Impco E Series User manual

November, 2014 IMPCO Technologies Inc. PPI-2 REV. J
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MODEL E & PE SERIES
TWO-STAGE REGULATOR REPAIR KIT INSTRUCTIONS
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 to prevent injury.
The IMPCO PPI-2 repair kit instructions will
provide the technician information to
successfully repair the model E and PE
regulators. 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
regulator being serviced. 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
excellent flexibility in cold weather climates
and is more resistant to chemical
contamination.
BLUE: Fluorosilicone diaphragm material
provides excellent high and low temperature
durability with increased chemical resistance.
This material is recommended for turbo
applications.
Model E Two Stage Regulator
Do not use Teflon tape to seal any fuel fittings.
Failure to follow this warning may cause the
regulator to leak internally, that may cause
serious injury and/or property damage.
Part # Description
RK-E Repair Kit Model E, Hydrin Diaphragm
RK-E-2 Repair Kit Model E, w/Silicone Diaphragm
RK-E-3 Repair Kit Model E, Fluorosilicone Diaphragm
RK-PE Repair Kit Model PE, Hydrin Diaphragm
RK-TE Repair Kit Model E, Turbo w/Silicone Diaphragm
REPAIR KIT PART NUMBERS

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MODEL E & PE SERIES REGULATORS
MODEL E SHOWN
ITEM # PART # DESCRIPTION
1S7-1 (NSS) Screen, Atmospheric Vent
2S1-3* Screw, 10-24 x 5/8" SEMS (8)
3AC1-22-10298-001 (NSS) Cover, Secondary
AD1-14-1* (1) (NSS) Diaphragm, Secondary, Hydrin Model E
AD1-23* (2) (NSS) Diaphragm, Secondary, Silicone Model E
AD1-23-4* (3) (NSS) Diaphragm, Secondary, Flourosilicone E
AD1-14-2* (4) (NSS) Diaphragm, Secondary, Hydrin PE
AD1-23-2* (5) (NSS) Diaphragm, Secondary, Silicone PE
5L1-86* (NSS) Lever, Secondary w/ or w/o Hole
6S4-37* (NSS) Seat, Secondary
S2-22 Spring, Secondary Regulator (Blue), Standard
S2-23 Spring, Secondary Regulator (Orange), Option
P1-7 (NSS) Pin, Secondary Lever Fulcrum (Early Model)
P1-8 (NSS) Pin, Secondary Lever Fulcrum (Later Model)
9S1-40* (NSS) Screw, 10-24 x 3/8" SEMS
10 S1-1555-002* (1)(2)(3)(NSS) Screw, 12-24 x 1 1/8" SEMS Model E Only
C1-20 (NSS) Cover, Primary Diaphragm (Early Model)
C1-50815-001 (NSS) Cover, Primary Diaphragm (Later Model)
12 S2-13 (NSS) Spring, Primary Regulator EB (2)
13 AD1-15* (NSS) Diaphragm Assy, Primary
14 P1-11* (NSS) Pin, Primary Valve
15 AB1-20A-10307-001 (NSS) Body, Regulator E Series
16 G1-37* (NSS) Gasket, Regulator Body
17 F3-1* (NSS) Sponge
18 S4-7* (NSS) Seat, Primary
19 AB1-19-10309-001 (NSS) Body, Assy, Heat Exchanger
20 P3-13 (NSS) Plug, Hex Head, 1/8 NPT (3)
21 G1-30079-1* Gasket, Heat Exchanger Cover
22 C1-21PM (NSS) Cover, Heat Exchanger
23 W1-27* (NSS) Washer, hand primer
24 S1-1560-004 (NSS) Screw 8-32 x .25" (Later Model)
25 W1-14187-016 (NSS) Flat Washer (Later Model)
26 P1-8* (NSS) Pin, Lever Diaphragm Link
4
7†
8
11
NSS = Not Serviced Separately
* Repair kit components. (1) = RK-E; (2) = RK-E-2;
(3) = RK-E-3; (4) RK-PE; (5) = RK-TE
† Two vapor outlet pressures are available. The Orange secondary
spring gives Neg. 0.50” w.c. (Neg 0.12 kPa) pressure. Blue secondary
spring gives a Neg. 1.50” w.c. (Neg. 0.37 kPa) pressure.

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COMPONENT MODEL PE
MODEL PE COMPONENTS SHOWN
ITEM # PART#
DESCRIPTION
1S7-1 (NSS)
Screen, Atmospheric Vent
2S1-3*
Screw, 10-24 x 5/8" SEMS (8)
3C1-22-2 (NSS)
Cover Assembly
AD1-14-2*
Diaphragm, Secondary, Hydrin
AD1-23-2*
Diaphragm, Secondary, Silicone
S2-37
Spring, Secondary Standard PE
S2-42
Spring, Secondary, PE (Optional)
27 S1-101*
Screw, 6-32 x 1/4" SEMS (4)
28 H3-3 (NSS)
Housing, Spring
29 G1-84*
Gasket, Spring Housing
NSS-Not Serviced Separately
*Repair Kit Components
7
4
REBUILD INSTRUCTIONS
1.Under normal conditions, installation of a complete
repair kit should be necessary only at the time of a major
engine overhaul or when the regulator has been out of
service for an extended period of time. Each kit includes
the necessary gaskets, diaphragms, seals and some
replacement screws.
2. Model PE Only (Skip for E): Remove the spring
retainer housing cover screws (27) and cover (28).
Remove the housing gasket (29) and secondary spring
(7).

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3.Remove the diaphragm cover (3) by taking out the eight
screws (2) around the circumference of the top cover.
4.Remove the secondary diaphragm (4). This requires
the assembly be moved about one inch away from
the gas outlet to disengage the two prongs of the
diaphragm link from the lever (5).
5.Diaphragm (4) and cover (3) removed showing
secondary lever (5).
Early Models Only (Skip to Step 9 for later models):
6.Loosen the screw (10) retaining the fulcrum pin (8).

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7. Extract the screw (10) in preparation for removal of
the fulcrum pin (8).
8. Slide out the fulcrum pin (8) and remove the pin.
Later Models Only (Skip to Step 10 for Early Models)
9. Using a T-20 Torx tool, remove the screw (24) and
washer (25) holding the fulcrum pin (8). Remove
fulcrum pin (8).
10. Remove the lever and seat assembly (5 & 6). E
Only: Remove Spring (7).

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11. Remove the primary diaphragm cover (11). This
requires removal of four fillister head screws (10)
and two pan head screws (9).
12. Remove springs (12) and the primary diaphragm
assembly (13).
13. Remove the primary valve pin (14) as shown by
the tip of the pen.
14. Remove the last two fillister screws (10).

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15. Loosen and separate the body (15) from the heat
exchanger (19).
16. Remove the old primary valve seat (18) and
sponge (17). Discard both.
17. Remove the back cover screws (2).
18. Tap the side of the cover (22) firmly with the
handle of the screw driver to break the cover
loose from the gasket (21).

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19. Deposits may accumulate from the use of hard
water. This condition can be alleviated through
the use of radiator additives or permanent
antifreeze solutions. Remove any accumulation
with a wire brush before assembly. Steel water
inlet and outlet fittings may cause erosion from
electrolysis. Use brass or plastic water fittings
only.
REASSEMBLY OF REGULATOR
•Carefully clean and inspect all metal parts; springs, levers, pivot pins and screws. Replace all parts
that are included in the repair kits.
•Carefully clean the body casting and inspect all sealing surfaces . Wipe with a clean rag. 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. Be sure no foreign material remains in
these passages.
•Inspect the primary orifice and the secondary orifice for nicks, scratches or uneven wear.
IMPORTANT!
If the primary or secondary seats show any of the above mentioned conditions, the regulator is not
rebuildable and must be replaced.
20. Reassemble the back cover (22) and gasket (21)
to the heat exchanger body (19). Replace six
screws (2). Match the mounting bosses in the
cover with those on the heat exchanger. Tighten
the two screws shown in the photo first, then
upper and lower screws diagonally opposite to
draw the cover down evenly. Torque to 25-35 in-
lbs (2.8-4.0 Nm).
21. The pen indicates the recess cast in the body
(19) to retain the sponge (17). Be sure to
accurately install the sponge in the recess.

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22. After the sponge (17) is in place, the primary seat
(18) can be installed. Place the seat so the
rubber side is down towards the jet.
23. Reinstall the body (15) and body gasket (16).
Mount the body gasket on the primary pin boss
and two locating pins on the underside of the
body. Use two screws (10) to locate the body on
the heat exchanger body (19). Finger tighten the
screws to hold the two parts in place.
24. Replace the primary valve pin (14).
25. The new primary diaphragm assembly (13) is
ready to be put into place.

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26. Install the primary diaphragm (13) over the
locating pins and screw bosses, providing
alignment for the assembly of the springs (12)
and cover (11).
27. Place the two primary valve springs (12) on their
locating perches extruded from the backup plate
on the primary diaphragm (13).
28. Press the primary cover (11) in place over the
primary valve springs (12) and diaphragm
assembly (13). Insert two screws (9) and finger
tighten.
Note that two screws (9) securing the top of
primary cover (11) and in the center are different
from the other four screws (10).
29. Early Models: Replace four of the five screws
(10). DO NOT replace the one shown by the
arrow. Torque to 35-45 in-lbs. (4.0-5.1 Nm).
Torque the two inner screws (9) to 22-28 in-lbs.
(2.5-3.2 Nm).
Later Models: Replace all five screws (10) and
torque to 35-45 in-lbs. (4.0-5.1 Nm). Torque the
two inner screws (9) to 22-28 in-lbs. (2.5-3.2
Nm).
Skip to Step 35.

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30. Slide the pin through the larger of the two hole
openings of the lever (5) and place over a socket
that will support the area of the lever around the
hole. Using a hammer, knock in the pin (26)
through the smaller hole until it is even on both
sides.
31. Inspect the tabs on the lever (5) to verify they are
not bent and the pin (26) is centered.
32. Insert the seat (6) by pressing the nub through
the hole in the lever (5).
Early Models Only (Skip to Step 35 for Later
Models)
33. Replace the secondary lever (5) and insert the
fulcrum pin (8).

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34. Replace the final screw (10) and finger tighten.
Skip to Step 36.
Later Models Only (Skip to Step 36 for Early Models)
35. Insert fulcrum pin (8) through lever (5) and place
in slot on top of primary diaphragm cover (11).
Place washer (25) on screw (24), insert and
tighten until snug.
36. Lightly pull the lever (5) up against the secondary
seat for measuring. Use a straight edge or the
IMPCO G2-2 gauge to check the lever height. The
secondary lever link pin should be approximately
1/32” (0.8mm) below the level of the body casting.
If the lever height is incorrect, continue to Step 37.
Once the lever height is correct, skip to Step 38.
37. If necessary, remove the fulcrum pin (8) and lever
(5) and bend slightly if required. Do not attempt to
bend the lever when installed--unnecessary force
on the lever may damage the secondary seat (6).

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Early Models Only (Skip to Step 39 for Later
models):
38. Tighten the screw to the left of the lever pin and
torque to 35-45 in-lbs. (4.0-5.1 Nm). Skip to Step
40.
Later Models Only (Continue to Step 40 for Early
Models)
39. Apply Loctite® 242 or equivalent
to screw threads.
Thread screw (24) into the diaphragm cover and
torque to 17-23 in-lbs. (1.9-2.6 Nm).
40. Model E Only (Skip for PE): Slip the spring (7)
under the secondary lever (5) making sure it is
retained by the two tabs at the sides and the
single tab punched through the top of the lever.
41. Replace the secondary diaphragm (4) engaging
the slotted link to lever pin shown.

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42. Photo shows the link and the link pin properly
connected.
43. Replace hand primer seal washer (6) indicated
by pencil.
44. Replace the cover (3). Turn the eight screws (2)
until all contact the cover. Then tighten in a criss-
cross pattern until are firmly seated. Torque to
25-35 in-lbs. (2.8-4.0 Nm).
45. PE Only (Skip for E): Place the secondary
spring (7) on the secondary diaphragm (4)
perch.

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46. PE Only (Skip for E): Install the gasket (28) and
spring housing (27). Align the spring retainer
housing screw holes to the cover (26) and insert
cover screws (23). Torque to 7-11 in-lbs.(0.8-1.2
Nm).
47. E Only: Apply 100 psi (6.9 Bar) 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 rebuild 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 regulator
outlet. Use soap and/or a commercial leak
detector solution to inspect the gasket seals
around the perimeter of the regulator for leaks.
If no leaks are found, the repair is now complete.
PE Only: Pressurize the PE with 100 psi (6.9
Bar) compressed air (the regulator should free
flow). Slowly reduce the flow at the outlet port (a
one inch NPT PVC pipe plug with a 1/8” or a 3
mm hole drilled in the center is ideal for this
test). Check for leaks around the PE body
gasket and test port plugs using a liquid leak
detector solution. Verify or reset final outlet
pressure for adjustable PE units. If no leaks are
found, the repair is now complete.

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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
APPLICATIONS.
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)
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 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
EXPERIENCED 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.