Zavoli GE User manual

Tec
h
nic
al
Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS
_R
G
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00
7
.01
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09/10/2009

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
-
007.00
-
E
09/10/2009
Page 2 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
Technical Document ID:
DT_IS_RG-007
Rev. Date Type of
Alteration Issued by Inspected/Approved by
0 May 23, 2007 First Issue ROS Technical
Office
DTE Technical
Manager
1 09/10/2009 Second Issue ROS Technical
Office DTE Technical Manager
INTRODUCTION
The following manual is not designed to offer a comprehensive guide on the simple overhaul
procedures for GE – GES – GEX – GEXL regulators/vaporizers.
Therefore, the goal of this manual is to provide general guidelines for the disassembly and
reassembly of these regulators/vaporizers. Such procedures may be subject to the replacement of
some of the internal components of the regulators, which will be performed at the installer’s
discretion.
ZAVOLI S.r.l. disclaims any responsibility for any malfunction of its regulators/vaporizers due
to alterations performed by non-authorized personnel. Illegal tampering with the systems will
cause their warranty to become null and void.
ZAVOLI S.r.l. reserves the right to change its devices in accordance with new applications and
techniques available in the future. ZAVOLI S.r.l. disclaims any responsibility for system
malfunctions caused by failure to update this manual.

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
-
007.00
-
E
09/10/2009
Page 3 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
General Index
Introduction ……………………………………………………. ……2
1. ……………….. GE – GES – GEX – GEXL Regulators/Vaporizers ……..…. ……5
2.
……………….. How to perform a proper overhaul ...……………………….. ……7
2.1
………… Replacement of the 1
st
stage lever cut-off ………………. ……8
2.2
………… Replacement of the 2
nd
stage lever rubber top ……………. ……9
2.3
………… Replacement of the movable core cut-off of the electrovalve and O-Ring sleeve of the electrovalve ………………………… ……10
2.4
………….
Replacement of all O-Rings.…………………………………. ……11
3. ………………...
Reassembly of the Regulator/Vaporizer …………………. ……14
3.1 …………. Installation of the cut-off valve on the 1
st
stage lever ………..
……14
3.2 …………. Installation of the cut-off valve on the 2
nd
stage lever ……...
……15
3.3 …………. Installation of the electrovalve piston rubber top ……………
……16
3.4 …………. Installation of the 1
st
stage lever …………………………… ……16
3.5 …………. Installation of the 2
nd
stage lever …………………………… ……17
3.6 …………. Installation of the high-pressure diaphragm ………………. ……17
3.7 …………. Installation of the 1
st
stage cover ……………………………… ……19
3.8 …………. Installation of the 2
nd
stage diaphragm ………………………. ……20
3.9 ………… Installation of the 2
nd
stage cover ……………………………. ……21
3.10 ………… Installation of the bleed valve screw top …………………….. ……21
3.11 ………… Installation of the sensitivity register ………………………… ……22
3.12 ………… Installation of the gas outlet connection …………………….. ……24
3.13 ………… Installation of the water inlet/outlet connections …………… ……25

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
-
007.00
-
E
09/10/2009
Page 4 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
3.14 …………. Installation of the electrovalve sleeve ……………………….. ……26
3.15 …………. Installation of the separate idle channel screw top ………… ……26
3.16 ………… Installation of the electrovalve and screw top ………………. ……27
3.17 ………… Installation of the screw top ………………………………….. ……27
4. ………………..
Testing procedures …..……………………………………… ……28

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
-
007.00
-
E
09/10/2009
Page 5 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
1. GE – GES – GEX – GEXL Regulators/Vaporizers
GE – GES – GEX - GEXL regulators/vaporizers are, as most people know, devices which allow
gas to change from a liquid to a gaseous state. Regulators also help reduce the operating
pressure.
In order to perform a proper overhaul of the GE regulator/vaporizer, please use the overhaul kit
(code 101K02) described in the following table:
ITEM DESCRIPTION QUANTITY
101K02 CNG SYSTEM OVERHAUL KIT– “101GE”
1001C 1
st
stage cut-off valve 1
1003/1 4x7.5 headless screw (threaded rod) 2
1003/2 4x7.5 regular screw 4
10012C Low-pressure lever/electrovalve cut-off 2
10015B 5.28x1.78 O-Ring – plunger/idle channel screw top 2
10021B 12.42x1.78 O-Ring – electrovalve sleeve/ register /channel 2
10025B 9.25x1.78 O-Ring – electrovalve screw top/bleed valve
screw top 2
10030B 18.77x1.78 O-Ring – gas outlet connection 1
10031B 10.82x1.78 O-Ring – water outlet connection 4
101COM004 1
st
stage diaphragm - “101GE” REGULATOR 1
100COM016 Full low-pressure diaphragm 1
In order to perform a proper overhaul of the GES - GEX regulators/vaporizers, please use the
overhaul kit (code 100K02) described in the following table:
ITEM DESCRIPTION QUANTITY
100K02 CNG SYSTEM OVERHAUL KIT - electronic
1001C 1
st
stage cut-off valve 1
1003/1 4x7.5 headless screw (threaded rod) 2
1003/2 4x7.5 regular screw 4
10012C Low-pressure lever/electrovalve cut-off 2
10015B 5.28x1.78 O-Ring – plunger/idle channel screw top 2
10021B 12.42x1.78 O-Ring – electrovalve sleeve/register/channel 2
10025B 9.25x1.78 O-Ring – electrovalve screw top/bleed valve
screw top 2
10030B 18.77x1.78 O-Ring – gas outlet connection 1
10031B 10.82x1.78 O-Ring – water outlet connection 4
100COM004 Full 1
st
stage diaphragm 1
100COM016 Full low-pressure diaphragm 1

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
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007.00
-
E
09/10/2009
Page 6 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
In order to perform a proper overhaul of the GEXL regulators/vaporizers, please use the
overhaul kit (code 100K05) described in the following table:
ARTICLE DESCRIPTION QUANTITY
100K05 CNG SYSTEM OVERHAUL KIT - electronic
1001C 1
st
stage cut-off valve 1
1003/1 4x7.5 headless screw (threaded rod) 2
1003/2 4x7.5 regular screw 4
10012C Low-pressure lever/electrovalve cut-off 1
10012CR Reinforced low-pressure lever cut-off 1
10015B 5.28x1.78 O-Ring – plunger/idle channel screw top 2
10021B 12.42x1.78 O-Ring – electrovalve sleeve/ register /channel 2
10025B 9.25x1.78 O-Ring – electrovalve screw top/bleed valve
screw top 2
10030B 18.77x1.78 O-Ring – gas outlet connection 1
10031B 10.82x1.78 O-Ring – water outlet connection 4
100COM004 Full 1
st
stage diaphragm 1
100COM016 Full low-pressure diaphragm 1

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
-
007.00
-
E
09/10/2009
Page 7 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
2. How to perform a proper overhaul
To perform a proper overhaul of a CNG regulator/vaporizer (Fig. 2-1) it is advisable to
disassemble the device in all its components (Fig. 2-2).
Fig. 2-1
Fig. 2-2

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
-
007.00
-
E
09/10/2009
Page 8 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
The main body of the regulator (Fig. 2-3 and 2-4) must be carefully cleaned with a brush (Fig. 2-
5 and 2-6) and a degreasing detergent to remove oil, grease, etc. Do not use sandblasting
machines or any other kind of abrasive tool/substance, as this may damage components which
are critical for the proper operation of the regulator. CAREFULLY BLOW COMPRESSED AIR
ON THE DEVICE UNTIL IT IS COMPLETELY DRY!!!!!
Fig. 2-3 Fig. 2-4
Fig. 2-5 Fig. 2-6
2.1 Replacement of the 1st stage lever cut-off
With a punch, apply a small amount of pressure to the cut-off valve so that it separates from its
housing (Fig. 2.1-1 / 2.1-2 and 2.1-3).

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
-
007.00
-
E
09/10/2009
Page 9 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
Fig. 2.1-1
Fig. 2.1-2 Fig. 2.1-3
2.2 Replacement of the 2nd stage lever rubber top
To replace the 2nd stage lever rubber top, pinch the top end of the rubber top with two fingers.
Then, carefully remove the rubber top (Fig. 2.2-1 / 2.2-2 and 2.2-3). When working with a
GEXL regulator, please use the 10012CR cut-off included in the 100K05 overhaul kit!!!!
Fig. 2.2-1 Fig. 2.2-2

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
-
007.00
-
E
09/10/2009
Page 10 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
2.3 Replacement of the movable core cut-off of the electrovalve and O-Ring sleeve of the
electrovalve
To replace the electrovalve rubber top, hold the sliding metallic component located inside the
valve in place with two fingers. Then carefully remove the rubber top with the other hand.
(Fig. 2.3-1 / 2.3-2 / 2.3-3 and 2.3-4)
Movable core
Fig. 2.3-1 Fig. 2.3-2
CAUTION:
When replacing O-Rings, make sure that seats do not get damaged!!
Electrovalve sleeve
Fig. 2.3-3 Fig. 2.3-4

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
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007.00
-
E
09/10/2009
Page 11 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
2.4 Replacement of all O-Rings
The following pictures show all the components in which O-Rings should be replaced.
Fig. 2.4 Fig. 2.4-1
Separate idle register
Fig. 2.4-2 Fig. 2.4-3
Sensitivity register
Fig. 2.4-4 Fig. 2.4-5

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
-
007.00
-
E
09/10/2009
Page 12 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
Gas outlet connection
Fig. 2.4-6 Fig. 2.4-7
Water outlet connection
Fig. 2.4-8 Fig. 2.4-9
Water outlet connection
Fig. 2.4-10 Fig. 2.4-11
Electrovalve screw top

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
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007.00
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09/10/2009
Page 13 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
Fig. 2.4-12 Fig. 2.4-13
Bleed valve screw top
Fig. 2.4-14 Fig. 2.4-15
Separate idle channel screw top

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
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007.00
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E
09/10/2009
Page 14 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
3 Reassembly of the Regulator/Vaporizer
Before proceeding to reassemble the components of the regulator/vaporizer (Fig. 3-1),
please make sure that all O-Ring seats are in perfect working condition to avoid potential
leaks. Also make sure that the new O-Rings are well lubricated before they are installed!!!
Fig. 3
3.1 Installation of the cut-off valve on the 1st stage lever
With a punch, insert the cut-off valve in its operating seat (Fig. 3.1 / 3.1-1 / 3.1-2 and 3.1-3),
making sure that the central part of the cut-off does not get damaged in the process.
Fig. 3.1 Fig. 3.1-1

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
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007.00
-
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09/10/2009
Page 15 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
Fig. 3.1-2 Fig. 3.1-3
3.2 Installation of the cut-off valve on the 2nd stage lever
To install the 2nd stage lever, you will need a pair of pliers (Fig. 3.2). Put the cut-off valve in
place as shown in Fig. 3.2-1 and 3.2-2. Pull the stem with the pliers and slightly twist it.
Fig. 3.2 Fig. 3.2-1
Fig. 3.2-2 Fig. 3.2-3

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
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007.00
-
E
09/10/2009
Page 16 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
Fig. 3.2-4
3.3 Installation of the electrovalve piston rubber top
Put the cut-off valve in place, as shown in Fig. 3.3. While pressing the valve down to insert it in
its seat, turn the piston clockwise. (Fig. 3.3-1)
Fig. 3.3 Fig. 3.3-1
3.4 Installation of the 1st stage lever
Insert the pin in the lever holes as shown in the pictures, and with a Phillips screwdriver secure
the 2 headless screws (threaded rods) into their seats.
Lever-
supporting
pin.
Fig. 10-1 Fig. 10-2

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
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007.00
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E
09/10/2009
Page 17 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
3.5 Installation of the 2nd stage lever
To place the 2nd stage lever in the correct operating position, please refer to the pictures below
(Fig. 3.5 and 3.5-1). Insert the pin and secure the regular screws into their seats (Fig. 3.5-2).
Fig. 3.5 Fig. 3.5-1
Fig. 3.5-2
3.6 Installation of the high-pressure diaphragm
To install the high-pressure diaphragm, please refer to the following directions.
Diaphragm for GE regulators/vaporizers

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
-
007.00
-
E
09/10/2009
Page 18 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
Fig. 3.6 Fig. 3.6-1
Diaphragm for GES – GEX – GEXL regulators/vaporizers
Fig. 3.6-2 Fig. 3.6-3
Insert the high-pressure
diaphragm hook on the bottom of
the 1st stage lever.
With a finger, press the 1st stage
lever down. The lever will sit in a
raised position, which will allow
the diaphragm hook to be
fastened to it.
FAILURE TO FASTEN THE
HOOK TO THE LEVER
WILL PREVENT THE
REGULATOR FROM
WORKING PROPERLY!
Fig. 3.6-4

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
-
007.00
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E
09/10/2009
Page 19 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
3.7 When installing the 1st stage cover, make sure that the notch on the side of the cover is
placed on the electrovalve housing (Fig. 3.7 / 3.7-1 / 3.7-2 / 3.7-3 and 3.7-4). Also make
sure that the cover screws are safely secured into place by means of a torque wrench
(MAX 5.5 Nm). Fasten the screws in the following order: top, bottom, left, right.
Repeat the procedure.
Notch on the cover to determine proper
positioning.
Hole for the installation of the electrovalve.
Fig. 3.7
Fasten with a 5.5 Nm torque wrench
Fig. 3.7-1 Fig. 3.7-2
Fig. 3.7-3 Fig. 3.7-4

Technical Directions
for the Overhaul of
GE – GES – GEX – GEXL
Regulators/Vaporizers
DT_IS_RG
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007.00
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E
09/10/2009
Page 20 of 32
ZAVOLI s.r.l. Via Pitagora n° 400 47023 Fr. Case Castagnoli, CESENA (FC), Italy
Tel. [phone] – Telefax (+39) 0547 / 646411
Web site: www.zavoli.com E-mail: [e-mail]
3.8 Installation of the 2nd stage diaphragm
Fig. 3.8 Fig. 3.8-1
Insert the 2
nd
stage diaphragm hook on the
bottom of the 2nd stage lever.
2nd stage lever
Fig. 3.8-2
MAKE SURE THAT THE DIAPHRAGM
IS PROPERLY FASTENED TO THE
LEVER. FAILURE TO DO SO WILL
PREVENT THE REGULATOR FROM
WORKING PROPERLY!!!!