Presentation on theme: "Prestige ex 2000 TECHNICAL MANUAL 2ND STAGE"— Presentation transcript:
1 Prestige ex 2000 TECHNICAL MANUAL 2ND STAGE A Manual for Repair and Maintenance Technicians
2 CAUTIONThis manual is designed to help technicians who are already experiencedin 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, thetechnician 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.
3 ex 2000 TOOLING REQUIREMENTS Apollo seat carrier adjusting tool P/No6” Flat blade screwdriverO ring pickTweezers12mm open end spanner11/16” open end spanner3/4” open end spannerApollo valve cone adjusting toolP/Noex 2000
5 DISASSEMBLY The ‘ex 2000’ has a unique ball and socket swivel hose. To remove the hose, firstslide back the rubber cover.
6 DISASSEMBLY An 11/16” open end spanner and 3/4“ spanner are used to remove the hosefrom the 2nd stage.Disconnect the hose from the2nd stage.
7 DISASSEMBLY To remove the front cover a small metal lock must be disengaged. The lock is showninside the red circle.Use a small screw driver or ano ring pick and gently prise thelock towards the hose fitting.At the same time turn the coverone quarter turn counter-clockwise.
8 DISASSEMBLY Remover the cover and place to one side. The diaphragm snap ring isremoved next. A screw drivercan be used to engage the lockring as shown.Turn the lock counter-clockwise.
9 DISASSEMBLY Remove the snap ring, then remove the diaphragm cover
10 DISASSEMBLY 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 oneto hold the valve housing.
11 DISASSEMBLY 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 laterfor cleaning and inspection.The seat carrier adjusting toolPart No is usedto compress the valve seatcarrier spring to enable removalof the demand lever.
12 DISASSEMBLY Carefully remove the demand lever one leg at the time. Remember to keep the springcompressed until the lever iscompletely removed.
13 DISASSEMBLY The valve and spring can now be removed by tilting the housing.Remove the two seat carriero rings and discard.
14 DISASSEMBLY The tip of the valve will have a slight witness mark plus a hole due to themoulding process. This hole is notcause for rejection. With normaluse the valve has a life expectancyof approx. 3 years.To take off the adjusting knobthe screw cover must be removed.Gently prise up the cover using ano ring pick.
15 DISASSEMBLY Place the cover to one side. Using a flat blade screw driverremove the knob retaining screw.
16 DISASSEMBLY Remove the knob and place to one side. Remove the exhaust cover. This isaccomplished by depressing themetal lock below the mouthpieceand turning the cover a quarter turncounter clockwise.
17 DISASSEMBLY Remove the cover and place to one side. Use a 12mm open end spanner toundo the bonnet. If the bonnet isvery tight use an 11/16“ spannerto hold the opposite end of thevalve housing.
18 DISASSEMBLY Remove the bonnet, the adjusting shaft and nut as a sub-assemblyand place to one side.Next slide the valve housingfrom the bottom box.Take care not to damage the airflow tube, it is held in position bythe valve housing.
19 DISASSEMBLY Slide the air flow tube off the air flow adjuster to remove.The air flow adjuster is held inposition by a spring clip.Grasp the head of the clip withtweezers and simply pull toremove.
20 DISASSEMBLY The air flow adjuster is removed through the top of the bottom box.Push from underneath, it could betight 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 nutfrom the shaft.DO NOT separate the plastic balance cylinder fromthe adjusting nut unless either part is damaged.Separate the valve cone from thevalve cone holder. Turn counter-clockwise with a screw driver untilthe thread is disengaged.Push the valve cone out using a softprobe so as not to damage the tip.
22 INSPECTION & CLEANINGA 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 maybe diluted using water, however diluting usually only means alonger soak period before the parts are clean.Only leave the parts in the vinegar bath until clean, do not leave inthe bath for prolonged periods. Eg; hours or over night.The parts must be rinsed in warm to hot fresh water after removalfrom the acid bath, this helps to neutralise the acid.Blow dry with clean filtered air.Metal parts must now be carefully inspected prior to refitting.
23 INSPECTION & CLEANINGNon-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 andcheck for perforations.Next check for swelling due tochemical contamination.
25 INSPECTION Carefully examine the tip of the valve cone for damage or imperfections.Check to ensure the air flow adjusterstop pin is not missing or damaged.
26 ASSEMBLYAll o rings and threads should be lubricated prior to assembly.Dynamic o rings should be liberally lubricated, static o ringsand threads should be very lightly lubricated.DO NOT lubricate all parts and then assemble, lubricationshould 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 inthe text.
27 ASSEMBLY Sub-assemblies will be assembled first. Lightly lubricate and install the o ringinto it’s groove on the valve cone holder.Lubricate and install the o ring on thevalve cone. Lightly lubricate the thread.
28 ASSEMBLY Install the valve cone into the holder, there is no need to screw the valvehome at this time. Place this sub-assy.to one side.Install the teflon washer onto theadjusting shaft.
29 ASSEMBLY Lubricate and install the o ring into the groove on the adjusting shaft.The shaft o ring and the adjustingthread are dynamic ensure theyare well lubricated.
30 ASSEMBLY The adjusting nut, together with the balance cylinder are now installedonto the adjusting shaft.This is a left hand thread,screw theshaft into the nut until it bottoms butdo not tighten.
31 ASSEMBLY The bonnet o ring is now installed. The adjusting shaft sub-assy. isnow fitted to the bonnet.
32 ASSEMBLY The completed sub-assy. should appear as the picture on the right.Next install the o ring onto thevalve housing.Remember to ensure the o ringis 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 thebottom 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 isfacing the diaphragm. The ellipticalhole faces the mouthpiece.
35 ASSEMBLY Ensuring the air flow tube does not become dislodged install the valvehousing.The housing outlet hole MUST beengaged with air flow tube.Fitting upside down will result inpoor performance.Install the bonnet and adjustingshaft assembly and tighten usinga 12mm open end spanner.
36 ASSEMBLY Two new valve seat carrier o rings are to be fitted to the grooves inthe seat carrier end.NOTE: These are self lubricating.The carrier spring is installed ontothe carrier.NOTE: The spring is tapered, thesmall diameter slides onto the carrierand rests against the shoulder asshown.
37 ASSEMBLY The carrier and spring are placed into the valve housing. 2nd stage Adjusting wrench PartNo is used tocompress 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 resultin the incorrect positioning of thedemand lever.While holding the carried springcompressed install the demandlever, gently fitting one leg at a time.If any doubt exists whether the leverlegs have been bent the lever mustbe removed inspected and refitted.
39 ASSEMBLY Depress the lever several times to ensure smooth operation. Next install the valve cone holderassembly.Tighten the valve cone holder usingan 11/16” spanner.
40 ASSEMBLY At this point the valve cone can be roughly adjusted. Using a screw driver turn the coneclockwise until the demand leverstarts to drop.This will require readjusting later.Fit the adjusting knob to theadjusting shaft.
41 ASSEMBLY Install the adjusting knob retaining screw and tighten using a screwdriver.The adjusting knob cap is nowgently 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 onthe 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 turnbayonet type screw.Engage as shown and turnclockwise until the metal lockengages.
45 ASSEMBLY The exhaust tee is refitted, again with a quarter turn clockwise untilthe metal lock engages.The basic assembly is now complete.The 2nd stage must now be tuned andtested. Ideally the first stage used forthe test and tuning should be the samefirst stage the unit will be used with fordiving.
46 TEST & TUNING Adjusting tool Part No. 319-02-00-014 is used for tuning the 2nd stage.A standard hose assembly must beused with this tool. The o ring sealingsurfaces are different on the new balljoint hose.
47 TEST & TUNING NOTE: If you have already fitted the bonnet o ring shown, it must beremoved 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-setprior to tuning the valve cone.The adjusting knob is turned counter-clockwise until it stops, then turnedclockwise one half turn.
49 TEST & TUNING Couple the hose assembly to the 1st stage. (Ensure the correctintermediate pressure 9.8 kg/cm2)With the air supply ‘on’ push the tool handwheel in against the pressure and engagethe screw driver slot. Turn the hand wheelcounter clockwise until a slight free flow isheard, then turn back to stop the free flow.Purge the 2nd stage several times, listen forfree 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 bonneto ring as shown.
51 ASSEMBLY Install the ball joint hose assembly and tighten using an 11/16” and 3/4”spannersSlide the rubber boot assemblyback into position.
52 The assembly is now complete. Final testing involves checking forair leaks and carry out the flow test.The flow test is simply turning theflow adjuster and checking thatthe regulator has a venturi flow.If NO venturi flow occurs:Check your air source isturned fully on.Check the intermediatepressure is correct.Check the valve cone isadjusted correctly.
53 HOSE ASSEMBLY (Appendix) If necessary the ball joint hosemaybe dismantled, cleaned andlubricated as follows.Two 3/4” open spanners are usedto split apart the ball housing.
54 HOSE ASSEMBLY (Appendix) Remove the coupling section of thehousing.Check the o ring and thread for damage.
55 HOSE ASSEMBLY (Appendix) To gain access to the o ring behind theball, slide the housing towards the hose.The o ring shown sits against the rearshoulder. Carefully remove with ano ring pick. Take care NOT to scratchthe sealing area.The coupling cannot be completely removed from the hose end.The hose ends and metal parts may be placed in your acid bathfor cleaning etc.
56 HOSE ASSEMBLY (Appendix) Lightly lubricate the o rings before fitting.Care must be taken to ensure the o ringbehind the ball is sitting correctly on theshoulder. If not, the o ring will be pinchedand damaged when tightening the couplinghalves together.Lightly lubricate the thread and fit thecoupling to the hose end.
57 HOSE ASSEMBLY (Appendix) Tighten the coupling using two 3/4”open end spanners. The fitting mustbe firm only, do not over tightenThe hose assembly is now readyfor service.