Impco Genius Max Bedienungsanleitung
December, 2014 IMPCO Technologies Inc. PPI-131 REV. A
3030 South Susan St. Page 1 of 16
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
Genius Max
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.
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
Part Number
Description
RK-GMAX-001
Repair Kit, Genius Max
RK-GMAX-002
Repair Kit, Genius Max (Includes the Pressure Relief Device or valve)
PPI-131 REV. A IMPCO Technologies Inc December, 2014
3030 South Susan St. Page 2 of 16
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
Genius Max Regulator (Internal Fittings)
See following page for External Fittings
ITEM # RK-GMAX
DESCRIPTION
1 -
Body, Lower, Genius Max Dc
2 -001, -002
Gasket, Bottom, Genius Max
3 -
Body, Center, Genius Max
4 -
Screw, Set M4x0.7x54mm
5 -001, -002
Gasket, Top, Genius Max
6
Body, Upper, Genius Max
7 -001, -002
Seat, Viton (80 Shore)
8 -
Holder, Seat, Genius Max
9 -
Lever, Genius Max
10 -
Pin, Steel, Ø3 X 30mm
11 -
Screw, Cross Head Pan M4 X 8mm (2)
12 -
Shaft, Link, Genius Max
13 -001, -002
O-Ring, Viton, Metric 1mm CS X 4mm ID
14 -
Plate, Diaphragm Bottom
15 -001, -002
Diaphragm, Genius Max
16 -
Plate, Top, Genius Max
17 -
Washer, Conical Spring, 5mm
18 -
Nut, Locking, M5
19 -
Spring, L48.5mm, O.D. 33.3mm, K11.8N/mm
20 -
Plate, Spring Load Adjustment
21 -
Screw, Adjustment
22 -001, -002
O-Ring, Fluorocarbon 0.070 Cs X 0.301 I.D. (2)1
23 -
Tube, Outlet, Genius Max
24 -
Screw, Shcs Pthd m6 x 40 Class 8.8 Zinc (6)
25 -002
Valve Subasm, Genius Max (includes 22 & 27)
26 -001, -002
Ring, Retaining, Internal
27 -
O-Ring, Fluorocarbon 0.070 Cs X 0.426 I.D.
December, 2014 IMPCO Technologies Inc. PPI-131 REV. A
3030 South Susan St. Page 3 of 16
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
Genius Max Regulator (External Fittings)
Genius Max Regulator (GMX-53400-001 shown)
ITEM # RK-GMAX
DESCRIPTION
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)
33 -
Filter, Inlet, Genius Max
34 -001, -002
O-Ring, Fluorocarbon (Fluorel/Viton) 0.07 Cs X .551 I.D.
35 -
Fitting, M8 X 1, Genius Max
36 -001, -002
O-Ring, Fluorocarbon (Fluorel/Viton) 0.070 Cs X .208 I.D.
37 -
Fitting, 12mm Hose BRC Standard
38 -
Fitting, Straight
39 -001, -002
O-Ring, Fluorocarbon (Fluorel/Viton) 0.070 Cs X .614 I.D.
40 -001, -002
Pin, Retainer (2)
32
31
-
-
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Genius Max Repair Kit Components.
Item#
Description
RK-GMAX-001
RK-GMAX-002
2
Gasket, Bottom, Genius Max
1
1
5
Gasket, Top, Genius Max
1
1
7
Seat, Viton (80 Shore)
1
1
13
O-Ring, Viton, Metric 1mm Cs X 4mm ID
1
1
15
Diaphragm, Genius Max
1
1
22
O-Ring, Fluorocarbon 0.070 Cs X 0.301 I.D.
2
1
25
Valve Subasm, Genius Max
-
1
26
Ring, Retaining, Internal
1
1
27
O-Ring, Fluorocarbon 0.070 Cs X 0.426 I.D.
1
-
34
O-Ring, Fluorocarbon (Fluorel/Viton) 0.07 Cs X .551 I.D.
1
1
36
O-Ring, Fluorocarbon (Fluorel/Viton) 0.070 Cs X .208 I.D.
1
1
39
O-Ring, Fluorocarbon (Fluorel/Viton) 0.070 Cs X .614 I.D.
6
6
40
Pin, Retainer (Part Number P1-30559)
2
2
Not Shown
Repair Kit Instructions, PPI-131
1
1
Note that Valve Subassembly (25) is only included in RK-GMAX-002 which includes O-rings 22 and 27.
December, 2014 IMPCO Technologies Inc. PPI-131 REV. A
3030 South Susan St. Page 5 of 16
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
DISASSEMBLY INSTRUCTIONS
1. Remove the MAP hose Fitting (35).
2. Remove the Pins (40) retaining the port Fittings (38)
and remove from the Body (1). Remove O-rings (39)
from Fittings.
3. Using a 5mm Allen wrench, remove the six Screws (24)
from the top of the regulator and remove the upper
Body (6).
4. If the Body components stick together, the Center
Body (3) includes two tabs (as shown in the photo)
where a slotted screw driver can be inserted to pry to
the Body components apart.
NOTE: Do not use a screwdriver or other sharp
instrument at any location other than the tabs on the
center body. Sharp objects may scratch or damage the
sealing surfaces, causing the regulator to leak.
.
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5. Remove the Nut (18) using an 8mm socket. Remove
the Washer (17) and Plate (16).
6. Lift the Body Center (3) from the Lower Body (1).
7. Remove the two screws (11) securing the fulcrum Pin
(10) and remove the Pin and Lever (9) complete with
Seat Holder (7 and 8).
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.
December, 2014 IMPCO Technologies Inc. PPI-131 REV. A
3030 South Susan St. Page 7 of 16
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 the Gaskets (2 and 5) from the Center
Body (3).
NOTE: Do not use any sharp objects that might
scratch any of the sealing surfaces.
10. Press on the Allen Key hole in the center of the
label to push the Adjustment Screw (21) and
Spring Load Plate (20) through the Link Shaft hole.
11. Using retaining ring pliers, remove the Retaining
Ring (26) securing the Pressure Relief Device or
Valve (25).
12. Note the bottom of the brass Valve (25) inside the
channel of the Upper Body (6) and using a small
regular flat-blade screwdriver, gently press the top
of the blade until the Valve pops out the top of the
Upper Body.
NOTE: Use care and avoid scratching any surfaces.
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13. RK-GMAX-001 Kit Only (this step is not required when
using RK-GMAX-002): Remove the O-rings (22 and
27) on the Valve (21).
NOTE: The Valve is a pre-set pressure relief device
and is not serviceable. Do not remove the label,
immerse in any fluid or cleaning solvent or attempt to
service the Valve.
14. Remove the LPG Inlet Fitting (32).
15. Remove the Seat (7) from the Lever (8 & 9) by
inserting a small blunt object through the hole from
behind. A ballpoint pen is shown in the picture.
16. Once all of the gaskets and O-rings have been
removed, thoroughly clean the body and metal
components using a solvent to remove any
deposits, varnish or contaminants.
NOTE: Do not use any solvent on the Valve (25) as it
may be rendered unusable.
NOTE: Do not use any type of mechanical tool to
scrape the sealing surfaces as they may cause the
regulator to leak.
December, 2014 IMPCO Technologies Inc. PPI-131 REV. A
3030 South Susan St. Page 9 of 16
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
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. Clear out the
inlet and outlet passages with compressed air. Be sure no foreign material remains in these passages.
17. Lightly lubricate with petroleum jelly or Vaseline
and place the O-ring (34) on the Fuel Inlet Fitting
(32).
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).
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20. Slide the O-ring (13) on the Link Shaft (13).
21. Place the Link Shaft (12) through the hole in the
Lever (9) and slide to the end of the slot in the
Lever. Slide the Pin (10) into the Lever, then
place the assembly into the Lower Body (1).
22. Secure the Pin (10) with two Screws (11) and
torque to 1.7-2.3 Nm (15-20 in-lbs.).
23. Lightly lubricate with petroleum jelly or Vaseline,
then place the Bottom Gasket (2) on the Center
Body (3). Press firmly into the grove, ensuring
the Gasket isn’t twisted and properly seated.
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