ATX 200 FIRST STAGE
Contents
1. ABRE nn 4 REASSEMBLY ARAB 7 ADJUSTING THE FIRST 9 FINAL ASSEMBLY 9 TABLE 1 FIRST STAGE TROUBLESHOOTING GUIDE 10 TABLE 2 RECOMMENDED TOOL LIST RR 11 TABLE 3 RECOMMENDED LUBRICANTS AND 12 PROCEDURE A CLEANING AND 13 TABLE 4 TORQUE2. Authorized Technician TECHNICAL MAINTENANCE MANUAL ATX 200 FIRST STAGE Copyright 2002 Aqua Lung America Inc Rev 9 2002 2 Apeks ATX200 First Stage Service Manual Contents EUIS ERNEUT 3 MAOD T mad eis es E EM M p M A E EE 3 WARNINGS CAUTIONS amp 3 SCHEDULED 3 GENERAL 3 GENERAL CONVENT IONS ww NRI EUR MEER 4 DISASSEMBLY
3. 14 TABLE 5 TEST BENCH SPECIFICATIONS RR RR RR SER RR RR 14 EXPLODED PARTS DRAWING 2 15 COPYRIGHT NOTICE 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 com puter bulletin board systems without prior consent in writing from Aqua Lung America 2002 Aqua Lung America Inc Apeks ATX200 First Stage Service Manual INTRODUCTION This manual provides factory prescribed procedures for the correct service and repair of the Apeks ATX 200 first stage regulator 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 Apeks Service amp Repair Seminar If you do not completely under stand 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 Pay special attention to information provided in warnings cautions and notes that are
4. 12 and 17 from the HP plug 18 Using a brass o ring tool remove the o ring 16 from inside the HP plug CAUTION Before proceeding make sure you 10 are working over a padded work surface oth erwise the crown 9 may be damaged during removal Insert a 1 8 wooden dowel into the center hole on the low pressure side diaphragm side of the first stage body While keeping the dowel slightly tilted press on the inside edge of the crown While pressing the crown out of the body prevent the crown from tilting by pressing evenly around the perimeter of the crown If the crown tilts insert the wooden dowel into the HP side and straighten the crown Once the crown is out remove the o ring 12 from the crown If the first stage has a yoke go to step 11A if it has a DIN con nector go to step 11B 11A Removing the Yoke Secure the vise mounting tool into a bench vise with the yoke facing upward Unscrew the yoke screw 24 and remove the dust cap 22 from the yoke Using a 3 4 box end wrench unscrew the yoke connector 20 Loosen the vise and remove the first stage Remove the vise mounting tool from HP port 11 12 Remove the o ring 12 from the bottom of the inlet fitting Go to step 12 for instructions on removing the filter Remove the DIN fitting Secure the vise mounting tool into a bench vise with the DIN adapter facing upward Remove the protective DIN cap 32 Using a 6
5. Seat Crown 37 AP1409 O ring 14 AP1419 H P Valve 15 AP1415 Spring 16 AP1299 O ring 17 AP1300 O ring Part numbers in BOLD ITALICS indicate standard overhaul replacement 18 AP5309 Balance Plug part 19 AP1403 S Yoke Clamp 20 AP1407 S Yoke Connector Distributed in the USA by Aqua Lung America Inc 2340 Cousteau Court Vista California 92083 www aqualung com Rev 9 2002
6. 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 tech A nique that will result in potential damage to the product or render the product unsafe instructions are not followed correctly NOTES are used to emphasize important points tios 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 Lifetime Warranty in ef fect If a regulator is subjected to more than 50 dives per year it should receive the complete overhaul An 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 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 A visual inspection of the filter for debris or discoloration 6 A visual inspection of t
7. could result in leakage Once an o ring sealing surface has been damaged the part must be replaced with new DO NOT use a dental pick or any other steel instrument 2 Using a face spanner Apeks ATX200 First Stage Service Manual 1 Remove the hoses from the first stage using the appropriate sized wrenches Install spare HP and MP port plugs into the empty ports except for one MP port and one HP port wrench unscrew the end cap 1 3 With your finger remove the secondary diaphragm 2 from the end cap Turn the first stage over so the piston 4 falls out into your hand yY Y 3 4 Using an 6mm hex wrench unscrew and remove adjustment screw 5 Lift out the main spring 7 5 Install the vise mounting tool pn 100395 into one of the HP ports Secure the vise mounting tool in a bench vise with the diaphragm clamp 6 facing upward Using a face spanner wrench unscrew the diaphragm clamp from the body Lift out the spring pad 8 Remove the first stage from the vise 7 remove the diaphragm 9 insert a low pressure air nozzle into the open MP port While holding your thumb over the diaphragm inject a small blast of air into the MP port to pop out the diaphragm Lift out the valve lifter 10 8 Using an 6mm hex wrench unscrew the HP plug 18 Separate the HP seat 14 and spring 15 from the HP plug 9 Remove the o rings
8. 000 psi cylinder Slowly open the cylinder valve and blow through the first stage to remove any particles or contaminates 2 Install new lubricated o rings 28 29 12 on all the port plugs 27 30 31 Install the port plugs using a 5mm hex wrench Note The primary MP port is 1 2 When adjusting the regulator install either a 1 2 blanking plug 30 or a 1 2 hose with a properly adjusted second stage Alternatively you may use a 3 8 female to 1 2 male adapter attached to the LP test gauge as long as the test gauge has a built in pressure relief 3 Attach a MP test gauge 0 to 400 psig to a medium pressure hose and thread the hose into an open MP port If your test gauge does not have an over pressure relief valve you must also attached a properly adjusted second stage to the first stage to act as the relief valve in case of a HP leak Make sure port plugs are installed in any open ports CAUTION If the pressure gauge rapidly ex ceeds 160 psi then there is a HP leak Quickly close the cylinder valve and purge the regula tor Refer to the troubleshooting table for the causes of HP leaks 4 Assuming there are no leaks adjust the medium pressure by turning the adjustment screw Turning in the adjustment screw increases the MP turning out the adjustment screw decreases the MP Turn the adjustment screw in 1 turn increments and cycle the relief valve several times after each adjustment When th
9. al 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 Muriatic AN acid even when strongly diluted 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 13 Procedure Cleaning amp Lubrication All Aqua Lung Regulators The ATX200 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 authroized service kit components and lubricants are compatible in elevated oxygen environments During cleaning a mild detergent must be used to remove condensed hydrocarbons compressor oils from the inside passage ways of the first stage For the first stage to remain EAN40 compatible only use hyperfiltered compressed gas hydrocarbons lt 0 1 mg m Ordinarry compressed breathing air Grade E usually does not meet this criterion Once ordinary breathing ai
10. e purging regulator 15 Exploded Parts Drawing cg Note In September 2002 the ATX200 first stage transitioned from a hi gloss black chrome finish to a satin chrome finish Specifi cally the parts affected are key item 1 11 19 and 20 These parts will no longer be available in black chrome Should you need to replace one of these you will need to order the part in satin Key Part Description Key Part Description 0210 1st Stage only w Yoke 21 AP1406 1 Filter Guard AP0211 S DIN Kit 22 AP1404 Protective Cap 241 Service Kit Diaphragm First Stage 23 AP1166 O ring 24 AP1400 Yoke Clamp Screw 1 AP1484 S Environmental End Cap 25 AP5015 Decal 2 AP1482 Hydrostatic Diaphragm 26 AP5723 Decal 3 AP5724 Decal 27 AP1413 7 16 Blanking Plug 4 AP1483 Hydrostatic Transmitter 28 AP1445 O ring 5 AP1474 Spring Adjuster 29 AP1410 O ring 6 AP1473 Diaphragm Clamp 30 AP1487 1 2 Blanking Plug 7 1475 Spring 31 AP1408 3 8 Blanking Plug 8 AP1476 Spring Carrier 32 AP1264 Protective Cap DIN 9 AP1478 Diaphragm 33 AP1166 O ring 10 AP5722 Valve Lifter 34 AP1471 S Handwheel Connector Satin 11 AP5720 S Valve Body 35 AP1470 S Handwheel 300 Bar Satin 12 AP1409 O ring 36 AP1472 Conical Filter 13 AP5721 Removable H P Valve
11. e MP is 135 psi cycle the gauge relief valve on and off 10 15 times After cycling watch the gauge needle The first stage MP should lock up at 135 psi Make any adjustments as necessary Allow the first stage to stay pressurized for several minutes and check the MP again to make sure it remains locked up at 135 psi If the MP creeps upward more than 3 psi then there is a leak Refer to the troubleshooting table for possible causes Close the cylinder valve and depressurize the regulator by opening the gauge relief valve or by pressing the sec ond stage purge button Close the gauge relief valve and repressurize the system The MP should still read 135 psi If the pressure reading is different than the original setting repeat steps 3 and 4 until the MP is stable FINAL ASSEMBLY With the regulator still pressurized insert the piston 4 into the dry chamber Press the secondary diaphragm 2 into the end cap 1 Thread the end cap 1 onto the dry chamber until hand tight Using the face spanner wrench tighten the end cap until snug Recheck the medium pressure to make sure it is still at 135 psig Close the cylinder valve and depressurize the regulator Remove the test gauge and reinstall the port plug s This Ends Resassembly 10 Apeks ATX200 First Stage Service Manual Table 1 Troubleshooting Guide SYMPTOM POSSIBLE CAUSE TREATMENT 3 Crown O ring 12 damaged or worn 4 HP plug 18 inter
12. ew it into the first stage body until finger tight Secure the first stage back in the vise with the yoke facing upward Attach a 3 4 box wrench adapter to a foot pound torque wrench Tighten the yoke connector to 12 foot pounds 9B Apeks ATX200 First Stage Service Manual With the logo side facing outward attach the dust cap 22 by stretching it over the flange located at the top of the yoke Thread the yoke screw 24 into the yoke Remove the first stage from the vise and remove the vise mounting tool Installing the DIN Adapter Install a new o ring 33 into the face of the DIN connector Insert the conical end of the filter 36 into the threaded end of the DIN connector 34 Install a new lubricated o ring 12 into the end of the DIN connector around the filter Remove the first stage from the vise Hold the first stage with the inlet opening facing downward Insert the threaded end of the DIN connector through the threaded side of the handwheel 35 and screw it into the first stage body until finger tight Secure the first stage back in the vise with the DIN connector facing upward Attach a 6mm hex key to a foot pound torque wrench Tighten the DIN connector to 12 foot pounds Remove the first stage from the vise and remove the vise mounting tool ADJUSTING THE FIRST STAGE 1 Attach the first stage with no port plugs in stalled to a fully charged 2500 to 3
13. g tool in the vise If you do not have a vise mounting tool use an EXPIRED CO cartridge attached to a high pressure adapter female to 74e male Never screw a CO directly into a low pressure port in case the neck of the CO cartridge breaks off leaving the threads stuck in the regulator 3 As the 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 first stage overhaul parts kit PN APO241 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 techniques are assumed 1 When instructed to remove unscrew or loosen a thread ed part turn t
14. he 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 In order to correctly perform the procedures outlined in this manual it is 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 learn which specialty tools and replacement parts will be required Keep the manual open beside you for reference while performing each procedure Do not rely on memory 2 All service 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 regulator body will need to be secured in a vise when removing certain threaded parts including the yoke clamp connector 21 and diaphragm clamp 6 NEVER SECURE THE REGULATOR BODY DIRECTLY IN A VISE Instead install a vise mounting tool PN 100395 into the high pressure port then secure the vise mountin
15. he 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 ring removal tool Avoid using hardened steel picks as they may damage the o ring sealing surface All o rings that are removed are discarded and replaced with brand new o rings Pinch Method Press upwards on sides of o ring to create protrusion Grab o ring or insert o ring tool at protrusion to remove S 4 following acronyms are used throughout the manual MP is Medium Pressure HP is High Pressure IP is Inter mediate Pressure 5 Numbers in parentheses reference the key numbers on the exploded parts schematics For example in the state ment remove the o ring 17 from the the number 17 is the key number to the HP plug o ring DISASSEMBLY PROCEDURES Note Before performing any disassembly refer to the 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 PN 944022 when removing o rings to prevent damage to the sealing surface Even a small scratch across an o ring seal ing surface
16. irst stage body Run your finger around the edge of the diaphragm to make sure it is properly seated Place the spring pad 8 flat side down in the center of the diaphragm Set the main spring 7 on the spring pad 3 Press the spring 15 onto the end of the HP plug 18 Pass the stem of the HP seat 14 through the spring and press it into the HP plug Insert this assembly into the body 11 and tighten the HP plug to 12 ft lbs using a 6mm hex key attached to a torque wrench Thread the diaphragm clamp 6 onto the body until hand tight Thread the adjustment screw 5 into the dia phragm clamp until the first two threads are still visible Screw a vise mounting tool into the open HP port and secure it in a vise with the diaphragm clamp facing upward Using the face spanner wrench tighten the diaphragm clamp until it stops metal meets metal If the first stage has a yoke go to step 9A if it has a DIN con nector go to step 9B 9A Installing the Yoke Insert the conical end of the filter 36 into the threaded end of the yoke connector 20 Install a new lubricated o ring 12 into the end of the connector around the filter Press the filter shield 21 raised tabs facing outward into the end of the yoke connector 20 Remove the first stage from the vise Hold the first stage with the inlet opening facing downward Pass the yoke connector 20 through the yoke 19 and scr
17. it is permissible to soak only the hose fittings in the ultrasonic cleaner as needed and not allow any solution to enter the 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 Dressing Wear powderless latex gloves when handling and lubricating o rings Keeping internal parts free from skin oils and other contami nates 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 dishwashing detergent diluted in warm water 14 Apeks ATX200 First Stage Service Manual Table 4 Torque Specifications PART NUMBER DESCRIPTION KEY NUMBER AP1407 BK AP1407 S Yoke Connector 20 12 foot lbs 4 AP1471 S DIN Connector 3 12 foot Ibs AP5309 HP Plug 18 12 foot Ibs AP1413 AP1408 HP Port Plug 27 LP Port Plug 31 16 18 inch pounds Table 5 Test Bench Specifications TEST CONDITION ACCEPTABLE RANGE Inlet 2 500 3 000 100 psig No leaks allowed Medium Pressure Creep Inlet 2 500 3 000 100 psig Sep
18. mm hex wrench unscrew the DIN connector 34 Remove the handwheel 35 Using an 1 8 wooden dowel or similar sized tool push the filter 36 out of the DIN con nector Remove the filter o ring 12 Remove the o ring 33 from the face of the DIN connector Removing the filter NOTE Up until September 2002 Apeks used a white disc filter known as the Porvair filter p n AP 1406 in its first stages that utilized a yoke connector While Por vair was an excellent filter for air it was determined that it was not the best material for use with enriched air nitrox EAN Since Apeks preferred all of its models to be EAN40 compatible new out of the box the Porvair filter was discontinued Apeks standard conical filter p n AP1472 as used with the DIN connection was sub stituted Please note that where the Porvair filter was loaded into the front of the yoke connector the conical Apeks ATX200 First Stage Service Manual filter gets loaded from the back of the connector See Heassembly Procedures for details To enhance the cosmetics of a regulator inlet that had a conical filter a new filter guard AP1406 1 was designed to install into the front of the connector Do not mistake the filter guard as a filter It is to be used only in conjunction with the conical filter Use the following pictures in steps A amp B to determine which filter is installed If the yoke connector 20 has a porvair filter go to s
19. nal wall damaged 5 HP O ring 16 damaged or worn 6 HP Plug O ring 12 damaged or worn 1 Port plug o rings 12 28 29 worn or damaged 2 Diaphragm 9 worn or damaged External air leakage 3 Diaphragm 2 worn or damaged vL 4 Diaphragm seating surface damaged UI diaphragm distended or 5 Bhewhwen 5 osse 6 Connector O ring 37 worn or damaged 7 HP Plug o ring 17 worn or damaged 1 Cylinder valve not completely open 2 Cylinder valve needs service 3 Filter 36 is clogged 1 HP Seat 14 is worn or damaged High pressure creep also causes second stage leaks Restricted air flow or high inhalation resistance through entire system 11 Table 2 Recommended Tool List PART NO DESCRIPTION APPLICATION n a Connector removal n a Connector installation w torque wrench n a HP plug DIN connector removal n a HP Plug DIN connector installation w torque wrench n a Crown Filter removal 12 Apeks ATX200 First Stage Service Manual Table 5 Recommended Lubricants amp Cleaners LUBRICANT CLEANER APPLICATION Christo Lube MCG 1 11 All O rings seals Aqua Lung PN 820466 or Lubrication Technologies 310 Morton Street Jackson 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 break down and premature deterioration of the materi
20. r is used the first stage is no longer EANAO compatible until it is cleaned and serviced again 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 dis tilled 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 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 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 prop erties of the component causing it to prematurely degrade and or break Cleaning Hoses If buildup of corrosion is severe
21. tep 12A if it has a conical filter 36 and filter guard 21 go to step 12B A B 13 Removing the Porvair filter Insert a dowel through the open end of the yoke clamp connector 21 and push out the filter Removing the Conical Filter and Filter Guard Remove the filter 36 and filter o ring 12 Using an 1 8 wooden dowel or similar sized tool push the filter guard 21 out of the connector Using a 5mm hex wrench remove all the port plugs 27 30 31 and their o rings 28 12 29 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 1 Install a new lubricated o ring 12 onto the crown 13 Slide the crown onto the seat installation tool with the sealing edge against the plastic handle Insert the crown into the body and press it into place Use the blunt end of the seat installation tool to make sure the crown is properly seated 2 Install a new lubricated o ring 16 into the end of the HP plug 18 Install new lubricated o rings 12 amp 17 on the HP plug Turn the regulator over so the medium pressure side is facing upward Drop the valve lifter 10 through the center hole Press on the pin support several times It should feel like a spring loaded button Press a new diaphragm 9 into the f
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