Service Instruction 2620003 NOTE/NOTES - …gazovik.kiev.ua/assets/downloads/manuals/Reducers/Manuale revision… · Service Instruction 1 ... With the car up and running on CNG adjust

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Service Instruction 1

Codice/Code Descrizione/Description

2620003 RMJ-3 LOW POWER REDUCER

NOTE/NOTES

3 16/02/09 MODIFICATO CODICE O-RING / O-RING CODE CHANGED A. TONIOLO C. SEGATO G. GRITTI

2 13/01/09 INSERITA COPIA DI SERRAGGIO MANOMETRO PRESSURE SENSOR TORQUE WRENCH SETTING INSERTED A. TONIOLO C. SEGATO G. GRITTI

1 13/01/09 INSERITE INSTRUZIONI DI FISSAGGIO DEL TUBO ACCIAIO STEEL PIPE FIXING INSTRUCTION ADDED A. TONIOLO C. SEGATO G. GRITTI

0 06/11/08 EMISSIONE DOCUMENTO/SERVICE INSTRUCTION ISSUE A. TONIOLO C. SEGATO G. GRITTI

REV.REV.

DATADATE

DESCRIZIONEDESCRIPTION

REDATTOWRITED BY

CONTROLLATOCHECKED

APPROVATOAPPROVED

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“RMJ-3 LOW POWER” REDUCER SERVICE INSTRUCTION

Here below you can fi nd the maintenance instruction for the “RMJ-3 LOW POWER” reducer.

For a correct maintenace you need the following items:1 maintenance kit code 1294022 which is complete with:

Code Description Q.ty7450027 D.17,00x2,00 HNBR 70 SHORE A O-RING 13330007 RMJ-3 SECOND STAGE DIAPHRAGM ASSEMBLY 14205004 RMJ-3 FILTER CARTRIDGE 14330007 RMJ-3 FIRST STAGE DIAPHRAGM 1

2 - a 4mm setscrew wrench,3 - a screwdriver for slotted head screws,4 - a 28mm wrench.





How to replace the high pressure fi lter cartridge

How to disassemble the reducer

Step Operation description Drawing

Step 1 Unscrew the CNG inlet connection using the 28mm wrench.

Step 2 Remove the fi lter cartridge and clean the fi lter com-partment using a wiping cloth. Do not use compres-sed air in order to avoid any impurity goes through the lock-off valve compartment compromising the operation.

How to reassemble the reducer


Step 1 Remove the gas inlet connection o-ring.

Step 2 Lubrifi cate the new gas inlet connection o-ring with silicone oil and insert on its seat. Be sure that you don’t ruin the o-ring during this operation, this will compromise its function.





Step 3 Insert the fi lter cartridge in its compartment.

Step 5 Screw the gas inlet connection using a 28mm wren-ch with 40 ±1 Nm torque wrench setting. install the reducer in the car and check the leackage on the gas inlet connection junction, gas inlet plug and gas outlet plug using soapy water.

How to replace the fi rst stage diaphragm



Step 1 Unscrew the reducer lower cap screws using the 4mm setscrew wrench. During this operation exert light pressure on the reducer cap to counter the spring for-ce.





Step 2 Remove the reducer lower cap.

Step 3 Remove the spring assembly.





Step 4 Unscrew the diaphragm fi xing screw using the 4mm setscrew wrench, remove the plain washer, the diaphragm plate and the diaphragm. Clean the fi rst stage compartment using a wiping cloth if necessary.



Step 1 Lubrifi cate the new gas fl ow control group o-ring with silicone oil and insert it on its seat.

Step 2 Place the diaphragm plate on the diaphragm.





Step 3 Place the diagphram washer and fi x them (dia-gphram, diagphram plate and washer) using the fi xing screw. Fix the screw with a 5 ± 0.5 Nm torque wrench setting.

Step 4 Place the springs assembly on diaphragm plate.

Step 5 Place the reducer lower cap on the springs assembly.





Step 6 Fix the reducer lower cap by screwing the fi ve screws using the 4mm setscrew wrench with 4 ±0.5 Nm tor-que wrench setting.

How to replace the second stage diaphragm


Step 1 Unscrew the reducer upper cap screws using the 4mm setscrew wrench. During this operation exert li-ght pressure on the reducer cap to counter the spring force.

Step 2 Remove the reducer upper cap.






Step 3 Remove the spring assembly.

Step 4 Remove the second stage diaphragm assembly.



Step 1 Place the second stage diaphragm assembly in its po-sition on the reducer body with the paper gasket on top.





Step 2 Place the second stage spring assembly on the diaphragm plate.

Step 3 Insert the seal on the gas fl ow control unit and push it to the gas fl ow control unit top surface.

Step 4 Fix the reducer upper cap by screwing the fi ve screws using the 4mm setscrew wrench with 4 ±0.5 Nm tor-que wrench setting.





Step 5 Install the reducer in the car. Check the leackage on the gas inlet plug, gas outlet plug and on the junction between the reducer body and the reducer caps using soapy water.With the car up and running on CNG adjust the ou-tput pressure to 2bar by screwing (to increase) or un-screwing (to decrease) the pressure regulation screw on the top of reducer upper cap.

Step 6 Install the pressure regulation cap exerting a slight pressure to send it in joke.





How to replace the pressure sensor

How to disassemble the pressure sensor

Step 1 Unscrew the pressure sensor (manometer) using a 14mm wrench and remove the seal washer.

How to resassemble the pressure sensor

Step 1 Insert the new seal washer on the pressure sen-sor seat. Screw the pressure sensor using a 14mm wrench with minimum 16 to maximum 20 Nm torque wrench setting





HOW TO FIX THE STEEL PIPE ON RMJ-3 PRESSURE REDUCER


1 Remove a part of the pipe coating.Insert a fi xing steel nut and a steel ferule as shown in the picture.

2 Insert this assembly on the inlet plug of the RMJ-3 pressure reducer

Screw the nut manually until the bar then fi x it using a 14mm wrench for minimum a round and maximum a round and a quater.

Documents

Service Instruction 2620003 NOTE/NOTES - …gazovik.kiev.ua/assets/downloads/manuals/Reducers/Manuale revision… · Service Instruction 1 ... With the car up and running on CNG adjust