Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
DT_IS_RRM-006.01-E 09/10/2009
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
DT_IS_RRM-006.01-E
09/10/2009
Technical Document ID:
DT_IS_RRM-006
Rev.
Date
0
April 19, 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 MES – MEX – MEXL 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
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Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
DT_IS_RRM-006.01-E
09/10/2009
General Index
Introduction ……………….……………………………………
……2
1. ………………..
MES – MEX – MEXL Regulators/Vaporizers ……..…….....
……5
2. ………………..
How to perform a proper overhaul...………………………….
……6
2.1
……….
Replacement of the 1st stage lever cut-off ……..........................
……7
2.2
…….....
Replacement of the 2nd stage lever cut-off…………………
……7
2.3
……….
Replacement of the movable core cut-off of the electrovalve
……….
Replacement of all O-Rings…………………………………...
……8
……8
3. ………………...
Reassembly of the Regulator/Vaporizer ……………………..
……10
2.4
3.1
…………
Installation of the 1st stage lever – CNG ……………………
……11
3.2
…………
Installation of the cut-off valve on the 2nd stage lever ……...
……11
3.3
…………
Installation of the 2nd stage lever - CNG……………………
……12
3.4
…..…….
Installation of the H.P. valve and swinging arm ………….
……13
3.5
…………
3.6
…………
Installation of the High Pressure and Medium Pressure
diaphragm ……………………………………………………….. ……14
Installation of the High Pressure and Medium Pressure
cover................................................................................................ ……16
3.7
…………
Installation of the separate idle...………………………………
……17
3.8
…………
Assembly of the safety valve...…………………………………..
……17
3.9
…………
Installation of the safety valve...……………………………….
……19
Installation of the 3rd stage lever –CNG …………………..
……19
3.10 …………
Page 3 of 32
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Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
DT_IS_RRM-006.01-E
09/10/2009
3.11 …………. Installation of the movable core cut-off of the electrovalve ….. ……20
3.12 …………. Installation of the electrovalve sleeve …...……………………... ……20
3.13 …………
Installation of the separate idle channel screw top ………….
……21
3.14 …………. Installation of the electrovalve .……………………………...
……21
3.15 …………. Installation of the 3rd stage diaphragm ………………………...
……22
3.16 …………. Installation of the Low Pressure cover.………………………… ……23
3.17 …………. Installation of the sensitivity register………………………….
……23
3.18 …………. Installation of the bleed valve screw top ……………………….
……25
3.19 …………. Installation of the gas outlet connection …………………….
……25
3.20 …………. Installation of the water inlet/outlet connections ……………...
……26
4. ………………...
Testing procedures...…………………………………………..
Page 4 of 32
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……27
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
DT_IS_RRM-006.01-E
09/10/2009
1. MES – MEX – MEXL Regulators/Vaporizers
MES – MEX - MEXL regulators/vaporizers are, as most people know, devices which help
reduce the operating pressure and dispense the exact amount of gas needed by the system.
In order to perform a proper overhaul of the MES regulator/vaporizer, please use the overhaul
kit (code 900K02) described in the following table:
ARTICLE
900K02
1001C
1003/1
1003/2
10012C
10015B
10021B
10025B
10030B
100COM016
9002F
9003C
9003D
90017B
900COM002
900COM007
900COM014
DESCRIPTION
CNG REVIOSE 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
Full low-pressure diaphragm
6.75x1.78 O-Ring – safety valve
15.88x2.62 O-Ring – swinging arm
14.00x1.78 O-Ring – valve body
11.11x1.78 O-Ring – water connection
OVERPRESSURE VALVE PISTON
1st stage H.P. VALVE – full
1st stage DIAPHRAGM – full
QUANTITY
1
2
4
2
2
2
2
1
1
1
2
1
2
1
1
1
In order to perform a proper overhaul of the MEX - MEXL regulators/vaporizers, please use
the overhaul kit (code 900K05) described in the following table:
ARTICLE
900K05
1001C
1003/1
1003/2
10012C
10012CR
10015B
10021B
10025B
10030B
100COM016
9002F
9003C
9003D
90017B
DESCRIPTION
CNG REVIOSE KIT – electronic
1st stage cut-off valve
4x7.5 headless screw (threaded rod)
4x7.5 regular screw
movable core cut-off of the electrovalve
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
Full low-pressure diaphragm
6.75x1.78 O-Ring – safety valve
15.88x2.62 O-Ring – swinging arm
14.00x1.78 O-Ring – valve body
11.11x1.78 O-Ring – water connection
Page 5 of 32
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QUANTITY
1
2
4
1
1
2
2
2
1
1
1
2
1
2
DT_IS_RRM-006.01-E
09/10/2009
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
900COM002
900COM007
900COM014
2
OVERPRESSURE VALVE PISTON
1st stage H.P. VALVE – full
1st stage DIAPHRAGM – full
1
1
1
How to perform a proper overhaul
To perform a proper overhaul of a CNG MEI regulator/vaporizer (Fig. 2-1) it is advisable to
disassemble the device in all its components.
Fig. 2-1
The main body of the regulator (Fig. 2-2 and 2-3) must be carefully cleaned with a brush (Fig. 24 and 2-5) 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. 2-2
Fig. 2-3
Page 6 of 32
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DT_IS_RRM-006.01-E
09/10/2009
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
2.1
Fig. 2-4
Replacement of the 1st stage lever cut-off
Fig. 2-5
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).
Fig. 2.1-1
Fig. 2.1-2
Fig. 2.1-3
2. 2 Replacement of the 2nd stage lever cut-off
To replace the 2nd stage lever cut-off, pinch the top of the cut-off with two fingers (Fig. 2.2-1 /
2.2-2). When working with a MEX or MEXL regulator, please use the 10012CR cut-off included
in the 900K05 overhaul kit!!!!
Page 7 of 32
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DT_IS_RRM-006.01-E
09/10/2009
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
Fig. 2.2-1
Fig. 2.2-2
2. 3 Replacement of the movable core cut-off of the electrovalve
To replace the electrovalve cut-off, hold the movable core in place with two fingers. Then
carefully remove the cut-off with the other hand. (Fig. 2.3-1 / 2.3-2)
Fig. 2.3-1
2. 4
Fig. 2.3-2
Replacement of all O-Rings
The following pictures show all the components in which O-Rings should be replaced before the
regulator/vaporizer is reassembled.
(Fig. 2.4-1 / 2.4-2 / 2.4-3 / 2.4-5 / 2.4-6 / 2.4-7 / 2.4-8 / 2.4-9 / 2.4-10)
PLEASE MAKE SURE NOT TO DAMAGE THE RING SEAT WHILE WORKING
WITH THE SCREWDRIVER!!!
Page 8 of 32
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DT_IS_RRM-006.01-E
09/10/2009
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
Fig. 2.4-1
Separate idle register
Fig. 2.4-2
PLEASE MAKE SURE NOT TO DAMAGE THE RING SEAT WHILE WORKING
WITH THE SCREWDRIVER!!!
Fig. 2.4-3
Sensitivity register
Fig. 2.4-4
PLEASE MAKE SURE NOT TO DAMAGE THE RING SEAT WHILE WORKING
WITH THE SCREWDRIVER!!!
Fig. 2.4-5
Gas outlet connection
Fig. 2.4-6
Bleed valve screw top
Page 9 of 32
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Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
DT_IS_RRM-006.01-E
09/10/2009
PLEASE MAKE SURE NOT TO DAMAGE THE RING SEAT WHILE WORKING
WITH THE SCREWDRIVER!!!
Fig. 2.4-7
Electrovalve sleeve
Fig. 2.4-8
Water inlet/outlet connection
Fig. 2.4-9
Separate idle channel screw top
Fig. 2.4-10
PLEASE MAKE SURE NOT TO DAMAGE THE RING SEAT WHILE WORKING
WITH THE SCREWDRIVER!!!
3
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!!!
Page 10 of 32
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Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
DT_IS_RRM-006.01-E
09/10/2009
Fig. 3-1
3.1
Installation of the 1st stage lever - CNG
Before installing the 1st stage lever, make sure that the seat is clean (Fig. 3.1-1). Proceed to
install the lever as indicated in Fig. 3.1-2 / 3.1-3 shown below.
Fig. 3.1-1
Fig. 3.1-2
Page 11 of 32
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DT_IS_RRM-006.01-E
09/10/2009
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
Fig. 3.1-3
3.2 Installation of the cut-off valve on the 2nd stage lever
Put the cut-off valve into place, and with a punch, insert it in its operating seat. Make sure that
the cut-off does not get scratched!!! (Fig. 3.2-1 / 3.2-2 / 3.2-3 / 3.2-4)
Fig. 3.2-1
Fig. 3.2-2
Fig. 3.2-3
Fig. 3.2-4
Page 12 of 32
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DT_IS_RRM-006.01-E
09/10/2009
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
3.3
Installation of the 2nd stage lever - CNG
Before installing the 2nd stage lever, make sure that the seat is clean (Fig. 3.3-1). Insert the pin in
its housing as shown in Fig. 3.3-2, making sure it is in the correct position. Mount the lever as
indicated in Fig. 3.3-3 and 3.3-4.
3.4
Fig. 3.3-1
Fig. 3.3-2
Fig. 3.3-3
Fig. 3.3-4
Installation of the H.P. (High Pressure) valve and swinging arm
To install the H.P. valve and the swinging arm, please follow Fig. 3.4-1 / 3.4-2 very carefully.
MAKE SURE THAT THE VALVE IS INSTALLED IN THE CORRECT POSITION!!!
Page 13 of 32
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DT_IS_RRM-006.01-E
09/10/2009
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
Fig. 3.4-1
Fig. 3.4-2
The following pictures illustrate the different steps to follow in order to install a H.P. valve
Fasten the H.P. valve using a 50 Nm torque wench
Fig. 3.4-3
Fig. 3.4-4
Fig. 3.4-5
Fig. 3.4-6
Page 14 of 32
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DT_IS_RRM-006.01-E
09/10/2009
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
Fig. 3.4-7
Fig. 3.4-8
Fig. 3.4-9
Fig. 3.4-10
3.5 Installation of the H.P. (High Pressure) and M.P. (Medium Pressure) diaphragm –
CNG
Fig. 3.5-1 shows how to install the H.P and M.P. diaphragm.
Insert the H.P and M.P. diaphragm hook in
the lever.
With a finger, apply a slight amount of
pressure to the lever, until it lifts up
completely. This will allow the diaphragm
hook to fasten to it more easily.
FAILURE TO FASTEN THE HOOK TO
THE LEVER WILL PREVENT THE
REGULATOR FROM WORKING
PROPERLY!
Fig. 3.5-1
Page 15 of 32
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DT_IS_RRM-006.01-E
09/10/2009
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
Insert the 1st stage lever pin in the hole on the diaphragm, as shown in Fig. 3.5-2
Fig. 3.5-2
Fig. 3.5-3 / 3.5-4 / 3.5-5 and 3.5-6 illustrate the proper steps to follow when installing the 1st
stage flat.
Fig. 3.5-3
Fig. 3.5-4
Fig. 3.5-5
Fig. 3.5-6
Page 16 of 32
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DT_IS_RRM-006.01-E
09/10/2009
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
CAUTION: THE SPRING WASHER MUST BE INSTALLED AS SHOWN
IN FIG. 3.5-5
3.6
Installation of the H.P. (High Pressure) and M.P. (Medium Pressure) cover
To install the H.P. and M.P. cover (Fig. 3.6-1 / 3.6-2 / 3.6-3 and 3.6-5), apply a small amount of
pressure to the regulator with your hand (Fig. 3.6-4), so that the springs get slightly compressed.
Then secure the 10 hexagonal screws into place using a size 8 T-wrench. Fasten the screws using
a 5.5 Nm torque wrench.
Fig. 3.6-1
Fig. 3.6-2
Fig. 3.6-3
Fig. 3.6-4
Page 17 of 32
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Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
Fig. 3.6-5
3.7
Installation of the separate idle
To install the separate idle, insert it in the housing as shown in Fig. 3.7-1 and 3.7-2, then screw it
down.
Fig. 3.7-1
3.8
Fig. 3.7-2
Assembly of the safety valve
Fig. 3.8-1 / 3.8-2 / 3.8-3 / 3.8-4 / 3.8-5 / 3.8-6 and 3.8-7 illustrate the proper steps to follow when
assembling the safety valve.
PLEASE MAKE SURE TO FOLLOW THESE STEPS VERY CAREFULLY!!!
Page 18 of 32
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DT_IS_RRM-006.01-E
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Technical Directions
for the Overhaul of
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Regulators/Vaporizers
Fig. 3.8-1
Fig. 3.8-2
Fig. 3.8-3
Fig. 3.8-4
Fig. 3.8-5
Fig. 3.8-6
Page 19 of 32
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Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
Fig. 3.8-7
3.9
Installation of the safety valve
Fig. 3.9-1 / 3.9-2 / 3.9-3 and 3.9-4 illustrate the proper steps to follow when assembling the
safety valve. Make sure to insert the O-Ring in its housing, as shown in Fig. 3.9-2. Fasten the
safety valve at 2 Nm.
Properly insert the O-Ring in its seat
Fig. 3.9-1
Fig. 3.9-2
Page 20 of 32
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Technical Directions
for the Overhaul of
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Regulators/Vaporizers
Fig. 3.9-3
Fig. 3.9-4
3.10 Installation of the 3rd stage lever - CNG
Fig. 3.10-1 / 3.10-2 / 3.10-3 and 3.10-4 illustrate the proper steps to follow when installing the
3rd stage lever.
Fig. 3.10-1
Fig. 3.10-2
Fig. 3.10-3
Fig. 3.10-4
3.11 Replacement of the movable core cut-off of the electrovalve
Insert the cut-off in its housing and while pressing it down, turn the movable core (Fig. 3.11-1
and 3.11-2).
Fig. 3.11-1
Fig. 3.11-2
Page 21 of 32
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Technical Directions
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Regulators/Vaporizers
3.12
DT_IS_RRM-006.01-E
09/10/2009
Installation of the electrovalve sleeve
Fig. 3.12-1 / 3.12-2 / 3.12-3 and 3.12-4 illustrate the proper steps to follow when installing the
electrovalve sleeve. Use a size 17 wrench and fasten at 3 Nm.
Fig. 3.12-1
Fig. 3.12-2
Fig. 3.12-3
Fig. 3.12-4
3.9 3.13 Installation of the separate idle channel screw top
Install the separate idle channel screw top by following the steps illustrated in Fig. 3.13-1 and
3.13-2. Use a size 3 hexagonal wrench.
Page 22 of 32
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Technical Directions
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Regulators/Vaporizers
Fig. 3.13-1
3.14
Fig. 3.13-2
Installation of the electrovalve
To install the electrovalve, follow the steps illustrated in Fig. 3.14-1 / 3.14-2 / 3.14-3 and 3.14-4:
Fig. 3.14-1
Fig. 3.14-2
Fig. 3.14-3
Fig. 3.14-4
3.15 Installation of the 3rd stage diaphragm
Fig. 3.15-1 and 3.15-2 illustrate how to properly install a 3rd stage diaphragm.
Insert the Low-Pressure diaphragm hook in
the lever.
Lever.
FAILURE TO FASTEN THE
DIAPHRAGM HOOK WILL PREVENT
THE REGULATOR FROM WORKING
PROPERLY!
Page 23 of 32
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DT_IS_RRM-006.01-E
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Fig. 3.15-1
Make sure that the hook is properly fastened,
as shown in the picture.
Fig. 3.15-2
3.16
Installation of the Low Pressure (L.P.) cover
To properly install the L.P. cover, please follow the steps illustrated in fig. 3.16-1 / 3.16-2 / 3.163 and 3.16-4.
Fig. 3.16-1
Fig. 3.16-2
Fig. 3.16-3
Fig. 3.16-4
Page 24 of 32
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Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
3.17
DT_IS_RRM-006.01-E
09/10/2009
Installation of the sensitivity register
To properly install the sensitivity register, please follow the steps illustrated in fig. 3.17-1 / 3.172 / 3.17-3 / 3.17-4 / 3.17-5 and 3.17-6
Fig. 3.17-1
Fig. 3.17-2
Grease the end of the spring to be inserted into the housing, as shown in Fig. 3.17-4 / 3.17-5 and
3.17.6. Insert the spring (Fig. 3.17-3).
Fig. 3.17-3
Fig. 3.17-4
The spring has been properly installed
Page 25 of 32
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Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
Fig. 3.17-5
DT_IS_RRM-006.01-E
09/10/2009
Fig. 3.17-6
In MEX and MEXL regulators/vaporizers, a stopper must be placed on the register spring (Fig.
3.17-7 and 3.17-8). The stopper is placed on the sensitivity register.
3.18
Fig. 3.17-7
Fig. 3.17-8
Fig. 3.17-9
Fig. 3.17-10
Installation of the bleed valve screw top
To install the bleed valve screw top, please follow the directions illustrated in Fig. 3.18-1 and
3.18-2.
Page 26 of 32
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Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
Fig. 3.18-1
3.19
DT_IS_RRM-006.01-E
09/10/2009
Fig. 3.18-2
Installation of the gas outlet connection
To install the gas outlet connection, please follow the directions illustrated in Fig. 3.19-1 and
3.19-2. The direction in which the connection is installed may vary, according to necessity.
Fig. 3.19-1
Fig. 3.19-2
3.20 Installation of the water inlet/outlet connections
To install the water inlet/outlet connections, please follow the directions illustrated in Fig. 3.20-1
/ 3.20-2 and 3.20-3. Fasten the connection with a size 17 wrench.
Fig. 3.20-1
Fig. 3.20-2
Page 27 of 32
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Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
DT_IS_RRM-006.01-E
09/10/2009
Fig. 3.20-3
4
Testing Procedures
To make sure that all components have been installed correctly, perform the following testing
procedures. You will need:





A threaded T-joint, to be used in combination with the pressure gauge
A valve
1 pressure gauge (min. 12-BAR)
CNG joints
Hoses, to connect the components
Fig. 4
Page 28 of 32
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DT_IS_RRM-006.01-E
09/10/2009
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
1
2
Connect the regulator/vaporizer to a compressed air circuit.
Fig. 4-1
Fig. 4-2
Fig. 4-3
Fig. 4-4
Energize the 12-Volt coil
Fig. 4-5
3
Fig. 4-6
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.
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Technical Directions
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MES – MEX – MEXL
Regulators/Vaporizers
DT_IS_RRM-006.01-E
09/10/2009
Slowly unscrew the sensitivity register, until
the air flow coming out of the gas outlet
connection increases.
Fig. 4-7
4
Separate idle test: check that the sensitivity register is tightly fastened. Slowly unscrew
the separate idle: the amount of air coming out of the gas outlet connection should be
slowly increasing (Fig. 4-8 e 4-9). Do not close the separate idle register.
Slowly unscrew the separate idle until the amount of air coming out of the gas outlet
connection increases.
5
Fig. 4-8
Fig. 4-9
After performing the testing procedures listed above, close the feed valve in the air
compressor and disconnect the coil from the power supply (Fig. 4-10). Unscrew the airfeed connection from the regulator/vaporizer (Fig. 4-11). After 3 minutes, feed power to
the coil again. If the electrovalve appears to be working properly when the coil is
connected to the power supply (Fig. 4-12) and the regulator is not leaking, a small
amount of air should come out of the gas outlet and gas inlet connections.
Page 30 of 32
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DT_IS_RRM-006.01-E
09/10/2009
Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
Fig. 4-10
Fig. 4-11
When the clamps are connected to the coil, a
small amount of air should come out of the
gas outlet and gas inlet connections.
Fig. 4-12
Page 31 of 32
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Technical Directions
for the Overhaul of
MES – MEX – MEXL
Regulators/Vaporizers
DT_IS_RRM-006.01-E
09/10/2009
REASSEMBLED
REGULATOR/VAPORIZER
Page 32 of 32
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