Operating instructions

Bonnet and Handwheel Inspection
Before evacuating the tank, make sure the bonnet assembly is in good working order. There must be at least 35
psig of cylinder pressure to perform this test. Plug the valve outlet with a POL plug. Open the outlet valve halfway
and thoroughly check the bonnet nut and stem for leaks using a commercial leak-test solution.
Turn the handwheel clockwise until the bonnet just bottoms on the seat. Tighten the handwheel approximately one
tenth of a turn further. Carefully remove the outlet plug. A small release of LP gas may occur as the plug is loosened.
Thoroughly check the outlet for leaks using a leak-test solution. Remove any excess liquid when complete. If any
leak is found during either of the above tests, the bonnet assembly must also be replaced (see Sherwood Instruction
Sheet R-3329).
Filler-Section Replacement Procedures
Step 1: Disassembly
1. Remove all traces of LP gas from the cylinder using the procedures specified in National Fire Protection
Association Pamphlet #58 and National Propane Gas Association Installation and Service Guide Book #4003.
2. Clean the valve with clean compressed air so dirt does not enter the valve’s interior.
3. Remove and destroy the liquid-level stem located on the side of the main valve body.
4. Prevent the valve from turning while
removing the ACME connector by
holding it steady with an adjustable
wrench (or 1
1
⁄8" open-end wrench)
applied at the valve’s wrench flats.
Use the other adjustable wrench (or
1
9
⁄16" open-end wrench) on the flats
of the ACME connector. Remove (turn
counterclockwise) and destroy the
ACME connector so it cannot be reused.
5. Remove the poppet and poppet spring.
Destroy the parts so they cannot be
reused. Do not remove the poppet
guide or the wire that holds the
poppet guide and the bottom check
valve together. See Paragraph 4
under Inspection.
6. Remove the O-ring that seals the ACME
connector to the valve body. Destroy
the O-ring so it cannot be reused.
SHERWOOD LPG PRODUCTS
Instruction Sheets
Tools Required
Step 2: Inspection
1. Inspect the internal valve shoulder where the O-ring seats. If the seat is nicked, scratched, or
distorted, replace the entire valve. Destroy the old valve so it cannot be reused.
2. Inspect all threaded connections. Replace the entire valve if any threaded connection is damaged or
has worn threads. Destroy the old valve so it cannot be reused.
3. Using a fine wire brush, clean the old threadlocking residue from the fine female threads where the
ACME connector screws into the valve. Blow the valve clean with compressed air. Clean all other
threads as necessary.
4. Inspect the poppet guide while it is installed in the valve. If rust is present, the entire valve must be
replaced. Destroy the old valve so it cannot be reused. Sherwood does not provide for the replacement
of the poppet guide or bottom check-valve parts.
5. Inspect the wire attaching the poppet guide to the bottom check valve. If it is missing and the poppet
guide is loose, the entire valve must be replaced. Destroy the old valve so it cannot be reused.
Sherwood does not provide for the replacement of the poppet guide or bottom check-valve parts.
6. Inspect the vent opening on the side of the valve. If the orifice sealing surface is corroded, clean it with
a toothbrush and alcohol. If the orifice sealing surface is gouged, dented, pitted, or scratched, replace
the entire valve. Destroy the old valve so it cannot be reused.
7. Inspect the safety relief device. If its openings are clogged with foreign matter or if it shows any sign
of tampering or is dented, bent, or damaged in any way, replace the entire valve. Destroy the old valve
so it cannot be reused. Never attempt to repair or clean a safety relief device.
8. Inspect the ACME cap. If it is cracked or broken, replace with a new cap.
Step 3: Re-Assembly
1.
Lightly lubricate a new #G021B O-ring with petroleum jelly and install it into the valve at the O-ring seat.
2. Make sure the poppet guide is in the correct position inside the valve. Install the new poppet spring onto the
new poppet stem. Guide the poppet stem through the guide hole in the middle of the poppet guide.
3. Push the poppet and spring all the way down and use a pencil or wooden dowel to hold it down. Slide
the new ACME connector over the dowel and turn clockwise until the fine threads engage.
4. Continue screwing the ACME connector until only two or three of the fine male threads remain
visible. Place two or three drops of omniFIT
®
1570 or Loctite
®
272 on the threads. NOTE: Loctite
272 will begin to cure within seconds of being confined within brass threads. If this happens before
the following tightening procedure is completed, the sections must be separated, cleaned, and
reassembled.
5. Tighten the ACME connector at 30 to 40 foot-pounds of torque by applying 30 to 40 pounds of pull at
the end of a standard 12-inch-long wrench, or 24 to 32 pounds at the end of a standard 15-inch-long
wrench. Do not overtighten.
6. Push the poppet down several times to make sure it moves without binding.
7. Install the new liquid-level stem into the side of the valve body and tighten finger tight.
8. Install the new filler gasket into the inlet of the new ACME connector.
Step 4: Testing
1. Pressurize the cylinder with LP gas at 50 to 150 psig. Using the commercial leak-test solution, check
for leaks where the ACME connector screws into the valve body.
2. Keep your body away from the valve inlet. Carefully place two or three drops of commercial leak-test
solution around the poppet seat and inspect for leaks. When complete, use a clean cloth or paper
towel to remove the excess liquid. Do not use a soap-and-water solution for this test — it could
corrode the internal parts.
3. If any leaks are found, evacuate the tank according to NFPA Pamphlet #58 and NPGA Installation and
Service Guide Book #4003. Remove and destroy the entire valve so it cannot be reused. Install a new
valve.
4. If no leaks were found, the valve may now be placed in service. Put the ACME cap tag on the valve so
the cap will be right-side up. Install the cap and tighten.
Warn Your Customer
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- Immediately call your gas supplier from a neighbor’s phone
- If you can’t reach your gas supplier, call the Fire Department
- Do not touch electrical switches or telephones
- Do not light appliances.
Figure 1
SAFETY RELIEF
DEVICE
HANDWHEEL
VALVE OUTLET
FILLER GASKET
#697-2
ACME CONNECTOR
#2030-2
POPPET
#2030-40
POPPET SPRING
#2030-7
BODY O-RING
#G021B
LIQUID-LEVEL STEM
#1931-24A
* Must be approved for use on brass and with LP gas.
Note: Torque wrench, socket wrench, and crowfoot adapter should all have the same drive size.
t A large adjustable wrench or open-end
wrench, 1
1
⁄8" and 1
9
⁄16"
t Spring scale, 20 to 40 pounds
t Small, fine wire brush
t Small wooden dowel
t
Petroleum jelly lubricant
t Toothbrush and alcohol
t Commercial leak-test solution*
SAFETY INSTRUCTIONS
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Figure 1
Handwheel
Valve Outlet
Safety Relief
Device
Figure 2
Filler Gasket
#697-2
ACME Connector
#2030-2
Poppet
#2030-40
Poppet Spring
#2030-7
Body O-Ring
#G021B
Liquid Level Stem
#1931-24A
NOTICE:
All Sherwood products must be used in strict compliance with the requirements
and provisions of National Fire Protection Association Pamphlets #54 and #58,
DOT, ANSI, and all applicable federal, state, provincial, and local standards, codes, regulations, and
laws. It is the responsibility of the sellers, installation and maintenance personnel, and end users to
remain knowledgeable of and in compliance with all standards, codes, regulations, and laws.
All Safe, Inc. 1-866-958-3473