Not a problem, thanks for your help and ideas. greatly appreciated

Awesome, glad its fixed. Thanks for the info.

Hello HRSPWR

So after few days of waiting for the new regulator too arrive, it has been fitted and all is ok running perfect without any issue.

So with the old regulator replaced decided to strip the regulator down more indepth too see if can see any damage or cause of the overfuelling.

Removed the diagphram with adjuster screw on for fuel pressure and was a valve in bottom on a spring, removed this too check behind for damage too find it was cracked and rubber seals were badly perished, (seal part on spring side has a 2mm piece missing which i suspect is how the fuel is bypassing all the time.

Did not get either of these parts in the reseal kit that was purchased from TVH, so deicded too do a little more digging and eventually found the part, it comes as an EXTRA kit on top of the rebuild it.

If its any interest too people ive put the part number below:
04221-U2030-71 Valve Kit $70/£80

Thanks for all your help and hope this is of use to you also.

I do however feel we should eliminate all other possibilities before replacing an expensive item such as the regulator, although it does sound as though you may be in need of that regardless. Have you checked the fuel injector to be sure it is not stuck open and leaking through? without the truck running there should be no fuel flow through the injector. The injector is located on the lower rear portion of the throttle body and has two wires going to it. It is held in by two ten mm bolts. Remove it and make sure there is no fuel flow when not cranking. (spray a little gum cutter into a cap and hold the end of the injector in the liquid to check for fuel flow) Then crank the engine and insure there is pulses of fuel flow while cranking.

Yes replacing the entire regulator is the simplest. It has been my experience that rebuilding is very tedious, due to the fact of getting the plunger to seal on the seat properly. This must be done, and tested while regulator is being reassembled and once you find the sweet spot you actually have to glue it in place. You may have noticed that the factory was glued as well.
The fuel can definitely create some major issues. The grade of propane you are being supplied can drastically differ in the amount of propylene contained with in it. Propylene is the black stinky sludge that came out of your regulators. Ask your supplier what grade of propane they are suppling you. It is best to run grade HD5 if possible (don't be fooled, HD5 is better quality than HD10). Another to consider is if the contaminates that you got from your filter housing are rust colored. If so are you running steel fuel tanks or aluminum. Best to run aluminum.

Hello HRSPWR,

So i did replace the seal kit for the regulator although others said too replace as is instead of wasting time but due too new regulator being around £500 it was worth a punt on the £85 rebuild it.

Unfortanlty it didnt work, so company have ordered replacement regulator for the machine.

As an odd issue the sister machine in same location doing the same daily jobs has just failed and doing the same issue. Removing the gas filter was extremely clogged with debris even been cleaned 6 months ago..

So now were led too believe could be issue with the gas there being supplied causing issue "dirty gas causing blockages/issues?

Thanks

Thanks for reply HRSPWR

i did actually do the 12mm head and was a vast amount parfin draining out, tried restart still same issue. After hours of trying different things. I did a reseal kit on the regulator and refitted later yesterday but unfortantly too no luck still have same issue with over gas flow.

Looking too maybe have too replace the regualtor unit its self.

Sounds like you have to much fuel flow. First thing I would check, is to see how much "black sewage" is in your regulator. To much of it will cause the diaphragm to stick open and cause to much fuel flow. There is a drain bolt (or valve) located on the bottom of the regulator. If it is the bolt style it will have a 12mm head and be quite short. Don't loose it. Remove that and let all the perfin drain out then retry to start truck.