GB

RIDUTTORI TN1 B SIC

TN1 B SIC REGULATORS
REDUCTORES TN1 B SIC
MANUALE INSTALLAZIONE E REGOLAZIONE
INSTALLATION AND ADJ USTMENT MANUAL
MANUAL DE INSTALACIN Y REGULACIN
I
E
LANDI RENZO S.p.A.
2/36
Fig. 1
Fig. 2
I
Technical drawings GB
Schemi tecnici Esquemas tcnicos E
LANDI RENZO S.p.A.
Installationand adjustament manual TN1 B SIC
14/36
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 its
use is recommended only when there is a
carburation vacuum in the main tube from idling
supply to off-idle. If used, always line it up in the
same 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 2
nd
stage.
1. SPECIFICHE TECNICHE
An electronically controlled device which redu-
ces the pressure of methane allowing a regular
flow of gas for every requirement of the engine.
It is fitted with three stages of methane reduction
which ensures stability at both high and low feed
pressures, and with a high pressure electrovalve
upstream of the 1
st
stage. Heat absorption, carried
out by elements of the reduction unit heated by
liquid 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 idle
is at positive pressure from the second stage and
is distributed via a gas conduit separate from the
main flow.
Included is an electronic device for starting with
a built-in safety system which closes the gas
electrovalve in cases where the engine is switched
off, even accidentally.
SPECIFICATIONS:
Type of reduction unit: 3 stage with electronic
starting device and positive pressure idling.
Use: autodrive
Type of fluid: CNG (Compressed methane gas)
Body: GDALSI 13 UNI 5079
Heating: liquid from engine cooling circuit
Test pressure: 300 bar
Inlet pressure: 220 bar
1
st
stage adjustment pressure: 3,5-4 bar
2
nd
stage adjustment pressure: 1,5 bar
Power supply: 12 V c.c.
High pressure electrovalve coil power : 20W
Idling electrovalve coil power: 18W
2. FUNCTIONING OF THE REDUCTION UNIT
(Fig. 2)
With the electrovalve (1) open, the methane gas
enters the 1
st
stage chamber (4). The pressure
exerted by the gas on the walls of the chamber
dilates the membrane (8), overcoming the resi-
stance of the spring (9). The membrane (8) atta-
ched to the lever (3) acts on the 1
st
stage valve (2),
creating a pressure equilibrium.
From the 1
st
stage chamber (4), the gas passes to
the 2
nd
stage (11)and the flow is delivered by the
pressure exerted by the gas on the membrane
(10), regulating the opening and closing of the
valve (13). Depressurisation of the engine activa-
tes an axial movement of the 3
rd
stage membrane
(6) which, connected to the lever (5), causes the
opening of the valve (7). Through the outlet (19),
the gas enters the engine.
Sealing of the valve (7) is obtained by correct
calibration of the spring (14). The starting and
idling device comprises an electrovalve (17) con-
trolled by an electronic device. The needle (15) is
displaced and frees the jet (18), the gas from the
second stage (11) exits, thus permitting the engine
to function at idling speed.
If the engine is switched off, the coil is deactivated
and the needle (15) closes the outlet jet (18).
Adjustment of the idling speed is carried out via the
adjuster (16). When the engine is started, the
electronic device activates the coil (17), the nee-
dle (15) frees the jet (18) and allows the amount
of gas necessary for starting to pass through.
Legend
Specification
GB
Operation GB
LANDI RENZO S.p.A.
Installationand adjustament manual TN1 B SIC
15/36
Detai l s: the following photographs show the
route of the methane with blue arrows A, with red
arrows B the forces exerted and with yellow
arrows C the internal channels for the passage of
the methane.
Figure 3 shows the TN1B SIC methane reduction
unit; the blue arrows show the flow of methane
at the inlet (on the left) and outlet (at the top).
It is a 3-stage reduction unit. That is to say, it
consists of two high-pressure stages (the first
reduces to 4.5 bar, the second to 1.5 bar) and a
final stage which operates at low pressure.
Figure 4 shows the 1
st
stage.
The pressure here is kept constant by the strength
of the spring which presses down by the effect
of the pressure below the membrane, which
pushes upwards (where the cover is located).
Under the plate note how the methane enters the
1
st
stage (at the rim) and progresses to the second
(blue arrows).
In practice the methane enters the stage. From the
effect of pressure, a force is generated which
pushes the plate upwards, but there is a spring
above it\: the opposing force pushes the plate
down and with corresponding force generates a
force in the stage of 4.5 bar (approximately), the
position of the lever shown in figure 5 closes the
gas inlet orifice (in the rim).
The transit channel through which the methane
passes to change stage is shown by the white
arrow on the left in figure 6.
In the second stage, the pressure is lowered still
further to 1.5 bar, again by means of a spring
opposing a lever figure 7 (arrow on right). When
methane enters, the plate indicated by the arrow
on the left swells, then generates a force upwar-
ds, which is however opposed by a downward
force generated by the spring shown in figure 7.
Fig. 3
Fig. 4
Fig. 5
Fig. 6
A
A A
B
A
Operation GB
LANDI RENZO S.p.A.
Installationand adjustament manual TN1 B SIC
16/36
This generation of two opposing forces results in
the lever closing the methane inlet orifice shown
in figure 9 (the blue arrows show the circulation
of methane passing from the second stage to
channel leading to the third stage).
Seal is ensured by valve B.
Figure 9 also clearly shows the passage of
methane from the inlet to the third stage channel
and 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 the
engine at idling speed is effected by means of the
small tube indicated in figure 10 with a yellow
arrow. The lever to which the membrane is fixed
is indicated by the large arrow.
Regulation of the quantity (which is possible with
the SIC reduction unit) is carried out by means of
the regulator located on the front of the reduction
unit.
Operation GB
LANDI RENZO S.p.A.
Installationand adjustament manual TN1 B SIC
17/36
Fig. 12
Fig. 13
Fig. 14
Fig. 16
B
C
A
B
B
A
B
A
By screwing in (reduction of the quantity of gas)
or unscrewing of the regulator (increase in the
quantity of gas) the conical seat of the regulator
allows the gas to pass through the larger jet
(coming from the channel shown by the yellow
arrow in figure 11) and to proceed to the small jet
(see blue arrow) which connects with the idling
speed tube. The seal of the regulator is effected
with an O-ring.
The third, low pressure, stage consists of a
membrane fixed to the steel lever in figure 10 by
an aluminium plate. In practice this stage is con-
nected to the engine via the gas outlet tube which
goes to the mixer, and is thus subject to depres-
sion generated within itself by the operating of the
accelerator butterfly valve.
Acceleration creates a force (whose vector is
indicated by F in figure 13) which pushes the
membrane towards the interior of the reduction
unit thus, by means of the orifice below shown in
figure 15, allowing the passage of the methane
into the third stage and finally it is breathed out
of the reduction unit towards the mixer and goes
Fig. 15
to feed the engine. The sensitivity of the spring
which supports the lever is controlled by the brass
regulator located on the side of the reduction unit.
In figure 16, the blue arrows show the gas flow
at idle (small arrow) and off idle (larger arrow).
The circle in figure 15 indicates the valve which
makes a seal when the lever is closed (that is,
when the depression of the engine is weak.
Operation GB
LANDI RENZO S.p.A.
Installationand adjustament manual TN1 B SIC
18/36
Figure 17 shows the methane outlet tube. Figure
18 shows the pressure reducer and the feed tube
to the mixer (directly on the finned body.
Fix with
M10 screws
Fig. 19
Fig. 20
Position of the reduction unit
NO
YES
NO
NO
Discharge cap
Fig. 18
Fig. 17
A
A
A
3. GENERAL INFORMATION
When installing the reduction unit, the following
instructions must be observed.
supplied with the reduction unit are the mounting
brackets for locating the reduction unit in the
engine compartment. These should be adapted to
suit the type of compartment.
Notices GB
LANDI RENZO S.p.A.
Installationand adjustament manual TN1 B SIC
19/36
install the reduction unit in the engine compart-
ment as close as possible to the point at which the
mixer unit is installed, fixing it securely to the
bodywork with the screws provided;
install the reduction unit outside the compartment
containing the equipment for collecting air for the
ventilation and heating of the drivers compart-
ment;
install the reduction unit at a distance of not less
than 150mm from the exhaust pipes and silencer.
If this distance is less than the minimum stated, but
more than 75mm, a sheet of metal not less than
1mm thick must be placed between the componen-
ts;
position the reduction unit parallel to the direction
of the vehicles motion, and in a vertical position,
so that it is easily accessible for adjustment and
maintenance;
ensure that the reduction unit is located in a
position lower than the highest point of the radiator
to prevent air bubbles forming in the water circuit;
The reduction unit should be connected to the
water of the engine cooling system or passenger
cabin heating system by means of suitable hoses.
Fit the T-connectors as shown in figure 22 and use
the hose clips provided to secure them.
A thermostat valve can be used, and should be
installed in the water outlet tube of the reduction
unit.
take care not to position the reduction unit so that
the discharge cap is located above the starter
motor or ignition coil;
carefully clean the high pressure methane tubes
before finally connecting them to the reduction
unit, to avoid impurities getting into the reduction
unit;
ensure that when the engine is running there is
no leakage from the water hoses (usually con-
nected to the passenger compartment heating
circuit);
never, under any circumstances, change the
position of the reduction units gas inlet assembly,
since this could alter the calibration of the 1
st
stage
valve\: this would risk hampering the passage of
gas with a possible increase in pressure in the 1
st
stage, which could cause the safety valve to
open, resulting in an escape of gas. As well as
making 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 by
means of the connections to the engine cooling
system.
Every time the engine cooling system is emptied,
the level of liquid should be replenished, taking
care to eliminate any air bubbles which could
hamper the heating of the reduction unit.
The gas outlet of the reduction unit must be
connected 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 reduction
unit for locating it in the engine compartment. They
should be adapted to suit the position selected for
mounting.
Notices GB
LANDI RENZO S.p.A.
Installationand adjustament manual TN1 B SIC
20/36
Fig. 22
Thermostat valve
4. ADJUSTING THE SENSITIVITY OF TN SIC
REDUCTION UNITS (Fig. 1)
The reduction units have already been adjusted by
the manufacturer, but if any problems should be
encountered such as uneven idling speed or flat
spots in acceleration, we recommend checking
the sensitivity of the reduction unit. The adjustment
screw (C) is not used for adjusting the idling speed
but only for adjusting the sensitivity of the reduc-
tion unit: unscrewing it lightens the load which the
spring exerts on the third stage lever, while
tightening it increases the load exerted by the
spring on the second stage lever towards closing.
In particular, being the idling flow, separated from
the maximum, the change from the idling regime to
a higher one happens without carburation flat
spots which are noted particularly when acce-
lerating very slowly (adjuster too tight) and at the
same time the reduction unit remains tight and does
not 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 mixer
from 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 gas
outlet tube (A) and loosen the adjuster (C) until gas
begins to come out of the reduction unit and
inflates the bubble;
5) The moment gas begins to come out of the
reduction unit, retighten the adjuster (C) until gas
no longer comes out, and at this point give the
adjuster an extra half-turn for safetys sake.
6) Install the sensitivity adjuster (C) protection cap
to prevent tampering.
An alternative, less accurate but quicker, way of
adjusting the sensitivity is as follows:
1) Fully tighten the sensitivity adjuster (C);
2) Start the engine and adjust the idling speed by
means of the adjuster (E) until the maximum value
of CO
2
is achieved;
3) Slowly undo the adjuster (C) until there is a
notable variation (reduction) in the CO
2
value;
4) At that moment, tighten the adjuster (C) until the
CO
2
value noted at point 2 is achieved.
5) Install the sensitivity adjuster (C) protection cap
to avoid tampering.
6) Check that there are no carburation flat spots
when accelerating slowly.
After the first 500 / 1.000 Km it is advisable to check
the sensitivity of the reduction unit.
Sensitivity adjustment GB
LANDI RENZO S.p.A.
Installationand adjustament manual TN1 B SIC
21/36
5. MAINTENANCE OPERATIONS REDUCTION
UNIT
To get the best from methane fuel, the engine
should be tuned and regularly maintained. This
applies both to the mechanical parts and electrical
system. As well as the normal maintenanc pre-
scribed by the vehicle manufacturer, the following
procedures are recommended:
every 30.000 Km check by means of the dischar-
ge cap that there is no oil or other deposits inside
the 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 instructions
below (paragraph 7).
6. SERVICING THE REDUCTION UNIT
To check correct closing of the third stage valve
(self-adjusting valves only), insert a piece of
white paper with a strip of carbon paper over it
between the valve and its seat. The valve must
reproduce an exact imprint of the rim of the valve.
If this is not the case, place a screwdriver in the
slot provided in the valve (without the white paper
and carbon paper) and move it until a correct
imprint is produced; then tighten the nut, ensuring
that the valve does not move.
3
rd
stage valve replacement
Fig. 23
Fig. 25
Fig. 24
Calibration distance
1
st
stage
Carbon paper
White paper
First imprint
White paper
C
a
r
b
o
n

p
a
p
e
r
Nut
Maintenance GB
LANDI RENZO S.p.A.
Installationand adjustament manual TN1 B SIC
22/36
7. SERVICING HIGH PRESSURE
ELECTROVALVE (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 and
spring 12 with the replacements in the service
package.
On the housing 10, replace O-ring 11 (OR 14x1.78
code no. 173151381).
Reassemble all components in the original order,
tighten the housing 10.
Replace coil 9 and secure it with nut 8 (torque 8
Nm).
8. SERVICING 1
ST
STAGE (Referto figure 26)
Remove 1
st
stage cover 57 by loosening nuts 59,
noting that the cover contains the compressed
spring.
Remove seal 87 and spring 56, undo nut 55,
remove washer 53, disc 54, membrane 52, disc 51
with O-ring 50 and housing 49.
Undo bolts 31 and remove lever 34 with pivot 35.
Remove 1
st
stage valve 36 and replace with the
valve from the service kit
Replace lever 34 and pivot 35 and tighten bolts 31
(torque 7 Nm).
Adjust the free play between lever 34 and 1
st
stage
valve 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 to
torque 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 to
torque 10 Nm.
Insert spring 56, replace seal 87 with a new one
from the service package.
Replace cover 57, washer 109, tightening the nut
59 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 one
from the service package.
Reassemble the spring with its pivot 76, taking
care to centre it on the stud on lever 86.
Replace bolt 74 after renewing O-ring 75 (OR
8.73x1.78 code no. 173007371.
Adjust the sensitivity as described in the manual
paragrafo 4.
Refit the idling adjuster cover 114.
10. SERVICING TIGHTNESS OF GAS OUTLET
JOINT
Undo bolt 28.
Remove joint 29 from the reduction unit and renew
O-rings 30 and 44 with those supplied in the
service package (OR 1715 code no. 173031371
and OR 2075 code no. 173068371.
Reassemble tube 29 complete with O-ring onto the
reduction unit. Secure by tightening bolt 28.
11. SERVICING IDLING ADJUSTMENT DEVICE
Remove nut 67 from housing 62.
Extract nut 67 complete with idling adjuster screw
69, idling adjuster knob 65 and its spring 66.
From housing 62, extract spring 71 and moving
needle 72.
Replace O-ring 73 in moving needle 72 with the one
from the service package (OR 1.5x1 code no.
173130371); reinsert the moving needle with its
new O-ring in housing 62.
Renew O-ring 70 on idling adjuster screw 69 with
the one from the service package (OR 108 code
no. 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 JOINT
Unscrew water joints 88, replace O-ring 46 with
a new one (OR 112 cod. 173009371), screw in
joints 88.
Servicing GB
LANDI RENZO S.p.A.
Installationand adjustament manual TN1 B SIC
23/36
13. SERVICING SECOND AND THIRD STAGES
(Refer to fi gure 26)
Remove the eight bolts 59 from 3
rd
stage cover 106.
Remove 3
rd
stage membrane 105 complete with
discs 45 and 104 and housing 94.
Undo 2
nd
stage spring adjustment screw 93.
Remove 2
nd
stage spring 103.
Remove bolts 93 and 102 from 2
nd
stage cover 100.
Unscrew nut 92, remove washers 91 and 101,
disc 99 and seal 87.
Remove membrane 90 and undo bolts 89 securing
2
nd
stage lever 96.
Replace lever 96 with the one from the service
package.
Secure the new lever with bolts 89 renew mem-
brane 90 with the one from the service package,
locating it correctly in the 2
nd
stage, replace disc99,
locate the two washers 91 and 101 and secure
by tightening nut 92 (torque 5 Nm).
Position 2
nd
stage cover on the membrane and
secure with bolts 93 and 102 (torque 5 Nm).
Renew spring 103 with the one from the service
package , secure the spring with bolt 93.
Position a 3 bar manometer in place of cap I (fig.
1) and calibrate 2
nd
stage pressure as specified,
by turning screw 93.
To carry out this calibration is is only necessary
to pump compressed air at 6-8 bar into the reduc-
tion units gas inlet.
Remove 3
rd
stage lever 86 and replace the valve
securing element 110 with the one in the service
package (disc D 11.70 thickness 1.20) as speci-
fied in paragraph 6 fig. 25.
Replace the lever by tightening the two bolts 89
which retain its axis.
Membrane replacement (position 105):
Remove nut 33 from the assembled membrane
assembly, remove washer 91 and disc 45, renew
the membrane using the one in the service packa-
ge, replace disc 45 and washer 91 and secure the
assembly with nut 33.
Replace the membrane on the reduction unit,
taking care to correctly hook housing 94 over lever
86.
Close the reduction unit by repositioning cover 106
and tightening bolts 59 onto washer 109 (torque
8 Nm).
At the end of every maintenance operation
i nvol vi ng di smant l i ng and reassembl y of
components, the reduction unit should be
tested as follows (fig.1):
Position a 3 bar scale manometer in place of
cap I.
Position a 10 bar scale manometer in place
of the safety valve on the 1
st
stage.
Charge t he reduct i on uni t wi t h ni t rogen
(aerosol ) from gas i nl et G to a pressure
between 200 and 50 bar.
Charge coil F with 12 Vcc; on the two mano-
meters check the internal pressure of the
two stages (see speci fi cati ons).
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 idling
tube B.
With a gas loss indicator spray, check that
there i s no gas escapi ng from the seal s,
especially in the high pressure area of the
1
st
stage cover, the safety valve and cap I.
The above tests shoul d al so be repeated
after mounting a manometer sensor on the
T position joint 108 in the exploded diagram
on p. 12.
For spare parts refer to servi ce package
Code no. 674011000
Servicing GB
LANDI RENZO S.p.A.
Installationand adjustament manual TN1 B SIC
24/36
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
- 1
st
and 2
nd
stage pressures
not as specified
3
The reduction unit works at very low
temperature
- Check water circulation
4 Difficult to adjust idling speed
- 2
nd
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
- 3
rd
stage lever is not correctly
set
10
Loss from safety valve (safety valve
opens and gas escapes)
- Check 1
st
stage pressure, if
necessary replace 1
st
stage
valve and membrane
Referto figure 1 p. 2
Trouble shooting
GB