SERVICE BULLETIN

TOPIC:
IDENT NO:
SUPERSEDES:
DATE:
SUBJECT:

Fuel System
9-2916A
9-2916
May 2, 2006

Mooney Fuel Regulators

MODELS AFFECTED:

VHP GSI/GL/LT

INTRODUCTION
Mooney regulators are now used on select VHP
engines. The new regulator will be standard equipment on all GSI, GL, and LT engines running on pipeline quality or 900 Btu field gas. It is currently not used
with GLD, GSID or AFM equipped engines. The new
regulator provides improved control and ease of maintenance.

PRINCIPLES OF OPERATION
The Mooney regulator system utilizes a pilot that controls a main valve (see Figure 1 and Figure 3). The
pilot assembly features a removable cartridge and a
10 micron gas filter. The main valve is a simple design
that uses few parts. These features make the regulator
assembly easy to maintain.

diaphragm is closed tightly against the throttle plate.

The pressure differential across the outlet half of the
diaphragm adds to the spring force in closing the
valve.
As demand for flow occurs in the downstream system,
the outlet pressure drops causing the pilot valve to
open and start bleeding pressure out of the spring
case faster than it can enter through the cartridge
restrictor, resulting in a reduction of pressure above
the diaphragm (see Figure 2). This allows the inlet
pressure to progressively lift the main valve diaphragm
off the throttle plate, opening the valve and satisfying
the demand for flow in the downstream system.

PILOT SENSE
CONNECTION

PILOT SUPPLY

PILOT SENSE
CONNECTION

RESTRICTOR
PILOT
CONTROL
PRESSURE

PILOT SUPPLY
RESTRICTOR

PILOT LOADING
CONNECTION

PILOT
VALVE
PILOT LOADING
CONNECTION

MAIN VALVE

INLET

PILOT OUTLET
CONNECTION
OUTLET

PILOT OUTLET
CONNECTION

INLET

OUTLET
DIAPHRAGM

Figure 1. Pressure Reducing Configuration

Fully Closed

At no flow, when the outlet pressure is greater than the

set point of the pilot, the pilot valve is closed and full
inlet pressure loads the spring case through the pilot
loading connection. In this condition the main valve
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DRESSER, INC.
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Figure 2. Pressure Reducing Configuration Fully Open

When demand for flow ceases or is reduced, the

downstream pressure increases causing the pilot
valve to close. Inlet pressure continues to pass
through the restrictor until the control pressure equals
the inlet pressure. The spring force, plus the pressure
differential across the outlet half of the main valve diaphragm, closes the diaphragm against the throttle
plate, shutting off the flow.
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Service Bulletin No. 9-2916A

PILOT OUTLET
CONNECTION

PILOT INLET (SUPPLY)

CONNECTION

PILOT SENSE
CONNECTION

CARTRIDGE

FIXED
RESTRICTOR
ORIFICE
OUTLET

VENT
MAIN VALVE

PILOT

PILOT
LOADING
CONNECTION

FILTER

INLET

Figure 3. Inline Regulator (Left Bank)

MAINTENANCE SCHEDULE
1. 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 and
Figure 4). Orifice inside diameter is 0.052 in.
(1.3 mm) (#55 drill).

ORIFICE
INSIDE DIAMETER
0.052 IN. (1.3 MM)

NOTE: Pilot parts are subject to normal wear and

must be inspected and replaced as necessary. The
frequency of inspection and replacement of parts
depends on severity of service conditions and/or the
requirements of local, state, and federal regulations.
Be certain that the name plates are updated to
accurately indicate any field changes in equipment,
materials, service conditions, or pressure settings.
3. Inspect all other components (replace as needed).

Page 2 of 16

Figure 4. Fixed Restrictor Orifice

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Service Bulletin No. 9-2916A

REPLACEMENT SERVICE PARTS
AND KITS

Table 2. Component Parts

P/N
DESCRIPTION

NOTE: The following updates have been added.

Improved balance lines (5/8 inch diameter) for GSI
and 7042GL engines. Updated main valve, contains
new spring and diaphragm that reduces CO emissions
on GSI engines. In addition, new regulator springs are
available for all engine models. See Table 2 for
information.
Table 1. Service Part Kits

214172

Pilot

489668

Cartridge

214174

Filter

214171B

Main Valve (Left Bank)

also used on inline engines
(updated spring and diaphragm)

214171C

Main Valve (Right Bank)

(updated spring and diaphragm)

214175

Fixed Restrictor Orifice

214172

Brown (10 40 IWC)

P/N

DESCRIPTION

214172A

White (5 15 IWC)

489669

Pilot Maintenance Kit (Pivot Assembly Oring, Diaphragm, Closing Cap O-ring,
Adjusting Assembly O-ring)

214172B

Yellow (1 3 PSIG)

214191

5/8 in. Balance Line 6 Cylinder GSI Engine

214191A

489667

Cartridge Assembly
Maintenance 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)

5/8 in. Balance Line 12 Cylinder GSI

Engine (Right Bank)

214191B

5/8 in. Balance Line 12 Cylinder GSI

Engine (Left Bank)

489670

1.5 in. Main Valve Maintenance Kit

(Diaphragm and Body Seal)

214055D

5/8 in. Balance Line 16 Cylinder GSI

Engine (Both Banks)

489671

1.5 in. Main Valve Overhaul Kit (Low

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

214191D

5/8 in. Balance Line 7042GL

Engine with ESM (Left Bank)

489666

Type 30A Filter Maintenance Kit

(Element and O-ring)

214191E

5/8 in. Balance Line 7042GL

Engine with ESM (Right Bank)

Table 3. Mooney Regulator Fuel Pressures

ENGINE MODEL

RECOMMENDED NATURAL GAS

SUPPLY PRESSURE TO ENGINE
MOUNTED REGULATOR

MAXIMUM NATURAL GAS SUPPLY

PRESSURE TO ENGINE MOUNTED
REGULATOR

F2895GSI; 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)

REGULATOR ADJUSTMENTS

PILOT

The Mooney regulators were designed to track similar

to the previous Fisher regulator. The gas/air setting
and carburetor adjustments will remain the same as
those used with the Fisher regulator. Mooney regulators require specific supply pressures depending on
engine model (see Table 3).

DISASSEMBLE PILOT

The gas over air adjustment is controlled by adjusting

the stem screw and lock nut located at the bottom of
the pilot assembly. Turning the stem screw clockwise
will increase spring tension increasing the gas/air.
Turning the screw counterclockwise will reduce spring
tension and reduce the gas/air setting. Initial setting is
a stem length of approximately 2.75 in. (6.98 cm)
measured from adjuster housing fitting (see
Figure 19).

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WARNING
Before disassembly make sure the regulator and
main valve have been isolated from the process by
closing block valves on the inlet and outlet sides
of each component. Safely release pressure and
process fluid from the valve body and pilot
system. Failure to properly complete these steps
may result in personal injury and/or property
damage.
NOTE: A spare cartridge may be installed and the
regulator returned to service if time is a factor. Make
sure the stem O-ring is still in place in the pilot body
before installing the new cartridge. If the O-ring was
removed, install a new O-ring over the stem of the
cartridge assembly prior to installing it in the pilot body
(see Figure 5 and Figure 6).
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Service Bulletin No. 9-2916A

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

CARTRIDGE BODY

CARTRIDGE

BOTTOM CAP
ASSEMBLY
ORIFICE
ASSEMBLY

Figure 7. Cartridge Assembly

Figure 5. Cartridge Assembly

2. Remove stem O-ring from pilot body using suitable

tool (a paper clip works well). Do not scratch O-ring
groove (see Figure 6).
NOTE: The loading and inlet ports are interchangeable
with one another.
INLET

LOADING

4. Loosen lock nut on spring adjuster stem. Unscrew

adjuster stem. Spring tension will release as stem
is unscrewed (see Figure 8).
5. Remove retainer plug located below outlet port
(see Figure 8).
6. Remove one 5/16 in. - 18 UNC capscrew that
secures spring case to pilot body (see Figure 8).
OUTLET

RETAINER
PLUG

INLET
LOADING

STEM O-RING

OUTLET

Figure 6. Stem O-ring

5/16 IN.-18 UNC

CAPSCREW

3. Remove bottom cap from cartridge body and

remove internal parts. Use a heavy paper clip or
0.045 in. (1.14 mm) diameter wire to push out
orifice assembly (pilot valve). Do not damage O-ring
sealing surface of body cartridge (see Figure 7).

LOCK NUT

SPRING
ADJUSTER STEM

Figure 8. Pilot Spring Barrel

7. Thread 5/16 in. - 18 UNC capscrew into pivot and

pull pivot and lever assembly out of pilot body (see
Figure 9).
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Service Bulletin No. 9-2916A

5/16 IN.-18 UNC
CAPSCREW

10. Remove diaphragm assembly from body. Remove

retaining nut and remaining components. Inspect
all parts for wear or damage (see Figure 12).
RETAINING NUT

DIAPHRAGM

Figure 9. Pivot And Lever Assembly Removal

8. Remove remaining capscrews that secure spring

case to pilot body. Separate spring case from pilot
body (see Figure 10).

Figure 12. Diaphragm Assembly

ASSEMBLE PILOT
PILOT BODY

NOTE: Use Parker Super O-Lube or an equivalent

silicone based lubricant on all O-rings in the pilot
assembly.
1. Apply Parker Super O-Lube and slide O-ring
onto pivot and lever assembly. Apply Lubriplate
No. 105 petroleum grease to roll pin and lever
(see Figure 13).
ROLL PIN

SPRING CASE

Figure 10. Spring Case And Pilot Body

9. Disconnect line connections and remove pilot body

(see Figure 11).
PILOT BODY
LEVER

O-RING

Figure 13. Pivot And Lever Assembly

2. Install pilot diaphragm with convex side toward

diaphragm plate and main spring. Secure with nut
and washer. Tighten to 5 - 6 ft-lbs (6.8 - 8.2 N m).
Do not overtighten, overtightening will distort the
pilot diaphragm (see Figure 14).

Figure 11. Pilot Body

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Page 5 of 16

Service Bulletin No. 9-2916A

LEVER

NUT

DIAPHRAGM
PLATE

WASHER

DIAPHRAGM

DIAPHRAGM
RETAINER
DIAPHRAGM

Figure 14. Pilot Diaphragm

3. Thread 5/16 in. - 18 UNC capscrew into pivot then

push pivot and lever assembly into pilot body. A
guide pin located at the bottom assures pivot and
lever assembly is correctly oriented in body.
Remove
capscrew
when
complete
(see
Figure 15).

Figure 16. Diaphragm Installation

6. Place spring washer onto diaphragm plate.

Lubricate spring washer with Lubriplate No. 105
or petroleum grease to hold in position (see
Figure 17). Washer prevents main spring from
binding
on
diaphragm
assembly
when
compressed.
SPRING WASHER

5/16 IN.-18 UNC

CAPSCREW

GUIDE PIN
NOTCH

Figure 15. Pivot And Lever Assembly

4. Install retainer plug into body. Plug should be flush

with body when installed correctly (see Figure 8).
5. Slide diaphragm assembly onto lever. Align
diaphragm with pivot and lever assembly.
Lubrication of pivot pin is not required (see
Figure 16).

Figure 17. Diaphragm Spring Washer

7. Place spring case on pilot body (see Figure 18).

Vent connection should face down when regulator
is mounted on engine. This allows condensation to
drain away instead of accumulating and possibly
freezing.
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 2.0
in. (5.0 cm) below the spring case when fully installed.

Page 6 of 16

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Service Bulletin No. 9-2916A

MAIN SPRING

SPRING CASE

ADJUSTER
FITTING

LOCK NUT

VENT

ADJUSTER
STEM

Figure 18. Spring Case

Figure 20. Spring Adjuster

10. Install O-ring on spring adjuster fitting (see

Figure 19). Screw adjuster stem out to relieve
spring pressure during installation.

NOTE: A spare cartridge may be installed and the

regulator returned to service if time is a factor. Make
sure the stem O-ring is still in place in the pilot body
before installing the new cartridge. If the O-ring was
removed, install a new O-ring over the stem of the
cartridge assembly prior to installing it in the pilot body
(see Figure 5 and Figure 6).

11. Install adjuster fitting in body. Turn adjuster stem

until it measures 2.75 in. (6.98 cm) from adjuster
fitting. Tighten lock nut (see Figure 19 and
Figure 20).

12. Assemble cartridge by placing O-ring on bottom

cap, then install return spring, orifice spring, stem
guide, plug and stem, orifice and O-ring, and backup washer (see Figure 21).

2.75 IN. 6.98 CM

ADJUSTER
STEM
O-RING

Figure 19. Spring Adjuster Assembly

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Page 7 of 16

Service Bulletin No. 9-2916A

STEM O-RING

13. Install bottom cap assembly into body insert.

Return spring will force orifice into position as cap
assembly is screwed into body insert (see
Figure 22). Tighten to 5 ft-lbs (6.8 N m).

O-RINGS
BODY INSERT

BOTTOM CAP
ASSEMBLY

BODY INSERT

O-RING
BACK-UP
WASHER
ORIFICE
O-RING

O-RING

Figure 22. Cartridge Body and Cap Assembly

14. Press stem against hard surface to verify it moves

freely and returns to extended position. Stem
should extend 0.32 in. (8.1 mm) from body insert
(see Figure 23).

ORIFICE
STEM
PLUG AND
STEM ASSEMBLY

0.32 IN.
(8.1 MM)

STEM
GUIDE

RETURN
SPRING

ORIFICE
SPRING

BODY
INSERT

Figure 23. Cartridge Stem Height

15. Apply Parker Super O-Lube and slide O-ring

onto stem.
O-RING

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 and
Figure 24).

BOTTOM CAP

Figure 21. Cartridge Assembly

Page 8 of 16

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Service Bulletin No. 9-2916A

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

CARTRIDGE

FILTER

FILTER
HOUSING

Figure 24. Cartridge Assembly

FILTER MAINTENANCE

Figure 26. Filter Element

The filter element is subject to plugging and must be

inspected and replaced as necessary. The frequency
of inspection and replacement of the filter element
depends on severity of service conditions and the
length of time in service.

3. Remove filter O-ring (see Figure 27). A paper clip

or other suitable tool can be used. Inspect for
defects and replace if necessary.

WARNING
Before disassembly make sure the regulator and
filter have been isolated from the process by
closing block valves on the inlet and outlet sides
of the regulator. Safely release pressure and
process fluid from body and pilot system. Failure
to properly complete these steps may result in
personal injury and property damage.
DISASSEMBLE FILTER
1. Depressurize main valve and filter. Remove filter
housing (see Figure 25).

O-RING

Figure 27. Filter Fitting

ASSEMBLE FILTER
1. Lubricate O-ring with Parker Super O-Lube (or
equivalent petroleum based lubricant) and install in
filter fitting.
NOTE: If the filter guide is removed, apply a small
quantity of Loctite (or equivalent) to the threaded
area and screw hand tight into filter body.
2. Lubricate threads of filter housing with Lubriplate
(or equivalent petroleum based lubricant).
FILTER
HOUSING

Figure 25. Filter Assembly

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3. Place filter element into housing. Screw housing

into fitting and tighten to 5 ft-lbs (6.8 N m). Do not
overtighten (overtightening an O-ring joint will not
improve seal). Element will guide itself into
position regardless of orientation.
Page 9 of 16

Service Bulletin No. 9-2916A

VALVE COVER

FILTER
HOUSING

PILOT LOADING
LINE

Figure 28. Filter Assembly

MAIN VALVE MAINTENANCE

5/16 IN.-18 UNC

CAPSCREWS

CAPSCREW

Figure 29. Pilot Loading Line

4. Remove main spring, diaphragm, and cover (see

Figure 30 and Figure 33). Inspect parts for wear.

NOTE: Updated main valves are available that

contain a new diaphragm and spring that reduce CO
emissions on GSI engines (see Table 2).

MAIN SPRING

Main valve parts are subject to normal wear and must

be inspected and replaced as necessary. The frequency of inspection and replacement of parts
depends on severity of service conditions and/or the
requirements of local, state, and federal regulations.
Be certain that the name plates are updated to accurately indicate any field changes in equipment, materials, service conditions, or pressure settings.

WARNING
Before disassembly make sure the main valve has
been isolated from the process by closing block
valves on the inlet and outlet sides of the main
valve. Safely release pressure and process fluid
from body and pilot system. Failure to properly
complete these steps may result in personal injury
and property damage.
DISASSEMBLE MAIN VALVE

COVER

DIAPHRAGM

Figure 30. Main Valve Cover

NOTE: Shutoff occurs at the downstream outside

rib located on the throttle plate. The outside edge of
the downstream (outlet) portion is the primary shutoff
surface and should be inspected more closely for wear
and damage. Nicks and/or wear on support ribs will
usually not affect shutoff (see Figure 31).

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 as
capscrews are removed (see Figure 29).

Page 10 of 16

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Service Bulletin No. 9-2916A

ASSEMBLE MAIN VALVE
OUTSIDE RIB
DOWNSTREAM

COVER

BOSS

MAIN SPRING

DIAPHRAGM

Figure 31. Throttle Plate

5. Remove and inspect nitrile body seal for wear or

damage (see Figure 32).
THROTTLE PLATE

NITRILE
BODY SEAL

INLET
NITRILE
BODY SEAL

BODY

Figure 32. Nitrile Body Seal

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

necessary.
CLEANING MAIN VALVE
1. Do not clean body seal grooves with sharp metal
tools. Bottom of groove and mating surface of
adjacent parts must have smooth finish to prevent
leakage.

FLOW
DIRECTION

OUTLET

Figure 33. Left Bank/Inline Main Valve Configuration

NOTE: The cover plate should be positioned so the

boss is located at the outlet (downstream) side of the
fuel line (see Figure 33 and Figure 37).
NOTE: The nitrile rubber body seal can swell after
disassembly of a main valve that has been in service
(due to gas permeating the nitrile rubber). This does
not necessarily mean it must be replaced. However,
before placing the seal back into service inspect for
defects. Set seal aside for several hours and it will
gradually return to normal size. Placing seal(s) on ice
will speed the process considerably.
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Page 11 of 16

Service Bulletin No. 9-2916A

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

MAIN SPRING

DIAPHRAGM

COVER
NITRILE
BODY SEAL

Figure 34. Nitrile Body Seal

NOTE: If the inlet sides of the throttle plate and

diaphragm are in better condition than the outlet sides,
the entire assembly can be rotated 180 degrees (outlet
to inlet) to renew the shutoff capability (see Figure 35).

Figure 36. Main Valve Cover

NOTE: The cover plate should be positioned so the

boss is located at the outlet (downstream) side of the
fuel line (see Figure 33 and Figure 37).
3. Place spring case cover assembly and bracket on
main valve and secure with four capscrews (see
Figure 38). Do not fully tighten.

OUTLET SIDES
COVER
CAPSCREW

BOSS

BRACKET
INLET SIDES

INLET

OUTLET

FLOW
DIRECTION

Figure 35. Throttle Plate

Figure 37. Inline/Left Bank Main Valve

2. Place spring on diaphragm. Spring case (cover)

fits on top of spring. Do not lubricate diaphragm
sealing surface (see Figure 33 and Figure 36).

4. Secure opposite end of bracket to pilot body with

5/16 in. - 18 UNC capscrews (see Figure 38).
Lubricating or overtightening valve cover
capscrews can damage the diaphragm. Disregarding this information could result in severe engine
damage.

CAUTION

Do not replace the

studs or nuts with any
capscrew or stud and nut combination that does
not have an SAE Grade 7 or ASTM Grade B7 rating. Disregarding this information could result in
severe engine damage.

CAUTION

Page 12 of 16

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Service Bulletin No. 9-2916A

5. Tighten spring case cover capscrews in
increments using a criss-cross pattern (see
Figure 38 and Figure 39). Tighten to 20 ft-lbs
(27 N m).
6. Install pilot loading line (see Figure 38).
BRACKET

PILOT LOADING
LINE

NOTE: Balance lines have been increased to 5/8

diameter 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.

COVER
CAPSCREW

5/16 IN.-18 UNC

CAPSCREW

Figure 38. Inline/Right Bank Main Valve

PIPE
MALE ELBOW
P/N 199111Y

DRESSER
COUPLING
161579B

5/8 IN. BALANCE TUBE

(GSI ONLY) P/N 214191
FLAT
WASHER

SPACER

LOCK
WASHER
CAPSCREW
5/8

Figure 39. 6 Cylinder Engine Regulator Mounting

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Page 13 of 16

Service Bulletin No. 9-2916A

5/8 IN. BALANCE TUBE (GSI ONLY)

P/N 214191A RIGHT BANK
P/N 214191B LEFT BANK

DRESSER
COUPLING
161579B

MALE ELBOW
P/N 199111Y
PIPE

FLAT
WASHER
LOCK
WASHER
1/2 CAPSCREW

Figure 40. 12 Cylinder Engine Regulator Mounting

Page 14 of 16

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Service Bulletin No. 9-2916A

DRESSER
COUPLING
161579B

PIPE
P/N 207155D
COUPLING
P/N 78211E
MALE ELBOW
P/N 199111E

5/8 IN. BALANCE TUBE

P/N 214191E RIGHT BANK
P/N 214191D LEFT BANK

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

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Page 15 of 16

Service Bulletin No. 9-2916A

ELBOW
DRESSER COUPLING
161592

PIPE

5/8 IN. BALANCE TUBE

P/N 214055D (BOTH BANKS)

Figure 42. 16 Cylinder Engine Regulator Mounting

Page 16 of 16

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