Microsoft Word Viewer - R 600 first stage Service
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1. A cavon Use only a plastic or brass o ring removal tool when removing o rings to prevent damage to the sealing surface Even a small scratch across an o ring sealing surface can result in leakage Once an o ring sealing surface has been damaged the part must be replaced with a new one Only plastic dental picks may be used 1 Remove the hoses from the first stage using the appropriate sized wrenches Install spare HP and LP port plugs into the empty parts except for one LP port and one HP port 2 Install the vice mounting too into one of the HP ports and secure in a bench vise with the Diaphragm Retaining Cap 6 facing upward Using a two faced spanner wrench unscrew the Antifreeze Retaining Cap 6 while holding the intermediate Ring Spanner Tool 5 stationary 3 With your finger remove the Antifreeze Membrane 21 the Antireeze Retaining Cap Tum the First Stage over so the piston 20 falls out into your hand 4 Using a 6mm hex wrench unscrew and remove the Spring Adjustment Screw 12 Lift out the main spring 2 5 8 Using a face spanner wrench unscrew the Intermediate Ring 5 from the body Lift out the Spring Plate 19 To remove the diaphragm 22 insert a low pressure air nozzle int the open LP port While holding your thumb over the diaphragm inject a small blast of air into the LP port to pop out the diaphragm Lift out the Guide Plate 24 and Piston Guide2. acceptable range 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 fiter for debris or discoloration 6 A visual inspection of the exhaust valve to see that it is in good shape and that its resting against a clean surface 7 Avisual 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 1 regulator fails item 1 2 or 4 the entire regulator should be overhauled If a regulator fails 4 5 6 or 7 it willbe up to the technician s discretion whether or not full overhaul is required GENERAL GUI DELI NES 1 In order to correctly perform the procedures outined in this manual itis important to follow each step exactly in the order given Read over the entire manual to become familiar with all procedures before attempting to disassemble the first stage and to leam which specialty tools and replacement parts wil be required Keep the manual open beside you for reference while performing each procedure Do not rely on memory 2 Allservce and repairs should be camied 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 tor an efficient repair facility The regulator body will need to be secured in a vise when removing certain thre
3. needs service 2 Switch to different cylinder resistance through entire system 3 Filter 4 is clogged 3 Replace filter Table 2 Recommended Tools LP test gauge Intermediate pressure testing O ring tool set O ring removal and installation Pin Spanner Wrench Diaphragm clamp end cap Seat extract install tool Piston removal Vise mounting tool Mounting first stage into vise 5 8 open end wrench Hose removal Torque wrench foot pound Inlet fitting HP plug 314 box wrench Connector removal 314 box wrench adapter Connector installation witorque wrench 5mm hex wrench Port plugs 6mm hex key HP plug DIN connector removal 6mm hex key adapter Plug DIN connector installation witorque wrench 1 8 wooden dowel Crown Fiter removal Table 3 Recommended Lubricants amp Cleaners Christo Lube MCG 111 or 129 All O rings seals Lubrication Technologies 310 Morton Street Jackson OH 45640 800 477 8704 CAUTION Silicone rubber requires no lubrication DO NOT apply grease or spray to silicone rubber parts cause deterioration of the material Doing so may Oakite 31 Acid bath for reusable stainless steel and brass parts White distilled vinegar 109 gr Acid bath for reusable stainless steel and brass parts CAUTION DO NOT use strong acids for the cleaning of any parts These
4. 16 Using a 6mm hex wrench unscrew the Balancing Chamber 7 Separate the Piston 17 and all associated parts from the Balancing Chamber 14 13 3 eel 7 Remove the O Rings 31 26 from the Balancing Chamber then remove the white Back Pressure Ring 23 from inside the Balancing Chamber 9 Using a 6mm hex wrench unscrew and remove the Screw Handwheel DIN Fitting 9 Side off the Handwheel 25 10 Remove the Conical Filter Element 4 Use a 7 8 open end or adjustable wrench to remove the Retainer Handwheel 15 ti 11 Remove the O Ring 29 from the Retainer Handwheel 12 Using a 4mm hex wrench remove all port plugs 10 11 and their O Rings 27 28 a 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 13 REASSEMBLY PROCEDURES 2 Assembly of the Balancing Chamber side of the regulator Install a new lubricated O Ring 31 on the Balancing Chamber followed by the white Back Pressure Ring 23 Follow with another lubricated O Ring 26 Following the diagram assemble the Balancing Chamber in sequential order 1 Cap 13 2 Spring 3 3 Guide Ring 14 4 Piston 17 Bed With a 6mm hex wrench install the Balancing Chamber assembly into the Body 8 Install the Body into the vice mounting tool secure to t
5. 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 MCG111 or 129 Dress the o rings with a very light film of the O2 grease and remove any visible excess by running the o ring between thumb and forefinger Avoid applying excessive amounts of 02 grease as this will attract particulate matter that may cause damage to the o ring Table 4 Torque Specifications Table 5 Test Bench Specifications TEST CONDITION Leak Test 100 1100 psig HOB SLL Ho ze Not Responsible for Typographical Errors OMS LLC P O Box 146 Montgomery New York 12549 www omsdive com
6. OMS LLC TECHNICAL MAINTENANCE MANUAL R 600 FIRST STAGE Contents COPYRIGHT NOTICE INTRODUCTION WARNINGS CAUTIONS amp NOTES SCHEDULED SERVICE GENERAL GUIDELINES GENERAL CONVENTIONS DISASSEMBLY PROCEDURES REASSEMBLY PROCEDURES ADJUSTING THE FIRST STAGE FINAL ASSEMBLY TABLE 1 FIRST STAGE TROUBLESHOOTING GUIDE TABLE 2 RECOMMENDED TOOL LIST TABLE 3 RECOMMENDED LUBRICANTS AND CLEANERS PROCEDURE CLEANING AND LUBRICATION TABLE 4 TORQUE SPECIFICATIONS TABLE 5 TEST BENCH SPECIFICATIONS EXPLODED PARTS DRAWING COPYRIGHT NOTICE This manual is copyrighted all rights reserved It may not in whole or in be copied photocopied reproduced translated or reduced to any electronic medium or machine readable form without prior consent in writing from OMS LLC It may not be distributed through the internet or computer bulletin board systems without prior consent in writing from OMS LLC copyright OMS LLC OMS D 600 First Stage Service Manual INTRODUCTION This manual provides factory prescribed procedures for the correct service and repair of the OMS 600 first stage regulator Itis 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 OMS LLC Service amp Repair Seminar Ifyou do not comple
7. acids even when strong a residue that ly diluted can harm chrome plating and may leave is harmful to O ring seals and other parts DAWN blue dishwashing detergent diluted with warm Degreaser for brass and stainless steel parts general cleaning solution for plastic and Household grade water rubber Procedure For Cleaning amp Lubrication All OMS Regulators The R 600 First Stage and Nitrox This first stage when properly cleaned and assembled is authorized for use with enriched air nitrox EAN that does not exceed 40 EAN 40 This model is authorized for nitrox use because it has undergone adiabatic compression testing and the authorized service kit components and lubricants are compatible in elevated oxygen environments During cleaning a mild detergent must be used to remove hydrocarbons compressor oils from the inside passage ways of the first stage For the first stage to remain EAN40 compatible only use filtered compressed gas hydrocarbons lt 0 1 mg m 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 itis cleaned and serviced again Cleaning Brass and Stainless Steel Parts 1 Preclean in warm soapy water using a nylon bristle tooth brush Thoroughly clean paris in an ultrasonic cleaner filled with soapy water If there are stubborn de
8. aded parts including the yoke clamp connector 21 and diaphragm clamp 6 NEVER SECURE THE REGULATOR BODY DIRECTLY IN A VISE Instead installa vise mounting tool into the high pressure por then secure the vise mounting fot inthe vise T Jouda not have VIE mounting tool use an EXPIRED CO2 cartridge attached to high pressure adapter female to s male Never screw a CO2 directly into a low pressure port in case the neck of the CO2 cartridge breaks off leaving the threads stuck in the regulator 4 As the regulator is disassembled reusable components should be segregated and not allowed to intermix with non reusable parts or parts from other units Delicate parts including inlet fitings and crowns which contain critical sealing surfaces must be protected and isolated from other parts to prevent damage during the cleaning procedure 5 Use only genuine OMS LLC parts provided in the first stage overhaul parts Item DO attempt to substitute another manufacturer s part 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 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 permane
9. ead the Antifreeze Retaining Cap 6 onto the dry chamber until hand tight Using the face spanner wrench tighten the end cap until snug 3 Recheck the medium pressure to make sure itis still at 145 psi 4 Close the cylinder valve and depressurize the regulator Remove the test gauge and reinsert the port plug s This Ends Reassembly Table 1 Troubleshooting Guide 1 Piston 17 is worn or damaged 1 Replace piston 2 Crown 21 damaged 2 Replace crown orifice 3 Crown O ring 19 damaged or wom Replace O ring High pressure creep also causes second stage leaks HP plug 11 internal wall damaged 4 Replace HP plug 5 HP o ring 27 damaged or worn 5 Replace O ring 6 LP Plug O ring 28 damaged or worn 6 Replace O ring T Port plug o rings 27 28 worn or Pia 28 1 Replace o rings damaged 2 Membrane 22 wom or damaged 2 Replace membrane External air leakage 3 Membrane 22 worn or damaged 3 Replace membrane OF 4 Membrane 22 seating surface damaged 4 Replace body Secondary diaphragm distended burst 5 Antifreeze Membrane 21 loose 5 Tighten spring retainer 12 6 Connector O ring 29 or damaged 6 Replace o ring 29 7 Plug o ring 27 or damaged 7 Replace o ring 1 Cylinder valve not completely open 1 Open valve check fill pressure Restricted air flow or high inhalation 2 Cylinder valve
10. he bench vise and then proceed to tighten the Balancing Chamber assembly into the body Assembly of the Intermediate Pressure side of the regulator Insert Rod Guide 1 into the Piston Guide 16 Place Guide Plate 24 on top of the Piston Guide Tum the regulator to the side so the low pressure side is facing sideways Drop the Guide Plate 24 into the center hold of the stage body Press on the Guide Plate support several times Assembly should have spring tension Press new diaphragm 22 into the first stage body Insert Friction Ring 18 Make sure both Diaphragm and Friction Ring edges are set into the groove of the body Run your finger around the edge of the diaphragm to make sure it is properly seated Place the Spring Plate 19 flat side down in the center of the diaphragm Screw a vice mounting tool into the open port securing it in a vice with the Intermediate Ring 5 facing upward Use the face spanner wrench to tighten the Intermediate Ring until it stops Insert the Main Spring 2 into the Intermediate Ring 5 Thread the Adjustment Screw 12 into the Intermediate Ring until the first two threads are stil visible 9 Installing the DIN Adaptor ADJUSTING THE FIRST STAGE Install a new O Ring 29 into the face of the Retainer Handwheel 15 Insert the Retainer into the body and tighten it to 12 foot pounds ji Insert the conical end of the filter 4 i
11. he pressure gauge rapidly exceeds 160 psi there is HP leak Quickly close the cylinder valve and purge the regulator Refer to the troubleshooting table for the causes of HP leaks 4 Assuming there are no leaks adjust the low pressure by turning the adjustment screw turning in the adjustment screw increases LP tuming it out decreases LP the adjustment screw in 1 8 tum increments and cycle the relief valve several times after each adjustment When the LP is 135 psi cycle the gauge relief valve on and off 10 15 times After cycling watch the gauge needle The first stage LP should lock up at 145 psi Make any adjustments as necessary Allow the first stage to stay pressurized for several minutes and check the LP again to make sure it remains locked up at 145 psi If the LP creeps up more than 3 psi then there is a leak Refer to the troubleshooting table for possible causes 5 Close the cylinder valve and depressurize the regulator opening the gauge relief valve by pressing the second stage purge button Close the gauge relief valve and repressurize the system The LP should stil read 145 psi I the pressure reading is different than the original setting repeat steps 3 and 4 until the LP is stable FINAL ASSEMBLY 1 With the regulator stil pressurized insert the Pressure Piston 20 into the dry chamber Insert the Antifreeze Membrane 21 into the Antitreeze Retaining Cap 6 2 Thr
12. ntly damaged by undue stress GENERAL TERMINOLOGY The following terminology and techniques are assumed unless otherwise stated 4 When instructed to remove unscrew loosen a threaded part turn the part counterclockwise 2 When instructed to install screw in or tighten a threaded part turn the part clockwise 3 When instructed to remove an o ring use the pinch method see figure If possible or use a brass or plastic o ing removal tool Avoid using hardened steel picks as they may damage the o ring sealing surface All that are removed are discarded and replaced with brand new o rings Pinch Method Press upwards on sides of Oring to create protrusion Grab o ring or insert o ring tool at protrusion to remove The following acronyms are used throughout the manual LP is low pressure HP is High pressure IP is Intermediate pressure 5 Numbers in parentheses reference the key numbers on the ploded parts schematics For example in the statement temave the o ring 17 from the the number 17 is the key number to the plug o ring DISASSEMBLY PROCEDURES Note Before performing any disassembly refer to the exploded parts drawing which references all mandatory replacement parts Used parts must be replaced with new Old parts 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
13. nto the threaded end of the Retainer Handwheel 15 Slide on the Handwheel 25 Install a new lubricated O Ring 30 into the end of the Screw Handwheel 9 Use a 6mm hex wrench to tighten itto 12 foot pounds iv Install lubricated o ring 32 o ring groove of handwheel screw 90 WARNING Use eye protection for the next step in case of high velocity particulates ejecting out of valve during cleaning 1 Attach the first stage with no port plugs installed to a fully charged 2500 3000 psi cylinder Slowly open the cylinder valve to blow out any particulate 2 Install new lubricated o rings 27 28 on all port plugs 10 11 Install the port plugs using hex wrench but leave one LP open for the next test Note The primary LP port is 3 8 When adjusting the regulator install either 3 8 blanking plug 10 or a 3 8 hose with a properly adjusted second stage Alternatively you may use 3 8 female to 3 8 male adaptor attached fo the LP test gauge long as the test gauge has a built in pressure relief 3 Attach an LP test gauge 0 400 psi to alow pressure hose and thread the hose into an open LP port If your test gauge does not have an over pressurization relief valve you must attach a properly adjusted second stage to the first stage to act as the relief valve in case of an HP leak Make sure port plugs are installed in any open ports CAUTION If t
14. posits household white distilled vinegar or OMS Corrostop 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 oil free ow pressure 25 psi filtered 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 ete may be soaked and cleaned in a solution of warm water mixed with OMS or Dawn dish soap Use only a soft nylon brush to scrub away any deposits Rinse in fresh water and thoroughly blow dry using low pressure Tiered air Do not place plastic and rubber parts acid solutions Doing may cause parts to prematurely degrade and or break Cleaning Hoses 1f buildup of corrosion is severe it is permissible to soak only the hose fittings in the ultrasonic cleaner as needed using OMS not allow any solution to enter hose Rinse in fresh water and allow to dry with the cleaned ends hanging down Blow filtered air through them prior to installing onto the regulator Lubrication and
15. tely understand all of the procedures outlined in this manual contact Aqua Lung America to speak directly with a Technical Advisor before proceeding any further WARNINGS CAUTIONS amp NOTES special attention to information provided in wamings cautions and notes that are accompanied by one of these symbols WARNINGS indicate a procedure or situation that may in serious injury death if instructions are not followed correctly CAUTIONS indicate any situation or technique that will It in potential damage to the product or render the product unsafe if instructions are not followed correctly NOTES used to emphasize important points tips and reminders SCHEDULED SERVICE Ifthe regulator is subjected to less than 50 dives per year itis permissible to overhaul it every other year with an inspection procedure being performed on the of 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 Owners Manual to keep the Limited Lifetime Warranty in effect If a regulator is subjected to more than 50 dives per year it should receive the complete overhaul Official Inspection consists of 1 A pressurized immersion test of the entire unit to check for air leakage 2 Checking for stable intermediate pressure that is within the
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