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REDUCER SERVICE MANUAL VERDAMPER REVISIE

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1. 0 15 bar if the pressure keeps on rising the reducer is leaking at the first stage valve reject the reducer Set the reducer to its minimum pressure rotating adjusting bolt clockwise Pressure should be less than 1 6 bar abs 10 Set the reducer to 2 2 bar abs factory default 42
2. 80 10004 H VEIN g H20 07 25 rins RINS AUTOGASSYSTEMEN B V TI LANDS 1474288 GE VSI 22 S 8 Torque setting 25 05 N 4 gt 3 Wi Q O O QO LJ Ul Q K Wi Be E pD O OOOO H D UT Gei e orque setting 35 05 Nm d Ee T setting 4 0 5 Nm 0 0 0 eee 305 or equal p f E Piate Threebond 1305 or equal LS TATTI T Torque setting 8 05 Nm During assembly use O ring grease silicon free use D ring grease EE ad Jet 17 Remove the six Allan screwsv1 separate the covers from the main body 1 Remove the rear Cover The water side O ring s will be replaced Replace all the plastic pipes with o rings 18 The water side O ring s will be replaced Remove the front covers The complete adjusting disc and conical spring 10 will be used again 19 install new pin Replace the gas side diaphragm Mount the disci12 with the sharp side facing the conical spring 10 T
3. ALTERNATIVE ef FUEL SYSTEMS Prins REDUCER SERVICE MANUAL VERDAMPER REVISIE HANDLEIDING VERDAMPFEER REVISION ANLEITUNG 2009 10 12 REDUCER SERVICE Tools and products Reducer replacement kit 180 10020 Reducer replacement kit 180 10025H Allan key 4 mm Thread cutting device M10x1 Ring spanner size 8 mm 16 mm 17 mm Torque spanner 0 10 Nm with socket 14 mm 8 mm 14 mm socket with ratchet Special 19 mm socket part nr 099 9980 with ratchet for H reducer Screwdriver flat head Hammer Air gun Brake cleaner carburettor cleaner Reducer parts not sold separately C D E reducer page 3 16 H reducer page 17 29 Damper modification in J reducer page 30 38 Testing Calibrating page 39 42 Reducer replacement kit 180 10020 Gas side diaphragm Water side diaphragm Pressure relief valve O ringi29 Locking nut M511 Jet 15 Locating Dina 3 pipes with 6 O rings Valve seat 1e Loosen the six Allen screws 18 NOT the Tensilock nuts 33 otherwise they will loose their locking function Remove the six Allan screwsv18 Use the recess in the diaphragms to separate the covers from the main body 1 Remove the rear cover 2 The valve spring 17 will be used again Remove the water side diaphragms from the rear cover 2 The water side diaphragms will be replaced Replace all the plastic pipes with o rings Remove the valve
4. e water side diaphragm 5 11 Install the new valve seatiis with the rubber compound facing the jet 15 Install the springi17 on the new valve seat i6 Install the new water side diaphragm 5 on the back of the main body 1 Make sure the valve spring 17 is in position on the valve seat 16 12 Place the rear cover on the diaphragm and insert the six Allan screws Flip the reducer 180 degrees Use one hand on the rear cover to keep the screws in place 13 Insert the new locating Dina into the jet 15 To check if the valve seaiue is installed properly press the locating pin The valve seat and location pin will be pushed back in start position Install the new gas side diaphragm on the main body 14 Front cover 3 Pressure adjusting discv7 Conical spring 10 Install the disc and spring into the front cover Use the drive in screw 8 for positioning the disc 7 in the cover Without the drive in screw the pressure can not be adjusted 15 Install the front cover on the main body Tighten the Allen screws and NOT the Tensilock nuts otherwise they will loose their locking function Torque setting 8 Nm Test the reducer for proper functioning according the test procedure 16 H reducer Reducer replacement kit 180 10025H fia aM H Sh RS S SS SZ VSI Reducer D1DIDDIIE HI 1
5. et a 16 mm hose with a pressure sensor a manually operated valve and a restriction 1 0 2 0 mm orifice depending of the restrictions of the INLET 3 If necessary connect a silencer on the outlet to reduce the noise 4 Connect 12 Volts to the coil Calibrating the test Use a new reducer to calibrate the restriction on the outlet 1 The outlet pressure should be 2 1 2 2 bar factory default 2 When air is flowing through the reducer monitor the outlet pressure value and close the valve on the outlet 3 The pressure may increase maximal 0 15 bar 4 If the pressure increases more than 0 15 bar decrease the restriction of the outlet 40 P rocedure for testing the reducer 5 bar air in Restriction Outlet x Valve to simulate FUEL CUT 0FF Pressure sensor 12 V DC Testing a reducer OO en 8 9 Connect to the inlet air with a pressure of 5 bar abs Connect to the outlet a 16 mm hose with a pressure sensor a manually operated valve and a restriction Connect 12 Volts to the coil Set the reducer to its maximum pressure rotating adjusting bolt counter clockwise Pressure should be greater than 2 6 bar abs When air is flowing through the reducer monitor the outlet pressure value and close the valve on the outlet The pressure may increase maximal
6. ighten the diaphragm bolt 13 and disc 12 with a new locking nut 11 Torque setting 2 5 Nm 20 New diaphragm ready to install Remove the lock off valve 31 for cleaning the gas inlet channel 21 Remove the jet 15 from the main body 1 Special 19 mm socket part nr 099 9980 Clean the main body thoroughly Remove the lock compound pollution Remove jet valve and spring Clean the main body thoroughly Remove all parts of the locking compound 22 Remove the pressure relief device Replace the o ring 29 from the pressure relief valve 24 and replace it with a new o ring 29 23 Clean the threaded hole with a thread cutting device M10x1 Clean the threaded hole and the main body thoroughly Clean the threaded hole with a thread cutting device M10x1 Clean the threaded hole and the main body thoroughly Clean the gas inlet with an air gun When the valve pin is removed clean the M10x1 threaded hole Mount the pressure relief device Mount the nipple22 with a locking compound threebond 1305 or equal Torque setting 2 5 Nm 24 insert spring into cleaned body and new valve NOT TO MUCH locking compound cleaned threaded center Otherwise the compound can glue the valve against the jet When the main body 1 is completely free from pollution Mount the new jet 15 wit a locking compound threebond 1305 or equal tighten the new jet Torque setti
7. ng 4 Nm 25 Place the rear cover with the new O ring and insert the six Allan screws Flip the reducer 180 degrees Use one hand on the rear cover to keep the screws in place 26 Insert the new locating Dina into the jet 15 To check if the valve seaiue is installed properly press the locating pin The valve seat and location pin will be pushed back in start position Install the new gas side diaphragm with the new locating Dip into the jet 15 To check if the valve seat 16 is installed properly press the locating pin The valve seat and location pin will be pushed back in start position 2 Front cover 3 Pressure adjusting discv7 Conical spring 10 Install the disc and spring into the front cover Use the drive in screw 8 for positioning the disc 7 in the cover Without the drive in screw the pressure can not be adjusted 28 Install the front cover on the main body Tighten the Allen screws and NOT the Tensilock nuts otherwise they will loose their locking function Torque setting 8 Nm Test the reducer for proper functioning according the test procedure 29 Damper modification in J reducer Loosen the six torx screws Do NOT rotate the Tension lock nuts otherwise they will loosen their locking function Remove the front cover membrane and adjustment disc together with the spring 30 Damper upgrade kit Take the piston of the upg
8. rade kit ot Sa A 7 fo 31 Remove the locknut for the membrane A Insert the membrane with needle back into the regulator Make sure that the needle is in its guidance clip underneath the membrane Take the adjustment bold that is in the upgrade kit and the adjustment disc with the spring 33 Remove the spring Remove the locking clip with a screwdriver make sure that you hold the locking clip it can jump away 34 Remove the old adjustment bold Insert the new adjustment bold into the disc 35 Fit the locking clip Mount the spring back into place 36 Insert the adjustment system into the top cover of the regulator E Mount the tension lock nuts and tighten the torx bolts with 8Nm torque No tightening Tighten with 8Nm torque Install the regulator back on the car Adjust the pressure back to the original settings as seen in the parameter list and test the regulator for leakage and functionality 38 How to Calibrate the test procedure Restriction Outlet x Valve to simulate FUEL CUT 0FF Pressure sensor Zo 5 bar air in H 12 V DC 39 First steps before calibrating the test 1 Connect to the inlet air with a pressure of 5 bar abs 2 Connect to the outl
9. seats and the locating pin 14 The valve seati1s and the locating pinc14 will be replaced Remove the front covers The complete adjusting disc and conical spring 10 will be used again Replace the gas side diaphragm The diaphragm bolt and disc will be used again Mount the disci12 with the sharp side facing the conical spring 10 Tighten the diaphragm bolt 13 and disc 12 with a new locking nut 11 Torque setting 2 5 Nm New diaphragm ready to install Remove the lock off valve 31 for cleaning the gas inlet channel Remove the jet 15 from the main body 1 Clean the main body thoroughly Remove the pressure relief device Replace the o ring 29 from the pressure relief valve 24 and replace it with a new o ring 29 Clean the threaded hole with a thread cutting device M10x1 Clean the threaded hole and the main body thoroughly Clean the threaded hole with a thread cutting device M10x1 Clean the threaded hole and the main body thoroughly Clean the gas inlet with an air gun When the valve pin is removed clean the M10x1 threaded hole 10 When the main bodya is completely free from pollution Mount the new jet 15 wit a locking compound threebond 1305 or equal Torque setting 4 Nm Mount the pressure relief device Mount the nipple22 with a locking compound threebond 1305 or equal Torque setting 2 5 Nm Replace th

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