Landi Ranzo Cng Kit

GB

RIDUTTORI TN1 B SIC

TN1 B SIC REGULATORS

REDUCTORES TN1 B SIC

MANUALE INSTALLAZIONE E REGOLAZIONEINSTALLATION AND ADJUSTMENT MANUALMANUAL DE INSTALACIN Y REGULACIN

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E

LANDI RENZO S.p.A.2/36

Fig. 1

Fig. 2

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Technical drawingsGB Schemi tecnici Esquemas tcnicosE

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

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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 itsuse is recommended only when there is acarburation vacuum in the main tube from idlingsupply to off-idle. If used, always line it up in thesame 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 TECNICHEAn electronically controlled device which redu-ces the pressure of methane allowing a regularflow of gas for every requirement of the engine.It is fitted with three stages of methane reductionwhich ensures stability at both high and low feedpressures, and with a high pressure electrovalveupstream of the 1st stage. Heat absorption, carriedout by elements of the reduction unit heated byliquid from the cooling circuit of the engine, preven-ts the methane freezing in the pressure fall stage.The flow of gas necessary for the engine at idleis at positive pressure from the second stage andis distributed via a gas conduit separate from themain flow.Included is an electronic device for starting witha built-in safety system which closes the gaselectrovalve in cases where the engine is switchedoff, even accidentally.

SPECIFICATIONS:Type of reduction unit: 3 stage with electronicstarting device and positive pressure idling.Use: autodriveType of fluid: CNG (Compressed methane gas)Body: GDALSI 13 UNI 5079Heating: liquid from engine cooling circuitTest pressure: 300 barInlet pressure: 220 bar1st stage adjustment pressure: 3,5-4 bar2nd stage adjustment pressure: 1,5 barPower supply: 12 V c.c.High pressure electrovalve coil power : 20WIdling electrovalve coil power: 18W

2. FUNCTIONING OF THE REDUCTION UNIT (Fig. 2)With the electrovalve (1) open, the methane gasenters the 1st stage chamber (4). The pressureexerted by the gas on the walls of the chamberdilates the membrane (8), overcoming the resi-stance of the spring (9). The membrane (8) atta-ched to the lever (3) acts on the 1st stage valve (2),creating a pressure equilibrium.From the 1st stage chamber (4), the gas passes tothe 2nd stage (11)and the flow is delivered by thepressure exerted by the gas on the membrane(10), regulating the opening and closing of thevalve (13). Depressurisation of the engine activa-tes an axial movement of the 3rd stage membrane(6) which, connected to the lever (5), causes theopening of the valve (7). Through the outlet (19),the gas enters the engine.Sealing of the valve (7) is obtained by correctcalibration of the spring (14). The starting andidling device comprises an electrovalve (17) con-trolled by an electronic device. The needle (15) isdisplaced and frees the jet (18), the gas from thesecond stage (11) exits, thus permitting the engineto function at idling speed.

If the engine is switched off, the coil is deactivatedand the needle (15) closes the outlet jet (18).Adjustment of the idling speed is carried out via theadjuster (16). When the engine is started, theelectronic device activates the coil (17), the nee-dle (15) frees the jet (18) and allows the amountof gas necessary for starting to pass through.

LegendSpecification

GBOperation GB


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Details: the following photographs show theroute of the methane with blue arrows A, with redarrows B the forces exerted and with yellowarrows C the internal channels for the passage ofthe methane.

Figure 3 shows the TN1B SIC methane reductionunit; the blue arrows show the flow of methaneat the inlet (on the left) and outlet (at the top).It is a 3-stage reduction unit. That is to say, itconsists of two high-pressure stages (the firstreduces to 4.5 bar, the second to 1.5 bar) and afinal stage which operates at low pressure.

Figure 4 shows the 1st stage.The pressure here is kept constant by the strengthof the spring which presses down by the effectof the pressure below the membrane, whichpushes upwards (where the cover is located).Under the plate note how the methane enters the1st stage (at the rim) and progresses to the second(blue arrows).

In practice the methane enters the stage. From theeffect of pressure, a force is generated whichpushes the plate upwards, but there is a springabove it\: the opposing force pushes the platedown and with corresponding force generates aforce in the stage of 4.5 bar (approximately), theposition of the lever shown in figure 5 closes thegas inlet orifice (in the rim).

The transit channel through which the methanepasses to change stage is shown by the whitearrow on the left in figure 6.

In the second stage, the pressure is lowered stillfurther to 1.5 bar, again by means of a springopposing a lever figure 7 (arrow on right). Whenmethane enters, the plate indicated by the arrowon the left swells, then generates a force upwar-ds, which is however opposed by a downwardforce generated by the spring shown in figure 7.

Fig. 3

Fig. 4

Fig. 5

Fig. 6

A

A A

B

A

OperationGB


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This generation of two opposing forces results inthe lever closing the methane inlet orifice shownin figure 9 (the blue arrows show the circulationof methane passing from the second stage tochannel leading to the third stage).Seal is ensured by valve B.

Figure 9 also clearly shows the passage ofmethane from the inlet to the third stage channeland to the idling tuble.

Fig. 7

Fig. 8

Fig. 9

Fig. 10

Fig. 11

C

A

A

B

B

A

A

A

A

C

A

The flow of methane in the functioning of theengine at idling speed is effected by means of thesmall tube indicated in figure 10 with a yellowarrow. The lever to which the membrane is fixedis indicated by the large arrow.

Regulation of the quantity (which is possible withthe SIC reduction unit) is carried out by means ofthe regulator located on the front of the reductionunit.

OperationGB


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Fig. 12

Fig. 13

Fig. 14

Fig. 16

B

CAB

B

A

B

A

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

The third, low pressure, stage consists of amembrane fixed to the steel lever in figure 10 byan aluminium plate. In practice this stage is con-nected to the engine via the gas outlet tube whichgoes to the mixer, and is thus subject to depres-sion generated within itself by the operating of theaccelerator butterfly valve.

Acceleration creates a force (whose vector isindicated by F in figure 13) which pushes themembrane towards the interior of the reductionunit thus, by means of the orifice below shown infigure 15, allowing the passage of the methaneinto the third stage and finally it is breathed outof the reduction unit towards the mixer and goes

Fig. 15

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

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Figure 17 shows the methane outlet tube. Figure18 shows the pressure reducer and the feed tubeto the mixer (directly on the finned body.

Fix withM10 screws

Fig. 19

Fig. 20

Position of the reduction unit

NO

YES

NO

NO

Discharge capFig. 18

Fig. 17

A

A

A

3. GENERAL INFORMATIONWhen installing the reduction unit, the followinginstructions must be observed. supplied with the reduction unit are the mountingbrackets for locating the reduction unit in theengine compartment. These should be adapted tosuit the type of compartment.

Notices GB


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install the reduction unit in the engine compart-ment as close as possible to the point at which themixer unit is installed, fixing it securely to thebodywork with the screws provided; install the reduction unit outside the compartmentcontaining the equipment for collecting air for theventilation and heating of the drivers compart-ment; install the reduction unit at a distance of not lessthan 150mm from the exhaust pipes and silencer.If this distance is less than the minimum stated, butmore than 75mm, a sheet of metal not less than1mm thick must be placed between the componen-ts; position the reduction unit parallel to the directionof the vehicles motion, and in a vertical position,so that it is easily accessible for adjustment andmaintenance; ensure that the reduction unit is located in aposition lower than the highest point of the radiatorto prevent air bubbles forming in the water circuit;The reduction unit should be connected to thewater of the engine cooling system or passengercabin heating system by means of suitable hoses.Fit the T-connectors as shown in figure 22 and usethe hose clips provided to secure them.

A thermostat valve can be used, and should beinstalled in the water outlet tube of the reductionunit.

take care not to position the reduction unit so thatthe discharge cap is located above the startermotor or ignition coil; carefully clean the high pressure methane tubesbefore finally connecting them to the reductionunit, to avoid impurities getting into the reductionunit; ensure that when the engine is running there isno leakage from the water hoses (usually con-nected to the passenger compartment heatingcircuit); never, under any circumstances, change theposition of the reduction units gas inlet assembly,since this could alter the calibration of the 1st stagevalve\: this would risk hampering the passage ofgas with a possible increase in pressure in the 1ststage, which could cause the safety valve toopen, resulting in an escape of gas. As well asmaking all types of guarantee invalid, LANDI REN-ZO can accept no responsibility for damage cau-sed by tampering with the above component check that the reduction unit heats up rapidly bymeans of the connections to the engine coolingsystem.Every time the engine cooling system is emptied,the level of liquid should be replenished, takingcare to eliminate any air bubbles which couldhamper the heating of the reduction unit.The gas outlet of the reduction unit must beconnected to the mixer taking care that the con-necting tube (which should be as short as possi-ble) has no kinks or sags.Mounting brackets are supplied with the reductionunit for locating it in the engine compartment. Theyshould be adapted to suit the position selected formounting.

NoticesGB


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Fig. 22

Thermostat valve

4. ADJUSTING THE SENSITIVITY OF TN SICREDUCTION UNITS (Fig. 1)The reduction units have already been adjusted bythe manufacturer, but if any problems should beencountered such as uneven idling speed or flatspots in acceleration, we recommend checkingthe sensitivity of the reduction unit. The adjustmentscrew (C) is not used for adjusting the idling speedbut only for adjusting the sensitivity of the reduc-tion unit: unscrewing it lightens the load which thespring exerts on the third stage lever, whiletightening it increases the load exerted by thespring on the second stage lever towards closing.In particular, being the idling flow, separated fromthe maximum, the change from the idling regime toa higher one happens without carburation flatspots which are noted particularly when acce-lerating very slowly (adjuster too tight) and at thesame time the reduction unit remains tight and doesnot 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 mixerfrom the gas outlet tube (A);2) Tighten the sensitivity adjuster (C) completely;3) Disconnect the wire leading to the idling electro-valve 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 gasoutlet tube (A) and loosen the adjuster (C) until gasbegins to come out of the reduction unit andinflates the bubble;5) The moment gas begins to come out of thereduction unit, retighten the adjuster (C) until gasno longer comes out, and at this point give theadjuster an extra half-turn for safetys sake.

6) Install the sensitivity adjuster (C) protection capto prevent tampering.

An alternative, less accurate but quicker, way ofadjusting the sensitivity is as follows:1) Fully tighten the sensitivity adjuster (C);2) Start the engine and adjust the idling speed bymeans of the adjuster (E) until the maximum valueof CO2 is achieved;3) Slowly undo the adjuster (C) until there is anotable variation (reduction) in the CO2 value;4) At that moment, tighten the adjuster (C) until theCO2 value noted at point 2 is achieved.5) Install the sensitivity adjuster (C) protection capto avoid tampering.6) Check that there are no carburation flat spotswhen accelerating slowly.

After the first 500 / 1.000 Km it is advisable to checkthe sensitivity of the reduction unit.

Sensitivity adjustmentGB


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5. MAINTENANCE OPERATIONS REDUCTIONUNITTo get the best from methane fuel, the engineshould be tuned and regularly maintained. Thisapplies both to the mechanical parts and electricalsystem. As well as the normal maintenanc pre-scribed by the vehicle manufacturer, the followingprocedures are recommended: every 30.000 Km check by means of the dischar-ge cap that there is no oil or other deposits insidethe 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 instructionsbelow (paragraph 7).

6. SERVICING THE REDUCTION UNITTo check correct closing of the third stage valve(self-adjusting valves only), insert a piece ofwhite paper with a strip of carbon paper over itbetween the valve and its seat. The valve mustreproduce an exact imprint of the rim of the valve.If this is not the case, place a screwdriver in theslot provided in the valve (without the white paperand carbon paper) and move it until a correctimprint is produced; then tighten the nut, ensuringthat the valve does not move. 3

rd stage valve replacement

Fig. 23

Fig. 25

Fig. 24

Calibration distance

1st stage

Carbon paper

White paper

First imprint

White paper

Car

bon

pap

er

Nut

MaintenanceGB


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7. SERVICING HIGH PRESSUREELECTROVALVE (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 andspring 12 with the replacements in the servicepackage.On the housing 10, replace O-ring 11 (OR 14x1.78code no. 173151381).Reassemble all components in the original order,tighten the housing 10.Replace coil 9 and secure it with nut 8 (torque 8Nm).

8. SERVICING 1ST STAGE (Referto figure 26)Remove 1st stage cover 57 by loosening nuts 59,noting that the cover contains the compressedspring.Remove seal 87 and spring 56, undo nut 55,remove washer 53, disc 54, membrane 52, disc 51with O-ring 50 and housing 49.Undo bolts 31 and remove lever 34 with pivot 35.Remove 1st stage valve 36 and replace with thevalve from the service kitReplace lever 34 and pivot 35 and tighten bolts 31(torque 7 Nm).Adjust the free play between lever 34 and 1st stagevalve 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 totorque 6 1 Nm.Replace pin 49 in lever 34, replace disc 51 with O-ring 50, replace membrane 52 with the one sup-plied in the service package.Replace disc 54, washer 53 and tighten nut 55 totorque 10 Nm.Insert spring 56, replace seal 87 with a new onefrom the service package.Replace cover 57, washer 109, tightening the nut59 to torque 8 Nm.

9. SERVICING SENSITIVITY SCREW(REFER TO FIGURE 26)Remove idling adjustment cover 114, undo bolt 74.Remove spring 77 and replace with a new onefrom the service package.Reassemble the spring with its pivot 76, takingcare to centre it on the stud on lever 86.Replace bolt 74 after renewing O-ring 75 (OR8.73x1.78 code no. 173007371.Adjust the sensitivity as described in the manualparagrafo 4.Refit the idling adjuster cover 114.

10. SERVICING TIGHTNESS OF GAS OUTLETJOINTUndo bolt 28.Remove joint 29 from the reduction unit and renewO-rings 30 and 44 with those supplied in theservice package (OR 1715 code no. 173031371and OR 2075 code no. 173068371.Reassemble tube 29 complete with O-ring onto thereduction unit. Secure by tightening bolt 28.

11. SERVICING IDLING ADJUSTMENT DEVICERemove nut 67 from housing 62.Extract nut 67 complete with idling adjuster screw69, idling adjuster knob 65 and its spring 66.From housing 62, extract spring 71 and movingneedle 72.Replace O-ring 73 in moving needle 72 with the onefrom the service package (OR 1.5x1 code no.173130371); reinsert the moving needle with itsnew O-ring in housing 62.Renew O-ring 70 on idling adjuster screw 69 withthe one from the service package (OR 108 codeno. 173093371.Replace nut 67 complete with all other componen-ts (position 70, 69, 67, 66, 65).Retighten nut 67 on housing 62 (torque 10 Nm).

12. SERVICING WATER JOINTUnscrew water joints 88, replace O-ring 46 witha new one (OR 112 cod. 173009371), screw injoints 88.

ServicingGB


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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 withdiscs 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 securing2nd stage lever 96.Replace lever 96 with the one from the servicepackage.Secure the new lever with bolts 89 renew mem-brane 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 secureby tightening nut 92 (torque 5 Nm).Position 2nd stage cover on the membrane andsecure with bolts 93 and 102 (torque 5 Nm).Renew spring 103 with the one from the servicepackage , 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 necessaryto pump compressed air at 6-8 bar into the reduc-tion units gas inlet.Remove 3rd stage lever 86 and replace the valvesecuring element 110 with the one in the servicepackage (disc D 11.70 thickness 1.20) as speci-fied in paragraph 6 fig. 25.Replace the lever by tightening the two bolts 89which retain its axis.

Membrane replacement (position 105):Remove nut 33 from the assembled membraneassembly, remove washer 91 and disc 45, renewthe membrane using the one in the service packa-ge, replace disc 45 and washer 91 and secure theassembly with nut 33.Replace the membrane on the reduction unit,taking care to correctly hook housing 94 over lever86.Close the reduction unit by repositioning cover 106and tightening bolts 59 onto washer 109 (torque8 Nm).

At the end of every maintenance operationinvolving dismantling and reassembly ofcomponents, the reduction unit should betested as follows (fig.1):Position a 3 bar scale manometer in place ofcap I.Position a 10 bar scale manometer in placeof the safety valve on the 1st stage.Charge the reduction unit with nitrogen(aerosol) from gas inlet G to a pressurebetween 200 and 50 bar.Charge coil F with 12 Vcc; on the two mano-meters check the internal pressure of thetwo stages (see specifications).Check the sensitivity of the reduction unit(paragraph 4).Charge coil D, checking its function by ob-serving the exit of gas from the small idlingtube B.With a gas loss indicator spray, check thatthere is no gas escaping from the seals,especially in the high pressure area of the1st stage cover, the safety valve and cap I.The above tests should also be repeatedafter mounting a manometer sensor on theT position joint 108 in the exploded diagramon p. 12.

For spare parts refer to service packageCode no. 674011000

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Trouble shooting SYMPTOM CAUSE

1 Gas does not exit from the reduction unit - Check the functioning of

electrovalve F, especially the state of the coil

2 The output from the reduction unit is inadequate

- Inlet filter blocked, - Opening of electrovalve F

incomplete - 1st and 2nd stage pressures

not as specified

3 The reduction unit works at very low temperature - Check water circulation

4 Difficult to adjust idling speed

- 2nd stage pressure not as specified

- Presence of oil or other impurities in the idling circuit

- Sensitivity calibration not optimum

5 Gas does not exit from the idling circuit (the vehicle stalls at idling speed) - Check electrovalve D

6 Loss of gas to the air - Check tightening torques - Check condition of

seals/membranes

7 Loss of gas internally with motor off - Check electrovalve F - Check Condition of internal

sealing elements

8 Loss of water from the reduction unit heating circuit - Check condition of sealing

elements at joint H (O-ring)

9 Difficult to adjust tightness/sensitivity of reduction unit - 3rd stage lever is not correctly

set

10 Loss from safety valve (safety valve opens and gas escapes)

- Check 1st stage pressure, if necessary replace 1st stage valve and membrane

Referto figure 1 p. 2

Trouble shootingGB

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Landi Ranzo Cng Kit