SECTION 5.

05
FUEL SYSTEM

FUEL SYSTEM COMPONENTS The fuel gas pressure regulators reduce the incoming
fuel supply pressure to the carburetors from 45 -- 50 psi
The function of the fuel system is to maintain a constant
(310 -- 345 kPa) to approximately 10 in. (254 mm) of
air/fuel ratio throughout the load range of the engine and
water above the carburetor air pressure, as measured at
to deliver the air/fuel mixture in the proper quantities.
the carburetor inlet.
The fuel system consists of the following components
(see Figure 5.05-1): NOTE: The actual carburetor inlet fuel pressure will
depend on the heating value of the fuel.
· Fuel Gas Pressure Regulators
From the fuel gas pressure regulators the fuel flows into
· Carburetors the carburetors where it is mixed with air to provide a
very lean mixture to the combustion chambers.
FUEL GAS PRESSURE REGULATORS
To ensure a steady fuel supply to each carburetor,
12 cylinder engines have a regulator on both the right
and left side of the engine.

CARBURETOR FUEL
REGULATOR

CARBURETOR

BALANCE LINE

BALANCE LINE

SENSING LINE SENSING LINE

FUEL REGULATOR FUEL REGULATOR

LEFT SIDE GAS SAFETY VALVES GAS SAFETY VALVES RIGHT SIDE
Figure 5.05-1. Fuel System Diagram -- GSI

FORM 6296 First Edition 5.05 -- 1

FUEL SYSTEM

OPERATION OF THE FISHER 99 FUEL GAS
PRESSURE REGULATOR
Changes in gas consumption cause the pressure in the
gas outlet system to rise and fall. Pressure changes are
transmitted to the main orifice chamber through the
downstream sensing line (see Figure 5.05-2).
When the pressure pushing down on the upper pilot
chamber diaphragm is lower than the force of the pilot
spring, the valve assembly is forced upward and the gas
inlet orifice is opened. High pressure gas flows into the
pilot chamber and then on through a supply line to a
chamber above the main diaphragm.
Higher pressure in the upper chamber opposes the main
spring to push the main diaphragm down. The down-
ward motion causes a lever to pull the disc valve farther
from its seat—the flow of gas to the outlet system
increases.
When the pressure pushing down on the upper pilot
chamber diaphragm exceeds the setting of the pilot
spring, the valve assembly moves down to close the gas
inlet orifice. The pressure in the upper chamber bleeds
into the main chamber allowing the main spring to pull up
the main diaphragm rod and move the disc valve
towards its seat—the gas flow to the outlet system
decreases.
A balance line connects the carburetor air inlet to a vent
in the pilot spring chamber (see Figure 5.05-2). This
ensures that a constant gas-over-air pressure differen-
tial is maintained regardless of changes in air filter
restriction and turbocharger boost.

UPPER PILOT
CHAMBER DIAPHRAGM GAS OUTLET
(TO CARBURETOR)

MAIN
SPRING

MAIN
DIAPHRAGM

MAIN
ORIFICE LEVER DISC
CHAMBER VALVE

GAS
INLET FUEL
FILTER MAIN
ORIFICE FUEL GAS CHAMBER
INLET ORIFICE
PILOT
CHAMBER PILOT BALANCE LINE
SPRING (TO CARBURETOR PILOT
AIR INLET) CHAMBER
SUPPLY
DOWNSTREAM TUBE
SENSING LINE SUPPLY
LINE
EXTERNAL PRESSURE
ADJUSTMENT SCREW

Figure 5.05-2. Fisher 99 Fuel Gas Pressure Regulator -- Sectional View

5.05 -- 2 FORM 6296 First Edition

 FUEL SYSTEM

OPERATION OF THE MOONEY FUEL GAS
PRESSURE REGULATOR
Ensure that the fuel source is completely shut off
prior to working on fuel system components. Clear
the engine supply lines and piping of accumulated
gas before performing any maintenance work on
the fuel system or severe personal injury or death
could result.
Principles Of Operation
Mooney Regulators are used on select VHP engines.
This regulator is standard equipment on all GL and GSI
engines running on pipeline quality or 900 Btu field gas.
It is currently not used with GLD, GSID or AFM--
equipped engines.
The Mooney regulator system uses a pilot that controls a
main valve (see Figure 5.05-3 and Figure 5.05-5). 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.
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 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 5.05-4). 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
RESTRICTOR

CONTROL
PRESSURE
PILOT SENSE
CONNECTION
PILOT
PILOT LOADING
CONNECTION

RESTRICTOR
INLET PILOT OUTLET
PILOT CONNECTION
VALVE
OUTLET
PILOT
LOADING MAIN VALVE
CONNECTION

Figure 5.05-4. Regulator Assembly

PILOT OUTLET
CONNECTION
INLET When demand for flow ceases or is reduced, the
OUTLET downstream pressure increases causing the pilot valve
DIAPHRAGM
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
Figure 5.05-3. Regulator Assembly across the outlet half of the main valve diaphragm,
closes the diaphragm against the throttle plate, shutting
off the flow.

FORM 6296 First Edition 5.05 -- 3

FUEL SYSTEM

PILOT SENSE
PILOT OUTLET CONNECTION
CONNECTION

PILOT INLET (SUPPLY)

CONNECTION CARTRIDGE

FIXED
RESTRICTOR
ORIFICE OUTLET

VENT
MAIN VALVE

PILOT

FILTER

PILOT LOADING
CONNECTION INLET

Figure 5.05-5. Left Bank Regulator

CARBURETORS The amount of air/fuel mixture flowing out of the

Twelve cylinder engines have two carburetors, one
mounted just below the center of the intake manifold on
the left side of the engine, the other at the same location
on the right side.
The carburetor produces a combustible mixture by
automatically mixing air and fuel in the proper propor-
tions. It consists of an air inlet housing, a gas inlet, two
air flow measuring valves, two diaphragm-operated gas
metering valves and a butterfly valve.
The amount of air going to the engine is sensed by the
air flow measuring valves that rise in direct proportion to
the volume of air passing through them. Each gas
metering valve is mechanically fixed to an air flow
measuring valve, so the gas passages are opened by an
amount that is proportional to the amount of air entering
the engine. The tapered gas metering valve is shaped to
admit the correct amount of gas at any height to which
the air flow measuring valve rises. This operation allows
the engine to maintain a specific air/fuel ratio throughout
its operating range.
carburetor is controlled by the position of the butterfly
valve in the carburetor throat.
The air/fuel mixture passes from the carburetor to the
intake manifold.
During engine operation, changes in gas consumption
cause the pressure in the gas outlet system to rise and
fall. A decrease in gas consumption causes the
pressure in the regulator outlet system to increase. This
increase counteracts the tension of the pilot spring.
Compression of the pilot spring allows the regulator
diaphragm to rise. When the guide stem is pulled up, the
valve spring pushes up the valve plug. Restriction of the
gas inlet orifice causes the gas flow to the outlet system
to decrease.

5.05 -- 4 FORM 6296 First Edition

 FUEL SYSTEM

CARBURETORS 3. Disconnect carburetor cross shaft from carburetor at

spider (see Figure 5.05-8).
CARBURETOR REMOVAL
Clean and inspect the carburetor diaphragms and
CARBURETOR CROSS
air/gas valves every 6 months (4320 hours). Replace SHAFT SPIDER
the carburetor diaphragm(s) once each year.

Ensure that the fuel source is completely shut off

prior to working on fuel system components. Clear
the engine supply lines and piping of accumulated
gas before performing any maintenance work on
the fuel system or severe injury or death could
result.

1. Turn off fuel supply.

2. Remove lock nut, two washers, capscrew and
governor rod from butterfly valve located on carburetor
(see Figure 5.05-6 and Figure 5.05-7). Disconnect
speed control lever from carburetor.
BUTTERFLY
VALVE
Figure 5.05-8. Carburetor And Butterfly Valve Cross
Shafts
4. Disconnect carburetor fuel supply piping from fuel
regulator at Dresser coupling (see Figure 5.05-9).
Remove piping with carburetor.

DRESSER COUPLING

Figure 5.05-6. Governor Rod -- GSI Engines

GOVERNOR LINKAGE
Figure 5.05-9. Fuel System Dresser Coupling

5. Remove four capscrews, lock washers, air horn

flange, air intake pipe and gasket from carburetor air
horn (see Figure 5.05-10).

6. Remove four nuts, lock washers, capscrews, gasket

and carburetor assembly from butterfly assembly (see
Figure 5.05-10).

THROTTLE CONTROL

Figure 5.05-7. Governor Rod -- L5794LT

FORM 6296 First Edition 5.05 -- 5

FUEL SYSTEM

CARBURETOR DISASSEMBLY
BUTTERFLY
VALVE 1. Remove four capscrews and remove air horn.

2. Remove six machine screws with lock washers from

edge of valve cover. Remove valve cover and slide out
air/gas valve (see Figure 5.05-11).

Always wear safety glasses when removing

springs. If the spring slips when being installed or
removed, it can be propelled with enough force to
cause a serious eye injury. Disregarding this infor-
mation could result in severe personal injury.
3. Remove spring inside center shaft of air/gas valve.
Inspect spring for corrosion. Any damage to spring
AIR HORN
requires replacement.
Figure 5.05-10. Carburetor Connections 4. Remove four machine screws with lock washers,
backup plate and diaphragm from air/gas valve. Any
damage to diaphragm requires replacement.

NO. 10
CARBURETOR CAPSCREW
BODY COVER

COLOR CODED NO. 8

SPRING CAPSCREW
O--RING

SPACER--GSID
ONLY

FLAT HEAD
CAPSCREW BACKUP
PLATE DIAPHRAGM

FUEL CONE
CAPSCREW

SHAFT
GAS JET
O--RING

AIR VALVE
CARBURETOR
BASE

O--RING

Figure 5.05-11. Impco 600 Carburetor

5.05 -- 6 FORM 6296 First Edition


CARBURETOR CLEANING AND INSPECTION
NOTE: A high altitude fuel cone (P/N 211291Y) is
available for GSI engines using carburetor P/N 59021V
or P/N 59021W. High altitude is defined as above
4000 ft. (1219 m).
1. Inspect center shaft of air/gas valve for wear,
especially area around tapered gas metering valve (see
Figure 5.05-12). Area may contact metal as gas inlet
orifice is opened and closed. Scratches or wear results
in sloppy action affecting gas metering precision. Any
damage to center shaft requires replacement of air/gas
valve.
GAS METERING
IMPCO PART NUMBER
VALVE
CENTER
SHAFT
Figure 5.05-12. Air/Gas Valve
2. Check tapered gas metering valve for wear. Inspect
O- ring for nicks or tears. Any damage to gas metering
valve or O-ring requires replacement.
3. Inspect backup plate for warpage, distortion or other
damage.
4. Inspect air horn for cracks.
5. Inspect diaphragm for dryness, stiffness or loss of
elasticity. Hold diaphragm up to light and carefully check
for pin holes. Gently stretch material to look for cracks
and tears. Look for charring from excessive heat or
backfiring. Excessive heat from exhaust manifold or
improperly cooled turbocharged air can greatly reduce
service life. Any damage to diaphragm requires
replacement.
FORM 6296 First Edition
FUEL SYSTEM
CARBURETOR ASSEMBLY
The variety of fuel sys-
tem designs, site operat-
ing conditions and fuel types used has made it
necessary for Waukesha to custom design gas
metering valves at some installations. If an Impco
part number is not stamped on the tapered end of
the gas valve, please contact the Waukesha Field
Service Department before ordering replacements.
Disregarding this information could result in prod-
uct damage and/or personal injury.
1. Position backup plate in center of diaphragm (see
Figure 5.05-11). Slide four machine screws with lock
washers through plate and diaphragm. Thread screws
into center shaft of air/gas valve and tighten.
2. Insert air/gas valve into valve housing until tapered
gas metering valve slides into gas inlet orifice. Align
air/gas valve, so holes on edge of diaphragm rest over
holes in valve housing.
Always wear safety glasses when removing
springs. If the spring slips when being installed or
removed, it can be propelled with enough force to
cause a serious eye injury. Disregarding this infor-
mation could result in severe personal injury.
3. Insert spring into center shaft of air/gas valve.
4. Place valve cover over air/gas valve assembly so
projection fits inside spring. Align cover, so holes on
edge rest over holes in diaphragm.
5. Slide six machine screws with lock washers through
valve cover and diaphragm. Thread screws into valve
housing and tighten.
6. Raise center shaft of air/gas valve several times to
check if it is free to travel. Verify valve closes tightly when
released.
CARBURETOR INSTALLATION
1. Install air horn on carburetor with gasket and four
capscrews.
2. Position a new gasket on upper flange of carburetor
assembly.
3. Raise center shaft of air/gas valve assemblies in
carburetor. Verify valve closes tightly when released.
4. Identify left and right side carburetors. Two carbure-
tors are not interchangeable.
5.05 -- 7
FUEL SYSTEM
5. With air/gas inlet port facing rear of engine, install
carburetor on butterfly assembly with gasket, four
capscrews, lock washers, and nuts.
6. With wings in vertical position, fit front spider onto
carburetor cross shaft to inside butterfly shaft of left side
carburetor. Leave spider shaft clamp fastener loose.
7. With air/gas inlet port facing rear of engine, position a
new gasket onto carburetor and install right side
carburetor (6 capscrews, 1/2 in. x 1-1/2 in. with lock
washers).
8. With wings in vertical position, fit front spider on
carburetor cross shaft to inside butterfly shaft of right
side carburetor. Leave front spider shaft clamp fastener
loose (see Figure 5.05-13).
CARBURETOR CROSS SHAFT
DISC
CROSS SHAFT
COVER
REAR SPIDER
SHAKEPROOF
FRONT SPIDER
WASHER
ROLL PIN
Figure 5.05-13. Carburetor Cross Shaft Assembly
The throttle plate must
be adjusted so that it just
touches the housing. Failure to properly adjust the
throttle plate will cause the plate to bind against the
housing. Disregarding this information could result
in product damage and/or personal injury.
NOTE: If the throttle plate cannot be heard contacting
the rear casing, then back off the idle stop screw.
9. On left side, turn outside butterfly shaft towards rear
of engine (clockwise) until throttle plate inside butterfly
valve housing contacts casting, indicating valve is in
fully closed position.
5.05 -- 8
10. Holding outside butterfly shaft to keep throttle plate
in fully closed position, tighten front spider shaft clamp to
lock it on inside butterfly shaft.
11. Pin front spider to cross shaft using a new 1/8 in. x
1-1/8 in. roll pin.
12. On right side, turn outside butterfly shaft towards
rear of engine (counterclockwise) until throttle plate
contacts casting, indicating valve is in fully closed
position.
13. Try to turn cross shaft to left (counterclockwise). If
shaft cannot be moved, then left side carburetor throttle
plate is also in fully closed position. Holding cross shaft
to prevent clockwise rotation, tighten front spider shaft
clamp to lock it on inside butterfly shaft.
14. Pin front spider to cross shaft using a new 1/8 in. x
1-1/8 in. roll pin.
15. Check all fasteners on both sides for tightness.
16. Open and close throttle plates to verify movement.
Listen for throttle plate contact with rear side of butterfly
valve housing (both sides).
17. Verify cross shaft does not strike or rub against
cross shaft cover when throttle plate is opened and
closed (both sides). Tighten fasteners securing cross
shaft covers to block (two capscrews per cover,
3/8 in.--16 x 3/4 in., with lock washers and flat washers).
18. Install carburetor gasket and carburetor elbow to air
horn with twelve capscrews and lock washers.
19. Refer to Section 5.00 Speed Governing System
and install and adjust governor linkage.
20. Connect main fuel line and balance line to carbure-
tor and air horn.
21. Remove four capscrews, lock washers, butterfly
valve housing and gasket from intake manifold.
LOW FUEL PRESSURE SYSTEM (LFPS)
CARBURETOR
LFPS CARBURETOR REMOVAL
VHP Series Four GSI engines have a Low Fuel
Pressure System (LFPS) option that have the carbure-
tors mounted on the air cleaner ducts (see
Figure 5.05-14). The fuel regulators are customer
mounted off the engine. See Section 5.15 Air Induction
System in this manual for LFPS Air Duct Removal.
FORM 6296 First Edition
 FUEL SYSTEM

METERING VALVE
FLANGE

LFPS CARBURETORS

Figure 5.05-14. VHP Series Four LFPS

METERING VALVE
Clean and inspect the carburetor diaphragms and SLEEVE ASSEMBLY
air/gas valves every 6 months (4320 hours). Replace
the carburetor diaphragm(s) once each year. Figure 5.05-16. Metering Valve Flange
NOTE: The air valves and diaphragms are accessible
2. Pull metering valve sleeve out of carburetor body.
without removing the carburetor assembly from the
O-rings are located inside of valve sleeve (see
engine. Remove the rain shield and air filter from the air
Figure 5.05-17 and Figure 5.05-18). Sealing O-ring is
duct (see Figure 5.05-15).
located in outer flange.

Figure 5.05-15. Impco 600 Carburetor Inside LFPS Air

Figure 5.05-17. Metering Valve Sleeve Assembly
Duct

LFPS CARBURETOR DISASSEMBLY O-RING

NOTE: The internal O-ring may be reached without

disassembling the whole carburetor.

1. Record degree setting on metering valve flange.

Mark metering valve flange and air/gas plenum housing
to ensure positions are maintained during reassembly.
Remove four capscrews, washers, lock washers, me-
tering valve flange, and three O--rings from upper
air/gas plenum (see Figure 5.05-16). Discard O--rings.

O-RING

Figure 5.05-18. Metering Valve Sleeve

FORM 6296 First Edition 5.05 -- 9

FUEL SYSTEM

3. Remove four capscrews and gas inlet adapter from
carburetor body (see Figure 5.05-19).
GAS INLET ADAPTER
5. Remove 20 capscrews, lock washers, gasket, and
upper air/gas plenum from air cleaner plenum.
6. Remove 16 capscrews, 8 locking plates, gas man-
ifold and carburetors from air cleaner plenum (see
Figure 5.05-22).

GAS MANIFOLD

SOCKET HEAD LOCKING

CAPSCREWS PLATES

Figure 5.05-22. Gas Manifold

Figure 5.05-19. Gas Inlet Adapter 7. Remove socket head capscrews and lock washers
(six per carburetor), and remove carburetors from gas
4. Pull gas inlet adapter from carburetor body. O-rings manifold (see Figure 5.05-23).
are located inside of valve sleeve (see Figure 5.05-20).
Sealing O-ring is located in outer flange. Remove three
CARBURETORS
O--rings from upper air/gas plenum (see
Figure 5.05-21). Discard O--rings.

O-RING

GAS MANIFOLD

Figure 5.05-23. Gas Manifold And Carburetors

8. If carburetor gas valve, O--ring, and gas jet need

replacement, refer to Figure 5.05-24 to replace these
components.
Figure 5.05-20. Gas Inlet Adapter

GAS INLET ADAPTER SCREW AND

WASHER

O--RING

GAS JET

O--RINGS GAS VALVE

Figure 5.05-21. Gas Inlet Adapter Figure 5.05-24. Draw--thru Carburetor

5.05 -- 10 FORM 6296 First Edition

 FUEL SYSTEM

1/2-13 X 1-3/4² GAS INLET

HEX HEAD CONNECTOR
CAPSCREW
O--RING

PLENUM

1/2² LOCK
WASHER O--RING

1/2-13 X 1-3/4²
HEX HEAD CAPSCREW
METER VALVE
LOCK PLATE SLEEVE
GAS
MANIFOLD 1/2² FLAT
WASHER

GASKET AIR
CLEANER PLENUM METER VALVE
FLANGE

1/2² LOCK
WASHER
1/2-13 X 1-3/4²
HEX HEAD CAPSCREW
3/8² LOCK
WASHER AIR CLEANER
PLENUM

3/8-13 X 1-1/4²
HEX HEAD
CAPSCREW

Figure 5.05-25. LFPS Carburetor

LFPS CARBURETOR ASSEMBLY
1. If removed, apply O--ring lubricant to new O--ring,
and install gas valve, gas jet, and O--ring on carburetor
with screw and lock washer (see Figure 5.05-24 and
Figure 5.05-25).
7. Install gas inlet adapter with O--rings on upper air/gas
plenum with four capscrews and lock washers (see
Figure 5.05-25 and Figure 5.05-26).
8. Apply O--ring lubricant to three new O--rings and
install onto metering valve sleeve assembly.

2. Install carburetors on gas manifold with socket head 9. Apply Bostik Never Seezâ Anti--Seize and Lubricat-
capscrews and lock washers (6 per carburetor) (see ing Compound to surface of metering valve sleeve (see
Figure 5.05-23). Figure 5.05-25 and Figure 5.05-26).

3. Install gas manifold and carburetors on air cleaner 10. Carefully compress metering valve sleeve to allow it
plenum with 16 capscrews and 8 locking plates (see to fit into gas manifold, and install metering valve sleeve
Figure 5.05-22 and Figure 5.05-25). assembly in air gas plenum and gas manifold.

4. Apply Permatexâ High Tack Spray--A--Gasketâ
Sealant to mating surfaces and position gasket on air
cleaner plenum (seeFigure 5.05-25).
5. Install upper air/gas plenum on air cleaner plenum
with 20 capscrews, lock washers and gasket.
6. Apply O--ring lubricant to new O-rings and install on
gas inlet adapter (see Figure 5.05-21).
11. Refer to match marks and position metering valve
flange on air gas plenum (see Figure 5.05-25 and
Figure 5.05-26).
12. Refer to notes and rotate metering valve sleeve
assembly to same degree setting set prior to removal.
Install four capscrews, washers and lock washers to
secure metering valve sleeve assembly in position.

FORM 6296 First Edition 5.05 -- 11

FUEL SYSTEM

O-RING O-RING

O-RING
O-RING

Figure 5.05-26. LFPS Carburetor

BUTTERFLY VALVE REMOVAL

CAPSCREW

Ensure that the fuel source is completely shut off

prior to working on fuel system components. Clear
the engine supply lines and piping of accumulated
gas before performing any maintenance work on
the fuel system or severe injury or death could
result.

1. Refer to “Carburetor Removal” in this section and

remove carburetor.

2. Refer to “Butterfly Cross Shaft Removal” and discon-

nect butterfly cross shaft.

3. Remove four capscrews, lock washers, butterfly

Figure 5.05-27. Butterfly Valve GSI
valve and gasket from the intake manifold (see
Figure 5.05-27).

5.05 -- 12 FORM 6296 First Edition

 FUEL SYSTEM

BUTTERFLY VALVE DISASSEMBLY -- GSI BUTTERFLY VALVE HOUSING

NOTE: Matchmark the spiders to aid in assembly.

1. Remove roll pins from spiders (see Figure 5.05-27). SEAL

2. Remove capscrews, lock washers and spiders from

butterfly shaft. SHAFT
ROLL
PIN
3. Remove two capscrews, lock washers, and butterfly
valve from butterfly housing (see Figure 5.05-28). BUSHING

BUSHING SHAKEPROOF
SEAL WASHER

Figure 5.05-29. Butterfly Valve Assembly

BUTTERFLY VALVE INSTALLATION

CAPSCREWS AND
LOCKWASHERS
1. Install butterfly valve on intake manifold, with new
gasket, four capscrews and lock washers (see
Figure 5.05-30).

2. Refer to “Carburetor/Butterfly Cross Shaft Installa-

tion” in this section and connect butterfly cross shaft.

3. Refer to “Carburetor Installation” in this section and

install carburetor.
Figure 5.05-28. Butterfly Valve
BUTTERFLY
VALVE
4. Remove butterfly shaft from butterfly housing.

5. Remove and discard butterfly shaft seals from SPIDERS

butterfly housing.

6. Remove and discard two bushings from butterfly

housing.

BUTTERFLY VALVE ASSEMBLY

1. Install two new bushings in butterfly housing (see
Figure 5.05-29).

2. Slide matching shaft through housing with flat side of

shaft facing up. Secure butterfly on shaft with shake- Figure 5.05-30. Butterfly Valve GSI
proof washers and slotted head capscrew. Apply
Loctiteâ 271 to butterfly fasteners. Flat edge of butterfly
valve must lay against housing.

3. Secure two spiders on butterfly shaft with roll pins,

capscrews and lock washers.
4. Install stop lever on shaft in original location.

FORM 6296 First Edition 5.05 -- 13

FUEL SYSTEM

CARBURETOR/BUTTERFLY CROSS SHAFT NOTE: The left universal joint disc assembly uses two
INSTALLATION spiders with different diameter bores (1/2 in. and 5/8 in.)
(see Figure 5.05-33). The spider with the 5/8 in. bore fits
1. Position carburetor/butterfly cross shaft through on the inside butterfly valve shaft, which has a larger
upper/lower center bore in crankcase until it exits diameter than the carburetor cross shaft. The right
opposite side (see Figure 5.05-31). universal joint disc assembly uses two identical spiders
(1/2 in. bore size).
BUTTERFLY
CROSS SHAFT 1/2² OR 5/8² SHAFT CLAMP
BORE BORE
WATER HEADER
PLUG

PIN
HOLE

CARBURETOR
CROSS SHAFT
BORE WINGS

Figure 5.05-31. Crankcase Center Bores -- Right Side Figure 5.05-33. Universal Joint Disc Spider

NOTE: The Low Fuel Pressure System (LFPS) butter-
fly cross shaft is located in the lower bore.
2. Position cross shaft cover down cross shaft until it
contacts crankcase. Finger tighten cross shaft cover to
block flange with two capscrews, 3/8 in.--16 x 3/4 in. with
lock washers and flat washers.
3. Align two parallel holes in wings of universal joint
spider with those in disc and tighten two capscrews,
5/16 in.--18 x 1/2 in. with external shakeproof washers.
Using remaining two holes on opposite side of disk,
install second spider perpendicular to first.
5. With butterfly wings in horizontal position, align pin
holes in rear spider (1/2 in. bore size) with those in cross
shaft. Install a new 1/8 in. x 1-1/8 in. roll pin.
6. Tighten capscrew in clamp portion of rear spider
(5/16 in.--18 x 1-1/8 in. with external shakeproof wash-
er). Start capscrew in front spider.
NOTE: Only one side of the spider shaft clamp fastener
bore is threaded. Start the fastener by inserting it into the
thru hole. Use the threaded side of the bore to tighten.
7. Repeat Steps 2 through 6 on other side.

4. Position universal joint spider assembly down cross CARBURETOR CROSS SHAFT
shaft (see Figure 5.05-32).
CARBURETOR CROSS SHAFT REMOVAL
BUTTERFLY CROSS SHAFT

Ensure that the fuel source is completely shut off

DISC prior to working on fuel system components. Clear
the engine supply lines and piping of accumulated
gas before performing any maintenance work on
CROSS SHAFT the fuel system or severe injury or death could
COVER
result.
REAR SPIDER
1. Turn off fuel supply. Turn carburetor shafts on both
carburetors to fully closed position.
SHAKEPROOF
WASHER
NOTE: Mark the spider assembly halves, disks, and
FRONT SPIDER shafts to aid in assembly.
ROLL PIN

Figure 5.05-32. Butterfly Cross Shaft Assembly

5.05 -- 14 FORM 6296 First Edition

 FUEL SYSTEM

2. Remove four capscrews 5/16 in.--18 x 1/2 in. with SHAFT CLAMP
external shakeproof washers from two rear spider 1/2² OR 5/8²
BORE
assemblies (see Figure 5.05-34 and Figure 5.05-35).

CARBURETOR CROSS PIN

SHAFT SPIDER HOLE

WINGS

Figure 5.05-36. Universal Joint Disc Spider

BUTTERFLY CROSS SHAFT -- GSI AND

L5774LT
Figure 5.05-34. Carburetor Cross Shaft -- GSI BUTTERFLY CROSS SHAFT REMOVAL

CARBURETOR CROSS SHAFT

Ensure that the fuel source is completely shut off

prior to working on fuel system components. Clear
DISC the engine supply lines and piping of accumulated
gas before performing any maintenance work on
CROSS SHAFT the fuel system or severe injury or death could
COVER result.
REAR SPIDER 1. Turn off fuel supply.

2. Turn butterfly shaft on to fully closed position.

SHAKEPROOF
WASHER
NOTE: Mark the spider assembly halves, disks, and
FRONT SPIDER
shafts to aid in assembly.
ROLL PIN
3. Remove four capscrews, 5/16 in. x 1/2 in. with
Figure 5.05-35. Carburetor Cross Shaft Assembly external shakeproof washers, from two rear spider
assemblies (see Figure 5.05-37 and Figure 5.05-38).
3. Refer to “Carburetor Removal” and remove one
carburetor.
BUTTERFLY VALVE SPIDER
4. Drive out roll pins, loosen capscrews on spider
clamps and remove rear spiders from cross shaft ends.

5. Remove two capscrews, 3/8 in. x 3/4 in. with lock

washers, and washers and cross shaft covers from
crankcase.

6. Remove carburetor cross shaft from crankcase.

NOTE: The left side universal joint disc assembly uses

two spiders with different diameter bores (1/2 in. and
5/8 in.) (see Figure 5.05-36). The spider with the 5/8 in.
bore fits on the inside butterfly valve shaft, which has a
larger diameter than the carburetor cross shaft. The
right sides universal joint disc assembly uses two Figure 5.05-37. Butterfly Valve Spider
identical spiders (1/2 in. bore size).

FORM 6296 First Edition 5.05 -- 15

FUEL SYSTEM

4. Refer to “Butterfly Valve Removal” to remove butter-

fly valves. SENSING LINE

5. Drive out roll pins, loosen capscrews on spider

clamps and remove rear spiders from cross shaft ends
(see Figure 5.05-38).

BUTTERFLY CROSS SHAFT

DISC
CROSS SHAFT
COVER
BALANCE LINE

REAR SPIDER Figure 5.05-40. Regulator Connections -- L5794LT

SHAKEPROOF 2. Disconnect Dresser coupling from carburetor.

WASHER
FRONT SPIDER
ROLL PIN

Figure 5.05-38. Butterfly Cross Shaft Assembly
6. Remove two capscrews, 3/8 in. x 3/4 in. with lock
washers, and washers and cross shaft covers from
crankcase. Remove butterfly cross shaft.
FUEL GAS PRESSURE REGULATOR REMOVAL
The Fisher 99 fuel gas pressure regulator weighs
approximately 80 lb. (36 kg). Use a suitable lifting
device and exercise caution during removal or
installation to avoid severe personal injury or death.
3. Attach a suitable lifting device to regulator.
4. Remove four nuts, lock washers, washers from
regulator and mounting bracket.

Ensure that the fuel source is completely shut off
prior to working on fuel system components. Clear
the engine supply lines and piping of accumulated
gas before performing any maintenance work on
the fuel system or severe personal injury or death
could result.
1. Shut off fuel supply and disconnect balance line from
regulator (see Figure 5.05-39 and Figure 5.05-40).
BALANCE LINE
5. Using a suitable lifting device, remove regulator from
mounting bracket.
6. Remove five capscrews, lock washers, washers and
mounting bracket from crankcase.
RIGHT SIDE INSTALLATION
NOTE: A slotted open-ended cut at bottom of bracket
provides access to #3 main bearing cap cross-tie bolt
(directly above oil level gauge).
1. Fasten right regulator mounting bracket to bolt holes
(see Figure 5.05-41) in engine block with five caps-
crews, lock washers and washers.

SENSING LINE

Figure 5.05-39. Regulator Connections -- GSI, L5774LT

5.05 -- 16 FORM 6296 First Edition

 FUEL SYSTEM

#3 MAIN BEARING UPPER CHAMBER FUEL

CAP CROSS-TIE BOLT SUPPLY TUBE (ALIGN LONG BOLTS WITH SPACERS
WITH SLOTTED CUT IN (ALIGN WITH SLOTTED
BRACKET) HOLES IN BRACKET)

REAR FRONT
OF OF
ENGINE ENGINE

OIL LEVEL GAUGE

Figure 5.05-41. Bolt Holes In Engine Block LONG BOLTS WITH SPACERS
(ALIGN WITH SLOTTED HOLES
IN BRACKET)
NOTE: The right regulator mounting bracket can be
distinguished from the left bracket by the two slotted
holes on the front edge (for mounting of the prechamber
air/gas valve and bracket) (see Figure 5.05-42). Figure 5.05-43. Regulator Right Side -- Top View

FRONT OF ENGINE
BOLT HOLES FOR
MOUNTING PRECHAMBER
AIR/GAS VALVE BRACKET The Fisher 99 fuel gas pressure regulator weighs
approximately 80 lb. (36 kg). Use a suitable lifting
device and exercise caution during removal or
installation to avoid severe personal injury or death.

4. Position regulator so fuel supply tube is directly

above slot in top of mounting bracket (see
Figure 5.05-44). Verify four long bolts slide through
spacers and bracket holes as regulator is lowered.
Alternately tighten fasteners (washers, lock washers
and hex nuts).

SLOTTED CUT FOR #3 MAIN SLOTTED CUT FOR

BEARING CAP CROSS-TIE BOLT FUEL SUPPLY TUBE FUEL SUPPLY
(PILOT CHAMBER TO TUBE
UPPER CHAMBER) LONG BOLT
AND SPACER
REAR OF ENGINE
Figure 5.05-42. Regulator Bracket -- Right Side

2. Remove four short bolts (7/16 in.--14 x 1-1/2 in.) from

regulator housing (see Figure 5.05-43). Install four long
bolts (7/16 in.--14 x 4-1/2 in.) in empty bolt holes.

3. Place spacers (2-5/8 in.) over four slotted holes in

regulator mounting bracket (see Figure 5.05-42).

OPEN-ENDED CUT

Figure 5.05-44. Fuel Gas Regulator -- Right Side

FORM 6296 First Edition 5.05 -- 17

FUEL SYSTEM

5. Use thread sealant on all pipe connections.
Rotate pipe elbow so carburetor inlet pipe nipple is
approximately 15 degrees above horizontal (see
Figure 5.05-45).
10. Install seals in ends of coupling elbow so rubber
face seats against beveled counterbore.
11. Position coupling between inlet header and carbu-
retor inlet flanges and alternately tighten hex nuts.

PIPE 12. Position coupling between regulator outlet and

ELBOW carburetor inlet pipe nipples and alternately tighten hex
nuts (see Figure 5.05-47).

GAS INLET
PIPE NIPPLE

Figure 5.05-45. Carburetor Gas Inlet -- Right Side DRESSER

COUPLING

6. Verify gas inlet piping and carburetor inlet pipe

Figure 5.05-47. Dresser Elbow Coupling
nipples are clean and completely free of dirt and oil.
Check surfaces where coupling seals contact pipe ends
NOTE: Based on the height of the Fisher 99 regulator
for gouges, grooves, burrs, nicks or dents.
bracket, it may be necessary to drop the free end of the
7. Disassemble both sides of Dresser elbow coupling carburetor inlet pipe a few degrees.
(see Figure 5.05-46). Remove and discard old rubber
13. Inspect Fisher 99 fuel gas pressure regulator filter
seals, if still in place. Obtain two new rubber seals.
for cleanliness. See “Fisher 99 Regulator Filter Clean-
ing And Inspection” in this section.
COUPLING ELBOW
14. Install gas supply tube between gas inlet tee (male
elbow tube fitting) and Fisher 99 regulator pilot chamber
SEAL gas inlet port (male elbow) (see Figure 5.05-48).
RETAINER

BALANCE LINE

RUBBER
HEX NUT SEAL

Figure 5.05-46. Dresser Elbow Coupling

8. With concave side facing pipe ends, slide coupling

hex nuts onto regulator outlet and carburetor inlet pipe
nipples. SENSING LINE

9. Wipe rubber seals clean and fit tapered end into Figure 5.05-48. Regulator Tube Connections -- GSI
hollowed side of seal retainers.

5.05 -- 18 FORM 6296 First Edition

 FUEL SYSTEM

NOTE: For best results, reattach both ends of each FUEL SYSTEM MAINTENANCE
tube before tightening.

15. On GSI, install downstream sensing line (see

Figure 5.05-48).
16. Connect balance line between Fisher 99 regulator
pilot spring chamber (male connector) and carburetor
air inlet tube on GSI (see Figure 5.05-48).
LEFT SIDE INSTALLATION
Ensure that the fuel source is completely shut off
prior to working on fuel system components. Clear
the engine supply lines and piping of accumulated
gas before performing any maintenance work on
the fuel system or severe personal injury or death
could result.

1. Follow steps in “Right Side Installation” to install left
Fisher 99 regulator. Pattern of regulator mounting
bracket to cylinder block bolt holes (see
Figure 5.05-49), as well as installation of long bolts in
regulator housing (see Figure 5.05-50), are reverse of
left configuration.
REAR OF
ENGINE
1. Run engine at idle with no load.
2. Close gas shutoff valve(s) upstream from Fisher 99
fuel gas pressure regulators.
3. Let engine run. Supply lines are clear when engine
stops.
If provision has been made for downstream shutoff and
bleed valves:
4. Close gas shutoff valve(s) upstream from Fisher 99
fuel gas pressure regulators.

5. Close downstream shutoff valve(s).

SLOTTED CUT FOR #3 MAIN SLOTTED CUT FOR

BEARING CAP CROSS-TIE BOLT FUEL SUPPLY TUBE Gas vented from engine components must be piped
(PILOT CHAMBER TO to a safe area in compliance with all applicable
FRONT OF ENGINE UPPER CHAMBER)
codes. Disregarding this information could result in
Figure 5.05-49. Regulator Bracket -- Left Side severe personal injury or death.

6. Open bleed valve between Fisher 99 regulator(s)

UPPER CHAMBER FUEL SUPPLY TUBE
(ALIGN WITH SLOTTED CUT IN BRACKET) and downstream shutoff valve(s).

BRACKET ATTACHMENT NOTE: Do not change the Fisher 99 fuel gas pressure
regulator spring adjustment. The regulator opens in
response to decreased outlet pressure, so all pressure
between the upstream and downstream shutoff valves
is released through the bleed valve.

FISHER 99 REGULATOR FILTER CLEANING AND

FRONT REAR INSPECTION
OF OF
ENGINE ENGINE Clean or replace the filter of the Fisher 99 fuel gas
pressure regulator(s) annually. If clogging is suspected
in the upstream regulator passages, more frequent
cleaning may be required.
Filter Element Removal
1. Loosen 5/8 in. hex nut on each end of pilot chamber
BRACKET ATTACHMENT
supply tube (see Figure 5.05-51). Detach pilot supply
tube from brass fitting threaded into body of filter
assembly.

Figure 5.05-50. Fisher 99 Regulator Left Side

FORM 6296 First Edition 5.05 -- 19

FUEL SYSTEM

FILTER BODY
ASSEMBLY

FILTER HEAD
HEX NUT

FILTER ELEMENT FLAT

WASHERS

FILTER HEAD HEX NUT

Figure 5.05-51. Fisher 99 Regulator Fuel Gas Filter

2. Remove 1-1/8 in. filter head hex nut from pilot

chamber orifice pipe nipple.
MACHINE
SCREW
3. Remove filter assembly. Disassemble as follows:

A. Remove 1-1/8 in. filter head hex nut from filter FILTER BODY
body.
B. Remove machine screw securing filter element to
filter head.
C. Remove two flat washers and filter element.
Cleaning/Inspection/Replacement
1. Thoroughly wash all parts of assembly in a
non-volatile cleaning solution or solvent. Blow dry with
low pressure compressed air.

2. Inspect filter element for stubborn deposits, peeling

or flaking. Replace as necessary. Figure 5.05-52. Fisher 99 Regulator Filter

Filter Element Installation 2. Thread other end of filter head hex nut onto pilot
chamber orifice pipe nipple.
1. Reassemble filter assembly as follows (see
Figure 5.05-52): 3. Attach pilot supply tube to brass fitting threaded into
body of filter assembly. Tighten hex nut (5/8 in.) on each
A. Place flat washer on support flange inside filter end of pilot chamber supply tube.
head.
MOONEY REGULATOR
B. Center filter element on top of washer.
MAINTENANCE
C. Center second flat washer on top of filter element.
1. Once a year replace seals, O--rings, diaphragms and
D. Slide machine screw through center of filter filter element.
element. Thread screw into filter head.
2. Inspect and clean fixed restrictor orifice located in
E. Thread filter head hex nut onto filter body. pilot inlet supply connection (see Figure 5.05-5 and
Figure 5.05-53). Orifice inside diameter is 0.052 in.
(1.3 mm) (#55 drill).

5.05 -- 20 FORM 6296 First Edition

 FUEL SYSTEM

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
nameplates are updated to accurately indicate any field
changes in equipment, materials, service conditions, or
pressure settings.
3. Inspect all other components (replace as needed).
DISASSEMBLE PILOT
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
INSIDE DIAMETER ORIFICE
0.052 IN. (1.3 MM) installing the new body insert assembly. 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 5.05-54 and Figure 5.05-55).

1. Depressurize pilot and main valve. Unscrew and

remove body insert assembly (see Figure 5.05-54).

CARTRIDGE

Figure 5.05-53. Fixed Restrictor Orifice

REGULATOR ADJUSTMENTS
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 5.05-1).
Table 5.05-1. Mooney Regulator Fuel Pressures
Figure 5.05-54. Cartridge Assembly
NATURAL GAS SUPPLY PRESSURE TO
ENGINE ENGINE MOUNTED REGULATOR
MODEL 2. Remove stem O--ring from pilot body using suitable
RECOMMENDED MAXIMUM
tool (a paper clip works well). Do not scratch O--ring
L5794GSI 24 – 50 psig 75 psig groove (see Figure 5.05-55).
L7044GSI (165 – 345 kPa) (517 kPa)
L5774LT 43 – 60 psig 75 psig NOTE: The loading and inlet ports are interchangeable
L5794LT (296 – 414 kPa) (517 kPa) with one another.
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 5.05-68).

FORM 6296 First Edition 5.05 -- 21

FUEL SYSTEM

LOADING SENSING LINE OUTLET RETAINER

PLUG

LOADING INLET

OUTLET STEM O--RING

Figure 5.05-55. Stem O--Ring

5/16 IN.-18 UNC
3. Remove bottom cap from cartridge and remove CAPSCREW
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 insert (see Figure 5.05-56).

CARTRIDGE SPRING
BODY LOCK NUT ADJUSTER STEM

Figure 5.05-57. 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 5.05-58).

5/16 IN.-18 UNC

CAPSCREW

ORIFICE BOTTOM CAP

ASSEMBLY ASSEMBLY

Figure 5.05-56. Cartridge Assembly

4. Loosen lock nut on spring adjuster stem. Unscrew

adjuster stem. Spring tension will release as stem is
unscrewed (see Figure 5.05-57).

5. Remove retainer plug located below outlet port (see

Figure 5.05-57).

6. Remove one 5/16 in.--18 UNC capscrew that se- Figure 5.05-58. Pivot And Lever Assembly Removal
cures spring case to pilot body (see Figure 5.05-57).
8. Remove remaining capscrews that secure spring
case to pilot body. Separate spring case from pilot body
(see Figure 5.05-59).

5.05 -- 22 FORM 6296 First Edition

 FUEL SYSTEM

ASSEMBLE PILOT
PILOT BODY
NOTE: Use Parker Super O--Lubeä or an equivalent
silicone based lubricant on all O--rings in the pilot
assembly.

1. Apply Parker Super O--Lubeä and slide O--ring onto

pivot and lever assembly. Apply Lubriplate No. 105ä
petroleum grease to roll pin and lever (see
Figure 5.05-62).

ROLL PIN

SPRING CASE

Figure 5.05-59. Spring Case And Pilot Body

9. Disconnect line connections and remove pilot body

(see Figure 5.05-60).

PILOT BODY

LEVER O--RING

Figure 5.05-62. Pilot 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-lb (6.8 -- 8.2 N×m). Do not
overtighten, overtightening will distort the pilot dia-
phragm (see Figure 5.05-63).

DIAPHRAGM NUT
PLATE
Figure 5.05-60. Pilot Body
WASHER
10. Remove diaphragm assembly from body. Remove
retaining nut and remaining components. Inspect all
parts for wear or damage (see Figure 5.05-61).

RETAINING DIAPHRAGM
NUT

DIAPHRAGM

DIAPHRAGM
RETAINER

Figure 5.05-63. Pilot Diaphragm

Figure 5.05-61. Diaphragm Assembly

FORM 6296 First Edition 5.05 -- 23

FUEL SYSTEM
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 5.05-64).
5/16 IN.-18 UNC GUIDE PIN
CAPSCREW NOTCH
Figure 5.05-64. Pivot And Lever Assembly
4. Install retainer plug into body. Plug should be flush
with body when installed correctly (see Figure 5.05-65).
LEVER
DIAPHRAGM
Figure 5.05-65. Diaphragm Installation
5. Slide diaphragm assembly onto lever. Align dia-
phragm with pivot and lever assembly. Lubrication of
pivot pin is not required (see Figure 5.05-65).
6. Place spring washer onto diaphragm plate. Lubricate
spring washer with Lubriplate No. 105ä or petroleum
grease to hold in position (see Figure 5.05-66). Washer
prevents main spring from “binding” on diaphragm
assembly when compressed.
5.05 -- 24
SPRING WASHER
Figure 5.05-66. Diaphragm Spring Washer
7. Place spring case on pilot body (see Figure 5.05-67).
Vent connection should face down when regulator is
mounted on engine. This allows condensation to drain
away instead of accumulating and possibly freezing.
SPRING CASE MAIN SPRING
VENT
Figure 5.05-67. Spring Case
8. Secure spring case to pilot body with cap screws.
Tighten in a criss--cross pattern to 5 ft-lb (6.8 N×m) (see
Figure 5.05-67).
9. Install main spring (brown) into spring case.
NOTE: The top of the main spring will be almost 2 in.
(5 cm) below the spring case when fully installed.
10. Install O--ring on spring adjuster fitting (see
Figure 5.05-68). Screw adjuster stem out to relieve
spring pressure during installation.
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 5.05-68 and
Figure 5.05-69).
FORM 6296 First Edition
 FUEL SYSTEM

STEM O--RING

2.75 IN. 6.98 CM

O--RINGS

ADJUSTER BODY INSERT

O--RING STEM

Figure 5.05-68. Spring Adjuster Assembly

ADJUSTER
FITTING
BACK-UP
WASHER

ORIFICE
O--RING

ORIFICE

ADJUSTER PLUG AND STEM

LOCK NUT STEM ASSEMBLY

Figure 5.05-69. Spring Adjuster

STEM GUIDE
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 RETURN
SPRING
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 ORIFICE
Figure 5.05-54 and Figure 5.05-55). SPRING

12. Assemble cartridge by placing O--ring on bottom

cap, then install return spring, orifice spring, stem guide, O-RING
plug and stem, orifice and O--ring, and back--up washer
(see Figure 5.05-70).

BOTTOM CAP

Figure 5.05-70. Bottom Cap Assembly

FORM 6296 First Edition 5.05 -- 25

FUEL SYSTEM

13. Install bottom cap assembly into body insert.

Return spring will force orifice into position as cap BODY INSERT
ASSEMBLY
assembly is screwed into body insert (see
Figure 5.05-71). Tighten to 5 ft-lb (6.8 N×m).

BODY INSERT BOTTOM CAP

ASSEMBLY

Figure 5.05-73. Body Insert Assembly

FILTER MAINTENANCE
O-RING O-RING
Filter element is subject to plugging and must be
inspected and replaced as necessary. The frequency of
Figure 5.05-71. Cartridge Body And Cap Assembly
inspection and replacement of the filter element de-
pends on severity of service conditions and the length of
14. Press stem against hard surface to verify it moves
time in service.
freely and returns to extended position. Stem should
extend 0.32 in. (8.1 mm) from body insert (see
Figure 5.05-72).
Before disassembly make sure the regulator and
filter have been isolated from the process by
STEM
closing block valves on the inlet and outlet sides of
O--RING
0.32 IN. the regulator. Safely release pressure and process
(8.1 MM)
fluid from body and pilot system. Failure to properly
complete these steps may result in personal injury
and property damage.

DISASSEMBLY
1. Depressurize main valve and filter. Remove filter
housing (see Figure 5.05-74).

BODY
INSERT

Figure 5.05-72. Cartridge Stem Height

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

onto stem.

16. Verify O--ring is lubricated and in position on stem.

Install cartridge into pilot body. Tighten to 5 ft-lb
(6.8 N×m). Do not overtighten (see Figure 5.05-72 and
Figure 5.05-73).

FILTER
HOUSING

Figure 5.05-74. Filter Assembly

5.05 -- 26 FORM 6296 First Edition


2. Inspect filter element and replace if necessary (see
Figure 5.05-75).
FILTER
FILTER HOUSING
Figure 5.05-75. Filter Element
3. Remove filter O--ring (see Figure 5.05-76). A paper
clip or other suitable tool can be used. Inspect for
defects and replace if necessary.
O-RING
Figure 5.05-76. Filter Fitting
ASSEMBLE FILTER
1. Lubricate O--ring with Parker O--Lubeä (or equiva-
lent petroleum based lubricant) and install in filter fitting.
NOTE: If the filter guide is removed, apply a small
quantity of Loctite â (or equivalent) to the threaded area
and screw hand tight into filter body.
2. Lubricate threads of filter housing with Lubriplateâ
(or equivalent petroleum based lubricant).
FORM 6296 First Edition
FUEL SYSTEM
3. Place filter element into housing. Screw housing into
fitting and tighten to 5 ft-lb (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 (see Figure 5.05-77).
FILTER
HOUSING
Figure 5.05-77. Filter Fitting
MAIN VALVE MAINTENANCE
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
nameplates are updated to accurately indicate any field
changes in equipment, materials, service conditions, or
pressure settings.
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 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 MAIN VALVE
1. Disconnect pilot loading line from pilot (see
Figure 5.05-78).
2. Remove two 5/16 in.--18 UNC capscrews that se-
cure main valve bracket to pilot (see Figure 5.05-78).
3. Loosen valve cover capscrews in a criss--cross
pattern. The main spring will lift the cover as capscrews
are removed (see Figure 5.05-78).
5.05 -- 27
FUEL SYSTEM

VALVE COVER OUTSIDE RIB

DOWNSTREAM

PILOT LOADING 5/16 IN.-18 UNC

LINE CAPSCREWS CAPSCREW

Figure 5.05-78. Pilot Loading Line Figure 5.05-80. Throttle Plate

4. Remove main spring, diaphragm, and cover (see 5. Remove and inspect nitrile O--ring for wear or
Figure 5.05-79). Inspect parts for wear. damage (see Figure 5.05-81).

MAIN SPRING

NITRILE
COVER DIAPHRAGM O-RING

Figure 5.05-79. Main Valve Cover Figure 5.05-81. Nitrile Body Seal

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 5.05-80).
6. Inspect all parts for wear and damage. Replace as
necessary.
CLEANING
1. Do not clean O--ring grooves with sharp metal tools.
Bottom of groove and mating surface of adjacent parts
must have smooth finish to prevent leakage.

5.05 -- 28 FORM 6296 First Edition

 FUEL SYSTEM

ASSEMBLE MAIN VALVE
NOTE: The cover plate should be positioned so the
boss is located at the outlet (downstream) side of the
fuel line (see Figure 5.05-82 and Figure 5.05-86).
COVER
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.

1. Install nitrile body seal (see Figure 5.05-83).

BOSS

MAIN SPRING

DIAPHRAGM

NITRILE
BODY SEAL
THROTTLE
PLATE
Figure 5.05-83. Nitrile O--Ring

NOTE: If the inlet sides of the throttle plate and

diaphragm is in better condition than the outlet sides,
the entire assembly can be rotated 180 degrees (outlet
NITRILE to inlet) to renew the shutoff capability (see
BODY SEAL
Figure 5.05-84).

OUTLET SIDES
INLET
BODY

FLOW
DIRECTION

OUTLET
INLET SIDES
Figure 5.05-82. Left Bank Main Valve Configuration
Figure 5.05-84. Throttle Plate

FORM 6296 First Edition 5.05 -- 29

FUEL SYSTEM

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

BRACKET COVER
on top of spring. Do not lubricate diaphragm sealing CAPSCREW
surface (see Figure 5.05-82 and Figure 5.05-85).

MAIN SPRING

PILOT 5/16 IN.-18 UNC

LOADING LINE CAPSCREW

Figure 5.05-87. Left Bank Main Valve

COVER DIAPHRAGM
Figure 5.05-85. 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 5.05-82 and Figure 5.05-86).
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.

5. Tighten spring cover capscrews in increments using

COVER BOSS OUTLET
CAPSCREW a criss--cross pattern (see Figure 5.05-87 and
Figure 5.05-88). Tighten to 20 ft-lb (27 N×m).

FLOW
BRACKET INLET DIRECTION

Figure 5.05-86. Left Main Valve

3. Place spring case cover assembly and bracket on

main valve and secure with four capscrews (see
Figure 5.05-86 and Figure 5.05-87). Do not fully tighten.

4. Secure opposite end of bracket to pilot body with

5/16 in.--18 UNC capscrews (see Figure 5.05-87).
COVER
CAPSCREW PILOT LOADING
Lubricating or overtigh- LINE
tening regulator valve
cover capscrews can damage the diaphragm. Disre- Figure 5.05-88. Right Bank Regulator
garding this information could result in severe
engine damage. 6. Install pilot loading line.

7. Reconnect pilot system. Follow approved start up

procedures when returning to operation.
5.05 -- 30 FORM 6296 First Edition