluidisation ring 100022 (1) is damaged, it

can be more difficult to remove the fluidisation
seal. Use a screwdriver if necessary. After
removing the fluidization seal, remove the 8 M4x8
thin cap screws 500032 (2) and pull the fluidization
ring out (2). Clean everything and put a new one.
1 Fasten slightly all the screws (2) with Loctite 542.
When the ring has about 1mm play, push the FEP
O-Ring 500022 (4) inside and start tightening
enough so that it doesn’t go out from the groove.
Continue screw after screw until it’s entirely inside
the groove. Then tighten the screws in cross with a
torque of 2.5 Nm.
If the fluidisation seal is damaged, replace it,
3 grease it with Klüber Paraliq GTE 703 and put it
back in, following the instruction from chapter 6.
2 Parts references
100022: Fluidisation ring

100198: Fluidisation seal
500032: M4x8 thin cap screw (8x)
500022: FEP O-Ring Ø248.76x2.62
500187: Loctite 542 (50ml)
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5.5 Replacing the lip seal and clamping seal

Inspect the seals and the O-Rings of the SoliValve® on a regular basis. If they are damaged they must
be replaced, especially the lip seal because it is responsible for the confinement. If the clamping seal is
damaged, it will not be possible to make the vacuum in the docking phase and the SoliValve® will be
out of order. When replacing the lip seal and/or the clamping seal, all the other seals and O-Rings
must be replaced when remounting the head.
5.5.1 Replacing the lip seal
To change the lip seal (1), the head of the

SoliValve® must be completely dismounted.
Follow the instructions from the chapter 2.1.1 to

2.1.9 to dismount the head.
If the clamping seal doesn’t need to be replaced, in

chapter 2.1.8, leave it mounted with the discs CS2
1 and CS3. It will be easier later for the remounting
of the head.
When you reach the point 2.1.9, don’t remove the

CS disc 1. Remove the damaged lip seal 100187 (1)
and replace it with a new one (2).
To remount the head, follow the instructions from

the chapters 3.6, 3.7 and 3.9. Always use new seals
and O-Rings and clean all the parts. If you don’t
2 replace the clamping seal, you can skip the chapter
3.6.3.
5.5.2 Replacing the clamping seal
Follow the same instructions as in chapter 5.5.1 for

the dismounting.
In chapter 2.1.8 remove the 4 M5x10 screws to

separate the CS disc 2 and 3 in order to remove the
damaged clamping seal. Leave the lip seal in place.
The remounting instructions are the same as for the

lip seal. Follow the chapters 3.6, 3.7 and 3.9.
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100187: Lip seal EPDM 5.5.3 Part references

100191: Clamping seal
100002: Non return lip seal (discharging station) This is the list of the parts that must be replaced if
100619: Non return lip seal (filling station) the SoliValve® is opened to change the Lip seal
500019: O-Ring Ø 221.92x2.62 and/or the clamping seal.
100634: Ø11/8x1 flat gasket (2x)
500004: O-Ring Ø 36x1.5 500952: O-Ring Ø 45x1.5
500951: O-Ring Ø 8x1.5 (2) 500751: O-Ring Ø 11x1 (3x)
500117: Spring Ø 8x1.25x15 (3x)
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5.6 Replacing the bearings in the vibrator

The ball bearings of the vibrator must be periodically replaced. Because the bearings wear depends on
how often the vibrator is used, it is impossible to give a timeline. Usually, they last many years. In case
of failure, the vibrator will stop working and will need new bearings. If the vibrator has a failure, it has
no impact on the other functions of the SoliValve®. It can still work without vibrator.
The bearings can be replaced in case of failure or preventively when the SoliValve® is dismounted for
a repair, for example when changing the lip seal or the clamping seal.
5.6.1 Dismounting the vibrator

1
Follow the instructions from the chapter 2.1.1 to
2.1.4 to dismount the vibrator (1).
5.6.2 Replacing the bearings
Open the vibrator cover (1) using the vibrator key

100044 (2).
1
Remove the rotor with the bearings (3). Remove the

2 2 bearings with a screwdriver, and replace them
with new bearings 500265(4).
3
Before remounting, Grease the O-Ring 500005 (5)
with Klüber Paraglid GTE 703. Position the Rotor
with the bearing as in the picture (6). The teeth must
point anticlockwise. If you put it the other way, the
vibrator will not work.
Before remounting the cover, put mounting paste,

Klüber UH184-201, on the threads (7).
4
100095: complete vibrator unit

5 500005: O-Ring Ø46x1.5 NBR
6 500265: Deep groove ball bearing (2x)
7
100044: Vibrator key (tool)
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5.6.3 Vibrator run in / Flow limitation
When the bearings are new, the vibrator will not

work to its full potential. A certain period of run in
is necessary.
After a few hours it will run faster and you will
notice that the noise level will increase. It’s normal
1
In some case where the vibrator is intensively used,
it is advised to put an adjustable airflow regulator
2
(1), so that the speed of the vibrator can be reduced.
3 Reference parts:
500196: Silencer G1/4 (2)
500364: Flow control regulator (3)
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5.7 Replacing the rotation sensor

The inductive sensor is very sensitive. Incorrect grounding or over tension can make it fail. There will
be an error message on the panel saying “SoliValve error lift adjustment” and it needs to be replaced
before continuing to work with the SoliValve®.
5.7.1 Checking the rotation sensor
The error message “SoliValve error lift adjustment”

can also have other sources. Before changing the
sensor, we need to make sure that it is out of order.
To check the sensor, open the control cabinet, and

activate manually the increase/decrease functions.
You must see a green led blinking on GE18.1 (1).
1 If it doesn’t turn on and off, it means that the sensor
is broken and must be replaced.
If it is blinking, the sensor is fine and the problem is
somewhere else.
5.7.2 Replacing the rotation sensor
The SoliValve® must be dismounted from its

1 support and turned upside down.
Follow the chapter 2.4.1 to dismount the electric

2 4 plug and the chapters 2.2.2, 2.2.3 and 2.2.4 to
dismount the pneumatic motor.
Remove the rotation sensor by losing the screw (1)

and pulling the cable (2) to take the sensor out.
Beware not pulling on the wrong cable; it must
come out without force.
Follow the instructions from chapter 3.3 to mount

and test the new sensor, chapter 3.4 to remount the
pneumatic motor and chapter 3.5 to remount the
electric connector.
100434: Seal for electric connector
100433: insert for electric connector 500280: Rotation sensor
501072: Namur sensor tester (tool) 100904: Rotation sensor fastening insert
100845: Connector mounting tool (tool) 501141: M6x5 hex socket set screw
100507: Magnetic key (tool) 500333: Electric connector
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Version 1.2
5.8 Pneumatic motor

Check on a regular basis the oil level in the control cabinet and refill it when necessary. Working
without oil will damaged the motor and shorten its life expectancy. Visval can’t give a lubrication
check interval because the using rate from the SoliValve® can be very different from one custom to
another. It is the customer responsibility to ensure that the system is always working with oil. In the
beginning it should be checked weekly until the maintenance team knows the oil using rate.
Since 2013 Visval is equipping the control cabinets with an oil receptacle of bigger capacity and a
level sensor that will give a warning message on the screen when oil needs to be refilled. Older control
cabinets can be updated by request.
5.8.1 Filling the oil receptacle
These are examples of oil receptacles for the

pneumatic motor. On the right is the small one (old
version) and on the left is the big one (new version)
with level sensor (1).
Usually in our control cabinet there is a little plastic
2 bottle (2) to put spare oil.
1
The oil receptacle on installations made by Guerin
System is different (3). It has no level sensor.
Following oil must be used or similar food grade:

3 Klüber Summit HySyn FG 32, Art No 0500130764
It can be ordered from Visval if not available in

your country (Visval ref number 500139).
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Version 1.2
5.8.2 Lubrication rate
The lubrication system must be set, to give:
3 1 drop of oil for every 4 complete pulsed strokes.
A pulsed stroke is a stroke with numerous starts and

stops. You must do 2 complete opening/closing with
the whole stroke and making manually many start
and stop during each stroke. The stroke is from
0mm to 109mm.
The lubrication rate can be adjusted by turning the

screw (3). Clockwise, the lubrication diminishes,
anticlockwise, it increases.
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Version 1.2
5.9 Manual lock opening/closing repair

If operators are trying to open/close the locks manually when the SoliValve® is under pressure, they
can break the pin in the nut by putting too much force on it. The pin will break and must be replaced.
5.9.1 Removing the broken pin
Use a drift pin or smaller than Ø3mm pin and a

hammer to push the old pin out.
5.9.2 Mounting the new pin
Put some Klüber UH184-201mounting paste in the

nut and around the new parallel pin Ø3 L16.
Center the holes from the nut with the axle, and
push the new pin inside using a drift pin and a
hammer.
The pin is shorter than the nut, so push it deeper

inside, so that it’s centered.
500066: parallel pin Ø3 L16 5.9.3 Parts references

100009: Locking nut
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Version 1.2
5.10 Compressed air lines

Check all compressed air lines for leakage; cut the end if worn out. A worn out end can cause leakage.
Pay extra attention when the SoliValve® has been dismounted, to connect the pneumatic tubes
correctly. Follow the marking (C1 with C1, C2 with C2, and so on).
It is a common mistake that the pneumatic tubes are not push deep enough in the connectors resulting
in air leaks.
When a pneumatic tube (1) is inserted in the

connector, you must feel twice a resistance. As we
can see in this picture, first you will feel resistance
on the O-Ring (2). The tube must be pushed 1 step
further until it reaches its stopper (3). If you only
1 feel once resistance, it means that the tube is not
3
fully inserted and you will have a leakage.
Inserting correctly the tube in the connector
2 requires a high force. It is important to push strait.
When removing a pneumatic tube, it is necessary
that no pressure is in the system. Push with the
finger or with a key against the release valve (4).
4 In the same time push the tube forward and then
pull it.
If you try to pull on the tube without pushing first,
you will not be able to remove it easily.
When the SoliValve® is disconnected from the control cabinet, activate the function manually one after
another to purge the pneumatic tubes. If some maintenance steps have not been made, or have
incorrectly been made, powder can be found in the pneumatic tubes. By purging the tubes, we ensure
that there is no powder in the system.
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D.Zimmermann
Version 1.2
5.11 Test of mechanical functions

Check ease of movement of the cone lifting unit. Select “Manual cleaning” which will slowly lift the
cone. After deselecting “Manual cleaning” the cone has to lower without jolting, otherwise the scraper
seals and the sleeves need to be replaced. This maintenance operation is done by Visval only. The
SoliValve® must be sent to Visval for repair.
5.12 Part, products and special tools list

This is the list of the parts, special tool and product needed to make all the above maintenance.
5.12.1 Tool list
This list contains the special tools needed to perform the maintenance and repair of the SoliValve®.
The maintenance team MUST have them in order to service the SoliValve®.
Visval Number Name For maintenance chapters

100507 Magnetic key 1,8,9,10
100044 Vibrator key 10
501072 Namur sensor testing device 9
100845 Connector mounting tool 9
Pneumatic tube Ø 6x180mm 9
0.1mm feeler gauge 9
5.12.2 Product list
These products are needed for the maintenance. They are all FDA approved.
Visval Number Name For maintenance chapters

500135 Klüber Klüberpast UH184-201 (60g) 1,9,10,11
500136 Klüber Paraliq GTE 703 (60g) 1,4,5,6,7,8,10
500187 Loctite 542 (50ml) 4,5,7,8,9,10
500139 Klüber Summit HySyn FG 32 (3.8l) 2
5.12.3 Part list
This list contains all the parts referenced in this maintenance document. For each part, it is specified if
it’s a wear part, in which chapter it is used and the quantity of parts. The maintenance team should
always have all the wear parts in stock, especially the vacuum filter.
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Version 1.2
Visval Name Wear Chapter(s) / Quantity

Number part
100094 Vacuum filter Yes 1,8
500751 O-Ring Ø 11x1 Yes 1 (1x), 8 (4x)
500336 O-Ring Ø 78.97x3.53 Yes 1,8,9,10
500042 M8x16 A4 No 1 (3x),8 (3x),10 (3x)
100187 Lip seal EPDM Yes 8
100191 Clamping seal Yes 8
100002 Non return lip seal (discharging station) Yes 8
100619 Non return lip seal (filling station) Yes 8
100634 Ø11/8x1 flat gasket Yes 8 (2x)
500019 O-Ring Ø 221.92x2.62 Yes 8
500004 O-Ring Ø 36x1.5 Yes 8
500951 O-Ring Ø 8x1.5 Yes 8 (2x)
500952 O-Ring Ø 45x1.5 Yes 8
500117 Spring Ø 8x1.25x15 Yes 8 (3x)
100095 Complete vibrator unit No 10
500005 O-Ring Ø46x1.5 NBR Yes 10
500265 Deep groove ball bearing Yes 10 (2x)
100453 Ball switch complete unit Yes 4
100032 Ball switch body new version Yes 4
1000xx Ball switch body old version Yes 4
500118 Compression spring conical Yes 4
500236 Elbow Ø6 G1/8 No 4
500276 Ball Ø8 Yes 4
500020 O-Ring Ø360x4 NBR Yes 4 (2x),5 (2x)
500263 Link switch with low activation force Yes 5
100178 Plate for locking pneumatic contact No 5
500048 M4x12 socket head cap screw No 5 (2x)
500047 M3x16 socket head cap screw No 5 (2x)
500058 M3 washer No 5 (2x)
100198 Fluidisation seal Yes 6
100022 Fluidisation ring Yes 6
500022 FEP O-Ring Ø 248.76x2.62 Yes 6
500055 M8x16 socket head cap screw No 8 (16x),10 (16x)
500066 Parallel pin Ø3 L16 No 11
100009 Locking nut No 11
100434 Seal for electric connector yes 9
100443 Insert for electric connector No 9
500333 Electric connector No 9
500280 Rotation sensor No 9
100904 Rotation sensor fastening insert No 9
501141 M6x5 headless screw No 9
100415 Pneumatic motor No 2,9
500238 Elbow Ø8 G1/4 No 2 (2x),9 (2x)
500231 Elbow Ø8 Ø8 No 2 (2x),9 (2x)
100396 Pneumatic motor (old version) No 2,9
100189 Flange for pneumatic motor (old version) No 2,9
500117 Compression spring No 2,9
500219 Straight fitting Ø8 G1/8 No 2 (2x),9 (2x)
100131 Magnetic cover unit No 1,8,9
100095 Vibrator dummy No 1,8
100243 Washer for vibrator dummy No 1 (3x),8 (3x)
100029 CS distributor cover No 1,8
100174 CS distributor cover without vibrator No 1,8
500035 M10x25 countersunk head screw No 1,8
Visval AG
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D.Zimmermann
Version 1.2
All modifications included in this version 1.2 are marked.
In the next revision the following points will be included:
- Packing/unpacking the Solivalve®

- Mounting the pneumatic cables on the housing
If you have any comments or suggestions, please send them to

david.zimmermann@visval.ch
Visval AG
Bonnstrasse 26
CH-3186 Düdingen
T +41 26 493 0175
F +41 26 493 0176
contact@visval.ch
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SV Maintenance V1.2 CONE VALE

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SV Maintenance V1.2 CONE VALE

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Maintenance and repair guide V1.

SoliValve® Maintenance guide

1. Tooling and products

1.1 Glue and cleaning products

500188: Loctite 638 (50ml)

High strength, general purpose. Used for fastening of bronze

500187: Loctite 542 (50ml)

This glue is used on all screws of the SoliValve® (except 2 or

500185: Loctite 262 (50ml)

This glue is used only on the screw fastening the stopper of

Instant glue, used for example to glue the cellastos on the

500136: Klüber Paraliq GTE 703 (60g)

500135: Klüber Klüberpaste UH184-201 (60g)

Also available as a 50g tube (500137)

500355: Würth industrial cleaner (5l)

500139: Klüber Summit HySyn FG 32 (3.8l)

Lubrication oil for the pneumatic motor. Must be filled in the

500128: Interflon stainless steel dry cleaner

This is used to make the parts in stainless steel look good.

500332: Würth Leak detection spray

This spray is very efficient to detect air leakage.

1.2 Special tools for mounting/dismounting the SoliValve®

100507 Magnetic key 100046 Ball screw anti-rotation

Used in chapters 2, 3, 4 Used in chapter 2.3.3, 3.2.3

Used in chapter 3.5.5, 5.7

Used in chapter 3.6.2 Used in chapters 3.3.2, 3.3.3, 3.5.4, 5.7

Used in chapter 3.6.2

500xxx Precision gauges 500xxx hydraulic cylinder

100044 Vibrator key 100841 TC straitening tool

Used in chapter 5.6

1.3 Torque table

Designation Torque Visval reference number

2 Dismounting the SoliValve®

2.1 Dismounting the head of the SoliValve

For most maintenance operation, it is necessary to

Remove the magnetic cover unit 100131 (1) with

2.1.3: Removal of the conical cover unit

1 Remove the 3 M8x16 countersunk head screws (1).

If the cone vacuum filter 100094 (2) is dirty it must

3 Remark: the color of the O-Ring can be red or

To dismount the vibrator unit 100095 (1), remove

If the SoliValve® is not fitted with a vibrator, the

Be careful not to lose the 3 distance washers

2.1.5: Removal of the CS distributor cover

Remove the M10x20 counter sunk screw 500035

If the SoliValve® is not fitted with a vibrator, the

Remark: If the distributor cover is fitted with 2

After removing the distributor cover, remove the 2

Remark: On older version, O-Rings Ø6x1 were

At this point, there is 2 options:

2.1.6: Removing the complete clamp system (CS)

This option is chosen if nothing needs to be done on

To remove the complete clamping system, pull it

Once the clamping system is removed, the

Remark: The CS distributor with Ø6x1 O-Rings

2.1.7: Opening the clamp system

This option is chosen when maintenance must be

Put again 2 M6x16 screws (1) and just screw them a

Remove the CS disc 5 100185 (3) by pulling it

To remove the clamping seal assembly, remove the

These 4 M5x10 screws are only dismounted if the

2.1.9 Removing the CS disc 1

The CS disc 1 100181 (1) with the lip seal 100187

Be careful not to damage the wiper seal 500344 (3)