Zavoli GEXL Manual

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG-007.01-E 09/10/2009
Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG-007.00-E
09/10/2009
Technical Document ID:
DT_IS_RG-007
Rev.
Date
0
May 23, 2007
Type of
Alteration
First Issue
1
09/10/2009
Second Issue
Issued by
ROS Technical
Office
Inspected/Approved
by
DTE Technical
Manager
ROS Technical
Office
DTE Technical
Manager
INTRODUCTION
The following manual is not designed to offer a comprehensive guide on the simple overhaul
procedures for GE – GES – GEX – GEXL regulators/vaporizers.
Therefore, the goal of this manual is to provide general guidelines for the disassembly and
reassembly of these regulators/vaporizers. Such procedures may be subject to the replacement of
some of the internal components of the regulators, which will be performed at the installer’s
discretion.
ZAVOLI S.r.l. disclaims any responsibility for any malfunction of its regulators/vaporizers due
to alterations performed by non-authorized personnel. Illegal tampering with the systems will
cause their warranty to become null and void.
ZAVOLI S.r.l. reserves the right to change its devices in accordance with new applications and
techniques available in the future. ZAVOLI S.r.l. disclaims any responsibility for system
malfunctions caused by failure to update this manual.
Page 2 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. (+39) 0547/ 646409 – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [email protected]
Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG-007.00-E
09/10/2009
General Index
Introduction …………………………………………………….
……2
1. ………………..
GE – GES – GEX – GEXL Regulators/Vaporizers ……..….
……5
2. ………………..
How to perform a proper overhaul ...………………………..
……7
2.1
…………
Replacement of the 1st stage lever cut-off ……………….
……8
2.2
…………
Replacement of the 2nd stage lever rubber top …………….
……9
2.3
…………
2.4
Replacement of the movable core cut-off of the electrovalve
and O-Ring sleeve of the electrovalve …………………………
…………. Replacement of all O-Rings.………………………………….
3. ………………...
Reassembly of the Regulator/Vaporizer ………………….
……10
……11
……14
3.1
…………. Installation of the cut-off valve on the 1st stage lever ………..
……14
3.2
…………. Installation of the cut-off valve on the 2nd stage lever ……...
……15
3.3
…………. Installation of the electrovalve piston rubber top ……………
……16
3.4
…………. Installation of the 1st stage lever ……………………………
……16
3.5
…………. Installation of the 2nd stage lever ……………………………
……17
3.6
…………. Installation of the high-pressure diaphragm ……………….
……17
3.7
…………. Installation of the 1st stage cover ………………………………
……19
3.8
…………. Installation of the 2nd stage diaphragm ……………………….
……20
3.9
…………
Installation of the 2nd stage cover …………………………….
……21
3.10 …………
Installation of the bleed valve screw top ……………………..
……21
3.11 …………
Installation of the sensitivity register …………………………
……22
3.12 …………
Installation of the gas outlet connection ……………………..
……24
3.13 …………
Installation of the water inlet/outlet connections ……………
……25
Page 3 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG-007.00-E
09/10/2009
3.14 …………. Installation of the electrovalve sleeve ………………………..
……26
3.15 …………. Installation of the separate idle channel screw top …………
……26
3.16 …………
Installation of the electrovalve and screw top ……………….
……27
3.17 …………
Installation of the screw top …………………………………..
……27
Testing procedures …..………………………………………
……28
4. ………………..
Page 4 of 32
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Tel. (+39) 0547/ 646409 – Telefax (+39) 0547 / 646411
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG-007.00-E
09/10/2009
1. GE – GES – GEX – GEXL Regulators/Vaporizers
GE – GES – GEX - GEXL regulators/vaporizers are, as most people know, devices which allow
gas to change from a liquid to a gaseous state. Regulators also help reduce the operating
pressure.
In order to perform a proper overhaul of the GE regulator/vaporizer, please use the overhaul kit
(code 101K02) described in the following table:
ITEM
101K02
1001C
1003/1
1003/2
10012C
10015B
10021B
10025B
10030B
10031B
101COM004
100COM016
DESCRIPTION
CNG SYSTEM OVERHAUL KIT– “101GE”
1st stage cut-off valve
4x7.5 headless screw (threaded rod)
4x7.5 regular screw
Low-pressure lever/electrovalve cut-off
5.28x1.78 O-Ring – plunger/idle channel screw top
12.42x1.78 O-Ring – electrovalve sleeve/ register /channel
9.25x1.78 O-Ring – electrovalve screw top/bleed valve
screw top
18.77x1.78 O-Ring – gas outlet connection
10.82x1.78 O-Ring – water outlet connection
1st stage diaphragm - “101GE” REGULATOR
Full low-pressure diaphragm
QUANTITY
1
2
4
2
2
2
2
1
4
1
1
In order to perform a proper overhaul of the GES - GEX regulators/vaporizers, please use the
overhaul kit (code 100K02) described in the following table:
ITEM
100K02
1001C
1003/1
1003/2
10012C
10015B
10021B
10025B
10030B
10031B
100COM004
100COM016
DESCRIPTION
CNG SYSTEM OVERHAUL KIT - electronic
1st stage cut-off valve
4x7.5 headless screw (threaded rod)
4x7.5 regular screw
Low-pressure lever/electrovalve cut-off
5.28x1.78 O-Ring – plunger/idle channel screw top
12.42x1.78 O-Ring – electrovalve sleeve/register/channel
9.25x1.78 O-Ring – electrovalve screw top/bleed valve
screw top
18.77x1.78 O-Ring – gas outlet connection
10.82x1.78 O-Ring – water outlet connection
Full 1st stage diaphragm
Full low-pressure diaphragm
Page 5 of 32
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Tel. (+39) 0547/ 646409 – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [email protected]
QUANTITY
1
2
4
2
2
2
2
1
4
1
1
Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG-007.00-E
09/10/2009
In order to perform a proper overhaul of the GEXL regulators/vaporizers, please use the
overhaul kit (code 100K05) described in the following table:
ARTICLE
100K05
1001C
1003/1
1003/2
10012C
10012CR
10015B
10021B
10025B
10030B
10031B
100COM004
100COM016
DESCRIPTION
CNG SYSTEM OVERHAUL KIT - electronic
1st stage cut-off valve
4x7.5 headless screw (threaded rod)
4x7.5 regular screw
Low-pressure lever/electrovalve cut-off
Reinforced low-pressure lever cut-off
5.28x1.78 O-Ring – plunger/idle channel screw top
12.42x1.78 O-Ring – electrovalve sleeve/ register /channel
9.25x1.78 O-Ring – electrovalve screw top/bleed valve
screw top
18.77x1.78 O-Ring – gas outlet connection
10.82x1.78 O-Ring – water outlet connection
Full 1st stage diaphragm
Full low-pressure diaphragm
Page 6 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. (+39) 0547/ 646409 – Telefax (+39) 0547 / 646411
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QUANTITY
1
2
4
1
1
2
2
2
1
4
1
1
Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG-007.00-E
09/10/2009
2. How to perform a proper overhaul
To perform a proper overhaul of a CNG regulator/vaporizer (Fig. 2-1) it is advisable to
disassemble the device in all its components (Fig. 2-2).
Fig. 2-1
Fig. 2-2
Page 7 of 32
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DT_IS_RG-007.00-E
09/10/2009
Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
The main body of the regulator (Fig. 2-3 and 2-4) must be carefully cleaned with a brush (Fig. 25 and 2-6) and a degreasing detergent to remove oil, grease, etc. Do not use sandblasting
machines or any other kind of abrasive tool/substance, as this may damage components which
are critical for the proper operation of the regulator. CAREFULLY BLOW COMPRESSED AIR
ON THE DEVICE UNTIL IT IS COMPLETELY DRY!!!!!
Fig. 2-3
Fig. 2-4
Fig. 2-5
Fig. 2-6
2.1 Replacement of the 1st stage lever cut-off
With a punch, apply a small amount of pressure to the cut-off valve so that it separates from its
housing (Fig. 2.1-1 / 2.1-2 and 2.1-3).
Page 8 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG-007.00-E
09/10/2009
Fig. 2.1-1
Fig. 2.1-2
Fig. 2.1-3
2.2 Replacement of the 2nd stage lever rubber top
To replace the 2nd stage lever rubber top, pinch the top end of the rubber top with two fingers.
Then, carefully remove the rubber top (Fig. 2.2-1 / 2.2-2 and 2.2-3). When working with a
GEXL regulator, please use the 10012CR cut-off included in the 100K05 overhaul kit!!!!
Fig. 2.2-1
Fig. 2.2-2
Page 9 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG-007.00-E
09/10/2009
2.3 Replacement of the movable core cut-off of the electrovalve and O-Ring sleeve of the
electrovalve
To replace the electrovalve rubber top, hold the sliding metallic component located inside the
valve in place with two fingers. Then carefully remove the rubber top with the other hand.
(Fig. 2.3-1 / 2.3-2 / 2.3-3 and 2.3-4)
Movable core
Fig. 2.3-1
Fig. 2.3-2
CAUTION:
When replacing O-Rings, make sure that seats do not get damaged!!
Electrovalve sleeve
Fig. 2.3-3
Fig. 2.3-4
Page 10 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
2.4
DT_IS_RG-007.00-E
09/10/2009
Replacement of all O-Rings
The following pictures show all the components in which O-Rings should be replaced.
Fig. 2.4
Separate idle register
Fig. 2.4-1
Fig. 2.4-2
Sensitivity register
Fig. 2.4-3
Fig. 2.4-4
Fig. 2.4-5
Page 11 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG-007.00-E
09/10/2009
Gas outlet connection
Fig. 2.4-6
Water outlet connection
Fig. 2.4-7
Fig. 2.4-8
Water outlet connection
Fig. 2.4-9
Fig. 2.4-10
Electrovalve screw top
Fig. 2.4-11
Page 12 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
Fig. 2.4-12
Bleed valve screw top
DT_IS_RG-007.00-E
09/10/2009
Fig. 2.4-13
Fig. 2.4-14
Separate idle channel screw top
Fig. 2.4-15
Page 13 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
3
DT_IS_RG-007.00-E
09/10/2009
Reassembly of the Regulator/Vaporizer
Before proceeding to reassemble the components of the regulator/vaporizer (Fig. 3-1),
please make sure that all O-Ring seats are in perfect working condition to avoid potential
leaks. Also make sure that the new O-Rings are well lubricated before they are installed!!!
Fig. 3
3.1
Installation of the cut-off valve on the 1st stage lever
With a punch, insert the cut-off valve in its operating seat (Fig. 3.1 / 3.1-1 / 3.1-2 and 3.1-3),
making sure that the central part of the cut-off does not get damaged in the process.
Fig. 3.1
Fig. 3.1-1
Page 14 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
Fig. 3.1-2
3.2
DT_IS_RG-007.00-E
09/10/2009
Fig. 3.1-3
Installation of the cut-off valve on the 2nd stage lever
To install the 2nd stage lever, you will need a pair of pliers (Fig. 3.2). Put the cut-off valve in
place as shown in Fig. 3.2-1 and 3.2-2. Pull the stem with the pliers and slightly twist it.
Fig. 3.2
Fig. 3.2-1
Fig. 3.2-2
Fig. 3.2-3
Page 15 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG-007.00-E
09/10/2009
Fig. 3.2-4
3.3
Installation of the electrovalve piston rubber top
Put the cut-off valve in place, as shown in Fig. 3.3. While pressing the valve down to insert it in
its seat, turn the piston clockwise. (Fig. 3.3-1)
Fig. 3.3
Fig. 3.3-1
3.4 Installation of the 1st stage lever
Insert the pin in the lever holes as shown in the pictures, and with a Phillips screwdriver secure
the 2 headless screws (threaded rods) into their seats.
Leversupporting
pin.
Fig. 10-1
Fig. 10-2
Page 16 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
3.5
DT_IS_RG-007.00-E
09/10/2009
Installation of the 2nd stage lever
To place the 2nd stage lever in the correct operating position, please refer to the pictures below
(Fig. 3.5 and 3.5-1). Insert the pin and secure the regular screws into their seats (Fig. 3.5-2).
Fig. 3.5
Fig. 3.5-1
Fig. 3.5-2
3.6
Installation of the high-pressure diaphragm
To install the high-pressure diaphragm, please refer to the following directions.
Diaphragm for GE regulators/vaporizers
Page 17 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
Fig. 3.6
DT_IS_RG-007.00-E
09/10/2009
Fig. 3.6-1
Diaphragm for GES – GEX – GEXL regulators/vaporizers
Fig. 3.6-2
Fig. 3.6-3
Insert the high-pressure
diaphragm hook on the bottom of
the 1st stage lever.
With a finger, press the 1st stage
lever down. The lever will sit in a
raised position, which will allow
the diaphragm hook to be
fastened to it.
FAILURE TO FASTEN THE
HOOK TO THE LEVER
WILL PREVENT THE
REGULATOR FROM
WORKING PROPERLY!
Fig. 3.6-4
Page 18 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
3.7
DT_IS_RG-007.00-E
09/10/2009
When installing the 1st stage cover, make sure that the notch on the side of the cover is
placed on the electrovalve housing (Fig. 3.7 / 3.7-1 / 3.7-2 / 3.7-3 and 3.7-4). Also make
sure that the cover screws are safely secured into place by means of a torque wrench
(MAX 5.5 Nm). Fasten the screws in the following order: top, bottom, left, right.
Repeat the procedure.
Notch on the cover to determine proper
positioning.
Hole for the installation of the electrovalve.
Fig. 3.7
Fasten with a 5.5 Nm torque wrench
Fig. 3.7-1
Fig. 3.7-2
Fig. 3.7-3
Fig. 3.7-4
Page 19 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
3.8
DT_IS_RG-007.00-E
09/10/2009
Installation of the 2nd stage diaphragm
Fig. 3.8
Fig. 3.8-1
Insert the 2nd stage diaphragm hook on the
bottom of the 2nd stage lever.
2nd stage lever
Fig. 3.8-2
MAKE SURE THAT THE DIAPHRAGM
IS PROPERLY FASTENED TO THE
LEVER. FAILURE TO DO SO WILL
PREVENT THE REGULATOR FROM
WORKING PROPERLY!!!!
Page 20 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
3.9
DT_IS_RG-007.00-E
09/10/2009
Installation of the 2nd stage cover
Place the cover on the regulator/vaporizer and, with the help of a Phillips screwdriver (3 Nm),
fasten the screws.
Fig. 3.9
3.10
Fig. 3.9-1
Installation of the bleed valve screw top
To install the bleed valve screw top, twist the top on by hand, as shown in Fig. 3.10 and 3.10-1.
Fig. 3.10
Fig. 3.10-1
Page 21 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
3.11
DT_IS_RG-007.00-E
09/10/2009
Installation of the sensitivity register
To install the sensitivity register, grease part of the spring, as shown in Fig. 3.11 and 3.11-1. Put
the greased end of the spring into place, as shown in Fig. 3.11-2. Fig. 3.11-5 shows the correct
position of the spring.
Fig. 3.11
Fig. 3.11-1
Place the greased end of the spring on the
“dot” indicated by the arrow!!!
Fig. 3.11-2
In GEX and GEXL regulators/vaporizers, a stopper must be placed on the register spring (Fig.
3.11-3 and 3.11-4). Make sure that the stopper is placed on the sensitivity register and not on the
“dot” indicated in Fig. 3.11-2.
Page 22 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
Fig. 3.11-3
DT_IS_RG-007.00-E
09/10/2009
Fig. 3.11-4
Spring installed correctly. This will ensure
that the regulator works properly.
GEX or GEXL regulator. The arrow
indicates the area where the stopper must be
placed (Fig. 3.11-3 and Fig. 3.11-4).
Fig. 3.11-5
Fig. 3.11-6
Fig. 3.11-7
Page 23 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
3.12
DT_IS_RG-007.00-E
09/10/2009
Installation of the gas outlet connection
Insert the connection in its housing, and twist it on (Fig. 3.12-1). Fasten the screws with a
Phillips screwdriver.
Fig. 3.12
Fig. 3.12-1
Fig. 3.12-2
Fig. 3.12-3
Page 24 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
3.13
DT_IS_RG-007.00-E
09/10/2009
Installation of the water inlet/outlet connections
Before proceeding to install the water inlet/outlet connections, grease the inside of their seats as
shown in Fig. 3.13 and 3.13-1. Then, secure the connections into place with a Phillips
screwdriver.
Fig. 3.13
Fig. 3.13-1
Fig. 3.13-2
Fig. 3.13-3
Page 25 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
3.14
DT_IS_RG-007.00-E
09/10/2009
Installation of the electrovalve sleeve
To install the electrovalve sleeve, insert it in its seat, screw it into place using a size 17 wrench
and fasten (3 Nm).
Fig. 3.14
3.15
Fig. 3.14-1
Installation of the separate idle channel screw top
To install the separate idle channel screw top, insert it in its seat and screw it into place using a
size 3 hexagonal wrench.
Fig. 3.15
Fig. 3.15-1
Page 26 of 32
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Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
3.16
DT_IS_RG-007.00-E
09/10/2009
Installation of the electrovalve and screw top
To install the electrovalve, refer to pictures 3.16 and 3.16-1. Please make sure the valve is placed
in the same position shown in the pictures. Fasten the screw top (5Nm).
3.17
Fig. 3.16
Fig. 3.16-1
Fig. 3.16-2
Fig. 3.16-3
Installation of the screw top
To install the screw top, please refer to the following pictures:
Fig. 3.17
Fig. 3.17-1
Page 27 of 32
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DT_IS_RG-007.00-E
09/10/2009
Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
4
Testing Procedures
To make sure that all components have been installed correctly, perform the following testing
procedures. You will need (Fig. 4):






A T-joint
A valve
A pressure gauge (min. 4-BAR)
A 12-Volt power supply
CNG joints
Hoses, to connect the components
Fig. 4
1. Connect the regulator/vaporizer to a compressed air circuit.
Fig. 4.1
Fig. 4.2
Page 28 of 32
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DT_IS_RG-007.00-E
09/10/2009
Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
2. Energize the 12-Volt coil
Fig. 4.3
Fig. 4.4
3. Sensitivity register test: make sure that the separate idle is secured into place. Check that
the sensitivity register is tightly fastened, so that no air is coming out of the gas outlet
connection. Slowly unscrew the sensitivity register: the amount of air coming out of the
gas outlet connection should be slowly increasing.
Slowly unscrew the sensitivity register, until
the air flow coming out of the gas outlet
connection is steady and even. If the air flow
is uneven, check that the sensitivity spring
has been properly placed in its housing (see
Fig. 3.11-5).
Fig. 4.5
4. Separate idle test: check that the sensitivity register is tightly fastened, so that no air is
coming out of the gas outlet connection. Slowly unscrew the separate idle: the amount of
air coming out of the gas outlet connection should be slowly increasing.
Page 29 of 32
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DT_IS_RG-007.00-E
09/10/2009
Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
Slowly unscrew the separate idle, until air
comes out of the gas outlet connection.
Fig. 4.6
CAUTION: after being tested, both the sensitivity register and the separate idle must be
slightly adjusted.


Slightly unscrew the tightly fastened separate idle (about ¼ turn), so that a small, steady
amount of air flows out of it.
Slightly unscrew the tightly fastened sensitivity register (about ______ turn, depending
on the type of vehicle). If the sensitivity register is fastened too tightly, the vehicle may
not be easily started.
5. After performing the testing procedures listed above, disconnect the coil from the power
supply (Fig. 4.7), turn off the compressed-air flow, and unscrew the air-feed connection
from the regulator/vaporizer (Fig. 4.8). After 3 minutes, energize the coil again. If the
electrovalve appears to be working properly when the coil is connected to the power
supply (Fig. 4.9) and the regulator is not leaking, a small amount of air should come out
of the gas inlet connection.
Fig. 4.7
Fig. 4.8
Page 30 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. (+39) 0547/ 646409 – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [email protected]
Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG-007.00-E
09/10/2009
When the clamps are connected to the coil, a
small amount of air should come out of the
gas inlet connection.
Fig. 4.9
Page 31 of 32
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Tel. (+39) 0547/ 646409 – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [email protected]
Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG-007.00-E
09/10/2009
REASSEMBLED
REGULATOR/VAPORIZER
Page 32 of 32
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Web site: www.zavoli.com E-mail: [email protected]
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