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A Manual for Repair and Maintenance Technicians 2ND STAGE.

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Presentation on theme: "A Manual for Repair and Maintenance Technicians 2ND STAGE."— Presentation transcript:

1 A Manual for Repair and Maintenance Technicians 2ND STAGE

2 This manual is designed to help technicians who are already experienced in workshop procedures and know how to handle tools. Only experienced technicians should attempt to use this manual. Improper use of tools could result in personal injury to the user, the technician or at the least damage to the regulator. To use this presentation effectively a parts exploded view must be on hand to determine the correct assembly order plus to check if any parts are missing prior to reassembly. CAUTION

3 TOOLING REQUIREMENTS Apollo seat carrier adjusting tool P/No ” Flat blade screwdriver O ring pick Tweezers 12mm open end spanner 11/16” open end spanner 3/4” open end spanner Apollo valve cone adjusting tool P/No ex 2000

4 VENTURI CONTROL (Adjust Airflow) SENSATIVITY CONTROL (Adjust Inhalation Effort) FEATURES

5 The ‘ex 2000’ has a unique ball and socket swivel hose. To remove the hose, first slide back the rubber cover. DISASSEMBLY

6 An 11/16” open end spanner and 3/4“ spanner are used to remove the hose from the 2nd stage. Disconnect the hose from the 2nd stage. DISASSEMBLY

7 To remove the front cover a small metal lock must be disengaged. The lock is shown inside the red circle. Use a small screw driver or an o ring pick and gently prise the lock towards the hose fitting. At the same time turn the cover one quarter turn counter-clockwise. DISASSEMBLY

8 Remover the cover and place to one side. The diaphragm snap ring is removed next. A screw driver can be used to engage the lock ring as shown. Turn the lock counter-clockwise. DISASSEMBLY

9 Remove the snap ring, then remove the diaphragm cover ring. DISASSEMBLY

10 Lift out the diaphragm. Use an 11/16“ spanner and undo the valve cone holder. NB: If tight use two spanners, one on the cone holder and one to hold the valve housing. DISASSEMBLY

11 The valve cone is inside the holder, (sometimes called a hose connector) place the cone and holder to one side. The valve cone will be removed later for cleaning and inspection. The seat carrier adjusting tool Part No is used to compress the valve seat carrier spring to enable removal of the demand lever. DISASSEMBLY

12 Carefully remove the demand lever one leg at the time. Remember to keep the spring compressed until the lever is completely removed. DISASSEMBLY

13 The valve and spring can now be removed by tilting the housing. Remove the two seat carrier o rings and discard. DISASSEMBLY

14 The tip of the valve will have a slight witness mark plus a hole due to the moulding process. This hole is not cause for rejection. With normal use the valve has a life expectancy of approx. 3 years. To take off the adjusting knob the screw cover must be removed. Gently prise up the cover using an o ring pick. DISASSEMBLY

15 Place the cover to one side. Using a flat blade screw driver remove the knob retaining screw. DISASSEMBLY

16 Remove the knob and place to one side. Remove the exhaust cover. This is accomplished by depressing the metal lock below the mouthpiece and turning the cover a quarter turn counter clockwise. DISASSEMBLY

17 DISASSEMBLY Remove the cover and place to one side. Use a 12mm open end spanner to undo the bonnet. If the bonnet is very tight use an 11/16“ spanner to hold the opposite end of the valve housing.

18 DISASSEMBLY Remove the bonnet, the adjusting shaft and nut as a sub-assembly and place to one side. Next slide the valve housing from the bottom box. Take care not to damage the air flow tube, it is held in position by the valve housing.

19 DISASSEMBLY Slide the air flow tube off the air flow adjuster to remove. The air flow adjuster is held in position by a spring clip. Grasp the head of the clip with tweezers and simply pull to remove.

20 DISASSEMBLY The air flow adjuster is removed through the top of the bottom box. Push from underneath, it could be tight due to o ring friction. The disassembly is complete except for the following sub-assemblies.

21 DISASSEMBLY Separate the adjusting assy. From the bonnet. Then separate the nut from the shaft. DO NOT separate the plastic balance cylinder from the adjusting nut unless either part is damaged. Separate the valve cone from the valve cone holder. Turn counter- clockwise with a screw driver until the thread is disengaged. Push the valve cone out using a soft probe so as not to damage the tip.

22 INSPECTION & CLEANING A quick check of parts to be reused is carried out prior to cleaning. This will ensure you do not clean obviously defective parts. All metal parts are cleaned using white vinegar. The vinegar may be diluted using water, however diluting usually only means a longer soak period before the parts are clean. Metal parts must now be carefully inspected prior to refitting. Only leave the parts in the vinegar bath until clean, do not leave in the bath for prolonged periods. Eg; hours or over night. The parts must be rinsed in warm to hot fresh water after removal from the acid bath, this helps to neutralise the acid. Blow dry with clean filtered air.

23 INSPECTION & CLEANING Non-metal parts eg; exhaust valve, bottom box, diaphragm etc. are cleaned by washing in warm water and a mild liquid detergent. Gentle scrubbing with a tooth brush will help remove stains. Parts should be rinsed in fresh water after washing. Parts must be carefully inspected for defects before refitting. Ensure ALL parts are inspected prior to refitting. Following are some areas presenting common problems.

24 INSPECTION Inspect the demand lever for distortion and misalignment of the legs. Gently stretch the diaphragm, hold it towards the light and check for perforations. Next check for swelling due to chemical contamination.

25 INSPECTION Carefully examine the tip of the valve cone for damage or imperfections. Check to ensure the air flow adjuster stop pin is not missing or damaged.

26 ASSEMBLY All o rings and threads should be lubricated prior to assembly. Dynamic o rings should be liberally lubricated, static o rings and threads should be very lightly lubricated. DO NOT lubricate all parts and then assemble, lubrication should be carried out immediately prior to assembly. (This avoids collecting dust particles.) DO NOT use silicone spray as a lubricant. DO NOT spray plastic components with silicone spray. Suitable lubricants for Apollo 2nd stages are ‘Food grade’ silicone grease or ‘Christo-lube’ except where mentioned in the text.

27 ASSEMBLY Sub-assemblies will be assembled first. Lightly lubricate and install the o ring into it’s groove on the valve cone holder. Lubricate and install the o ring on the valve cone. Lightly lubricate the thread.

28 ASSEMBLY Install the valve cone into the holder, there is no need to screw the valve home at this time. Place this sub-assy. to one side. Install the teflon washer onto the adjusting shaft.

29 ASSEMBLY Lubricate and install the o ring into the groove on the adjusting shaft. The shaft o ring and the adjusting thread are dynamic ensure they are well lubricated.

30 ASSEMBLY The adjusting nut, together with the balance cylinder are now installed onto the adjusting shaft. This is a left hand thread,screw the shaft into the nut until it bottoms but do not tighten.

31 ASSEMBLY The bonnet o ring is now installed. The adjusting shaft sub-assy. is now fitted to the bonnet.

32 ASSEMBLY The completed sub-assy. should appear as the picture on the right. Next install the o ring onto the valve housing. Remember to ensure the o ring is against the shoulder as shown.

33 ASSEMBLY Lubricate and install the air flow adjuster shaft o ring. Be sure to fit it to the correct groove. Install the air flow adjuster into the bottom box, aligning the stop pin.

34 ASSEMBLY Secure the air flow adjuster by installing the spring clip as shown. The air flow tube can now be fitted. Ensure the round hole in the tube is facing the diaphragm. The elliptical hole faces the mouthpiece.

35 ASSEMBLY Ensuring the air flow tube does not become dislodged install the valve housing. The housing outlet hole MUST be engaged with air flow tube. Fitting upside down will result in poor performance. Install the bonnet and adjusting shaft assembly and tighten using a 12mm open end spanner.

36 ASSEMBLY Two new valve seat carrier o rings are to be fitted to the grooves in the seat carrier end. NOTE: These are self lubricating. The carrier spring is installed onto the carrier. NOTE: The spring is tapered, the small diameter slides onto the carrier and rests against the shoulder as shown.

37 ASSEMBLY The carrier and spring are placed into the valve housing. 2nd stage Adjusting wrench Part No is used to compress the carrier spring.

38 ASSEMBLY When compressing the spring the adjusting wrench must be hard against the valve housing as shown. Failure to observe this rule will result in the incorrect positioning of the demand lever. While holding the carried spring compressed install the demand lever, gently fitting one leg at a time. If any doubt exists whether the lever legs have been bent the lever must be removed inspected and refitted.

39 ASSEMBLY Depress the lever several times to ensure smooth operation. Next install the valve cone holder assembly. Tighten the valve cone holder using an 11/16” spanner.

40 ASSEMBLY At this point the valve cone can be roughly adjusted. Using a screw driver turn the cone clockwise until the demand lever starts to drop. This will require readjusting later. Fit the adjusting knob to the adjusting shaft.

41 ASSEMBLY Install the adjusting knob retaining screw and tighten using a screw driver. The adjusting knob cap is now gently pressed into position.

42 ASSEMBLY The adjusting knob cap should be flush around the edges if fitted correctly. The 2nd stage diaphragm is installed. NOTE: Use no lubricants or sprays on the diaphragm or it’s seating area.

43 ASSEMBLY The cover ring is placed on top of the diaphragm. Install the diaphragm snap ring, the four legs face upper most.

44 ASSEMBLY Tighten the snap ring using a screw driver as shown. The front cover can now fitted. The cover has a quarter turn bayonet type screw. Engage as shown and turn clockwise until the metal lock engages.

45 ASSEMBLY The exhaust tee is refitted, again with a quarter turn clockwise until the metal lock engages. The basic assembly is now complete. The 2nd stage must now be tuned and tested. Ideally the first stage used for the test and tuning should be the same first stage the unit will be used with for diving.

46 TEST & TUNING Adjusting tool Part No is used for tuning the 2nd stage. A standard hose assembly must be used with this tool. The o ring sealing surfaces are different on the new ball joint hose.

47 TEST & TUNING NOTE: If you have already fitted the bonnet o ring shown, it must be removed for using the adjusting tool.

48 TEST & TUNING Install the adjusting tool to the 2nd stage. Remember to use a standard hose. The adjusting knob must be pre-set prior to tuning the valve cone. The adjusting knob is turned counter- clockwise until it stops, then turned clockwise one half turn.

49 TEST & TUNING Couple the hose assembly to the 1st stage. (Ensure the correct intermediate pressure 9.8 kg/cm 2 ) With the air supply ‘on’ push the tool hand wheel in against the pressure and engage the screw driver slot. Turn the hand wheel counter clockwise until a slight free flow is heard, then turn back to stop the free flow. Purge the 2nd stage several times, listen for free flowing. If free flow is present, re-adjust.

50 ASSEMBLY The adjusting tool must be removed to carry out the flow (breathing) test. Lightly lubricate and install the bonnet o ring as shown.

51 ASSEMBLY Install the ball joint hose assembly and tighten using an 11/16” and 3/4” spanners Slide the rubber boot assembly back into position.

52 ASSEMBLY The assembly is now complete. Final testing involves checking for air leaks and carry out the flow test. The flow test is simply turning the flow adjuster and checking that the regulator has a venturi flow. If NO venturi flow occurs: Check your air source is turned fully on. Check the intermediate pressure is correct. Check the valve cone is adjusted correctly.

53 HOSE ASSEMBLY (Appendix) If necessary the ball joint hose maybe dismantled, cleaned and lubricated as follows. Two 3/4” open spanners are used to split apart the ball housing.

54 HOSE ASSEMBLY (Appendix) Remove the coupling section of the housing. Check the o ring and thread for damage.

55 HOSE ASSEMBLY (Appendix) To gain access to the o ring behind the ball, slide the housing towards the hose. The o ring shown sits against the rear shoulder. Carefully remove with an o ring pick. Take care NOT to scratch the sealing area. The coupling cannot be completely removed from the hose end. The hose ends and metal parts may be placed in your acid bath for cleaning etc.

56 HOSE ASSEMBLY (Appendix) Lightly lubricate the o rings before fitting. Care must be taken to ensure the o ring behind the ball is sitting correctly on the shoulder. If not, the o ring will be pinched and damaged when tightening the coupling halves together. Lightly lubricate the thread and fit the coupling to the hose end.

57 HOSE ASSEMBLY (Appendix) Tighten the coupling using two 3/4” open end spanners. The fitting must be firm only, do not over tighten The hose assembly is now ready for service.


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