sb 09-2916a reg. mooney

SERVICE BULLETIN

Page 1 of 16WAUKESHA ENGINEDRESSER, INC.WAUKESHA, WI 53188-4999

INTRODUCTIONMooney regulators are now used on select VHPengines. The new regulator will be standard equip-ment on all GSI, GL, and LT engines running on pipe-line quality or 900 Btu field gas. It is currently not usedwith GLD, GSID or AFM equipped engines. The newregulator provides improved control and ease of main-tenance.

PRINCIPLES OF OPERATIONThe Mooney regulator system utilizes a pilot that con-trols a main valve (see Figure 1 and Figure 3). Thepilot assembly features a removable cartridge and a10 micron gas filter. The main valve is a simple designthat uses few parts. These features make the regulatorassembly easy to maintain.

Figure 1. Pressure Reducing Configuration Fully Closed

At no flow, when the outlet pressure is greater than theset point of the pilot, the pilot valve is closed and fullinlet pressure loads the spring case through the pilotloading connection. In this condition the main valve

diaphragm is closed tightly against the throttle plate.The pressure differential across the outlet half of thediaphragm adds to the spring force in closing thevalve.

As demand for flow occurs in the downstream system,the outlet pressure drops causing the pilot valve toopen and start bleeding pressure out of the springcase faster than it can enter through the cartridgerestrictor, resulting in a reduction of pressure abovethe diaphragm (see Figure 2). This allows the inletpressure to progressively lift the main valve diaphragmoff the throttle plate, opening the valve and satisfyingthe demand for flow in the downstream system.

Figure 2. Pressure Reducing Configuration Fully Open

When demand for flow ceases or is reduced, thedownstream pressure increases causing the pilotvalve to close. Inlet pressure continues to passthrough the restrictor until the control pressure equalsthe inlet pressure. The spring force, plus the pressuredifferential across the outlet half of the main valve dia-phragm, closes the diaphragm against the throttleplate, shutting off the flow.

TOPIC: Fuel SystemIDENT NO: 9-2916A

SUPERSEDES: 9-2916DATE: May 2, 2006

SUBJECT: Mooney Fuel RegulatorsMODELS AFFECTED: VHP GSI/GL/LT

INLETPILOT OUTLETCONNECTION

PILOT SENSE CONNECTION

OUTLET

PILOT SUPPLY

PILOT LOADINGCONNECTION

RESTRICTOR

PILOT

PILOTVALVE

MAIN VALVE

DIAPHRAGM

INLETPILOT OUTLETCONNECTION

PILOT SENSE CONNECTION

OUTLET

PILOT SUPPLY

PILOT LOADINGCONNECTION

RESTRICTOR

CONTROLPRESSURE

Service Bulletin No. 9-2916A

Page 2 of 16 WAUKESHA ENGINEDRESSER, INC.WAUKESHA, WI 53188-4999

Figure 3. Inline Regulator (Left Bank)

MAINTENANCE SCHEDULE1. Once a year replace seals, O-rings, diaphragms

and filter element (see Table 1 and Table 1).2. Inspect and clean fixed restrictor orifice located in

pilot inlet supply connection (see Figure 3 andFigure 4). Orifice inside diameter is 0.052 in.(1.3 mm) (#55 drill).

NOTE: Pilot parts are subject to normal wear andmust be inspected and replaced as necessary. Thefrequency of inspection and replacement of partsdepends on severity of service conditions and/or therequirements of local, state, and federal regulations.Be certain that the name plates are updated toaccurately 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

PILOT SENSECONNECTION

PILOT OUTLETCONNECTION

PILOT INLET (SUPPLY)CONNECTION

VENT

PILOT

PILOTLOADING

CONNECTION FILTER

FIXED RESTRICTOR

ORIFICE

MAIN VALVE

OUTLET

INLET

CARTRIDGE

ORIFICEINSIDE DIAMETER 0.052 IN. (1.3 MM)



REPLACEMENT SERVICE PARTSAND KITSNOTE: The following updates have been added.Improved balance lines (5/8 inch diameter) for GSIand 7042GL engines. Updated main valve, containsnew spring and diaphragm that reduces CO emissionson GSI engines. In addition, new regulator springs areavailable for all engine models. See Table 2 forinformation.

Table 2. Component Parts

REGULATOR ADJUSTMENTSThe Mooney regulators were designed to track similarto the previous Fisher regulator. The gas/air settingand carburetor adjustments will remain the same asthose used with the Fisher regulator. Mooney regula-tors require specific supply pressures depending onengine model (see Table 3).The gas over air adjustment is controlled by adjustingthe stem screw and lock nut located at the bottom ofthe pilot assembly. Turning the stem screw clockwisewill increase spring tension increasing the gas/air.Turning the screw counterclockwise will reduce springtension and reduce the gas/air setting. Initial setting isa stem length of approximately 2.75 in. (6.98 cm)measured from adjuster housing fitting (seeFigure 19).

PILOT DISASSEMBLE PILOT

NOTE: A spare cartridge may be installed and theregulator returned to service if time is a factor. Makesure the stem O-ring is still in place in the pilot bodybefore installing the new cartridge. If the O-ring wasremoved, install a new O-ring over the stem of thecartridge assembly prior to installing it in the pilot body(see Figure 5 and Figure 6).

Table 1. Service Part KitsP/N DESCRIPTION

489669Pilot Maintenance Kit (Pivot Assembly O-

ring, Diaphragm, Closing Cap O-ring, Adjusting Assembly O-ring)

489667

Cartridge AssemblyMaintenance 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)

489670 1.5 in. Main Valve Maintenance Kit (Diaphragm and Body Seal)

4896711.5 in. Main Valve Overhaul Kit (Low

Differential Main Spring (Brown), Diaphragm, Throttle Plate, Body Seal)

489666 Type 30A Filter Maintenance Kit (Element and O-ring)

P/N DESCRIPTION214172 Pilot 489668 Cartridge214174 Filter

214171BMain Valve (Left Bank)

also used on inline engines(updated spring and diaphragm)

214171C Main Valve (Right Bank)(updated spring and diaphragm)214175 Fixed Restrictor Orifice214172 Brown (10 40 IWC)

214172A White (5 15 IWC)214172B Yellow (1 3 PSIG)214191 5/8 in. Balance Line 6 Cylinder GSI Engine

214191A 5/8 in. Balance Line 12 Cylinder GSI Engine (Right Bank)214191B 5/8 in. Balance Line 12 Cylinder GSI Engine (Left Bank)214055D 5/8 in. Balance Line 16 Cylinder GSI Engine (Both Banks)214191D 5/8 in. Balance Line 7042GLEngine with ESM (Left Bank)214191E 5/8 in. Balance Line 7042GLEngine with ESM (Right Bank)

Table 3. Mooney Regulator Fuel Pressures

ENGINE MODELRECOMMENDED NATURAL GAS SUPPLY PRESSURE TO ENGINE

MOUNTED REGULATOR

MAXIMUM NATURAL GAS SUPPLY PRESSURE TO ENGINE MOUNTED

REGULATORF2895GSI; F3521GSI; L5790GSI;

L7042GSI; P9390GSI 30 - 60 psig (207 - 414 kPa) 75 psig (517 kPa)F3524GSI; L5794GSI; L7044GSI 30 - 60 psig (207 - 414 kPa) 75 psig (517 kPa)F2895GL; F3521GL; L5790GL;

L7042GL; F9390GL 43 - 60 psig (296 - 414 kPa) 75 psig (517 kPa)L5794LT; L5774LT 43 - 60 psig (296 - 414 kPa) 75 psig (517 kPa)

WARNINGBefore disassembly make sure the regulator andmain valve have been isolated from the process byclosing block valves on the inlet and outlet sidesof each component. Safely release pressure andprocess fluid from the valve body and pilotsystem. Failure to properly complete these stepsmay result in personal injury and/or propertydamage.



1. Depressurize pilot and main valve. Unscrew andremove cartridge (see Figure 5).

Figure 5. Cartridge Assembly

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

NOTE: The loading and inlet ports are interchangeablewith one another.

Figure 6. Stem O-ring

3. Remove bottom cap from cartridge body andremove internal parts. Use a heavy paper clip or0.045 in. (1.14 mm) diameter wire to push outorifice assembly (pilot valve). Do not damage O-ringsealing surface of body cartridge (see Figure 7).


4. Loosen lock nut on spring adjuster stem. Unscrewadjuster stem. Spring tension will release as stemis unscrewed (see Figure 8).

5. Remove retainer plug located below outlet port(see Figure 8).

6. Remove one 5/16 in. - 18 UNC capscrew thatsecures spring case to pilot body (see Figure 8).

Figure 8. Pilot Spring Barrel

7. Thread 5/16 in. - 18 UNC capscrew into pivot andpull pivot and lever assembly out of pilot body (seeFigure 9).

CARTRIDGE

OUTLET

INLET

STEM O-RING

LOADING

BOTTOM CAPASSEMBLY

ORIFICE ASSEMBLY

CARTRIDGE BODY

SPRING ADJUSTER STEM

INLETLOADING

LOCK NUT

5/16 IN.-18 UNCCAPSCREW

OUTLET RETAINERPLUG



Figure 9. Pivot And Lever Assembly Removal

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

Figure 10. Spring Case And Pilot Body

9. Disconnect line connections and remove pilot body(see Figure 11).

Figure 11. Pilot Body

10. Remove diaphragm assembly from body. Removeretaining nut and remaining components. Inspectall parts for wear or damage (see Figure 12).

Figure 12. Diaphragm Assembly

ASSEMBLE PILOT NOTE: Use Parker Super O-Lube or an equivalentsilicone based lubricant on all O-rings in the pilotassembly.1. Apply Parker Super O-Lube and slide O-ring

onto pivot and lever assembly. Apply LubriplateNo. 105 petroleum grease to roll pin and lever(see Figure 13).

Figure 13. Pivot And Lever Assembly

2. Install pilot diaphragm with convex side towarddiaphragm plate and main spring. Secure with nutand washer. Tighten to 5 - 6 ft-lbs (6.8 - 8.2 N m).Do not overtighten, overtightening will distort thepilot diaphragm (see Figure 14).


SPRING CASE

PILOT BODY

PILOT BODY

RETAINING NUT DIAPHRAGM

ROLL PIN

LEVER O-RING



Figure 14. Pilot Diaphragm

3. Thread 5/16 in. - 18 UNC capscrew into pivot thenpush pivot and lever assembly into pilot body. Aguide pin located at the bottom assures pivot andlever assembly is correctly oriented in body.Remove capscrew when complete (seeFigure 15).

Figure 15. Pivot And Lever Assembly

4. Install retainer plug into body. Plug should be flushwith body when installed correctly (see Figure 8).

5. Slide diaphragm assembly onto lever. Aligndiaphragm with pivot and lever assembly.Lubrication of pivot pin is not required (seeFigure 16).

Figure 16. Diaphragm Installation

6. Place spring washer onto diaphragm plate.Lubricate spring washer with Lubriplate No. 105or petroleum grease to hold in position (seeFigure 17). Washer prevents main spring frombinding on diaphragm assembly whencompressed.

Figure 17. Diaphragm Spring Washer

7. Place spring case on pilot body (see Figure 18).Vent connection should face down when regulatoris mounted on engine. This allows condensation todrain away instead of accumulating and possiblyfreezing.

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).

NOTE: Different springs are available (see Table 2).9. Install main spring (brown) into spring case.NOTE: The top of the main spring will be almost 2.0in. (5.0 cm) below the spring case when fully installed.

DIAPHRAGMPLATE

NUT

WASHER

DIAPHRAGM

DIAPHRAGMRETAINER

GUIDE PINNOTCH


DIAPHRAGM

LEVER

SPRING WASHER



Figure 18. Spring Case

10. Install O-ring on spring adjuster fitting (seeFigure 19). Screw adjuster stem out to relievespring pressure during installation.

11. Install adjuster fitting in body. Turn adjuster stemuntil it measures 2.75 in. (6.98 cm) from adjusterfitting. Tighten lock nut (see Figure 19 andFigure 20).

Figure 19. Spring Adjuster Assembly

Figure 20. Spring AdjusterNOTE: A spare cartridge may be installed and theregulator returned to service if time is a factor. Makesure the stem O-ring is still in place in the pilot bodybefore installing the new cartridge. If the O-ring wasremoved, install a new O-ring over the stem of thecartridge 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, stemguide, plug and stem, orifice and O-ring, and back-up washer (see Figure 21).

MAIN SPRINGSPRING CASE

VENT

ADJUSTERSTEM

2.75 IN. 6.98 CM

O-RING

ADJUSTERFITTING

ADJUSTERSTEMLOCK NUT




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

Figure 22. Cartridge Body and Cap Assembly

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

Figure 23. Cartridge Stem Height

15. Apply Parker Super O-Lube and slide O-ringonto stem.

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 andFigure 24).

PLUG ANDSTEM ASSEMBLY

STEM GUIDE

ORIFICE SPRING

RETURNSPRING

BACK-UPWASHER

ORIFICEO-RING

BOTTOM CAP

STEM O-RING

O-RINGS

BODY INSERT

ORIFICE

O-RING

BODY INSERT

O-RINGO-RING

BOTTOM CAPASSEMBLY

0.32 IN.(8.1 MM)

STEM

BODY INSERT




FILTER MAINTENANCEThe filter element is subject to plugging and must beinspected and replaced as necessary. The frequencyof inspection and replacement of the filter elementdepends on severity of service conditions and thelength of time in service.

DISASSEMBLE FILTER1. Depressurize main valve and filter. Remove filter

housing (see Figure 25).

Figure 25. Filter Assembly

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

Figure 26. Filter Element

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

Figure 27. Filter Fitting

ASSEMBLE FILTER1. Lubricate O-ring with Parker Super O-Lube (or

equivalent petroleum based lubricant) and install infilter fitting.

NOTE: If the filter guide is removed, apply a smallquantity of Loctite (or equivalent) to the threadedarea 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 notovertighten (overtightening an O-ring joint will notimprove seal). Element will guide itself intoposition regardless of orientation.

WARNINGBefore disassembly make sure the regulator andfilter have been isolated from the process byclosing block valves on the inlet and outlet sidesof the regulator. Safely release pressure andprocess fluid from body and pilot system. Failureto properly complete these steps may result inpersonal injury and property damage.

CARTRIDGE

FILTERHOUSING

FILTER

FILTERHOUSING

O-RING



Figure 28. Filter Assembly

MAIN VALVE MAINTENANCENOTE: Updated main valves are available thatcontain a new diaphragm and spring that reduce COemissions on GSI engines (see Table 2).Main valve parts are subject to normal wear and mustbe inspected and replaced as necessary. The fre-quency of inspection and replacement of partsdepends on severity of service conditions and/or therequirements of local, state, and federal regulations.Be certain that the name plates are updated to accu-rately indicate any field changes in equipment, materi-als, service conditions, or pressure settings.

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 ascapscrews are removed (see Figure 29).

Figure 29. Pilot Loading Line

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

Figure 30. Main Valve Cover

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

WARNINGBefore disassembly make sure the main valve hasbeen isolated from the process by closing blockvalves on the inlet and outlet sides of the mainvalve. Safely release pressure and process fluidfrom body and pilot system. Failure to properlycomplete these steps may result in personal injuryand property damage.

FILTERHOUSING

PILOT LOADINGLINE CAPSCREW

VALVE COVER

5/16 IN.-18 UNCCAPSCREWS

DIAPHRAGMCOVER

MAIN SPRING



Figure 31. Throttle Plate

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

Figure 32. Nitrile Body Seal

6. Inspect all parts for wear and damage. Replace asnecessary.

CLEANING MAIN VALVE1. Do not clean body seal grooves with sharp metal

tools. Bottom of groove and mating surface ofadjacent parts must have smooth finish to preventleakage.

ASSEMBLE MAIN VALVE

Figure 33. Left Bank/Inline Main Valve Configuration

NOTE: The cover plate should be positioned so theboss is located at the outlet (downstream) side of thefuel line (see Figure 33 and Figure 37).NOTE: The nitrile rubber body seal can swell afterdisassembly of a main valve that has been in service(due to gas permeating the nitrile rubber). This doesnot necessarily mean it must be replaced. However,before placing the seal back into service inspect fordefects. Set seal aside for several hours and it willgradually return to normal size. Placing seal(s) on icewill speed the process considerably.

OUTSIDE RIB DOWNSTREAM

NITRILEBODY SEAL

NITRILEBODY SEAL

DIAPHRAGM

MAIN SPRING

BODY

COVER

THROTTLE PLATE

BOSS

INLET

OUTLETFLOW DIRECTION



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

Figure 34. Nitrile Body Seal

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

Figure 35. Throttle Plate

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

Figure 36. Main Valve Cover

NOTE: The cover plate should be positioned so theboss is located at the outlet (downstream) side of thefuel line (see Figure 33 and Figure 37).3. Place spring case cover assembly and bracket on

main valve and secure with four capscrews (seeFigure 38). Do not fully tighten.

Figure 37. Inline/Left Bank Main Valve

4. Secure opposite end of bracket to pilot body with5/16 in. - 18 UNC capscrews (see Figure 38).

Lubricating or over-tightening valve cover

capscrews can damage the diaphragm. Disregard-ing this information could result in severe enginedamage.

Do not replace thestuds or nuts with any

capscrew or stud and nut combination that doesnot have an SAE Grade 7 or ASTM Grade B7 rat-ing. Disregarding this information could result insevere engine damage.

NITRILEBODY SEAL

OUTLET SIDES

INLET SIDES

DIAPHRAGMCOVER

MAIN SPRING

FLOW DIRECTIONINLET

OUTLETBOSSCOVERCAPSCREW

BRACKET

CAUTION

CAUTION



5. Tighten spring case cover capscrews inincrements using a criss-cross pattern (seeFigure 38 and Figure 39). Tighten to 20 ft-lbs(27 N m).

6. Install pilot loading line (see Figure 38).

Figure 38. Inline/Right Bank Main Valve

NOTE: Balance lines have been increased to 5/8diameter on GSI and 7042 GL engines (see Figure 39,Figure 40, Figure 41, Figure 42, and Table 2).7. Reconnect pilot system. Follow approved start up

procedures when returning to operation.

BRACKET


PILOT LOADINGLINE

COVERCAPSCREW

Figure 39. 6 Cylinder Engine Regulator Mounting

DRESSERCOUPLING

161579B

PIPE

SPACER

5/8 IN. BALANCE TUBE(GSI ONLY) P/N 214191

CAPSCREW5/8

FLATWASHER

LOCKWASHER

MALE ELBOWP/N 199111Y




PIPE

MALE ELBOWP/N 199111Y

1/2 CAPSCREW

FLATWASHER

LOCKWASHER

DRESSERCOUPLING

161579B

5/8 IN. BALANCE TUBE (GSI ONLY)P/N 214191A RIGHT BANKP/N 214191B LEFT BANK



Figure 41. 12 Cylinder 7042GL Engine Left Bank Regulator Mounting

MALE ELBOWP/N 199111E

DRESSERCOUPLING

161579B

5/8 IN. BALANCE TUBEP/N 214191E RIGHT BANKP/N 214191D LEFT BANK

PIPEP/N 207155D

COUPLINGP/N 78211E




PIPE

5/8 IN. BALANCE TUBE P/N 214055D (BOTH BANKS)

ELBOWDRESSER COUPLING

161592

sb 09-2916a reg. mooney

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