SERVICE BULLETIN

TOPIC: IDENT NO: SUPERSEDES: DATE: SUBJECT: Mooney Fuel Regulators MODELS AFFECTED: VHP GSI/GL/LT Fuel System 9-2916 New April 15, 2003

INTRODUCTION
Mooney regulators are now used on select VHP engines. The new regulator will be standard equipment on all GSI, GL, and LT engines running on pipeline quality or 900 Btu field gas. It is currently not used with GLD, GSID or AFM equipped engines. The new regulator provides improved control and ease of maintenance.

diaphragm is closed tightly against the throttle plate. The pressure differential across the outlet half of the diaphragm adds to the spring force in closing the valve. As demand for flow occurs in the downstream system, the outlet pressure drops causing the pilot valve to open and start bleeding pressure out of the spring case faster than it can enter through the cartridge restrictor, resulting in a reduction of pressure above the diaphragm (see Figure 2). This allows the inlet pressure to progressively lift the main valve diaphragm off the throttle plate, opening the valve and satisfying the demand for flow in the downstream system.
PILOT SENSE CONNECTION PILOT SUPPLY RESTRICTOR CONTROL PRESSURE

PRINCIPLES OF OPERATION
The Mooney regulator system utilizes a pilot that controls a main valve (see Figure 1 and Figure 3). The pilot assembly features a removable cartridge and a 10 micron gas filter. The main valve is a simple design that uses few parts. These features make the regulator assembly easy to maintain.

PILOT SENSE CONNECTION PILOT PILOT SUPPLY RESTRICTOR PILOT VALVE PILOT LOADING CONNECTION

PILOT LOADING CONNECTION

MAIN VALVE PILOT OUTLET CONNECTION OUTLET DIAPHRAGM

INLET

PILOT OUTLET CONNECTION OUTLET

INLET

Figure 2. Pressure Reducing Configuration Fully Open

Figure 1. Pressure Reducing Configuration Fully Closed

When demand for flow ceases or is reduced, the downstream pressure increases causing the pilot valve

At no flow, when the outlet pressure is greater than the set point of the pilot, the pilot valve is closed and full inlet pressure loads the spring case through the pilot loading connection. In this condition the main
WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

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valve to close. Inlet pressure continues to pass through the restrictor until the control pressure equals the inlet pressure. The spring force, plus the pressure differential across the outlet half of the main valve diaphragm, closes the diaphragm against the throttle plate, shutting off the flow.

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WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

Service Bulletin No. 9-2916

PILOT OUTLET CONNECTION

PILOT SENSE CONNECTION

PILOT INLET (SUPPLY) CONNECTION

CARTRIDGE

FIXED RESTRICTOR ORIFICE OUTLET

VENT MAIN VALVE PILOT PILOT LOADING CONNECTION

FILTER

INLET

Figure 3. Inline Regulator (Left Bank)

MAINTENANCE SCHEDULE
1. Once a year replace seals, O-rings, diaphragms and filter element (see Table 1 and Table 2).
INSIDE DIAMETER 0.052 IN. (1.3 MM) ORIFICE

2. Inspect and clean fixed restrictor orifice located in pilot inlet supply connection (see Figure 3 and Figure 4). Orifice inside diameter is 0.052 in. (1.3 mm) (#55 drill). NOTE: Pilot parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of inspection and replacement of parts depends on severity of service conditions and/or the requirements of local, state, and federal regulations. Be certain that the name plates are updated to accurately indicate any field changes in equipment, materials, service conditions, or pressure settings. 3. Inspect all other components (replace as needed).

Figure 4. Fixed Restrictor Orifice

REPLACEMENT SERVICE PARTS AND KITS

Table 1. Component Assemblies P/N DESCRIPTION
214172 489668 214174 214171 214171A 214175 Pilot Cartridge Filter Main Valve (RB) Main Valve (LB) also used on inline engines Fixed Restrictor Orifice

Table 2. Service Part Kits P/N

489669

DESCRIPTION

Pilot Maintenance Kit (Pivot Assembly Oring, Diaphragm, Closing Cap O-ring, Adjusting Assembly O-ring) Cartridge Assembly Maintenance Kit (Bottom Cap O-ring, Plug and Stem Assembly, Orifice O-ring, Lower Body Insert O-ring, Upper Body Insert O-ring, Stem O-ring) 1.5 in. Main Valve Maintenance Kit (Diaphragm and Body Seal) 1.5 in. Main Valve Overhaul Kit (Low Differential Main Spring, Diaphragm, Throttle Plate, Body Seal) Type 30A Filter Maintenance Kit (Element and O-ring)

489667

489670 489671 489666

Table 3. Mooney Regulator Fuel Pressures ENGINE MODEL

F2895GSI; F3521GSI; L5790GSI; L7042GSI; P9390GSI F3524GSI; L5794GSI; L7044GSI F2895GL; F3521GL; L5790GL; L7042GL; F9390GL L5794LT; L5774LT

RECOMMENDED NATURAL GAS SUPPLY PRESSURE TO ENGINE MOUNTED REGULATOR

24 - 50 psig (165 - 345 kPa) 24 - 50 psig (165 - 345 kPa) 38 - 60 psig (262 - 414 kPa) 43 - 60 psig (296 - 414 kPa)

MAXIMUM NATURAL GAS SUPPLY PRESSURE TO ENGINE MOUNTED REGULATOR

75 psig (517 kPa) 75 psig (517 kPa) 75 psig (517 kPa) 75 psig (517 kPa)

REGULATOR ADJUSTMENTS
The Mooney regulators were designed to track similar to the previous Fisher regulator. The gas/air setting and carburetor adjustments will remain the same as those used with the Fisher regulator. Mooney regulators require specific supply pressures depending on engine model (see Table 3). The gas over air adjustment is controlled by adjusting the stem screw and lock nut located at the bottom of the pilot assembly. Turning the stem screw clockwise will increase spring tension increasing the gas/air. Turning the screw counterclockwise will reduce spring tension and reduce the gas/air setting. Initial setting is a stem length of approximately 2.75 in. (6.98 cm) measured from adjuster housing fitting (see Figure 19).

NOTE: A spare cartridge may be installed and the regulator returned to service if time is a factor. Make sure the stem O-ring is still in place in the pilot body before installing the new cartridge. If the O-ring was removed, install a new O-ring over the stem of the cartridge assembly prior to installing it in the pilot body (see Figure 5 and Figure 6). 1. Depressurize pilot and main valve. Unscrew and remove cartridge (see Figure 5).
CARTRIDGE

PILOT
DISASSEMBLE PILOT

WARNING
Before disassembly make sure the regulator and main valve have been isolated from the process by closing block valves on the inlet and outlet sides of each component. Safely release pressure and process fluid from the valve body and pilot system. Failure to properly complete these steps may result in personal injury and/or property damage.
Figure 5. Cartridge Assembly

2. Remove stem O-ring from pilot body using suitable tool (a paper clip works well). Do not scratch O-ring groove (see Figure 6).

NOTE: The loading and inlet ports are interchangeable with one another.
LOADING INLET

OUTLET

RETAINER PLUG

INLET LOADING

OUTLET

STEM O-RING

5/16 IN.-18 UNC CAPSCREW

Figure 6. Stem O-ring

3. Remove bottom cap from cartridge body and remove internal parts. Use a heavy paper clip or 0.045 in. (1.14 mm) diameter wire to push out orifice assembly (pilot valve). Do not damage Oring sealing surface of body cartridge (see Figure 7).
CARTRIDGE BODY

LOCK NUT

SPRING ADJUSTER STEM

Figure 8. Pilot Spring Barrel

7. Thread 5/16 in. - 18 UNC capscrew into pivot and pull pivot and lever assembly out of pilot body (see Figure 9).
5/16 IN.-18 UNC CAPSCREW

BOTTOM CAP ASSEMBLY ORIFICE ASSEMBLY

Figure 7. Cartridge Assembly

4. Loosen lock nut on spring adjuster stem. Unscrew adjuster stem. Spring tension will release as stem is unscrewed (see Figure 8). 5. Remove retainer plug located below outlet port (see Figure 8). 6. Remove one 5/16 in. - 18 UNC capscrew that secures spring case to pilot body (see Figure 8).

Figure 9. Pivot And Lever Assembly Removal

8. Remove remaining capscrews that secure spring case to pilot body. Separate spring case from pilot body (see Figure 10).

PILOT BODY

ASSEMBLE PILOT NOTE: Use Parker Super O-Lube or an equivalent silicone based lubricant on all O-rings in the pilot assembly. 1. Apply Parker Super O-Lube and slide O-ring onto pivot and lever assembly. Apply Lubriplate No. 105 petroleum grease to roll pin and lever (see Figure 13).
ROLL PIN

SPRING CASE

Figure 10. Spring Case And Pilot Body

9. Disconnect line connections and remove pilot body (see Figure 11).
PILOT BODY LEVER O-RING

Figure 13. Pivot And Lever Assembly

2.

Install pilot diaphragm with convex side toward diaphragm plate and main spring. Secure with nut and washer. Tighten to 5 - 6 ft-lbs (6.8 - 8.2 N m). Do not overtighten, overtightening will distort the pilot diaphragm (see Figure 14).
DIAPHRAGM PLATE NUT WASHER

Figure 11. Pilot Body

10. Remove diaphragm assembly from body. Remove retaining nut and remaining components. Inspect all parts for wear or damage (see Figure 12).
RETAINING NUT DIAPHRAGM DIAPHRAGM RETAINER DIAPHRAGM

Figure 14. Pilot Diaphragm

3. Thread 5/16 in. - 18 UNC capscrew into pivot then push pivot and lever assembly into pilot body. A guide pin located at the bottom assures pivot and lever assembly is correctly oriented in body. Remove capscrew when complete (see Figure 15).

Figure 12. Diaphragm Assembly

SPRING WASHER

5/16 IN.-18 UNC CAPSCREW

GUIDE PIN NOTCH

Figure 15. Pivot And Lever Assembly

Figure 17. Diaphragm Spring Washer

4. Install retainer plug into body. Plug should be flush with body when installed correctly (see Figure 8). 5. Slide diaphragm assembly onto lever. Align diaphragm with pivot and lever assembly. Lubrication of pivot pin is not required (see Figure 16).
LEVER

7. Place spring case on pilot body (see Figure 18). Vent connection should face down when regulator is mounted on engine. This allows condensation to drain away instead of accumulating and possibly freezing. 8. Secure spring case to pilot body with cap screws. Tighten in a criss cross pattern to 5 ft-lbs (6.8 N m) (see Figure 18). 9. Install main spring (brown) into spring case. NOTE: The top of the main spring will be almost 2.0 in. (5.0 cm) below the spring case when fully installed.
SPRING CASE MAIN SPRING

DIAPHRAGM

Figure 16. Diaphragm Installation

6. Place spring washer onto diaphragm plate. Lubricate spring washer with Lubriplate No. 105 or petroleum grease to hold in position (see Figure 17). Washer prevents main spring from binding on diaphragm assembly when compressed.

VENT

Figure 18. Spring Case

10. Install O-ring on spring adjuster fitting (see Figure 19). Screw adjuster stem out to relieve spring pressure during installation. 11. Install adjuster fitting in body. Turn adjuster stem until it measures 2.75 in. (6.98 cm) from adjuster fitting. Tighten lock nut (see Figure 19 and Figure 20).

2.75 IN. 6.98 CM

STEM O-RING O-RINGS

ADJUSTER STEM O-RING

BODY INSERT

Figure 19. Spring Adjuster Assembly

ADJUSTER FITTING

BACK-UP WASHER ORIFICE O-RING

ORIFICE

PLUG AND STEM ASSEMBLY LOCK NUT ADJUSTER STEM

Figure 20. Spring Adjuster

NOTE: A spare cartridge may be installed and the regulator returned to service if time is a factor. Make sure the stem O-ring is still in place in the pilot body before installing the new cartridge. If the O-ring was removed, install a new O-ring over the stem of the cartridge assembly prior to installing it in the pilot body (see Figure 5 and Figure 6). 12. Assemble cartridge by placing O-ring on bottom cap, then install return spring, orifice spring, stem guide, plug and stem, orifice and O-ring, and backup washer (see Figure 21).

STEM GUIDE RETURN SPRING

ORIFICE SPRING

O-RING

BOTTOM CAP

Figure 21. Cartridge Assembly

13. Install bottom cap assembly into body insert. Return spring will force orifice into position as cap assembly is screwed into body insert (see Figure 22). Tighten to 5 ft-lbs (6.8 N m).
BOTTOM CAP ASSEMBLY

CARTRIDGE

BODY INSERT

Figure 24. Cartridge Assembly

O-RING O-RING

FILTER MAINTENANCE
The filter element is subject to plugging and must be inspected and replaced as necessary. The frequency of inspection and replacement of the filter element depends on severity of service conditions and the length of time in service.

Figure 22. Cartridge Body and Cap Assembly

14. Press stem against hard surface to verify it moves freely and returns to extended position. Stem should extend 0.32 in. (8.1 mm) from body insert (see Figure 23).

WARNING
Before disassembly make sure the regulator and filter have been isolated from the process by closing block valves on the inlet and outlet sides of the regulator. Safely release pressure and process fluid from body and pilot system. Failure to properly complete these steps may result in personal injury and property damage. DISASSEMBLE FILTER

STEM

0.32 IN. (8.1 MM)

BODY INSERT

1. Depressurize main valve and filter. Remove filter housing (see Figure 25).

Figure 23. Cartridge Stem Height

15. Apply Parker Super O-Lube onto stem.

and slide O-ring

16. Verify O-ring is lubricated and in position on stem. Install cartridge into pilot body. Tighten to 5 ft-lbs (6.8 N m). Do not overtighten (see Figure 6 and Figure 24).

FILTER HOUSING

Figure 25. Filter Assembly

2. Inspect filter element and replace if necessary (see Figure 26).

FILTER

FILTER HOUSING FILTER HOUSING

Figure 28. Filter Assembly

Figure 26. Filter Element

MAIN VALVE MAINTENANCE

Main valve parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of inspection and replacement of parts depends on severity of service conditions and/or the requirements of local, state, and federal regulations. Be certain that the name plates are updated to accurately indicate any field changes in equipment, materials, service conditions, or pressure settings.

3. Remove filter O-ring (see Figure 27). A paper clip or other suitable tool can be used. Inspect for defects and replace if necessary.

WARNING
Before disassembly make sure the main valve has been isolated from the process by closing block valves on the inlet and outlet sides of the main valve. Safely release pressure and process fluid from body and pilot system. Failure to properly complete these steps may result in personal injury and property damage. DISASSEMBLE MAIN VALVE 1. Disconnect pilot loading line from pilot (see Figure 29). 2. Remove two 5/16 in. - 18 UNC capscrews that secure main valve bracket to pilot (see Figure 29). 3. Loosen valve cover capscrews in a criss-cross pattern. The main spring will lift the cover as capscrews are removed (see Figure 29).

O-RING

Figure 27. Filter Fitting

ASSEMBLE FILTER 1. Lubricate O-ring with Parker Super O-Lube (or equivalent petroleum based lubricant) and install in filter fitting. NOTE: If the filter guide is removed, apply a small quantity of Loctite (or equivalent) to the threaded area and screw hand tight into filter body. 2. Lubricate threads of filter housing with Lubriplate (or equivalent petroleum based lubricant). 3. Place filter element into housing. Screw housing into fitting and tighten to 5 ft-lbs (6.8 N m). Do not overtighten (overtightening an O-ring joint will not improve seal). Element will guide itself into position regardless of orientation.

VALVE COVER

OUTSIDE RIB DOWNSTREAM

PILOT LOADING LINE

5/16 IN.-18 UNC CAPSCREWS

CAPSCREW

Figure 29. Pilot Loading Line

Figure 31. Throttle Plate

4. Remove main spring, diaphragm, and cover (see Figure 30 and Figure 33). Inspect parts for wear.
MAIN SPRING

5. Remove and inspect nitrile body seal for wear or damage (see Figure 32).

COVER

DIAPHRAGM

NITRILE BODY SEAL

Figure 30. Main Valve Cover

Figure 32. Nitrile Body Seal

NOTE: Shutoff occurs at the downstream outside rib located on the throttle plate. The outside edge of the downstream (outlet) portion is the primary shutoff surface and should be inspected more closely for wear and damage. Nicks and/or wear on support ribs will usually not affect shutoff (see Figure 31).

6. Inspect all parts for wear and damage. Replace as necessary. CLEANING MAIN VALVE 1. Do not clean body seal grooves with sharp metal tools. Bottom of groove and mating surface of adjacent parts must have smooth finish to prevent leakage.

ASSEMBLE MAIN VALVE

COVER

1. Install nitrile body seal (see Figure 34 and Figure 34).

BOSS

MAIN SPRING

DIAPHRAGM NITRILE BODY SEAL

Figure 34. Nitrile Body Seal

THROTTLE PLATE

NOTE: If the inlet sides of the throttle plate and diaphragm are in better condition than the outlet sides, the entire assembly can be rotated 180 degrees (outlet to inlet) to renew the shutoff capability (see Figure 35).
OUTLET SIDES

NITRILE BODY SEAL

INLET BODY

INLET SIDES FLOW DIRECTION

OUTLET

Figure 35. Throttle Plate

Figure 33. Left Bank/Inline Main Valve Configuration

2. Place spring on diaphragm. Spring case (cover) fits on top of spring. Do not lubricate diaphragm sealing surface (see Figure 33 and Figure 36).

NOTE: The cover plate should be positioned so the boss is located at the outlet (downstream) side of the fuel line (see Figure 33 and Figure 38). NOTE: The nitrile rubber body seal can swell after disassembly of a main valve that has been in service (due to gas permeating the nitrile rubber). This does not necessarily mean it must be replaced. However, before placing the seal back into service inspect for defects. Set seal aside for several hours and it will gradually return to normal size. Placing seal(s) on ice will speed the process considerably.

MAIN SPRING

5. Tighten spring case cover capscrews in increments using a criss-cross pattern (see Figure 38 and Figure 39). Tighten to 20 ft-lbs (27 N m). 6. Install pilot loading line (see Figure 38).
BRACKET COVER CAPSCREW

COVER

DIAPHRAGM

Figure 36. Main Valve Cover

NOTE: The cover plate should be positioned so the boss is located at the outlet (downstream) side of the fuel line (see Figure 33 and Figure 37). 3. Place spring case cover assembly and bracket on main valve and secure with four capscrews (see Figure 38). Do not fully tighten.
COVER CAPSCREW BOSS OUTLET

PILOT LOADING LINE

5/16 IN.-18 UNC CAPSCREW

Figure 38. Inline/Left Bank Main Valve

BRACKET INLET

FLOW DIRECTION

Figure 37. Inline/Left Bank Main Valve

4. Secure opposite end of bracket to pilot body with 5/16 in. - 18 UNC capscrews (see Figure 38). Lubricating or overtightening valve cover capscrews can damage the diaphragm. Disregarding this information could result in severe engine damage.

COVER CAPSCREW PILOT LOADING LINE

CAUTION

Figure 39. Right Bank Regulator

7. Reconnect pilot system. Follow approved start up procedures when returning to operation.

CAUTION

Do not replace the studs or nuts with any

capscrew or stud and nut combination that does not have an SAE Grade 7 or ASTM Grade B7 rat- ing. Disregarding this information could result in severe

engine damage.