SERVICE BULLETIN

NOTICE: The Type of Change and Recommended Compliance specified reflects Solar’s best judgment regarding the
Service Bulletin. All questions should be directed to your Solar Field Service Representative. Solar, Saturn,
Centaur, Taurus, Mercury, Mars, Titan, SoLoNOx, and Turbotronic are trademarks of Solar Turbines Incorporated.
Cat and Caterpillar are trademarks of Caterpillar Inc. Specifications subject to change without notice.

NUMBER: 3.1/100
ISSUED: May 1977
REVISED:
PRODUCT: All
MODEL(S): All
Specifics: Units with natural gas fuel system

SUBJECT: VERSA VALVES AND VERSA VALVE O-RING KITS

—REVISION NOTICE—
This Service Bulletin revises and supersedes Service Bulletin No.
1168 of the same subject, dated July 1973.
Service Bulletin No. 1168 announced availability of Versa gas
valves, Solar part numbers 44795-4, 901434C2, and 909583C2,
replacement vented pilot cap P/N 946246Cl and solenoid end
cap P/N 946247C2, and O-Ring and packing replacement kit
P/N 946245C2. In addition, valve repair and O-Ring kit P/N
8007814R91 was obsoleted, and Dow Corning 55M lubricant
was substituted for Molykote 77 lubricant. Main fuel solenoid
replacement kit P/N 8007820R93 and modification kit P/N
8007838R94 were listed for ordering.

Type of Change: Product Improvement

Recommended
Compliance: Next maintenance

Purpose:
This revision makes the following changes to the preceding part numbers, and Incorporates those
changes in the text previous issued:

1. O-Ring and packing replacement kit P/N 8007995R91 is substituted for kit P/N
946245C2, which is obsolete;

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NUMBER: 3.1/100
 2. Dow Corning grease FS-3451 is substituted for Dow Corning lubricant 55M, and is
available in 3-ounce tubes under Solar P/N 915484C1.
3. References Service Bulletin 2. 1S/100 for maintenance precautions in installation of
grommets, Versa P/N 4302-52B.

GENERAL INFORMATION:
This service bulletin provides instructions for either replacing the main fuel valve with an improved
Versa valve, or modifying the existing valves.

It is recommended that either the main fuel valve be replaced or the existing valve be modified
immediately if fuel shutoff problems are being experienced.

The main fuel valve presently used contains O-Rings that are able to withstand a low temperature
of approximately 0F. Therefore, if usage is anticipated where the gas or ambient temperature at the
valve may drop below zero, it is mandatory that the existing valve be replaced or modified to such
a configuration that contains the O-Rings capable of withstanding temperatures as low as -40F.

NOTE
This replacement or modification is associated with the main fuel valve; how-
ever, it can also be applied to the other Versa Valves on the package.

While the instructions provided will suffice for most installations, it is rec-
ommended that they be used only as guidelines to develop an appropriate
procedure prior to starting the change or modification. If additional assis-
tance is required, contact Solar Power Support.

Valves operating in a pipeline are sometimes subjected to dirty (chemically sour) gas containing
water, hydrogen sulfide, ferric sulfide, sulfurous acid, and sand. The large solid particles are filter-
able, but the acid in the fuel gas will react with molybdenum disulfide, the primary ingredient of
Molykote 77, and cause it to decompose. Replacement of Molykote 77 with Dow Corning FS3451
grease is recommended. This grease provides superior chemical resistance, lubricates at tempera-
tures from -40F to 450F (-40C to 232C), is highly resistant to oxidation, and resists deterioration
by solvents as well as other severe chemicals.

CONFIGURATION DATA:

Two- and Three-Port Valves (See Figure 1).

Three-port Versa valves originally used the third port for venting. Solar subsequently found this port
unnecessary, consequently, only two-port valves are presently being used. Older three-port valves
may be directly replaced by two-port valves, when the overboard vent port is sealed off in the valve

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NUMBER: 3.1/100
mounting plate subplate. A 1. 00-inch diameter cork, soaked in Room Temperature Vulcanizing
(RTV) sealant, is suggested for subplate vent sealing.

Figure 1 Versa Valve Configurations

Rotated Solenoid Head Valves.

To facilitate direct installation and replacement, use the solenoid-operated gas valves with heads
rotated 90 CCW, P/N 901434C2. This is a "make from" the standard valve, P/N 909583C2.

Updated Older Valves.

Some older solenoid- and pilot-operated valves may be updated to the latest configuration, if and
when parts are needed, except for obsolete valves listed in Table 1. These valves lack chrome-plated
internal parts and other features, and should be replaced with the new comparable valves when parts
are required.

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NUMBER: 3.1/100
 Table 1 Obsolete Valves and Replacement Valves
Obsolete P/N Replacement P/N
41026-1 909583C2
41026-2 909583C2
41028-1 909583C2
41028-2 909583C2
44795-1 44795-4
44795-2 44795-4

The following valves (See Table 2) can be updated to the latest configuration by using the new caps
and the O-Ring kit. Steel stamp new part number on valve body.

Table 2 Updated Valves and Required Materials

Old Valve O-Ring Kit Solenoid Pilot Cap Spring Cap New Valve
P/N Cap P/N
Solenoid-Operated Valves
41026-3 8007995R91 946247C2 N/A 908331C2 *
41028-3 8007995R91 946247C2 N/A 908331C2 909583C2
909583C1 8007995R91 946247C2 N/A 908331C2 909583C2
901425C1 8007995R91 946247C2 N/A 908331C2 *
901434C1 8007995R91 946247C2 N/A 908331C2 909583C2
901996C1 8007995R91 946247C2 N/A 908331C2 909583C2
901999C1 8007995R91 946247C2 N/A 908331C2 *
The overboard vent port (third hole in the three-hole valve body) does not permit this
updated valve to become a completely new valve, P/N 909583C2.
Pilot-Operated Valves
44795-3 8007995R91 N/A 946246C1 908331C1 44795-4
901997C1 8007995R91 N/A 946246C1 908331C1 44795-4

MAINTENANCE:
When a valve is disassembled for cleaning, all rubber goods must be replaced. The O-Ring and
packing kit P/N 8007995R91, which replaces O-Ring kit P/N 8007814R91, contains O-Rings and
U-cup for the two- and three-port valves.

NOTE
The O-Ring kit includes a solenoid gasket (O-Ring), P/N P-1100-21. This
O-Ring should be used only when a solenoid assembly, P/N 900924925,
and/or solenoid cap, P/N 946247C2, is replaced. The O-Ring is not usually
replaced during normal valve maintenance.

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NUMBER: 3.1/100
Mineral spirits, or kerosene, may be used when valve cleaning is necessary. Thoroughly air dry or
wipe clean before applying lubricant. Dow Corning FS3451 is the approved lubricant for internal
moving and wearing parts of the valve. Apply lubricant sparingly.

NOTE
This lubricant may be obtained through Solar in 3-ounce tubes under P/N
915484C1.

The grommets, P/N 4302-52B (see Figure 2), are used as plugs in the body-mating surface of the
solenoid cap, P/N 946247C2, and are normally supplied with the cap.

NOTE
These grommets may be obtained through Solar under material code num-
ber 861412235 (one each). Refer to Service Bulletin 2.1S/100 for mainte-
nance precautions.

SPARE PARTS (SEE FIGURE 2)

1. The Versa valve O-Ring and packing kit (-40F to 180F), P/N 8007995R91, table 3,
contains all O-Rings and U-cup for two- and three-port valves. This new kit obsoletes
and replaces O-Ring kits P/N 8007814R94 and 946245C2.
2. The pilot cap, P/N 946246C1, and the solenoid cap, P/N 946247C2, are used to convert
existing valves to the new configurations. These caps have the threaded 1/8-inch NPT
overboard vent connection.
3. The spring cap, P/N 908331C2, having the threaded 1/8-inch NPT overboard vent, is
also required to convert those older valves, whose overboard vent was not threaded, to
the new valve configuration.

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NUMBER: 3.1/100
 Figure 2 Versa Valves, Exploded View

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NUMBER: 3.1/100
 Table 3 Versa Valve O-Ring and Packing Kit (-40F to
180F), P/N 8007995R91
Part Number Description Qty.
P-1000-25-44 O-Ring (Center body, OD) 2
P-1000-17-44 O-Ring (Plunger end grooves) 2
P-1004-02-44 O-Ring (Body to cap interface) 2
P-1100-17 O-Ring (Plunger inlet seal) 1
P-1000-21-44 O-Ring (Subplate) 3
P-1100-21 O-Ring (Retainer to bushing) 1
P-1100-05X-155 Gasket, Solenoid (O-Ring) 1
P-1016-52 Uncup 1
4. The main fuel valve solenoid replacement kit, P/N 8007820R93 (see table 4), can be
used to update older valve installations. This kit contains a valve, P/N 909583C2, plus
the required hardware and plumbing. The new overboard vent connections in the valve
should be plumbed to the existing vent system. Refer to REPLACEMENT, this Bulletin,
for detailed instructions.
5. The main fuel solenoid valve modification kit, P/N 8007838R94 (see table 5), can be
used to update older valves. This kit includes a new solenoid cap, P/N 946247C2, a new
spring cap, P/N 908331C2, an O-Ring kit, P/N 8007995R91 and the required hardware
and plumbing. The new overboard vent connections in the caps may be plumbed as
necessary. Refer to MODIFICATION, this Bulletin, for detailed instructions.

Table 4 Main Fuel Solenoid Valve Replacement Kit, P/N 800782OR93

Part Number Description Qty.
24028R1 Tee 1
909583C2 Valve, Solenoid (Versa Products, P/N, 1
VSG 2711-2187B)
P-1100-21-44 O-ring 3
Coml Tubing, 321 Cres stainless steel, 0.25 inch OD x 2
0.035 inch wall, 30 inches long
908008C1 Nut, Imperial Hi-Seal 1
908007C1 Sleeve, Imperial Hi-Seal 1
908003C1 Tee 1
24O81R1 Sleeve 7
24072R1 Nut 7
23115R1 Connector 1
90800C1 Elbow 1

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NUMBER: 3.1/100
 Table 5 Main Fuel Solenoid Valve Modification Kit, P/N 8007838R94
Part Number Description Qty.
24028R1 Tee 1
908331C2 Cap, Spring 1
946247C2 Cap, Solenoid 1
946245C2 Kit, O-Ring and Packing; Versa Valve (-40F to 1
180F)
Coml Tubing, 321 Cres stainless steel, 0.25 Inch OD x 2
0.035 inch wall, 30 inches long)
908008C1 Nut, Imperial Hi-Seal 1
908007C1 Sleeve, Imperial Hi-Seal 1
908003C1 Tee 1
24081R1 Sleeve 7
24072R1 Nut 7
28115R1 Connector 1
908001C1 Elbow 1

REPLACEMENT OF MAIN FUEL VALVE

NOTE
In mechanical drive package plumbing configuration, a tee is used to make
connections to the top of the valve. It will be necessary to use the existing
tee and to install tee, P/N 24028R1, by cutting into the line as shown in
Figure 3, detail B.

1. Shut off fuel at source and tag MASTER switch to indicate that unit is being serviced.
2. Remove pilot gas supply line between valve and manifold.
3. Disconnect electrical leads to valve solenoid.

NOTE
Prior to removing valve from subplate, analyze the installation to determine
if there is sufficient room for an elbow, or if a union should be installed on the
spring cap which would permit alternate method of routing the line assembly
(See Figure 3, detail A).

4. Remove attaching hardware and remove valve from subplate.

5. Install new valve P/N 909583C2 on subplate, using two new O-Rings, P/N
P-1000-21-44. Install a 1.00-inch diameter RTV-soaked cork to seal the existing
overboard vent plumbing port.

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NUMBER: 3.1/100
 6. Install elbow, P/N 908001C1, or connector, P/N 23115R1, in spring cap, P/N 908331C2.

Figure 3 Valve Modification Plumbing (New End Cap Shown)

7. Perform step 7.a. or 7.b. as appropriate.
a. Remove existing elbow, and install tee, P/N 908003C1.
b. Use existing tee and tee, P/N 24028Rl, as shown in Figure 3, detail B.
8. Fabricate 0.25-inch tube assembly as shown in appropriate view of Figure 3, using
stainless steel tube (0.25-inch OD, 0.035-inch wall thickness), two sleeves, P/N
24081R1, and two B-nuts, P/N 24072R1.

NOTE
If necessary, drill hole in skid to provide clearance for the 0.25-inch run-
around line.

9. Perform step 9.a. or 9.b. as appropriate.

a. Fabricate 0.25-inch pilot gas line for connection from tee on cap of main gas valve
to pilot gas source using parts as shown in Figure 3, and install the line.
b. Insert tee, P/N 24028R1, into gas line using two sleeves, P/N 24O81R1, and two
B-nuts, PIN 24072R1.

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NUMBER: 3.1/100
 10. Connect electrical leads to valve.
11. Perform a test start and verify proper operation of valve; check all new connections for
leakage.

MODIFICATION OF EXISTING TWO- AND THREE-PORT VALVES

1. Disassemble and clean valve. Refer to MAINTENANCE, this Bulletin.
2. Remove and discard O-Rings; replace with new O-Rings from the O-Ring and packing
kit, P/N 8007995R91.
3. Remove and discard the old solenoid cap and the spring cap.

NOTE
Index, or clock, the new spring cap during valve assembly so that the over-
board vent connection is in the proper position for connection to the new
overboard vent drain system.

4. Sparingly lubricate moving and wearing parts. Refer to MAINTENANCE, this Bulletin,
and using new solenoid cap, P/N 946247C2, and new spring cap, P/N 908331C2,
assemble valve.
5. Connect kit hardware and plumbing in the appropriate configuration (see Figure 3).

NOTE
• Three subplate O-Rings, P/N P-1000-21-44, are required for three-hole
valves.

• No sealant is required.

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NUMBER: 3.1/100