I MANUALE INSTALLAZIONE E REGOLAZIONE GB INSTALLATION AND ADJUSTMENT MANUAL E MANUAL DE INSTALACIN Y REGULACIN

RIDUTTORI TN1 B SIC TN1 B SIC REGULATORS REDUCTORES TN1 B SIC

Schemi tecnici

GB

Technical drawings

Esquemas tcnicos

I
Fig. 1

Fig. 2 LANDI RENZO S.p.A.

2/36

GB

Legend Specification

Operation

GB

KEY (FIG. 1) A Gas outlet tube; B Idling supply tube (the tube is not installed on the reduction unit but is supplied separately as its use is recommended only when there is a carburation vacuum in the main tube from idling supply to off-idle. If used, always line it up in the same direction as the gas outlet tube; C Sensitivity regulator; D Idling electrovalve positive contact; E Idling regulator; F High pressure electrovalve; G Gas inlet joint; H Fluid heating joint; I cap 2nd stage. 1. SPECIFICHE TECNICHE An electronically controlled device which reduces the pressure of methane allowing a regular flow of gas for every requirement of the engine. It is fitted with three stages of methane reduction which ensures stability at both high and low feed pressures, and with a high pressure electrovalve upstream of the 1st stage. Heat absorption, carried out by elements of the reduction unit heated by liquid from the cooling circuit of the engine, prevents the methane freezing in the pressure fall stage. The flow of gas necessary for the engine at idle is at positive pressure from the second stage and is distributed via a gas conduit separate from the main flow. Included is an electronic device for starting with a built-in safety system which closes the gas electrovalve in cases where the engine is switched off, even accidentally. SPECIFICATIONS: Type of reduction unit: 3 stage with electronic starting device and positive pressure idling. Use: autodrive Type of fluid: CNG (Compressed methane gas) Body: GDALSI 13 UNI 5079 Heating: liquid from engine cooling circuit Test pressure: 300 bar Inlet pressure: 220 bar 1st stage adjustment pressure: 3,5-4 bar 1,5 bar 2nd stage adjustment pressure: Power supply: 12 V c.c. High pressure electrovalve coil power : 20W Idling electrovalve coil power: 18W

2. FUNCTIONING OF THE REDUCTION UNIT (Fig. 2) With the electrovalve (1) open, the methane gas enters the 1st stage chamber (4). The pressure exerted by the gas on the walls of the chamber dilates the membrane (8), overcoming the resistance of the spring (9). The membrane (8) attached to the lever (3) acts on the 1st stage valve (2), creating a pressure equilibrium. From the 1st stage chamber (4), the gas passes to the 2nd stage (11)and the flow is delivered by the pressure exerted by the gas on the membrane (10), regulating the opening and closing of the valve (13). Depressurisation of the engine activates an axial movement of the 3rd stage membrane (6) which, connected to the lever (5), causes the opening of the valve (7). Through the outlet (19), the gas enters the engine. Sealing of the valve (7) is obtained by correct calibration of the spring (14). The starting and idling device comprises an electrovalve (17) controlled by an electronic device. The needle (15) is displaced and frees the jet (18), the gas from the second stage (11) exits, thus permitting the engine to function at idling speed. If the engine is switched off, the coil is deactivated and the needle (15) closes the outlet jet (18). Adjustment of the idling speed is carried out via the adjuster (16). When the engine is started, the electronic device activates the coil (17), the needle (15) frees the jet (18) and allows the amount of gas necessary for starting to pass through.

LANDI RENZO S.p.A. Installationand adjustament manual TN1 B SIC

14/36

GB

Operation
In practice the methane enters the stage. From the effect of pressure, a force is generated which pushes the plate upwards, but there is a spring above it\: the opposing force pushes the plate down and with corresponding force generates a force in the stage of 4.5 bar (approximately), the position of the lever shown in figure 5 closes the gas inlet orifice (in the rim).

Details: the following photographs show the route of the methane with blue arrows A, with red arrows B the forces exerted and with yellow arrows C the internal channels for the passage of the methane. Figure 3 shows the TN1B SIC methane reduction unit; the blue arrows show the flow of methane at the inlet (on the left) and outlet (at the top). It is a 3-stage reduction unit. That is to say, it consists of two high-pressure stages (the first reduces to 4.5 bar, the second to 1.5 bar) and a final stage which operates at low pressure.

A A A A

Fig. 5 The transit channel through which the methane passes to change stage is shown by the white arrow on the left in figure 6. Fig. 3 Figure 4 shows the 1st stage. The pressure here is kept constant by the strength of the spring which presses down by the effect of the pressure below the membrane, which pushes upwards (where the cover is located). Under the plate note how the methane enters the 1st stage (at the rim) and progresses to the second (blue arrows).

B Fig. 6 In the second stage, the pressure is lowered still further to 1.5 bar, again by means of a spring opposing a lever figure 7 (arrow on right). When methane enters, the plate indicated by the arrow on the left swells, then generates a force upwards, which is however opposed by a downward force generated by the spring shown in figure 7. Fig. 4

LANDI RENZO S.p.A. Installationand adjustament manual TN1 B SIC

15/36

GB

Operation
The flow of methane in the functioning of the engine at idling speed is effected by means of the small tube indicated in figure 10 with a yellow arrow. The lever to which the membrane is fixed is indicated by the large arrow. C

A A Fig. 7 This generation of two opposing forces results in the lever closing the methane inlet orifice shown in figure 9 (the blue arrows show the circulation of methane passing from the second stage to channel leading to the third stage). Seal is ensured by valve B. A

Fig. 10 Regulation of the quantity (which is possible with the SIC reduction unit) is carried out by means of the regulator located on the front of the reduction unit.

A B

B C Fig. 8 Figure 9 also clearly shows the passage of methane from the inlet to the third stage channel and to the idling tuble. A Fig. 11 A

Fig. 9

LANDI RENZO S.p.A. Installationand adjustament manual TN1 B SIC

16/36

Operation
By screwing in (reduction of the quantity of gas) or unscrewing of the regulator (increase in the quantity of gas) the conical seat of the regulator allows the gas to pass through the larger jet (coming from the channel shown by the yellow arrow in figure 11) and to proceed to the small jet (see blue arrow) which connects with the idling speed tube. The seal of the regulator is effected with an O-ring.

GB

to feed the engine. The sensitivity of the spring which supports the lever is controlled by the brass regulator located on the side of the reduction unit. In figure 16, the blue arrows show the gas flow at idle (small arrow) and off idle (larger arrow). The circle in figure 15 indicates the valve which makes a seal when the lever is closed (that is, when the depression of the engine is weak.

Fig. 14 Fig. 12 The third, low pressure, stage consists of a membrane fixed to the steel lever in figure 10 by an aluminium plate. In practice this stage is connected to the engine via the gas outlet tube which goes to the mixer, and is thus subject to depression generated within itself by the operating of the accelerator butterfly valve. A B B Fig. 15 C

B Fig. 13 Acceleration creates a force (whose vector is indicated by F in figure 13) which pushes the membrane towards the interior of the reduction unit thus, by means of the orifice below shown in figure 15, allowing the passage of the methane into the third stage and finally it is breathed out of the reduction unit towards the mixer and goes

Fig. 16

LANDI RENZO S.p.A. Installationand adjustament manual TN1 B SIC

17/36

Notices
Figure 17 shows the methane outlet tube. Figure 18 shows the pressure reducer and the feed tube to the mixer (directly on the finned body. Fig. 17

GB

3. GENERAL INFORMATION When installing the reduction unit, the following instructions must be observed. supplied with the reduction unit are the mounting brackets for locating the reduction unit in the engine compartment. These should be adapted to suit the type of compartment.

Fix with M10 screws

Fig. 19

Position of the reduction unit

A

YES

Fig. 18

Discharge cap

NO

NO

NO
Fig. 20 LANDI RENZO S.p.A. Installationand adjustament manual TN1 B SIC

18/36

GB

Notices
A thermostat valve can be used, and should be installed in the water outlet tube of the reduction unit. take care not to position the reduction unit so that the discharge cap is located above the starter motor or ignition coil; carefully clean the high pressure methane tubes before finally connecting them to the reduction unit, to avoid impurities getting into the reduction unit; ensure that when the engine is running there is no leakage from the water hoses (usually connected to the passenger compartment heating circuit); never, under any circumstances, change the position of the reduction units gas inlet assembly, since this could alter the calibration of the 1st stage valve\: this would risk hampering the passage of gas with a possible increase in pressure in the 1st stage, which could cause the safety valve to open, resulting in an escape of gas. As well as making all types of guarantee invalid, LANDI RENZO can accept no responsibility for damage caused by tampering with the above component check that the reduction unit heats up rapidly by means of the connections to the engine cooling system. Every time the engine cooling system is emptied, the level of liquid should be replenished, taking care to eliminate any air bubbles which could hamper the heating of the reduction unit. The gas outlet of the reduction unit must be connected to the mixer taking care that the connecting tube (which should be as short as possible) has no kinks or sags. Mounting brackets are supplied with the reduction unit for locating it in the engine compartment. They should be adapted to suit the position selected for mounting.

install the reduction unit in the engine compartment as close as possible to the point at which the mixer unit is installed, fixing it securely to the bodywork with the screws provided; install the reduction unit outside the compartment containing the equipment for collecting air for the ventilation and heating of the drivers compartment; install the reduction unit at a distance of not less than 150mm from the exhaust pipes and silencer. If this distance is less than the minimum stated, but more than 75mm, a sheet of metal not less than 1mm thick must be placed between the components; position the reduction unit parallel to the direction of the vehicles motion, and in a vertical position, so that it is easily accessible for adjustment and maintenance; ensure that the reduction unit is located in a position lower than the highest point of the radiator to prevent air bubbles forming in the water circuit; The reduction unit should be connected to the water of the engine cooling system or passenger cabin heating system by means of suitable hoses. Fit the T-connectors as shown in figure 22 and use the hose clips provided to secure them.

LANDI RENZO S.p.A. Installationand adjustament manual TN1 B SIC

19/36

GB

Sensitivity adjustment Thermostat valve

Fig. 22
4. ADJUSTING THE SENSITIVITY OF TN SIC REDUCTION UNITS (Fig. 1) The reduction units have already been adjusted by the manufacturer, but if any problems should be encountered such as uneven idling speed or flat spots in acceleration, we recommend checking the sensitivity of the reduction unit. The adjustment screw (C) is not used for adjusting the idling speed but only for adjusting the sensitivity of the reduction unit: unscrewing it lightens the load which the spring exerts on the third stage lever, while tightening it increases the load exerted by the spring on the second stage lever towards closing. In particular, being the idling flow, separated from the maximum, the change from the idling regime to a higher one happens without carburation flat spots which are noted particularly when accelerating very slowly (adjuster too tight) and at the same time the reduction unit remains tight and does not lose gas every time the engine is switched off (adjuster too loose). To adjust the sensitivity of the reduction unit, follow the instructions below: 1) Remove the tube which carries gas to the mixer from the gas outlet tube (A); 2) Tighten the sensitivity adjuster (C) completely; 3) Disconnect the wire leading to the idling electrovalve positive contact (D) and connect it to a +30 (battery pos.) to charge the gas reduction unit; 4) Form a bubble of soapy water over the gas outlet tube (A) and loosen the adjuster (C) until gas begins to come out of the reduction unit and inflates the bubble; 5) The moment gas begins to come out of the reduction unit, retighten the adjuster (C) until gas no longer comes out, and at this point give the adjuster an extra half-turn for safetys sake. 6) Install the sensitivity adjuster (C) protection cap to prevent tampering. An alternative, less accurate but quicker, way of adjusting the sensitivity is as follows: 1) Fully tighten the sensitivity adjuster (C); 2) Start the engine and adjust the idling speed by means of the adjuster (E) until the maximum value of CO2 is achieved; 3) Slowly undo the adjuster (C) until there is a notable variation (reduction) in the CO2 value; 4) At that moment, tighten the adjuster (C) until the CO2 value noted at point 2 is achieved. 5) Install the sensitivity adjuster (C) protection cap to avoid tampering. 6) Check that there are no carburation flat spots when accelerating slowly. After the first 500 / 1.000 Km it is advisable to check the sensitivity of the reduction unit.

LANDI RENZO S.p.A. Installationand adjustament manual TN1 B SIC

20/36

GB

Maintenance
Carbon paper White paper First imprint Nut

5. MAINTENANCE OPERATIONS REDUCTION UNIT To get the best from methane fuel, the engine should be tuned and regularly maintained. This applies both to the mechanical parts and electrical system. As well as the normal maintenanc prescribed by the vehicle manufacturer, the following procedures are recommended: every 30.000 Km check by means of the discharge cap that there is no oil or other deposits inside the reduction unit; every 100.000 Km, if any malfunction arises, carry out a general service of the reduction unit, using our service kit, following the instructions below (paragraph 7). 6. SERVICING THE REDUCTION UNIT To check correct closing of the third stage valve (self-adjusting valves only), insert a piece of white paper with a strip of carbon paper over it between the valve and its seat. The valve must reproduce an exact imprint of the rim of the valve. If this is not the case, place a screwdriver in the slot provided in the valve (without the white paper and carbon paper) and move it until a correct imprint is produced; then tighten the nut, ensuring that the valve does not move.

Carbon paper

White paper

Fig. 24

3rd stage valve replacement

Fig. 25

Calibration distance

1st stage

Fig. 23

LANDI RENZO S.p.A. Installationand adjustament manual TN1 B SIC

21/36

GB

Servicing
9. SERVICING SENSITIVITY SCREW (REFER TO FIGURE 26) Remove idling adjustment cover 114, undo bolt 74. Remove spring 77 and replace with a new one from the service package. Reassemble the spring with its pivot 76, taking care to centre it on the stud on lever 86. Replace bolt 74 after renewing O-ring 75 (OR 8.73x1.78 code no. 173007371. Adjust the sensitivity as described in the manual paragrafo 4. Refit the idling adjuster cover 114. 10. SERVICING TIGHTNESS OF GAS OUTLET JOINT Undo bolt 28. Remove joint 29 from the reduction unit and renew O-rings 30 and 44 with those supplied in the service package (OR 1715 code no. 173031371 and OR 2075 code no. 173068371. Reassemble tube 29 complete with O-ring onto the reduction unit. Secure by tightening bolt 28. 11. SERVICING IDLING ADJUSTMENT DEVICE Remove nut 67 from housing 62. Extract nut 67 complete with idling adjuster screw 69, idling adjuster knob 65 and its spring 66. From housing 62, extract spring 71 and moving needle 72. Replace O-ring 73 in moving needle 72 with the one from the service package (OR 1.5x1 code no. 173130371); reinsert the moving needle with its new O-ring in housing 62. Renew O-ring 70 on idling adjuster screw 69 with the one from the service package (OR 108 code no. 173093371. Replace nut 67 complete with all other components (position 70, 69, 67, 66, 65). Retighten nut 67 on housing 62 (torque 10 Nm). 12. SERVICING WATER JOINT Unscrew water joints 88, replace O-ring 46 with a new one (OR 112 cod. 173009371), screw in joints 88.

7. SERVICING HIGH PRESSURE ELECTROVALVE (Refer to figure 26) Undo nut 8, remove the coil 9 and undo housing 10. Sulla valvola di intercettazione 14 sostituire lOR 18 (3.68x1.78 cod. 173152381). On the interception valve 14, replace O-ring 18 (3.68x1.78 code no. 173152381). Replace the electrovalve moving needle 13 and spring 12 with the replacements in the service package. On the housing 10, replace O-ring 11 (OR 14x1.78 code no. 173151381). Reassemble all components in the original order, tighten the housing 10. Replace coil 9 and secure it with nut 8 (torque 8 Nm). 8. SERVICING 1ST STAGE (Referto figure 26) Remove 1st stage cover 57 by loosening nuts 59, noting that the cover contains the compressed spring. Remove seal 87 and spring 56, undo nut 55, remove washer 53, disc 54, membrane 52, disc 51 with O-ring 50 and housing 49. Undo bolts 31 and remove lever 34 with pivot 35. Remove 1st stage valve 36 and replace with the valve from the service kit Replace lever 34 and pivot 35 and tighten bolts 31 (torque 7 Nm). Adjust the free play between lever 34 and 1st stage valve to 0.5 mm fig. 23 using bolt 32 and locknut 33. Measure the 0.5mm free play with a feeler gauge. After adjustment, secure bolt 33 and its locknut to torque 6 1 Nm. Replace pin 49 in lever 34, replace disc 51 with Oring 50, replace membrane 52 with the one supplied in the service package. Replace disc 54, washer 53 and tighten nut 55 to torque 10 Nm. Insert spring 56, replace seal 87 with a new one from the service package. Replace cover 57, washer 109, tightening the nut 59 to torque 8 Nm.

LANDI RENZO S.p.A. Installationand adjustament manual TN1 B SIC

22/36

GB

Servicing
At the end of every maintenance operation involving dismantling and reassembly of components, the reduction unit should be tested as follows (fig.1): Position a 3 bar scale manometer in place of cap I. Position a 10 bar scale manometer in place of the safety valve on the 1st stage. Charge the reduction unit with nitrogen (aerosol) from gas inlet G to a pressure between 200 and 50 bar. Charge coil F with 12 Vcc; on the two manometers check the internal pressure of the two stages (see specifications). Check the sensitivity of the reduction unit (paragraph 4). Charge coil D, checking its function by observing the exit of gas from the small idling tube B. With a gas loss indicator spray, check that there is no gas escaping from the seals, especially in the high pressure area of the 1st stage cover, the safety valve and cap I. The above tests should also be repeated after mounting a manometer sensor on the T position joint 108 in the exploded diagram on p. 12.

13. SERVICING SECOND AND THIRD STAGES (Refer to figure 26) Remove the eight bolts 59 from 3rd stage cover 106. Remove 3rd stage membrane 105 complete with discs 45 and 104 and housing 94. Undo 2nd stage spring adjustment screw 93. Remove 2nd stage spring 103. Remove bolts 93 and 102 from 2nd stage cover 100. Unscrew nut 92, remove washers 91 and 101, disc 99 and seal 87. Remove membrane 90 and undo bolts 89 securing 2nd stage lever 96. Replace lever 96 with the one from the service package. Secure the new lever with bolts 89 renew membrane 90 with the one from the service package, locating it correctly in the 2nd stage, replace disc99, locate the two washers 91 and 101 and secure by tightening nut 92 (torque 5 Nm). Position 2nd stage cover on the membrane and secure with bolts 93 and 102 (torque 5 Nm). Renew spring 103 with the one from the service package , secure the spring with bolt 93. Position a 3 bar manometer in place of cap I (fig. 1) and calibrate 2nd stage pressure as specified, by turning screw 93. To carry out this calibration is is only necessary to pump compressed air at 6-8 bar into the reduction units gas inlet. Remove 3rd stage lever 86 and replace the valve securing element 110 with the one in the service package (disc D 11.70 thickness 1.20) as specified in paragraph 6 fig. 25. Replace the lever by tightening the two bolts 89 which retain its axis. Membrane replacement (position 105): Remove nut 33 from the assembled membrane assembly, remove washer 91 and disc 45, renew the membrane using the one in the service package, replace disc 45 and washer 91 and secure the assembly with nut 33. Replace the membrane on the reduction unit, taking care to correctly hook housing 94 over lever 86. Close the reduction unit by repositioning cover 106 and tightening bolts 59 onto washer 109 (torque 8 Nm).

For spare parts refer to service package Code no. 674011000

LANDI RENZO S.p.A. Installationand adjustament manual TN1 B SIC

23/36

GB

Trouble shooting

Trouble shooting
SYMPTOM
1 Gas does not exit from the reduction unit 4 Difficult to adjust idling speed 5 6 Gas does not exit from the idling circuit (the vehicle stalls at idling speed) Loss of gas to the air -

CAUSE
Check the functioning of electrovalve F, especially the state of the coil Inlet filter blocked, Opening of electrovalve F incomplete 1st and 2nd stage pressures not as specified Check water circulation 2nd stage pressure not as specified Presence of oil or other impurities in the idling circuit Sensitivity calibration not optimum Check electrovalve D Check tightening torques Check condition of seals/membranes Check electrovalve F Check Condition of internal sealing elements Check condition of sealing elements at joint H (O-ring) 3rd stage lever is not correctly set Check 1st stage pressure, if necessary replace 1st stage valve and membrane
Referto figure 1 p. 2

The output from the reduction unit is inadequate The reduction unit works at very low temperature

7 8 9 10

Loss of gas internally with motor off Loss of water from the reduction unit heating circuit Difficult to adjust tightness/sensitivity of reduction unit Loss from safety valve (safety valve opens and gas escapes)

LANDI RENZO S.p.A. Installationand adjustament manual TN1 B SIC

24/36