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  9. Impco T60 Setup guide

Impco T60 Setup guide

April, 2019 IMPCO Technologies PPI-68 REV. E
3030 South Susan St. Page 1 of 15
Santa Ana, CA 92704
www.impcotechnologies.com
3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
T60 REGULATOR REPAIR KIT
INSTRUCTIONS
This PPI covers the repair of Series I and II T60 regulators using either a minor or major repair kit.
Important: Any maintenance, service or repair
should be performed by trained and experienced
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 technician should always wear
protective clothing and eyewear to prevent injury.
The IMPCO PPI-68 repair kit instructions will provide
the technician information to successfully repair
Model T60 regulators. Always inspect the major
casting pieces for damage, corrosion or cracks
before attempting a service repair.Refer to the
illustrations at right to properly identify the T60 as a
Series I or II.
NOTE: The T60 Series I uses imperial screws and
the Series II uses metric. Extra imperial and metric
screws are included in the repair kits—be sure to use
the correct screws when reassembling the regulator.
NOTE: Although identical in dimensions and
appearance, the primary and secondary seats are
made of different material. To differentiate the two
seats, the secondary seat is red in color, or black but
marked by a small white dot.
Do not use Teflon tape to seal any fuel
fittings. Fragments of the tape may enter
into the fuel system, causing damage or
malfunction of critical fuel system
components that may result in serious
injury and/or property damage.
Part # Description
T60-RK Repair Kit-Minor
T60-RBK Repair Kit-Major
REPAIR KIT PART NUMBERS
T60 Regulator, Series I
T60 Regulator, Series II
Sept, 2019 IMPCO Technologies PPI-68 REV. E
3030 South Susan St. Page 2 of 15
Santa Ana, CA 92704
www.impcotechnologies.com
3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
MODEL T60 REGULATORS
Item # P/N DESCRIPTION
P3-13 PLUG, 1/8-27 NPT* (1) (SERIES I)
P3-16699-001 PLUG, 1/8 SOCKET HEAD STEEL (SERIES II)
2 NSS CASTING, REGULATOR BODY
3 NSS DIAPHRAGM ASSEMBLY* (1), (2)
4 NSS COVER, PRIMARY REGULATOR
5 NSS SPRING, PRIMARY* (1)
6 NSS SCREW, RETAINER, ADJUSTABLE SPRING
7 P3-17956-8 PLUG, EXPANSION* (1), (2)
8 60-4 SPRING, PRIMARY LEVER* (1)
LEVER ASSY, PRIMARY* (1), (2) (SERIES I)
LEVER ASSY, PRIMARY (SERIES II)
SCREW, FIL HD, 10-32 UNF-2A x .31 L (SERIES I)
SCREW, M5 x 0.8 7.9 FIL HD, TORX (SERIES II)
11 NSS BRIDGE, PRIMARY
12 NSS PIN, PRIMARY PIVOT* (1)
SCREW, 10-32 x.62 TORX* (1) (SERIES I)
SCREW, TORX TAMP RES M5 X16MM* (1), (2) (SERIES II)
14 NSS ORIFICE, PRIMARY REGULATOR (SERIES I)
15 NSS DIAPHRAGM ASSEMBLY, VACUUM LOCK* (1), (2)
16 NSS SPRING, VACUUM LOCK* (1)
17 NSS DIAPHRAGM, SECONDARY* (1), (2)
COVER ASSY (SERIES I)
COVER ASSY W/PRIMER (SERIES I)
COVER ASSY (SERIES II)
COVER ASSY W/PRIMER (SERIES II)
COVER ASSY, W/PRIMER & MTG TABS (SERIES II)
COVER ASSY, W/MOUNTINGS TABS (SERIES II)
SCREW, PAN HD 10-32 x .38* (1) (SERIES I)
SCREW, TORX TAMP RES M5 X16MM (SERIES II)
20 60-16 RING, VACUUM LOCK
21 NSS SPRING, SECONDARY LEVER* (1)
22 NSS PIN, SECONDARY PIVOT* (1)
LEVER ASSY, SECONDARY* (1), (2) (SERIES I)
LEVER ASSY, SECONDARY (SERIES II)
24 NSS ORIFICE, SECONDARY REGULATOR (SERIES I)
S1-17367 SCREW, ADJUSTMENT (SERIES I)
NSS SCREW, ADJUSTMENT* (1) (SERIES II)
26 NSS LABEL
27 400-25 VALVE, NEOPRENE* (1), (2) (SERIES I)
28 NSS WASHER, COPPER* (1), (2) (SERIES I)
29 NSS PLUG, WATER CORE (SERIES I)
30 NSS PLUG, FREEZE .50 DIS. X .38* (1)(SERIES II)
SCREW, PAN HD, 10-32 UNF-2A X .25 L* (1) (SERIES I)
SCREW, TORX TAMP RES M5 X16MM* (1) (SERIES II)
32 P3-17956-1 PLUG, EXPANSION* (1), (2)
33 NSS GASKET, DIAPHRAGM* (1), (2)
34 W1-5 WASHER, SPLIT LOCK* (1) (SERIES I)
35 NSS SCREW, FIL HD 1/4-28 UNF-2A* (1) (SERIES I)
36 NSS WASHER, COPPER-SPECIAL (SERIES I)
37 NSS SEAT, T60* PRIMARY (1), (2) (SERIES II)
38 NSS SEAT, T60* SECONDARY (1), (2) (SERIES II) WHITE DOT
NSS
31
NSS
NSS
NSS
19
25
23
18
1
NSS
10
NSS
13
NSS
9
NSS=Not Sold/Serviced Separately
*Repair Kit. (1)=T60-RBK; (2)=T60-RK
Note that some components will vary among the different
T-60 Models.
April, 2019 IMPCO Technologies PPI-68 REV. E
3030 South Susan St. Page 3 of 15
Santa Ana, CA 92704
www.impcotechnologies.com
3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
Series I Levers Series II Levers &
Replaceable Seats
The primary and secondary levers and seats
in the Series I and Series II regulators are
different and are not interchangeable. The
Series I seats are permanently mounted and
included preassembled with the levers in the
repair kits. The Series II seats are replaceable
and are also included in the repair kits (the
original levers are reused). Be sure to
properly identify the regulator and correct
lever and seat prior to assembly.
DISASSEMBLY INSTRUCTIONS
1. Remove the five cover screws (13) and washers (34)
(Series I only), then lift the cover (18) off the
regulator body (2) and secondary diaphragm (17).
The cover may stick to the diaphragm. If necessary,
tap on the edge of the cover with a screwdriver
handle or a soft face hammer to loosen the cover.
Note: Do not attempt to use a screwdriver or other
object to pry between the cover and the body. Prying
with sharp objects may damage the sealing surface,
rendering the regulator unusable.
2. After the cover (18) has been removed, lift up an
edge of the diaphragm (17) and observe how it is
attached to the secondary lever (23). If equipped
with a vacuum-lock diaphragm (15), depress the
vacuum diaphragm and slide the diaphragm off the
lever.
Sept, 2019 IMPCO Technologies PPI-68 REV. E
3030 South Susan St. Page 4 of 15
Santa Ana, CA 92704
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3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
3. Loosen the two screws (31) holding the secondary
lever pivot pin (22) in place and remove pin, lever
(23) and spring (21).
Vacuum Lock Models Only (Skip to Step 5 for
models without a Vacuum Lock):
4. Remove the four screws (19) holding the vacuum-
lock ring (20) and diaphragm (15) in place. Lift ring,
diaphragm and spring (16) from regulator body (2).
5. Remove the expansion plug (7) by drilling a small
hole in the plug, carefully threading in a small sheet
metal screw, then pulling the plug out using a slide
hammer (as shown in the photo of Step 11). Once
the plug is removed, also remove the primary
pressure adjusting screw (6) and spring (5).
Use care when drilling the expansion plug
hole by not drilling further into the retaining
screw.
April, 2019 IMPCO Technologies PPI-68 REV. E
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3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
6. Remove the five primary cover screws (13) and
washers (34)(Series I only), then lift the cover (4) off
the regulator body (2).
7. Remove the cover (4), gasket (33) and primary
diaphragm (3). Note that the primary diaphragm
requires spinning 90 degrees to remove the primary
diaphragm pin from the primary lever (9).
8. Remove the two screws (10) holding the primary
lever bridge (11) in place.
Sept, 2019 IMPCO Technologies PPI-68 REV. E
3030 South Susan St. Page 6 of 15
Santa Ana, CA 92704
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3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
9. Remove primary lever (9), pivot pin (12) spring (8),
and primary bridge (11).
Series I only (Skip to Step 11 for Series II)
10. Remove the water core plug (29), copper washer
(28) and neoprene plug (27) from the regulator
body (2).
Series II only (Skip to Step 15 for Series I)
11. If the freeze plug (30) shows signs of corrosion or
leakage, replace it with a new plug included in
repair kit. To remove the freeze plug, drill a small
hole into its center, thread in a sheet metal screw
and remove using a slide hammer.
Use care when drilling the freeze plug hole
by not drilling further into the regulator body.
April, 2019 IMPCO Technologies PPI-68 REV. E
3030 South Susan St. Page 7 of 15
Santa Ana, CA 92704
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3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
12. Remove the seats (37) of both the primary lever
(9) and secondary lever (23) by cutting off the nub
on the back of the seat.
REASSEMBLY OF REGULATOR
Carefully clean and inspect all metal parts to be reused, including springs, levers, pivot pins and
screws. Replace all parts that are included in the repair kit.
Carefully clean the regulator body and inspect for cracks, corrosion or damage and examine the
primary and secondary orifices for nicks, scratches or uneven wear. If any of these conditions are
found, the regulator is not rebuildable and must be replaced.
Wipe with a clean rag and inspect the primary section for foreign materials that might loosen and
damage the soft face valves.
Clear out the inlet and outlet passages with compressed air, including the atmospheric vent
on the secondary cover. Be sure no foreign material remains in these passages.
Series II only (Skip to Step 3 for Series I)
1. Inspect and identify the primary and secondary
seats (To differentiate the two, the secondary seat
is either red, or black but marked with a white dot).
Do not swap the seats.
Primary Seat
Secondary Seat
Press the primary (37) seat into the primary lever
(9) and secondary seat (38) into the secondary
lever (23), ensuring that both are properly seated.
2. Apply Loctite 680 or equivalent to the perimeter of
the freeze plug (30), then press in so the opened
end is flush with the regulator body (2).
Sept, 2019 IMPCO Technologies PPI-68 REV. E
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3030 S Susan Street, Santa Ana, CA 92704
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Series I only (Continue to Step 4 for Series II)
3. Insert the neoprene valve (27) with the cupped or
open side down into the water core plug (29) and
press all the way in until it contacts the back of the
relief plug. Apply Loctite 567 or equivalent sealer
on the threads of the relief plug, then slide the
copper gasket (28) over the relief plug and insert
the plug assembly into the regulator body (2).
Torque to 25 ±5 ft. lbs. (33.9 ± 6.8 N•m).
Vacuum Lock Models Only (Skip to Step 7 for
models without a Vacuum Lock):
4. Place the vacuum lock spring (16) into the recess
of the regulator body (2).
5. Place vacuum lock diaphragm (15) on top of
spring (16), and position so the wide edge of the
gasket is seated on the bottom (6 o’clock) position
of the regulator body (2), while making sure the
spring is properly seated over the diaphragm
spring perch. Place the vacuum lock ring (20)
over the diaphragm (15) rotating it to the same
position as the diaphragm and align with screw
holes. Insert four screws (19) and tighten evenly
to 25 in. lbs. ±5 in. lbs. (2.825 N•m ± 0.565 N•m).
April, 2019 IMPCO Technologies PPI-68 REV. E
3030 South Susan St. Page 9 of 15
Santa Ana, CA 92704
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3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
6. Push down on the vacuum-lock diaphragm (15)
and hold a finger over the vacuum connection on
the front of the regulator (below “VAC” on the
regulator face). Release the diaphragm and the
diaphragm will stay depressed and down against
the regulator body (2) if there are no leaks. Pull
up on the center of the diaphragm assembly for
further leak inspection. Release your finger
sealing the vacuum port and the diaphragm will
rise with spring pressure. If the diaphragm rises
when the vacuum connection is sealed, a leak
exists. Inspect the diaphragm for tears and the
regulator body (2) for damage. If the diaphragm is
torn, it must be replaced. If damage is found in
the regulator body, the regulator cannot be
serviced and must be replaced.
7. Place secondary valve spring (21) in the spring
recess of the regulator body (2) near the
secondary orifice.
8. Place a small amount (thin film) of petroleum jelly
(Vaseline) on the surface of the secondary seat.
Install the secondary lever (23), pivot pin (22) and
two screws (31). Tighten screws evenly to 25 in.
lbs. ±5 in. lbs. (2.83 N•m ± 0.57 N•m).
Sept, 2019 IMPCO Technologies PPI-68 REV. E
3030 South Susan St. Page 10 of 15
Santa Ana, CA 92704
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3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
9. Inspect the height of the secondary lever (23).
Using a ruler or straight edge, verify that the tip or
end of the lever rod is level or flush with the top of
the regulator body (2). If the lever requires
adjusting, DO NOT bend while installed (bending
may damage the valve seat). Remove the lever,
bend, reinstall, then recheck lever height.
10. Lay the regulator body (2) flat on a clean working
surface with the primary section up. Place the
primary spring (8) in the recess as shown.
NOTE: Repair kit T60-RK does not include the
primary spring; T60-RBK does.
11. Insert primary pin (12) into the primary lever (9).
NOTE: The Series I lever is shown on the left.
The Series I lever is included in both minor and
major repair kits preassembled with the seat rivted
into place.
April, 2019 IMPCO Technologies PPI-68 REV. E
3030 South Susan St. Page 11 of 15
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3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
12. Place a small amount (thin film) of petroleum jelly
(Vaseline) on the surfaces of the primary seat.
Install the lever pin (12), primary lever (9) and the
primary bridge (11) with two screws (10). Tighten
screws evenly to 25 in. lbs. ±5 in. lbs. (2.82 N•m ±
0.56 N•m). pin
13. Place the primary diaphragm (3) on top of the
regulator body (2), then spin the diaphragm 90
degrees and insert the primary diaphragm pin into
the oval hole in the primary lever (9). Once
inserted, rotate the diaphragm back so it aligns to
the body and screw holes. Note that the breather
hole must line up with the breather passage in the
regulator body (2), as shown in the photo.
14. Place the gasket (33) on top of diaphragm (3) and
install primary cover (4) and five screws (13).
Torque evenly to 30 in. lbs. ±5 in. lbs. (3.39 N•m
±0.565 N•m).
Sept, 2019 IMPCO Technologies PPI-68 REV. E
3030 South Susan St. Page 12 of 15
Santa Ana, CA 92704
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3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
15. Install the primary pressure spring (5) and screw in
the spring retainer (6) about four turns.
16. Remove plug (1) in the primary test port and insert
a 1/8” NPT to hose barb adapter and attach a
pressure gauge to test port.* SLOWLY turn on air
pressure to 90-100 psi (621-689kPa) and using a
screwdriver, adjust the spring retainer (6) until the
primary pressure is between 4 and 5 psi (27.6-
34.5 kPa).
NOTE: Hose barb and pressure gauges are
included IMPCO ITK test kits.
17. Test the primary diaphragm (3) by plugging the
breather vent (the small 1/8˝ or 3.1mm diameter
hole in the regulator body (2) located near the top
and right side of the secondary lever. Using the
eraser end of a pencil, block or plug the vent and
observe the primary pressure. The pressure
should not change. If the pressure increases, the
primary pressure seat or diaphragm is not sealing
properly and leaking. In this case, the rebuild has
failed and the regulator must be replaced.
April, 2019 IMPCO Technologies PPI-68 REV. E
3030 South Susan St. Page 13 of 15
Santa Ana, CA 92704
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3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
18.Apply two drops, one each on opposite sides
(180° apart) of the threads on the primary
pressure adjustment.
19. Once tested to ensure no leaks exist and a stable
pressure between 4 and 5 PSI (27.6-35.5 kPa) is
obtained, remove the test port fitting and replace
the primary test port plug (1) at the top of the
regulator. Apply Loctite 567 or equivalent thread
sealer, then torque to 1-2 turns past finger tight.
Replace the tamper resistant plug (7) on to the
primary cover (4).
Idle Screw Models Only (Continue to next Step for
models without an Idle Screw):
20. Remove the tamper resistance plug covering the
idle screw (32) (refer to the process shown in Step
11). Replace the idle screw (25) by unscrewing it
counterclockwise. Install the new idle screw,
turning it until the screw makes contact with the
lever, then make one additional turn.
Use care when drilling the expansion plug hole
by not drilling further into the idle screw or
regulator body.
Sept, 2019 IMPCO Technologies PPI-68 REV. E
3030 South Susan St. Page 14 of 15
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3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
21. Place the secondary diaphragm (23) on the
regulator body (2) so the straight edge of
diaphragm is at the top (12 o’clock position).
Placing your finger between the vacuum lock
diaphragm (15) and the secondary lever (23),
depress the diaphragm, lift the lever then slide the
lever rod through the center pin of the diaphragm.
22. Place the secondary diaphragm (17) so the
straight edge is at the top of the regulator, then
place the cover (18) on the regulator body and
align the screw holes. Carefully start all five
screws (13) and washers (34)(Series I only)
through the cover and diaphragm holes, then
tighten evenly to 30 in. lbs. ± 5 in. lbs. (3.29 N•m ±
0.57 N•m).
23. Install the regulator.
NOTE: The atmospheric vent (small opening on the edge of the back cover) must be at the lower 45°
position when mounted.
24. Leak check all fittings, covers and fuel connections using an electric leak detector or a commercial
leak detector solution:
a. Run the engine until it is at full operating temperature.
b. Reset idle mixture carbon monoxide (CO) percent to factory specifications.
c. Replace idle mixture tamper-resistant cap (32).
April, 2019 IMPCO Technologies PPI-68 REV. E
3030 South Susan St. Page 15 of 15
Santa Ana, CA 92704
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3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
WARNING:
IMPROPER INSTALLATION OR USE OF THIS PRODUCT MAY CAUSE
SERIOUS INJURY, DEATH AND/OR PROPERTY DAMAGE
Natural Gas or LPG Installations in the US:
NFPA 37 Standard for the Installation and USE of Stationary Combustion Engines and Gas Turbines
NFPA 52 Vehicular natural Gas Fuel Systems Code
NFPA 58 Liquefied Petroleum Gas Code
SERVICE TECHNICIANS AND USERS SHALL CAREFULLY READ AND ABIDE BY THE PROVISIONS SET FORTH IN
NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET (NFPA) #37 FOR STATIONARY COMBUSTION ENGINE
STANDARDS, NFPA #52 FOR NATURAL GAS FUEL SYSTEMS OR NFPA 58 FOR STORAGE, HANDLING,
TRANSPORTATION AND USE OF LPG.
INSTALLERS LPG INSTALLATIONS IN THE UNITED STATES MUST BE PERFORMED IN ACCORDANCE WITH FEDERAL,
STATE, 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 AND/OR LOCAL LAW.
COUNTRIES OUTSIDE OF USA REFER TO THE GOVERNING AGENCIES OVERSEEING CNG AND PROPANE
APPLICATIONS.
CNG INSTALLATIONS IN THE UNITED STATES MUST BE PERFORMED IN ACCORDANCE WITH FEDERAL, STATE,
LOCAL LAW AND NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET #52, COMPRESSED NATURAL GAS (CNG)
VEHICULAR 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 PERFORMED IN ACCORDANCE
WITH FEDERAL, STATE, LOCAL LAW AND NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET #37, STANDARD
FOR THE INSTALLATION AND USE OF STATIONARY COMBUSTION ENGINES AND GAS TURBINES, 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 MUST NOT BE
INSTALLED OR USED BY PERSONS NOT KNOWLEDGEABLE OF THE HAZARDS ASSOCIATED WITH THE USE OF
GASEOUS FUELS. ANY MAINTENANCE, SERVICE OR REPAIR SHALL BE PERFORMED BY TRAINED AND
EXPERIENCED SERVICE TECHNICIANS.
PROPER TOOLS AND EQUIPMENT PROPER TOOLS AND EQUIPMENT MUST BE USED TO PREVENT INJURY TO THE
SERVICING TECHNICIAN, PROPERTY OR SYSTEM COMPONENTS. SERVICE REPAIRS SHALL ALWAYS BE
PERFORMED IN A SAFE ENVIRONMENT AND THE TECHNICIAN MUST ALWAYS WEAR PROTECTIVE CLOTHING TO
PREVENT INJURY.
INSPECT PRIOR TO USE ALWAYS INSPECT THE MAJOR CASTING PIECES FOR DAMAGE, CORROSION OR CRACKS
BEFORE ATTEMPTING TO SERVICE AND/OR 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.
PROPOSITION 65 WARNING:THIS PRODUCT CAN EXPOSE YOU TO CHEMICALS INCLUDING NICKEL, WHICH IS
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER. FOR MORE INFORMATION GO TO
www.P65Warnings.ca.gov

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