Impco L Setup guide

July, 2015 IMPCO Technologies Inc. PPI-16 REV. D
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MODEL L
TWO-STAGE REGULATOR REPAIR KIT INSTRUCTIONS
Important: Any maintenance, service or repair
should be performed by trained and experi-
enced service technicians. Proper tools and
equipment should be used to prevent injury to
the servicing technician, property or system
components. Service repairs should always be
performed in a safe environment and the tech-
nician should always wear protective clothing
to prevent injury.
The IMPCO PPI-16 repair kit instructions will
provide the technician information to success-
fully repair the Model L regulator. Always in-
spect the major casting pieces for damage,
corrosion or cracks before attempting a service
repair. Be sure the repair kit part number you
are using is correct for the regulator being ser-
viced. Diaphragms are color coded and have
different performance characteristics:
BLACK: Hydrin diaphragm material is the
standard material and is well suited for the
most common applications.
YELLOW: Silicone diaphragm material is the
optional upgrade material that provides excel-
lent flexibility in cold weather climates and is
more resistant to chemical contamination.
Model L Two Stage Converter
Do not use Teflon tape to seal any fuel fittings.
Failure to follow this warning may cause the
regulator to leak internally, possibly resulting in
serious injury and/or property damage and may
void any warranty coverage.
Part # Description
RK-L Repair Kit Model L, Hydrin Diaphragm
RK-L-2 Repair Kit Model L, w/Silicone Diaphragm
REPAIR KIT PART NUMBERS

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MODEL L SERIES CONVERTERS
ITEM# PART# DESCRIPTION
1 S7-1 NSS Screen, atmospheric vent
2 S1-59* NSS Screw, 8-32 x 5/8" SEMS (8)
3 AC1-63 NSS Cover ass'y, secondary
4 W1-27* NSS Washer, hand primer
AD1-30* NSS Diaphragm ass'y, secondary, Hydrin
AD1-31* NSS Diaphragm ass'y, secondary, Silicone
6 L1-87* NSS Lever, secondary
7 S4-37* NSS Seat, secondary
P1-7 NSS Pin, sec. lever fulcrum (early models)
P1-8 NSS Pin, sec. lever fulcrum (later models)
9 S2-97 NSS Spring, secondary regulator (blue)
10 S1-59* NSS Screw, 8-32 x 5/8" SEMS (6)
C1-62 NSS Cover, primary diaphragm (early models)
C1-50816-001 NSS Cover, primary diaphragm (later models)
12 S2-92 NSS Spring, primary regulator (2)
13 AD1-32* NSS Diaphragm ass'y, primary
14 AB1-57 NSS Body ass'y
15 P3-13 NSS Plug, hex head, 1/8 NPT (2)
16 S1-59* NSS Screw, 8-32 x 5/8" SEMS (5)
17 C1-61 NSS Cover, water passage
18 G1-118* NSS Gasket, water passage
19 S1-5 NSS Screw, 1/4-20 x 5/8" SEMS (2)
20 P1-34 NSS Pin, primary valve
21 G1-119* NSS Gasket, vaporizing chamber
22 AC1-64 NSS Cover, vaporizing chamber
23 S1-3* NSS Screw, 10-24 x 5/8" SEMS (9)
24 S4-18* NSS Seat, primary
25 S4-23* NSS Seat support, primary
26 S2-93 NSS Spring primary valve
27 B3-25551 NSS Bushing, fuel inlet
28 S1-1560-004 NSS Pan HD, Torx (2)--later models
NSS=Not Sold/Serviced Separately
* Item included in repair kit
5
8
11

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REBUILD INSTRUCTIONS
1. Model L Repair Kit (RK-L) contains all nec-
essary parts to replace components subject
to deterioration (see page 2 for repair kit
components). Installation of repair kit should
be necessary only at the time of a major
overhaul or when converter has been out of
service for a significant length of time.
Note: Gaskets and diaphragms deteriorate if
converter is stored after use.
2. Inspect repair kit component parts to ensure
the kit is complete. Start disassembly by
removing the eight screws (2) securing sec-
ondary cover assembly (3).
3. Tap cover (3) loose with plastic screwdriver
handle and remove secondary diaphragm
assembly (5). The diaphragm assembly
must be moved away from water inlet-outlet
to disengage diaphragm link from the lever
assembly. Discard diaphragm assembly.
4. Early Models Only For later models, skip to
step 7. Loosen screw (10) which retains ful-
crum pin (8).

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5. Remove screw (10).
6. Slide fulcrum pin (8) to side as shown to
release lever assembly (6 & 7). In some
cases, the pin may come out entirely.
Retain it for reassembly steps. Skip to
Step 8.
7. Later Models Only For early models,
skip to Step 8. Remove two screws (28)
with T-20 Torx tool to release the fulcrum
pin (8).
8. Remove secondary lever and seat as-
sembly (6 & 7) and secondary regulator
spring (9). Retain pin and spring; discard
lever and seat.

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9. Remove remaining screws (10) securing
primary diaphragm cover (11) and re-
move the cover.
10. Removal of primary diaphragm cover
(11) frees two primary springs (12) and
primary diaphragm assembly (13). Re-
move springs and retain for reuse.
11. Remove primary diaphragm assembly
(13). Slide the diaphragm assembly to
disengage slot from primary valve pin
(20). Discard primary diaphragm as-
sembly. Pencil tip points out pin.
Note: Primary valve is actuated by this
pin through the body. This isolates the
diaphragm from any contact with liquid
propane.
12. Turn over and loosen fuel inlet bushing
(27) using a tube wrench or six sided
socket.

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13. Removal of fuel inlet bushing (27) re-
leases primary valve spring (26).
14. Remove primary valve spring (26) and
retain for reuse.
15. Remove primary valve seat (24) and
support (25) and discard.
16. Loosen and remove nine screws (23) in
vaporizing chamber cover (22).

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17. Break cover (22) loose by tapping with a
screw driver handle. Remove cover and
vaporizing chamber gasket (21). Discard
gasket.
18. Remove primary valve pin (20) from con-
verter body and retain for reuse.
19. Remove five screws (16) from water
passage cover (17).
20. Tap cover to loosen and remove cover
(17) and water passage gasket (18). Dis-
card gasket.
Clean covers, body and metal parts as
necessary with a safety solvent and al-
low to dry prior to reassembly. Do not
use harsh solvents such as brake or car-
buretor cleaner on any of the non-
metallic components as they will damage
the material.

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21. Replace water passage cover gasket
(18) and cover (17). Tighten screws
(16), alternating from side to side.
Torque to 25-35 in-lbs. (1.8-4.0 Nm).
22. Install primary valve pin (20) as shown,
in converter body (14). Check that pin
moves up and down freely.
23. Put new vaporizing chamber gasket (21)
in place on vaporizing chamber cover
(22). Press gasket firmly.
24. Reassemble cover (22) and gasket (21)
to heat exchanger body (14). Check to
assure gasket is not folded under cover
at any point.

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25. Hand tighten nine screws (23) in place.
Then tighten from side to side until all are
firmly seated and torque to 25-35 in-lbs.
(1.8-4.0 Nm). Replace any screws dam-
aged during use or disassembly.
26. Insert new primary valve seat support
(25) into primary valve spring (26). Ta-
pered neck of valve seat will slide inside
spring (26) opening at either end.
27. Place the primary valve seat (24), seat
support (25) and spring (26) in vaporizing
chamber cover. Clean seat area with
compressed air or a rag.
Note: The seat (24) must be in-
stalled with the rubber side against
the pin, not against the primary seat
support (25).
28. Fuel inlet bushing (27) ready to insert
over primary spring (26).
Note: Apply Loctite®567 or equivalent to
ensure a gas tight seal. DO NOT USE
TEFLON TAPE.

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29. Tighten fuel inlet bushing (27) 2 to 3
turns past finger tight using a tube
wrench or 6 sided socket.
30. New primary diaphragm assembly (13)
ready to be put in place. Extrusions on
plate on underside of diaphragm slide in-
to groove on primary pin (20) to connect
two components. Be sure the extruded
slot is engage in the pin groove.
31. After diaphragm (13) is in place, pull up
gently on diaphragm to verify that it is
firmly connected to primary pin (20).
32. Place two primary regulator springs (12)
upon locating perches extruded from
back-up plate on primary diaphragm as-
sembly (13).

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33. Early Models Only For later models,
skip to Step 34. Press the nub of the
seat (7) through the lever (6), ensuring a
proper fit. Place secondary lever and
seat assembly (6 & 7) on primary dia-
phragm cover (11). Push fulcrum pin (8)
into place to retain lever.
34. Later Models Only For early models,
skip to 35. Press the nub of the seat (7)
through the lever (6), ensuring a proper
fit. Place the fulcrum pin (8) through the
lever and seat assembly (6 & 7), center,
then place the lever on the cover (11)
with the fulcrum pin seated inside the
slot. Secure the fulcrum pin with two
screws with a T-20 Torx tool and torque
to 17-23 in-lbs. (1.9-2.6 Nm).
35. Press primary cover (11) in place over
the primary springs (12) and diaphragm
(13). Be sure to place over locator pins
closest to water passage cover first, then
over pins at opposite end. Check that di-
aphragm is equally visible all around the
cover and that no portion is folded under.
36. Replace all screws (10) and tighten until
they just contact body. (Use new screws
from repair kit if old ones are damaged).
Then tighten again solidly, first on one
side then diagonally across body on the
opposite side until all screws are firmly
tightened and torque to 25-35 in-lbs.
(1.8-4.0 Nm).

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37. Insert secondary regulator spring (9) in
place between secondary lever and seat
assembly (6 & 7) spring perch on primary
cover. Make sure springs snaps into
place ahead of detent in lever.
38. Use IMPCO G2-2 gauge or a straight
edge to check lever height. When using
a straight edge, the lever should be 5/32”
above the body (lightly pull the lever up
against the secondary seat to measure).
If adjustment is needed, bend lever as
close to the fulcrum as possible.
39. Install new secondary diaphragm (5).
Note slot in position to slide into place
and engage secondary lever (6).
40. Replace hand primer seal washer (4)
indicated by pencil.

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41. Secondary cover (3) with screws (2) in
place, positioned over diaphragm (5).
42. Replace cover (3). Finger tighten eight
screws (2) until all contact the cover.
Tighten screws, alternating sides, until all
screws are firmly seated and torque to
25-35 in-lbs. (1.8-4.0 Nm).
43. Apply 100 psi of air pressure to the inlet
side of the regulator and test for leaks.
Draw a soap bubble across the regulator
outlet to verify that no air is flowing
through the outlet. If air escapes, the re-
build has failed and the regulator must
be replaced. Actuate the primer button
and the soap bubble should burst and air
flow should be noted at the converter
outlet. Use soap and/or a commercial
leak detector solution to inspect the gas-
ket seals around the perimeter of the
converter for leaks. If leaks are found,
the regulator must be replaced. If no
leaks are found, the regulator can be re-
installed and returned to service.
Note: Use only brass or plastic fittings in
the water inlet and outlet passages. A
steel fitting will cause the casting to dete-
riorate due to electrolysis.

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WARNING:
IMPROPER INSTALLATION OR USE OF THIS PRODUCT MAY CAUSE
SERIOUS INJURY, DEATH AND/OR PROPERTY DAMAGE
SERVICE TECHNICIANS AND USERS SHOULD CAREFULLY READ AND ABIDE BY THE PROVISIONS SET FORTH IN
NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET #37 FOR STATIONARY ENGINES, #52 FOR CNG VEHICULAR
FUEL SYSTEMS OR #58 FOR LPG SYSTEMS.
INSTALLERS LPG INSTALLATIONS IN THE UNITED STATES MUST BE DONE IN ACCORDANCE WITH FEDERAL, STATE
AND LOCAL LAWS AND NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET #58, STANDARD FOR STORAGE
AND HANDLING OF LIQUEFIED PETROLEUM GASES, TO THE EXTENT THESE STANDARDS ARE NOT IN VIOLATION
OF FEDERAL, STATE OR LOCAL LAW.
COUNTRIES OUTSIDE OF USA REFER TO THE GOVERNING AGENCIES OVERSEEING CNG AND PROPANE APPLICA-
TIONS.
CNG INSTALLATIONS IN THE UNITED STATES MUST BE DONE IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL
LAW AND NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET #52, COMPRESSED NATURAL GAS (CNG) VEHIC-
ULAR FUEL SYSTEMS, TO THE EXTENT THESE STANDARDS ARE NOT IN VIOLATION OF FEDERAL, STATE OR LOCAL
LAW.
LPG AND/OR NATURAL GAS INSTALLATIONS ON STATIONARY ENGINES MUST BE DONE IN ACCORDANCE WITH
FEDERAL, STATE AND LOCAL LAW AND NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET #37, STATIONARY
COMBUSTION ENGINES AND GAS TURBINE ENGINES, TO THE EXTENT THESE STANDARDS ARE NOT IN VIOLATION
WITH FEDERAL, STATE OR LOCAL LAW. FAILURE TO ABIDE BY THE ABOVE WILL VOID ANY IMPCO WARRANTY ON
THE PRODUCTS AND MAY CAUSE SERIOUS INJURY OR PROPERTY DAMAGE.
SERVICE TECHNICIANS DUE TO THE INHERENT DANGER OF GASEOUS FUELS, IMPCO PRODUCTS SHOULD NOT BE
INSTALLED OR USED BY PERSONS NOT KNOWLEDGEABLE OF THE HAZARDS ASSOCIATED WITH THE USE OF
GASEOUS FUELS. ANY MAINTENANCE, SERVICE OR REPAIR SHOULD BE PERFORMED BY TRAINED AND EXPERI-
ENCED SERVICE TECHNICIANS.
PROPER TOOLS AND EQUIPMENT PROPER TOOLS AND EQUIPMENT SHOULD BE USED TO PREVENT INJURY TO
THE SERVICING TECHNICIAN, PROPERTY OR SYSTEM COMPONENTS. SERVICE REPAIRS SHOULD ALWAYS BE
PERFORMED IN A SAFE ENVIRONMENT AND THE TECHNICIAN SHOULD ALWAYS WEAR PROTECTIVE CLOTHING TO
PREVENT INJURY.
INSPECT BEFORE USE ALWAYS INSPECT THE MAJOR CASTING PIECES FOR DAMAGE, CORROSION OR CRACKS
BEFORE ATTEMPTING A SERVICE REPAIR. BE SURE THE REPAIR KIT PART NUMBER YOU ARE USING IS CORRECT
FOR THE COMPONENT(S) BEING SERVICED.
NO TEFLON TAPE DO NOT USE TEFLON TAPE TO SEAL ANY FUEL FITTINGS. FAILURE TO FOLLOW THIS WARNING
MAY CAUSE THE REGULATOR TO LEAK INTERNALLY, POSSIBLY RESULTING IN SERIOUS INJURY, DEATH AND/OR
PROPERTY DAMAGE AND MAY VOID ANY WARRANTY COVERAGE.