one leaking valve on discontinued manifold


 
Grüezi guys, I have a similar problem, and have been following this thread for help. I could sure use some advice. I am not sure if, by coincidence, all five burner valves (3 installed, 2 old ones I found laying around) I have are leaking, or perhaps the regulator has failed.

I'm working on a exported (to Switzerland) 2008 model Genesis S-310 s/n DZ 0173425. The grill spec sticker inside the cabinet says "37mb PROPN" which, in freedom units, is 0.53 PSI. The regulator has a sticker that shows 30 mbars (0.435 PSI).

GrillSticker.jpeg
Reg.jpeg

So far, everything seems to be spec'd correctly. However, all three burner valves leak gas like crazy when A) the LP canister is opened and B) the burner valves are closed. (YES those two little screws are good and tight. Any tighter will probably either trip the screwhead or the threads).


I have switched out to some older valves I found from a previous repair. (I moved in with mother in law recently and don't really know the history fo this grill) and exhibit the same problems. The gaskets appear intact. The only questionable thing I notice is that upon inspection of the mating surfaces of the valves. The upper aluminum (?) part looks ok, but the brass surface on the bottom bit is quite scratched up:

ValveTop.jpeg

BrassValve.jpeg

There is also no gasket here. None of the five valves I have have gaskets between these two mating parts. Although there are gaskets, in good shape, elsewhere on the valve assembly (i.e., the bolt holding it to the manifold gas rail as well as the opposite side).

My ideas are:

  1. Perhaps there is schmutz on the rotating valve cone, or in the recess in which it sits, that causes the valve cone to sit slightly proud, which consequently does not allow proper mating of the valve's upper & lower parts. (The two small screws to hold these parts together are on TIGHT). Cleaning and re-greasing is first on my agenda to address.
  2. Perhaps there were gaskets that have been lost, which helped seal the upper & lower parts of the valve. This would be quite a coincidence considering how all the other gaskets are intact and in good shape, but is certainly a possibility.
  3. The lower part of the valve's brass mating surface is scratched / pitted enough to cause the leaks, and I need to half *** it with some RTV or other liquid gasket material.
  4. The regulator has failed, and these valves (which show "1/2 PSI" on the sides) are receiving higher gas pressure than they are rated to handle, and that is why they leak. But wouldn't a failed regulator also produce quite a crazy burner flame? I don't have a pressure tester, but the burner flame seems quite normal to me.
Any advice?
 
If the cone or mating surface of the cone is damaged in any way THAT is your leak. As it's the cone which is supposed to form the actual seal inside the housing. There are no gaskets. Clean it very well. Take a VERY tiny bit of high temp lube, literally about the size of the head of a pin, spread it all around the cone, reassemble. If it still leaks the valve is damaged beyond repair
 
Yah, don't sweat it either, even if it is a bad valve. There are plenty of those grills out there that are being scrapped or sold cheap. Just get the parts off one of those.
 
Bruce said:
Yah, don't sweat it either, even if it is a bad valve. There are plenty of those grills out there that are being scrapped or sold cheap. Just get the parts off one of those.
Click to expand...
He's in Zurich CH not the US. So, not really sure those things will be floating around over there that readily
 
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