ATX SECOND STAGE
Contents
1. Authorized Technician TECHNICAL MAINTENANCE MANUAL ATX SECOND STAGE Contents COPYRIGHT NOTICE E 3 INTRODUCTION Pes 3 WARNINGS CAUTIONS amp NOTES 22 25 sae nares cR BENNE ENADE 3 SCHEDULED xz1 iLid eli 3 GENERAL GUIDELINES PAN 3 GENERAL CONVENTIONS 4 DISASSEMBLY PROCEDURES 2 2 nnam unn x arae CE vs 4 REASSEMBLY PROCEDURES vene cvv ve paolo cvv s eod 7 FINAL gzlxglcmeee 10 ITOnBEcopniecunmnggnljcc 10 Second Stage Air FlOW amp E 10 Second Stage Purge FloW Test cce erronee eset reina edenda sacco boca anas cd assa caseus ta Scy 10 External Leak TeSt 10 Subjective Breathing 10 TABLE 1 FIRST STAGE TROUBLESHOOTING G2. Do not rely on memory 2 Allservice and repair should be carried out in a work area specifically set up and equipped for the task Adequate lighting cleanliness and easy access to all required tools are essential for an efficient repair facility 3 Asthe regulator is disassembled reusable components should be segregated and not allowed to intermix with nonreusable parts or parts from other units Delicate parts including inlet fittings and crowns which contain critical sealing surfaces must be protected and isolated from other parts to prevent damage during the cleaning procedure 4 Use only genuine Apeks parts provided in the ATX second stage overhaul parts kit APO219 AA DO NOT attempt to substitute an Apeks part with another manufacturer s regardless of any similarity in shape or size 5 Do not attempt to reuse mandatory replacement parts under any circumstances regardless of the amount of use the product has received since it was manufactured or last serviced 6 When reassembling it is important to follow every torque specification prescribed in this manual using a calibrated torque wrench Most parts are made of either marine brass or plastic and can be permanently damaged by undue stress GENERAL CONVENTIONS Unless otherwise instructed the following terminology and tech niques are assumed 1 When instructed to remove unscrew or loosen a threaded part turn the part counterclockwise When in
3. for the clamp 8 Wrap the clamp around the mouthpiece so that the buckle points to ward the hose Tighten the clamp and snip the excess strap with side cutters FINAL TESTING Second Stage Opening Effort Test ils Connect the first stage regulator to a calibrated test bench and pressurize the system to 3000 100 psi Slowly open the flowmeter control knob start vacuum while watching both the magnahelic gauge and the intermediate pressure gauge When the intermediate pressure begins to drop indicat ing the second stage valve is open the magnahelic gauge should indicate an opening effort of 0 8 to 1 4 If the reading exceeds these specifications refer to refer to Table 1 Troubleshooting for corrective actions External Leak Test ie After disconnecting the regulator from the flow bench con nect it to a scuba cylinder filled to approximately 3 000 psi Open the cylinder valve to repressurize the regulator and submerge the entire system in a test tank of clean water Observe any bubbles arising from the submerged regula tor over a one minute period The recommended time is necessary due to slower bubble formation that occurs in smaller leaks Bubbles indicate a leak which requires that the system must be disassembled at the source to check sealing surfaces assembly sequence and component posi tioning in order to correct the problem s NOTE Extremely small leaks may b
4. so it sits evenly in the box bottom Install the diaphragm cover 5 into the case over the diaphragm Place the small diameter end of the purge spring 3 onto the purge but ton 2 Orient the case cover with the slotted openings pointing to the right Properly align the purge button and press it into the case cover until it snaps into place 10 20 21 22 Screw the case cover onto the case Using the cover tool p n AT31 tighten the cover until it stops Confirm that the purge button is properly aligned If air flows au dibly the lever is set too high To lower the lever turn in the crown until the flow stops Perform the purge test Slowly press the purge button unti air flows The button should not travel more than 2mm Excessive travel indicates that the lever is set too low Adjust the crown out slightly until the purge is satisfactory Screw the hose onto the second stage Using an 11 16 crows foot and torque wrench tight the hose to 40 inch pounds NOTE If your facility is equipped with a test bench per 23 form the tests before installing the mouthpiece General instructions for performing bench tests are located in the next section Final Testing If equipped with a Comfo bite mouthpiece make sure the bridge of the mouth i piece 9 is facing upward Stretch the mouthpiece over the second stage mouth piece boss At the base of the mouthpiece is a groove
5. two o rings 16 amp 17 from the body o ring 12 that will probably be left behind in the left spring adjuster side of the box bottom as you look at it 7 Grasp the venturi lever 14 and pull it out of the box bottom Remove the o ring 13 from the venturi lever NOTE The venturi lever may have come out with the valve body in step 6 If this is the case depress the lever and slide the lever off from right to left 11 Remove the o ring 12 from the valve body 8 the knob clockwise inward one turn The pin 29 should drop out If the pin remains in the valve body use a 1 16 dowel or punch to push it partially out then use needlenose pliers to completely remove it from the valve bogy 13 Insert a small 1 8 wooden dowel into the threaded end of the valve body and push out the shuttle valve assembly 20 24 Separate the shuttle valve assembly by pulling on each end 14 Using a fingernail remove the LP seat 24 and small o ring 17 Fold back the edges of 22 from the shuttle valve the exhaust valve 30 and inspect underneath The seating surface should be clean and free of damage Inspect the exhaust valve It should be supple and have well defined edges If it looks good there is no need to remove it and it may be reused If there is any sign of deterioration it should be replaced 15 Using a medium blade screwdriver turn the crown 27 si
6. AP2028 AP1154 AP2033 AP2035 1151 1429 5801 5801 Venturi Lever ATX50 Venturi Lever Yellow ATX50 Octopus Adjuster Spring O ring O ring Adjusting Screw ATX200 Adjusting Screw ATX50 O ring Counter Balance Cylinder Spring O ring Shuttle Valve Rubber Seat Valve Spindle ATX200 Valve Spindle ATX50 O ring Seat Lever Spring Pin Exhaust Valve Cover Exhaust Valve Cover Exhaust Valve Yellow Apeks ATX Second Stage Service Manual 17 Q apexx Authorized Technician TECHNICAL MAINTENANCE MANUAL ATX SECOND STAGE Aqua Lung America 2340 Cousteau Court Vista CA 92083
7. UIDE 11 TABEE2 RECOMMENDED TOOL LIST vu accen vU Gne nu Y ge su Rav vU scare v GC cpu v So Dc nn 12 TABLE RECOMMENDED LUBRICANTS AND nnne nnnm nens nnns 13 PROCEDURE A CLEANING AND LUBRICATION eeeeeeeeeseeeeen nne 14 TABLE 4 TORQUE SPECIFICATIONS 15 TABLE 5 TEST BENCH 5 v npe dn Ex o no nv nuc pv 15 EXPLODED PARTS DIAGRAM sa dass a sna atn sas 16 This manual is copyrighted all rights reserved It may not in whole or in part be copied photocopied reproduced translated or reduced to any electronic medium or machine readable form without prior consent in writing from Aqua Lung America It may not be distributed through the internet or computer bulletin board systems without prior consent in writing from Aqua Lung America 2002 Aqua Lung America Inc ATX Second Stage Service Manual INTRODUCTION This manual provides factory prescribed procedures for the cor rect service and repair of the A
8. aged the part must be replaced with new DO NOT use a dental pick or any other steel instrument 4 Lift out the diaphragm 1 Using two 14e wrenches hold the retaining nut 11 station ary while turn the hose swivel counterclockwise Remove the o ring from inside the hose swivel Exercise caution not to scratch the o ring groove Remove the o ring from the male end of the hose 2 Pull back the two hose protectors and inspect the hose crimps The crimps should be free from damage and the hose should not be pulling out of the crimp If it is the hose must be replaced 3 Using the Apeks front cover tool see note on page 13 regarding the modification of the front cover tool unscrew the case cover 4 To remove the purge button and spring 2 amp 3 squeeze two adjacent tabs inward cover 5 and diaphragm 6 Apeks ATX Second Stage Service Manual 5 5 Using 1146 wrench re move the heat exchanger 11 9 Unscrew the adjustment knob 18 and completely remove it from the valve body 6 Turn the adjustment knob counterclockwise until it stops Press the lever 28 against the valve body 25 While 10 Remove the o ring 19 from the adjustment knob Using keeping the lever depressed grasp the knob and pull the the Spring Adjuster Tool p n AT45 unscrew the spring valve body assembly out of the case 7 Remove the adjuster 15 Remove the
9. ckson OH 45640 800 477 8704 CAUTION Silicone rubber requires no lubrication or preservative treatment DO NOT apply grease or spray to silicone rubber parts Doing so may cause a chemical breakdown and premature deterioration of the material Oakite 31 Acid bath for reusable stainless Oakite Products Inc steel and brass parts 50 Valley Road Berkeley Heights NJ 07922 White distilled vinegar 100 gr Acid bath for reusable stainless Household grade steel and brass parts CAUTION Do not use muriatic acid for the cleaning of any parts Even if strongly di luted muriatic acid can harm chrome plating and may leave a residue that is harmful to O ring seals and other parts Liquid dishwashing detergent Degreaser for brass and stainless Household grade diluted with warm water steel parts general cleaning solu tion for plastic and rubber 14 Procedure Cleaning amp Lubrication The ATX Regulator and Nitrox When it comes to issues of nitrox safety and compatibility the concerns lie primarily with the first stage as it is subjected to high inlet pressures High inlet pressures lead to adiabatic compression or heating of the gas The ATX first stage when properly cleaned and assembled is authorized for use with enriched air nitrox EAN that does not exceed 40 EAN 40 It is authorized because it has undergone adiabatic compression testing and the authorized service kit components and lubricants a
10. e better detected by applying a soap solution or Snoop to the leak area Bubble streams will indicate the source of the leak Before disassembling to correct any leaks rinse the entire regula tor thoroughly with fresh water and blow out all residual moisture with filtered low pressure 50 psi air Disassem ble and remedy the problem referring to Table 1 Trouble shooting Subjective Breathing Test 1 Depress the purge cover fully to ensure that adequate volume of air needed to clear the second stage flows through the mouthpiece Then inhale slowly but deeply from the mouthpiece A properly serviced and adjusted regulator should deliver air upon deep inhalation without excessive inhalation effort freeflow or fluttering of the second stage diaphragm When exhaling there should be no fluttering or sticking of the exhalation valve If any of these problems occur refer to Table 1 Troubleshooting This Ends Reassembly Apeks ATX Second Stage Service Manual Table 1 Troubleshooting Guide SYMPTOM POSSIBLE CAUSE High first stage intermediate pres Refer to first stage Troubleshoot sure should be 135 5 psi ing Guide 2 LP seat 24 damaged or worn 2 Replace LP seat 3 Reset crown preliminary set 3 Crown 27 adjusted incorrectly tings and repeat Adjustment lever set too high Leakage or freeflow from second stage Procedures 4 Lever 28 bent 4 Replace lever 5 Crow
11. ed air and inspect closely to ensure proper cleaning and like new condition Cleaning Anodized Aluminum Plastic amp Rubber Parts Anodized aluminum parts and parts made of plastic or rubber such as box bottoms box tops dust caps etc may be soaked and cleaned in a solution of warm water mixed with mild dish soap Use only a soft nylon toothbrush to scrub away any deposits Rinse in fresh water and thoroughly blow dry using low pressure filtered air CAUTION Do not place plastic and rubber parts in acid solutions Doing so my alter the physical properties of the component causing it to prematurely degrade and or break Cleaning Hoses Hose fittings Ultrasonically clean with soapy water vinegar OK on tough corrosion Run soapy water through hose if need Thoroughly rinse with fresh water Blow out hose before install Lubrication and Dressing Wear powderless latex gloves when handling and lubricating o rings Keeping internal parts free from skin oils and other contaminates is important when running enriched air nitrox through a first stage All o rings should be lubricated with Christo Lube MCG 111 Dress the o rings with a very light film of grease and remove any visible excess by running the o ring between thumb and forefinger Avoid applying excessive amounts of Christo Lube grease as this will attract particulate matter that may cause damage to the o ring Soapy water is defined as household grade liquid dish
12. ever Continue to screw clockwise until the holes for the locking pin are clear Install the locking pin 29 Be sure that it sits evenly in the 13 hole Back the adjustment knob out counterclockwise to ap ply tension on the pin and keep it from falling out 12 Install a new lubricated o ring 13 onto the venturi lever 14 Point the venturi lever upward and insert it into the case Press it against the case so the o ring is captured While depressing the lever insert the valve body through the venturi lever and into the box bottom Be sure that the two index flats and the two lever feet engage the tabs molded into the box bottom Slide a new lubricated o ring 12 down the threaded end of the valve body into the box bottom Screw the heat exchanger 11 wrench flats facing outward onto the valve body until finger tight Using an Me crows foot or deep Socket tighten the nut to a torque of 45 2 inch lbs Apeks ATX Second Stage Service Manual 14 15 16 Fit a new lubricated o ring 26 onto the adjustable crown 27 Press the adjustable crown threaded end first into the valve body Using blunt end of the seat extractor tool push the adjustable crown into the valve body as far as it will go While holding the rim of the box bottom at eye level turn the adjustable crown orifice in clockwise until the lever drops about 4mm below the case rim Then turn the cro
13. fetime Warranty in effect If a regulator is subjected to more than 50 dives per year it should receive the complete overhaul An Official Inspection consists of 1 Apressurized immersion test of the entire unit to check for air leakage 2 Checking for stable intermediate pressure that is within the acceptable range 3 Checking for opening effort that is within the acceptable range 4 Checking for smooth operation of the control knob and venturi switch 5 Avisual inspection of the filter for debris or discoloration 6 Avisual inspection of the exhaust valve to see that it is in good shape and that it s resting against a clean surface 7 A visual inspection of the mouthpiece looking for tears or holes 8 Pulling back hose protectors and checking that the hoses are secure in the hose crimps If a regulator fails item 1 2 3 or 4 the entire regulator should be overhauled If a regulator fails 4 5 6 or 7 it will be up to the technician s discretion whether or not a full overhaul is required GENERAL GUIDELINES 1 Inorder to correctly perform the procedures outlined in this manual it is important to follow each step exactly in the or der given Read over the entire manual to become familiar with all procedures before attempting to disassemble the first stage and to learn which specialty tools and replace ment parts will be required Keep the manual open beside you for reference while performing each procedure
14. ly 5mm of the tail behind 1 3 d 5 Fitthe valve spring 21 onto the leading edge of the coun terbalance cylinder 20 Carefully guide the stem of the shuttle valve through the spring and into the counterbalance cylinder Orient the exhaust cover 31 with the logo facing outward the side with two tabs pointing to the left Slide the two tabs into the exhaust port then press down on the right side of the exhaust cover to snap it into place 6 If you removed the lever replace it so that the lever is on the side opposite the two pin holes The air outlet hole should point to the left with the threaded end facing you 7 With the feet of the shuttle valve pointing downward away from the lever and the lever pointing straight up perpen dicular to the valve body insert the valve assembly into the valve body Using your finger press the shuttle valve assembly all the way into the valve body Install a new lubricated o ring 12 onto the valve body 25 8 Install a new lubricated o ring 19 onto the adjustment 11 knob Install a new lubricated o rings 16 amp 17 onto the spring adjuster 15 Using the spring adjuster tool p n AT45 thread the spring adjuster into the adjustment knob 18 until it is flush with the end of the adjustment knob then turn in one additional revolution 10 Install the adjustment knob into the valve body There should now be spring tension on the l
15. n 27 sealing surface dam 5 Replace crown aged 6 Poppet spring 21 damaged 6 Replace spring 1 Low first stage intermediate pres 1 Refer to first stage Troubleshoot sure should be 135 5 psi ing Guide 2 Reset crown to preliminary 2 Crown 27 adjusted incorrectly settings and repeat Adjustment i lever set too low Low purge or excessive work of breath ever se Procedures ing full cylinder 3 Intermediate pressure hose clogged Glean or replace hose or obstructed 3 Exhaust valve 30 damaged 4 Venturi lever o ring 13 dirty dam 4 Disassemble and replace o ring aged or worn 5 Remove front cover 3 and 5 Diaphragm improperly seated in box properly reassemble did ring bottom 7 with diaphragm check for distor tion 6 Box bottom damaged Check ex 6 Disassemble and replace box haust valve sealing surface bottom Inlet o ring 12 damaged 7 Replace o ring 8 Valve spindle o ring 12 worn or 8 Replace o ring damaged Water entering second stage 12 Table 2 Recommended Tool List PART NO DESCRIPTION APPLICATION NOTE The front cover tool must be modified by removing one of the pins Apeks Second Stage Service Manual 13 Table 5 Recommended Lubricants amp Cleaners LUBRICANT CLEANER APPLICATION SOURCE Christo Lube MCG 111 All O rings seals Aqua Lung PN 820466 or Lubrication Technologies 310 Morton Street Ja
16. peks ATX second stage regula tor It is not intended to be used as an instructional manual for untrained personnel The procedures outlined within this manual are to be performed only by personnel who have received factory authorized training through an Aqua Lung Service amp Repair Sem inar If you do not completely understand all of the procedures outlined in this manual contact Aqua Lung to speak directly with a Technical Advisor before proceeding any further WARNINGS CAUTIONS amp NOTES Pay special attention to information provided in warnings cau tions and notes that are accompanied by one of these symbols WARNINGS indicate a procedure or situation that may result in serious injury or death if instructions are not followed correctly CAUTIONS indicate any situation or technique that will result in potential damage to the prod uct or render the product unsafe if instructions are not followed correctly NOTES are used to emphasize important points tips and reminders SCHEDULED SERVICE If the regulator is subjected to less than 50 dives per year it is permissible to overhaul it every other year with an inspection procedure being performed on the off years For example Year 1 Inspection Year 2 Overhaul Year 3 Inspection Year 4 Overhaul and so on Both Inspections and Overhauls need to be documented in the Annual Service amp Inspection Record in the back of the Owner s Manual to keep the Limited Li
17. re compatible in elevated oxygen environments During cleaning a mild detergent must be used to remove condensed hydrocarbons compressor oils from the inside passageways of the first stage For the first stage to remain EAN40 compatible only use hyperfiltered compressed gas hydrocarbons lt 0 1 mg m3 Ordinary compressed breathing air Grade E usually does not meet this criterion Once ordinary breathing air is used the first stage is no longer EAN40 compatible until it is cleaned and serviced again Although regulator second stage components are not exposed to high pressure EAN Aqua Lung recommends that the same cleaning procedures be followed for the complete regulator This prevents the possibility of cross contamination and guarantees the cleanliness of the entire regulator Cleaning Brass and Stainless Steel Parts Preclean in warm soapy water using a nylon bristle tooth brush 2 Thoroughly clean parts in an ultrasonic cleaner filled with soapy water If there are stubborn deposits household white distilled vinegar acetic acid in an ultrasonic cleaner will work well DO NOT place plastic rubber silicone or anodized aluminum parts in vinegar 3 Remove parts from the ultrasonic cleaner and rinse with fresh water If tap water is extremely hard place the parts in a bath of distilled water to prevent any mineral residue Agitate lightly and allow to soak for 5 10 minutes Remove and blow dry with low pressure 25 psi filter
18. structed to install screw in or tighten a threaded part turn the part clockwise When instructed to remove an O ring use the pinch method see figure if possible or use a brass or plastic O ring removal tool Avoid using hardened steel picks as they may damage the o ring sealing surface All o rings that are re moved are discarded and replaced with brand new o rings Pinch Method Press upwardson sides of O ring to create a protrusion Grab O ring or insert O ring tool at protrusion The following acronyms are used throughout the manual MP is Medium Pressure HP is High Pressure IP is Inter mediate Pressure Numbers in parentheses reference the key numbers on the exploded parts schematics For example in the statement remove the o ring 20 from the the number 20 is the key number to the crown o ring DISASSEMBLY PROCEDURES Note Before performing any disassembly refer to the N exploded parts drawing which references all mandatory replacement parts These parts should be replaced with new and must not be reused under any circumstances regardless of the age of the regulator or how much use it has received since it was last serviced CAUTION Use only a plastic or brass o ring removal tool p n 944022 when removing o rings to prevent damage to the sealing surface Even a small scratch across an o ring sealing surface could result in leakage Once an o ring sealing surface has been dam
19. washing detergent diluted in warm water Apeks ATX Second Stage Service Manual PART NUMBER Table 4 Torque Specifications DESCRIPTION KEY NUMBER TORQUE AP2031 Heat Exchanger 11 45 2 inch lbs TEST Leak Test Intermediate Pressure Intermediate Pressure Creep Opening Effort Table 5 Test Bench Specifications CONDITION ACCEPTABLE RANGE Inlet 2 500 3 000 100 psig No leaks allowed Inlet 2 500 3 000 100 psig 135 5 psi 5 psi max between 5 to 15 seconds after Inlet 2 500 3 000 100 psig eyeing purging regulator Inlet 2 500 3 000 100 psig Intermediate pressure 135 5 psi 0 8 to 1 4 in 0 15 16 3 2 1 AP0219 AA 4 AP5819 AP5820 2 AP5805 5 AP2020 4 AP5804 AP5807 AP5807 Y 5 AP5802 C AP5802 6 5805 7 5800 8 104913 9 109438 104138 10 AP2037 aq 5013 5 5002 12 AP1267 13 AP1438 14 AP5339 Q Exploded Parts Diagram Universal 2nd Stage Repair Kit Decal ATX200 Decal ATX50 Purge Button Spring Case Cover ATX200 Case Cover ATX50 Case Cover ATX50 Octopus Diaphragm Cover ATX200 Diaphragm Cover ATX50 Diaphragm Case Mouthpiece Clip Mouthpiece Comfobite Mouthpiece Standard Octopus Deflector Heat Exchanger ATX200 Heat Excahnger ATX50 O ring O ring Venturi Lever ATX200 AP2039 AP2039 Y AP6578 AP1159 AP5711 AP6577 S AP6577 1 AP1409 AP2038 AP2021 AP2041 AP2036 AP2034 AP2028 S
20. wn counterclockwise until the lever is even with the case rim Add a new o ring to the male end of the medium pressure hose Install a new lubricated o ring into the swivel end of the hose 17 Adjust the lever height Cg NOTE The inline adjustment tool can be use with crowns with a screwdriver slot or a hex hole Make sure the inline tool is set to use the appropriate fitting a Attach the Aqua Lung in line tool p n 100190 to the second stage It can accommodate both the crown orifice with the 5mm hex and the crown orifice with the slot The tool is shown with the optional in line medium pressure gauge p n 111605 b Attach the swivel end of the medium pressure hose to the other end of the inline tool Attach the male end of the hose to a properly adjusted first stage regula tor 135 5 Attach the first stage to a fully charged cylinder Slowly open the cylinder valve to pressurize the regulator c Press inward on the adjustment wheel of the inline tool Slowly rotate the adjustment wheel until the inline tool engages the crown orifice Turn the crown in until the lever drops approximately 1 This will coin the rubber seat to help achieve a better seal Now back the crown orifice out counterclockwise The lever will raise Continue until the lever is even with the rim of the box bottom Position the diaphragm 6 into the box bottom 7 Using your finger work the edges of the diaphragm into place
21. x to seven full turns counterclockwise Since the crown is o ring sealed it will not completely unscrew from the valve body Insert the pin end of the seat extractor tool 18 Using side cutters snip the mouthpiece clamp 8 Remove p n 109436 into the valve body grasp the and pullthe the mouthpiece 9 crown completely out of the valve body Remove the o ring 26 from the crown This Ends Disassembly Before starting reassembly perform parts cleaning and lubrication according to the procedures outlined in Procedure A titled Cleaning amp Lubrication on page 15 CE Note The exhaust tee is a molded part of the case and cannot be removed Only the exhaust cover can be re moved see next step 16 To remove the exhaust cover 31 locate the retaining tab located inside the exhaust port see picture Using a wooden dowel press in on the upper ledge of the tab at an angle and pop out the exhaust cover Apeks ATX Second Stage Service Manual 7 REASSEMBLY PROCEDURES 4 Install a new lubricated o ring 22 onto the stem of the shuttle valve 23 Press a new low pressure seat 24 into If the exhaust valve 30 was removed thread the tail the front of the shuttle valve through the retaining hole on the outside of the box bottom until the barb engages on the inside Align the rib so it is horizontal If it is a new valve cut the excess stem with side cutters leaving approximate
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