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Technical Directions

for the Overhaul of

GE – GES – GEX – GEXL

Regulators/Vaporizers

DT_IS_RG-007.01-E 09/10/2009

Summary of Contents for GE

Page 1: ...Technical Directions for the Overhaul of GE GES GEX GEXL Regulators Vaporizers DT_IS_RG 007 01 E 09 10 2009...

Page 2: ...rhaul 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 pro...

Page 3: ...leeve of the electrovalve 10 2 4 Replacement of all O Rings 11 3 Reassembly of the Regulator Vaporizer 14 3 1 Installation of the cut off valve on the 1st stage lever 14 3 2 Installation of the cut of...

Page 4: ...023 Fr Case Castagnoli CESENA FC Italy Tel 39 0547 646409 Telefax 39 0547 646411 Web site www zavoli com E mail zavoli zavoli com 3 14 Installation of the electrovalve sleeve 26 3 15 Installation of t...

Page 5: ...ger idle channel screw top 2 10021B 12 42x1 78 O Ring electrovalve sleeve register channel 2 10025B 9 25x1 78 O Ring electrovalve screw top bleed valve screw top 2 10030B 18 77x1 78 O Ring gas outlet...

Page 6: ...LE DESCRIPTION QUANTITY 100K05 CNG SYSTEM OVERHAUL KIT electronic 1001C 1st stage cut off valve 1 1003 1 4x7 5 headless screw threaded rod 2 1003 2 4x7 5 regular screw 4 10012C Low pressure lever elec...

Page 7: ...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 zavoli zavoli com 2 How to perform a proper overhaul To perform a prop...

Page 8: ...fully cleaned with a brush Fig 2 5 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 componen...

Page 9: ...9 0547 646411 Web site www zavoli com E mail zavoli zavoli com 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 e...

Page 10: ...i zavoli com 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 in...

Page 11: ...00 47023 Fr Case Castagnoli CESENA FC Italy Tel 39 0547 646409 Telefax 39 0547 646411 Web site www zavoli com E mail zavoli zavoli com 2 4 Replacement of all O Rings The following pictures show all th...

Page 12: ...2 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 zavoli zavoli com Gas outlet connection Fig 2 4 6 Fi...

Page 13: ...00 E 09 10 2009 Page 13 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 zavoli zavoli com Fig 2...

Page 14: ...er 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 tha...

Page 15: ...Tel 39 0547 646409 Telefax 39 0547 646411 Web site www zavoli com E mail zavoli zavoli com Fig 3 1 2 Fig 3 1 3 3 2 Installation of the cut off valve on the 2nd stage lever To install the 2nd stage lev...

Page 16: ...voli zavoli com 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 pist...

Page 17: ...li com E mail zavoli zavoli com 3 5 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 p...

Page 18: ...www zavoli com E mail zavoli zavoli com Fig 3 6 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 l...

Page 19: ...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...

Page 20: ...Italy Tel 39 0547 646409 Telefax 39 0547 646411 Web site www zavoli com E mail zavoli zavoli com 3 8 Installation of the 2nd stage diaphragm Fig 3 8 Fig 3 8 1 Insert the 2nd stage diaphragm hook on t...

Page 21: ...646409 Telefax 39 0547 646411 Web site www zavoli com E mail zavoli zavoli com 3 9 Installation of the 2nd stage cover Place the cover on the regulator vaporizer and with the help of a Phillips screwd...

Page 22: ...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...

Page 23: ...ase Castagnoli CESENA FC Italy Tel 39 0547 646409 Telefax 39 0547 646411 Web site www zavoli com E mail zavoli zavoli com Fig 3 11 3 Fig 3 11 4 Spring installed correctly This will ensure that the reg...

Page 24: ...agora n 400 47023 Fr Case Castagnoli CESENA FC Italy Tel 39 0547 646409 Telefax 39 0547 646411 Web site www zavoli com E mail zavoli zavoli com 3 12 Installation of the gas outlet connection Insert th...

Page 25: ...taly Tel 39 0547 646409 Telefax 39 0547 646411 Web site www zavoli com E mail zavoli zavoli com 3 13 Installation of the water inlet outlet connections Before proceeding to install the water inlet out...

Page 26: ...11 Web site www zavoli com E mail zavoli zavoli com 3 14 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...

Page 27: ...411 Web site www zavoli com E mail zavoli zavoli com 3 16 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 pla...

Page 28: ...Telefax 39 0547 646411 Web site www zavoli com E mail zavoli zavoli com 4 Testing Procedures To make sure that all components have been installed correctly perform the following testing procedures Yo...

Page 29: ...at 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 se...

Page 30: ...bout 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...

Page 31: ...0 2009 Page 31 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 zavoli zavoli com When the clamps...

Page 32: ...gulators Vaporizers DT_IS_RG 007 00 E 09 10 2009 Page 32 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 co...

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