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Impco Genius Max Instructions Manual

Impco Genius Max Instructions Manual

Regulator repair kit

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REGULATOR REPAIR KIT INSTRUCTIONS
NOTE: Only die cast Genius Max
regulators manufactured late 2014 and
after can be repaired using the repair kits
listed below. Repairable units are
identified by the IMPCO logo and the
words Genius Max cast into the top
cover. All Genius Max regulators black
in color are not serviceable using these
repair kits.
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-131 repair kit instructions
will provide the technician information to
successfully repair the Genius Max
regulator. 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.
Prior to disassembly, inspect the body for
any signs of impact, cracks or other damage
to the body that might render the regulator
non-repairable.
Part Number
RK-GMAX-001
RK-GMAX-002
December, 2014
Genius Max
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.
Genius Max Regulator Repair Kit Part Numbers
Repair Kit, Genius Max
Repair Kit, Genius Max (Includes the Pressure Relief Device or valve)
IMPCO Technologies Inc.
3030 South Susan St.
Santa Ana, CA 92704
www.impcotechnologies.com
Description
3030 S Susan Street, Santa Ana, CA 92704
Ph: +1 714 656 1200 Fax: +1 714 656 1400
PPI-131 REV. A
Page 1 of 16

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Summary of Contents for Impco Genius Max

  • Page 1 Genius Max Regulator Repair Kit Part Numbers Part Number Description RK-GMAX-001 Repair Kit, Genius Max RK-GMAX-002 Repair Kit, Genius Max (Includes the Pressure Relief Device or valve) December, 2014 IMPCO Technologies Inc. PPI-131 REV. A 3030 South Susan St. Page 1 of 16 Santa Ana, CA 92704 www.impcotechnologies.com...
  • Page 2 O-Ring, Fluorocarbon 0.070 Cs X 0.301 I.D. (2) Tube, Outlet, Genius Max Screw, Shcs Pthd m6 x 40 Class 8.8 Zinc (6) -002 Valve Subasm, Genius Max (includes 22 & 27) -001, -002 Ring, Retaining, Internal O-Ring, Fluorocarbon 0.070 Cs X 0.426 I.D.
  • Page 3 Genius Max Regulator (GMX-53400-001 shown) DESCRIPTION ITEM # RK-GMAX Genius Max Sub Assy w/M12 x 1 fitting Genius Max Sub Assy w/1/4" x 18 NPT Fitting, LPG Inlet, Genius Max (M12 X 1) Fitting, LPG Inlet, Genius Max (1/4"-18 Npt)
  • Page 4 3030 S Susan Street, Santa Ana, CA 92704 Ph: +1 714 656 1200 Fax: +1 714 656 1400 Genius Max Repair Kit Components. Item# Description RK-GMAX-001 RK-GMAX-002 Gasket, Bottom, Genius Max Gasket, Top, Genius Max Seat, Viton (80 Shore) O-Ring, Viton, Metric 1mm Cs X 4mm ID Diaphragm, Genius Max O-Ring, Fluorocarbon 0.070 Cs X 0.301 I.D.
  • Page 5 Sharp objects may scratch or damage the sealing surfaces, causing the regulator to leak. December, 2014 IMPCO Technologies Inc. PPI-131 REV. A 3030 South Susan St. Page 5 of 16 Santa Ana, CA 92704 www.impcotechnologies.com...
  • Page 6 8. Remove the Link Shaft (12) and its O-ring (13). NOTE: Do not use any sharp objects that might scratch the brass Link Shaft. PPI-131 REV. A IMPCO Technologies Inc December, 2014 3030 South Susan St. Page 6 of 16 Santa Ana, CA 92704 www.impcotechnologies.com...
  • Page 7 Valve pops out the top of the Upper Body. NOTE: Use care and avoid scratching any surfaces. December, 2014 IMPCO Technologies Inc. PPI-131 REV. A 3030 South Susan St. Page 7 of 16 Santa Ana, CA 92704...
  • Page 8 NOTE: Do not use any type of mechanical tool to scrape the sealing surfaces as they may cause the regulator to leak. PPI-131 REV. A IMPCO Technologies Inc December, 2014 3030 South Susan St. Page 8 of 16 Santa Ana, CA 92704...
  • Page 9 18. Install the LPG fuel fitting (32). Torque to 18-22 Nm (13.3-16.2 ft-lbs.). 19. Press the Seat (7) into the Holder (8), installed on the Lever (9). December, 2014 IMPCO Technologies Inc. PPI-131 REV. A 3030 South Susan St. Page 9 of 16 Santa Ana, CA 92704...
  • Page 10 Bottom Gasket (2) on the Center Body (3). Press firmly into the grove, ensuring the Gasket isn’t twisted and properly seated. PPI-131 REV. A IMPCO Technologies Inc December, 2014 3030 South Susan St. Page 10 of 16 Santa Ana, CA 92704 www.impcotechnologies.com...
  • Page 11 Diaphragm. Place the Washer (17) concave side down so its perimeter is in contact with the Plate. Hand thread Nut (18) on Link Shaft (12). December, 2014 IMPCO Technologies Inc. PPI-131 REV. A 3030 South Susan St. Page 11 of 16 Santa Ana, CA 92704 www.impcotechnologies.com...
  • Page 12 Top Body (6) so the Adjustment Screw fits flush with the top of the Body. PPI-131 REV. A IMPCO Technologies Inc December, 2014 3030 South Susan St. Page 12 of 16 Santa Ana, CA 92704...
  • Page 13 NOTE: When using repair kit RK-GMAX-002, discard the old Valve and use the new one included in the kit, complete with new O-rings. December, 2014 IMPCO Technologies Inc. PPI-131 REV. A 3030 South Susan St. Page 13 of 16 Santa Ana, CA 92704...
  • Page 14 38. Insert the Coolant Fittings (38) into the ports on the Lower Body (1) and secure with Retaining Pins (40). PPI-131 REV. A IMPCO Technologies Inc December, 2014 3030 South Susan St. Page 14 of 16 Santa Ana, CA 92704...
  • Page 15 39. Insert the Fuel Outlet Fitting (37) into the port of the Upper Body (6) and secure with Retaining Clips (40) as pictured. 40. Install the Genius Max regulator in the vehicle and turn on the fuel supply to pressurize the regulator. Using soap and/or a commercial leak detector solution, check for leaks, especially around the Center Body (3).
  • Page 16 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.