AirPlusSecondStage767 KBytes
Contents
1. install another new lubricated O ring 30 into the swivel end of the hose tessi svb 13 ADJUSTING THE SECOND STAGE A medium pressure air supply of 135 5 is required to properly adjust the second stage Make sure the first stage that you are using is properly ad justed before performing the second stage adjustments Please refer to the appropriate Cressi first stage repair manual for proper first stage adjustment procedures The first stage should be attached to a fully charged cylinder 2500 to 3000 psi The use of an in line adjustment tool makes adjusting the adjustable orifice easier but is not required In line tools are available from other 3 party sup pliers Both adjustment methods are outlined below ADJUSTING THE SECOND STAGE WITHOUT AN IN LINE ADJUSTMENT TOOL 1 Screw the threaded end of the hose into the first stage Using an 11 16 wrench tighten the hose until snug Thread the swivel end of the hose onto the second stage inlet fitting until finger tight 2 Slowly open the cylinder valve and pressurize the regulator When the regulator pressurizes the lever will drop 3 Insert a 5 5mm nutdriver through the open port on the second stage bogy Tighten the locknut until the top of the lever is even with the bottom of the first lowest thread 4 Turn off the cylinder valve and depressurize the regulator by pressing on the lever Unscrew the hose from the second stage With a medium blade screwdriver tur2. Service Manual Air Plus Second Stage Includes XS Series Second Stage Copyright 2002 Cressi sub Revised 3 2002 Air Plus Second Stage Service Manual Contents BEFORE STARTING na Be 3 DISASSEMBEN E E E 3 PARTS CLEANING AND LUBRICATION 4 1 8 GLEEANING METABPARTS ER AR ISDN Ur ep Epi 8 CLEANING PEASTIC ONLY PARTS piste ner 8 LUBRICATION SA EP 8 Types Of LUDHCANU etin radon it dn Ais cus 8 DNUS 9 PTUCAC CO TEM 9 REASSEMBL Y ee 9 ADJUSTING THE SECOND STAGE nn een 13 ADJUSTING THE SECOND STAGE WITHOUT AN IN LINE ADJUSTMENT TOOL 13 ADJUSTING THE SECOND STAGE WITH AN IN LINE ADJUSTMENT TOOL 13 FINAL HEASSEMBLY a 14 TABLE 1 TROUBLESHOOTING ee 17 TABLE 2 REQUIRED TOOLS 2 ee 17 EXPLODED PARTS DIAGRAM niunt nnum annu k nir naa ana ua nia n 18 tessi svb BEFORE STARTING This manual is not a training document It is meant to be a A guide for experienced technicians who have also received factory training at a Cressi sanctioned repair seminar Do not attempt to repair this or any regulator without the proper train ing Before starting Cressi recommends that you read through the entire manual to familiarize yoursel
3. This ends reassembly and testing 17 TABLE 1 TROUBLESHOOTING Air leak at hose swivel a O ring 26 worn or damaged a Replace O ring b O ring 25 worn or damaged b Replace O ring Second stage leaks air a Adjustable orifice 29 damaged a Replace adjustable orifice b O ring 28 damaged or worn b Replace O ring C LP seat 25 Damaged or worn c Replace seat d Locknut 16 tightened too much d Loosen locknut a Locknut 16 too loose a Tighten locknut b Adjustable orifice 29 in too far b Back out adjustable orifice TABLE 2 REQUIRED TOOLS Tool Description Used for 1 9 16 open end wrench Removing hose 31 2 3 4 open end wrench Removing inlet fitting 27 3 Side cutters Removing mouthpiece clamp 12 4 Phillips screwdriver Removing installing exhaust tee screw 10 5 Flat blade jeweler s screwdriver Removing locking tab 5 6 6mm hex wrench Removing installing port plug 8 7 O ring tool Removing O rings 8 2 medium blade screwdrivers Removing adjustable orifice 29 Clip 15 9 Small wooden dowel Removing adjustable orifice 29 10 5 5mm nut driver Removing installing locknut 16 10 Torque Wrench Tightening inlet fitting 27 Hose swivel 31 11 9 16 crows foot Used with torque wrench 12 3 4 crows foot Used with torque wrench Air Plus Second Stage Service Manual NS P EXPLODED PARTS DIAGRAM 74 29 20 m Key Description 15 Retaining Clip 16 Lo
4. apy water solution Use a soft bristle toothbrush to clean the threads and remove any flaky corro sion 2 After washing in the hot soapy water rinse all the parts in fresh water 3 Place the metal parts in an ultrasonic cleaner with an appropriate cleaning solution Avoid using harsh acids such as muriatic acid in ultrasonic cleaners Clean the parts for 5 to 15 minutes depending on the amount of corrosion 4 Remove the parts from the ultrasonic cleaner and rinse them in fresh water Blow dry the parts using low pressure filtered air CLEANING PLASTIC ONLY PARTS Avoid placing plastic parts in an ultrasonic cleaner with an acidic cleaning solution To properly clean plastic parts perform the same steps listed above 1 Wash all the plastic parts in a hot soapy water solution Use a soft bristle toothbrush to clean the threads and remove any flaky corro sion 2 After washing in the hot soapy water rinse all the parts in fresh water 3 Blow dry the parts using low pressure filtered air LUBRICATION Types of Lubricant Cressi recommends using only food grade silicone grease or more prefer ably Christo lube MCG 111 Gessi sub CAUTION DO NOT use spray silicones as the aerosol propellants may chemically attack the rubber compound O rings All O rings should be treated with a thin film of lubrication Do not over lubri cate the O rings with large amounts of grease Simply place a s
5. cknut 17 Washer 18 Venturi Channel 19 Lever P d ie 20 Valve Body d 21 Orting 22 Spring Key Description Key Description 23 LP Seat Retainer 1a Retaining Ring Assy Air Plus 7 O ring 24 Poppet Stem 1b Front Cover Air Plus 8 Port Plug 25 LP Seat 1c Front Cover XS Series 9 Exhaust Tee 26 O ring 2 Washer 10 Screw 27 Inlet Fitting 3 Diaphragm 11 Mouthpiece 28 O ring 4 Second Stage Body 12 Mouthpiece Clamp 29 Adjustable orifice 5 Locking Tab 13 Flow Control Switch 30 O ring 6 Exhaust Valve 14 O ring 31 Hose Gessisub v Gessi sub Air Plus Second Stage Service Manual aD e dessi sub PROFESSIONAL UNDERWATER EQUIPMENT 1 Charles Street Westwood NJ 07675 Tel 800 338 9143 Fax 800 493 2680
6. f with all the required tools and techniques Use this manual as a guide during the servicing process to avoid missing any critical steps Make sure the work area is clean and that you work over a cushioned work surface so critical parts do not get damaged Pay close attention to all warnings and cautions as they will alert you to any potential hazard that may cause damage or injury Also pay attention to the notes as they provide important tips and reminders DISASSEMBLY 1 Using a 9 16 wrench unscrew the 2 stage hose from the first stage Remove the O ring from the end of the hose 2 While holding the inlet fitting 27 with a 3 4 19mm wrench unscrew the swivel hose fitting using an 11 16 wrench see figure 1 Using a brass or plastic O ring pick remove the O ring 30 located inside the hose swivel Figure I Removing the hose A 6 7b Figure 4 Removing the front cover locking tab 8 Air Plus Second Stage Service Manual Using side cutters snip the mouthpiece clamp 12 Pull the mouth piece 11 off the second stage body 4 Using a Phillips screwdriver remove the exhaust tee retaining screw 10 as shown in figure 2 To remove the exhaust tee 9 place your thumb on the top corner of the exhaust tee and press downward Figure 2 Removing the Figure 3 Press down on top corner of exhaust tee screw exhaust tee to remove Remove the exhaust valve 6 by gra
7. heard turn the hand wheel clockwise until the leak stops then an additional eighth turn If adjusting an octopus second stage go an additional half turn Close the cylinder valve and purge the regulator by pressing the lever Pull back on the in line tool handwheel and unscrew the in line tool from the second stage Unscrew the hose from the in line tool FINAL REASSEMBLY 1 Install a new lubricated O ring 7 on the second stage port plug 8 Using a 6mm hex wrench tighten the port plug until snug see figure 28 Figure 28 Install port plug Note the two notches at the top Tab and bottom of the diaphragm 3 These notches mate with two tabs inside the second stage housing see figure 29 On the backside of the dia phragm is a metal strike plate With the strike plate facing the lever place the diaphragm into the second stage housing Figure 29 Align notches in diaphragm with tabs in housing 15 3a Air Plus second stage only 3b Orient the front cover so the purge button logo is properly aligned Align the notches in the front cover with the tabs in the second stage figure 30 While holding the front cover down with your thumb screw the retaining ring onto the second stage housing Figure 30 Align notches in front cover with tabs in housing Air Plus second stage only XS second stages only Lay the washer 2 on top of the diaphragm Before installing the front cover no
8. mall amount of grease between your thumb and forefinger and run the O ring between them Threaded parts You may lightly lubricate the first two threads As you tighten parts together the lubricant will spread to the other threads REASSEMBLY 1 Install a new lubricated O ring 14 onto the flow control knob 13 Insert the flow control knob into the second stage body and press down so that the groove for the retaining clip is visible in the mouthpiece opening 2 Hold the second stage body with the flow control knob facing downward One side of the retaining clip 15 has a sharp edge the other side has a rounded edge Set the retaining clip into the mouthpiece opening with rounded edge against the 2 stage housing and the open side against the flow control knob Using your finger or a flat blade screwdriver press the retaining clip against the flow control knob until it snaps into place figure 15 Move the flow control knob back and forth to ensure that it operates smoothly Figure 15 Install C clip 10 Air Plus Second Stage Service Manual Insert the stem of a new exhaust valve 6 through the center hole in the exhaust port on the outside of the 274 stage housing 4 as shown in figure 16 Grasp the stem with your fingers and pull it until the barb pops through figure 17 Coah n E Figure 16 Install exhaust valve Figure 17 Pull barb all the way through Install a new lubricated O ring 21 onto the val
9. n the adjustable orifice counterclockwise about 1 8 turn 45 Thread the hose onto the second stage 5 Slowly open the cylinder valve and listen for an audible air leak from the second stage 6 If there is no leak repeat steps 4 amp 5 until a leak is heard If there is leak close the cylinder valve remove the hose from the second stage and turn the adjustable orifice clockwise an eighth of a turn 45 If adjusting the XS octopus go an addition half turn 180 ADJUSTING THE SECOND STAGE WITH AN IN LINE ADJUSTMENT TOOL 1 Screw the threaded end of the second stage hose into the first stage Using an 11 16 wrench tighten the hose until snug Pull back the adjust ment wheel of the in line tool and thread the in line tool into the second stage inlet fitting Thread the swivel end of the second stage hose onto the in line tool until finger tight 14 Air Plus Second Stage Service Manual Slowly open the cylinder valve and pressurize the regulator When the regulator pressurizes the lever will drop Insert a 5 5mm nutdriver through the open port on the second stage body Tighten the locknut until the top of the lever is even with the bottom of the first thread Press the handwheel of the in line tool inward until it stops Rotate the handwheel until the in line tool engages the screwdriver slot in the adjustable orifice Slowly rotate the handwheel counterclockwise until there is an audible air leak Once the leak is
10. ng onto poppet Figure 23 Install washer followed by and compress into valve body locknut While keeping the poppet com pressed install the feet of the lever behind the washer and into the groove in the face of the valve body as shown in figure 24 Figure 24 Lever installed 12 Air Plus Second Stage Service Manual 10 Install a new lubricated O ring Insert a 5 5mm nutdriver through the open port and tighten the locknut until the face of the poppet is flush with the opening of the valve body see figure 25 Figure 25 Tighten locknut until poppet is flush with valve body opening Install a new lubricated O ring 26 into the face of the inlet fitting 27 28 onto the adjustable orifice 29 Insert the sealing edge of the adjustable orifice into the coarse threaded side of the inlet fitting 27 as shown in figure 26 Press the adjustable orifice into the inlet fitting until it stops Using a medium blade screwdriver screw in the adjustable orifice until it stops then unscrew it two Figure 26 Press adjustable orifice into complete turns inlet fitting While depressing the lever thread the inlet fitting into the valve body Attach a 3 4 19mm crows foot to an inch pound torque wrench Tighten the inlet fitting to 60 inch pounds as shown in figure 27 Figure 27 Torque inlet fitting to 60 inch pounds 14 Install a new lubricated O ring onto the threaded end of the hose
11. or plastic dowel into the inlet fitting against the sealing edge of the adjustable orifice Press on the orifice and remove it from the inlet fitting figure 7 Figure 6 Unscrew adjustable orifice to Figure 7 Use a dowel to push disengage threads adjustable orifice out of inlet fitting Air Plus Second Stage Service Manual 11 12 Insert a small flat bladed screw Remove the adjustable orifice O ring 28 with a brass or plastic O ring pick Press on the poppet assembly 23 25 to compress the spring While keeping the poppet spring compressed insert a 5 5mm nutdriver through the open port on the right side of the second stage housing and unscrew the locknut 16 After the locknut is removed slowly release the pressure on the spring Remove the poppet assembly spring 22 lever 19 and washer 17 as shown in figure 9 Figure 8 Compress poppet and remove Figure 9 Remove all the valve locknut with 5 5mm nut driver components Separate the spring from the poppet assembly Hold the threaded end of pe the poppet stem 24 and slide the white plastic seat retainer 23 toward the threads and remove it from the poppet stem Remove the rubber seat 25 from the end of the poppet stem See figure 10 Figure 10 Separate poppet assembly driver through the open port on the right side of the second stage housing Slide the edge of the screwdriver blade into the small slot located in the middle of
12. sping it with your thumb and forefinger and pulling it straight out For the Air Plus second stage only Using your fingers unscrew the front cover retaining ring 1b Separate the front cover assembly 1a from the retaining ring Lift out the diaphragm 3 For the XS series second stage only Using a small flat tipped jewelers screwdriver pry out the front cover locking tab 5 as shown in figure 4 Using the palm of your hand unscrew the front cover assembly 1c Lift out the diaphragm washer 2 and remove the diaphragm 3 XS series only Using an 6 mm hex wrench unscrew the port plug 8 Remove the O ring 7 from the port plug Gessi sub 9 Using a 3 4 19mm wrench unscrew the inlet fitting 27 from the sec ond stage housing as shown in figure 5 Using a brass or plastic O ring pick remove the O ring 26 located in the face of the inlet fitting Figure 5 Remove inlet fitting CAUTION Take special care when removing the adjustable orifice so the sealing edge is damaged Place the orifice on a cushioned surface while disassembling the remainder of the second stage Keep it away from the edge of the work bench so it doesn t fall to the floor and become damaged 10 Using a medium flat blade screwdriver unscrew the adjustable orifice 29 until the threads are disengaged about five complete turns counter clockwise as shown in figure 6 Insert a small wooden
13. the venturi channel 18 Gently pry the venturi channel loose and remove with your fingers See figure 11 Figure 11 Remove venturi channel Figure 12 Push in the valve body and remove from second Gessi sub N Using your finger press the valve body 20 inward see figure 12 Ro tate the valve body counterclockwise so it clears the small plastic bump on the inside of the second stage body Completely remove the valve body from the second stage housing Remove the O ring 21 from the valve body stage body Using a medium blade screwdriver rotate the retaining clip 15 so the open side of the clip faces the mouthpiece opening Lay the second stage body on the workbench with the mouthpiece opening facing up ward Using a second flat blade screwdriver press the two legs of the retaining clip and pop it off the flow control knob 13 See figure 13 Lift the flow control knob 13 out of the second stage body figure 14 Remove the O ring 14 from the flow control knob Figure 13 Push on both legs Figure 14 Remove flow of the c clip to remove control knob This ends disassembly Air Plus Second Stage Service Manual PARTS CLEANING AND LUBRICATION CLEANING METAL PARTS CAUTION Keep the adjustable orifice 26 separate from the other parts while cleaning If the sealing surface is damaged the part will have to be replaced 1 Wash all the metal parts in a hot so
14. tice the hole in the threads on the right side of the front cover see figure 31 This hole will align with the hole in the second stage body Thread the front cover onto the second stage body until the two holes align the front cover logo should be prop erly aligned Press the locking tab 5 into the second stage body figure 32 Try to unscrew the front cover If it does not turn that means the locking tab is installed correctly Figure 31 Holes in front cover and housing Figure 32 Press locking tab into place to line up when cover screwed in secure front cover Hang the exhaust tee 9 from the top edge of the flange see figure 33 Press on the bottom of the exhaust tee until it snaps into place Figure 33 Hang exhasut tee on top edge of flange 16 Air Plus Second Stage Service Manual 5 Using a Phillips screwdriver install the exhaust tee retaining screw 10 Note Do not install the mouthpiece at this time if you will be performing bench tests 6 Install the mouthpiece onto the 2 stage body Secure the mouthpiece with a new clamp 12 The clamp s locking tab should be positioned on the hose side of the mouthpiece Using side cutters trim the clamp so it is flush with the locking tab 7 Thread the hose swivel onto the inlet fitting until finger tight Attach an 11 16 crows foot to a torque wrench While holding the inlet fitting with a 3 4 19mm wrench tighten the hose swivel to 40 inch pounds
15. ve body 20 The valve body has an air outlet hole located in one corner of the square face Place the valve body into the second stage body with the air outlet hole against the back wall of the 274 stage housing and pointing upward toward the mouthpiece figure 18 Press the inlet fitting into place making sure that the squared face is pressed against the 2 stage housing Figure 18 Valve body installed Inside the second stage housing just above valve body is the slot for the venturi channel 18 Slide the venturi channel all the way into the slot until it sits against the back wall of the second stage housing and covers the air outlet hole figure 19 Figure 19 Venturi channel installed 7 9 Gessi sub 11 Insert the threaded end of the poppet stem 24 into the squared side of the seat retainer 23 as shown in figure 20 Press a new rubber seat 25 into the seat retainer as shown in figure 21 Figure 20 Insert poppet stem into seat Figure 21 Press new LP seat into seat retainer retainer Place the spring 22 over the poppet stem so it rests against the seat retainer Insert the poppet spring assembly threaded end first into the threaded open side of the valve body Press inward on the poppet to compress the spring figure 22 Place the washer 17 over the end of the poppet and thread the locknut 16 onto the end of the poppet figure 23 gan e 1 Locknut Figure 22 Install spri
Download Pdf Manuals
Related Search