Gauge Consoles
Contents
1. Replace Contents Gauge 5 3 Damaged Blocked or worn HP Hose 2 3 Replace HP Hose 2 1 7 16 Male O ring damaged 1 1 Replace O Ring 1 2 Nipple connection O rings eee damaged 3 2 Replace O Rings 3 Gauge Console Leaking Air 2 Nipple 4 Damaged 2 Replace Nipple 4 3 Damaged HP Hose 2 3 Replace HP Hose 2 4 Damaged Contents Gauge 5 4 Replace Contents Gauge 5 1 Blocked Depth Pressure water 1 Clean Depth Gauge 10 Depth Gauge needle not moving or Intakes 10 reading incorrectly 2 Damaged Depth Gauge 10 2 Replace Depth Gauge 10 1 Close to other Magnets 1 Remove Magnetic Source Compass not reading correctly or leaking fluid 2 Damaged Compass 9 2 Replace Compass 9 11 A PEI CE Maintenance Manual Table 2 Recommended Tool List PART NO DESCRIPTION APPLICATION O Ring Removal Tool Removing O Rings 1 2 Open Ended Spanner Removal Reattachment of HP Hose AP7610 from to Contents Gauge 14mm Open Ended Spanner Removal of HP Hose AP7610 from Contents Gauge 14mm Crows Foot Reattachment of HP Hose AP7610 to Contents Gauge Torque Wrench Reattachment of HP Hose AP7610 to Contents Gauge Notes 1 Photos not to scale 2 Actual tools may differ from photos 14mm Crows Foot to suit Torque Wrench 12 Q Gauge Consoles Maintenance Manual Table 3 Recommended Lubricants amp Cleaners LUBRICANT CLEANER APPLICATION SOURCE Chri2. combustion Therefore if a Gauge Console has had use with Grade E or EN 12021 breathing air or become contaminated it cannot be used again with oxygen levels with a greater partial pressure of oxygen 2196 The gauge cannot be re cleaned using any type of oxygen cleaning method This is due to the gauge internal mechanism Once contaminated it can never be used again for oxygen levels greater than 21 WARNING Please check the regulations regarding Nitrox in your particular country as this may differ from Apeks standard policy 14 Q Gauge Consoles Maintenance Manual Table 4 Torque Specifications PART NUMBER DESCRIPTION KEY NUMBER TORQUE AP7610 Thermoplastic HP Hose 800mm Long 14Nm 10 31bs ft NOTE Table 4 Torque Specification refers to the female 7 16 UNF Thread Nut only See the appropriate 1st Stage user manual for the Correct Torque for the Male 7 16 UNF Thread of HP Hose AP7610 Table 5 Test Bench Specifications TEST ACCEPTABLE RANGE Pressure Reading Tolerances 50 bar or 5 bar 100 bar or 10 bar Q 200 bar or 10 bar 300 bar or 15 bar Accuracy of Contents Gauge 5 15 A PEI Consoles Maintenance Manual AP0633 Single Contents Gauge Exploded Parts Diagram v All marked items must be replaced when serviced Thermoplastic HP Hose 800mm Long O Ring APEKS Contents Gauge Metric JAP5745 APEKS Contents Gauge Imperial 6 AP5701 X Conten
3. 6 away from the Bezel 7 as shown below prior to disassembly will assist with the ease to which the boot 6 can be removed from the bezel 7 3 Using a 14mm open ended spanner on the HP Hose nut 2 and a 1 2 open ended spanner on the Contents Gauge 5 undo the assembly CAUTION Avoid using a screw driver or pry bar as damage to components could OCCU Gauge Consoles Maintenance Manual 1 To remove a damaged HP Hose 2 pull the HP Hose 2 from the Boot 6 in the direction shown Dismantled Assembly 2 To remove the compass 9 from the Housing either for adjustment Diver preference Left Hand Right Hand or Central or replacement of a damaged unit 4 Using an O Ring removal tool PN AT54 remove the two O rings 3 from the nipple 4 3 Peel the edge of the Boot 6 from around the Compass 9 prior to disassembly will assist with the ease to which the Compass 9 can be removed from the Boot 6 9 Using an O Ring removal tool PN AT54 remove the O ring 1 from the 7 16 Male thread of the HP Hose CAUTION Avoid using a screw driver or 2 pry bar as damage to components could occur 6 Visually inspect HP hose 2 for damage This Ends Disassembly For General Service e This Ends Disassembly REASSEMBLY PROCEDURES Before starting reassembly perform parts cleaning NVapers Gauge Consoles Maintenance Manual and lubrica
4. Compass 9 rotates and tilts freely within its housing and the Bezel is easy to adjust If a Gauge Console fails any of the 4 steps it should be fully serviced 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 and to learn which specialty tools and replacement parts will be required before commencing disassembly Keep the manual open beside you for reference while performing each procedure Do not rely on memory 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 During disassembly reusable components should be segregated and not allowed to intermix with non reusable parts or parts from other units Cleaning the inside of the Contents Gauge 5 must be avoided during the cleaning procedure Use only genuine Apeks parts DO NOT attempt to substitute an Apeks part with another manufacturer s regardless of any similarity in shape or size 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 When reassembling it is important to follow every torque specificatio
5. DER SUPPORT MAINTENANCE MANUAL FOR COMPETENT TECHNICIANS Issue 1 Document No AP 5929 26 11 09 APEKS MARINE EQUIPMENT LTD NEPTUNE WAY BLACKBURN LANCASHIRE BB1 2BT Tel 0044 0 1254 692200 Fax 0044 0 1254 692211 E mail info apeks co uk Web www apeks co uk A PEI Consoles Maintenance Manual AMENDMENTS RECORD Amendments and approval of this document can only be carried out by the relevant people listed on the Approved list of signatures which is listed in the Apeks Quality Manual To instigate a change a Task Change request form Form No DESI 10002 must be completed and passed to the relevant person s for approval which are listed on the Approved List of Signatures When approval has been granted and recoreded this table can then be completed and the document up issued Change Change Description amp Comments Change New Issue Changed Approved No Request No Date No By By Q Gauge Consoles Maintenance Manual Contents ead cus 9I le 4 Je Ce e G IR B T r OI 4 WARNINGS CAUTIONS amp NOTES Keenan id the puia mia ale tuletas ic sai apis nid sau aas en aa 4 SE el RUE GR Mn eee eee 4 CENERAEGUDE LINE Sc 4 GENEKAE CONVENTION n a 5 DISASSEMBLY PROCEDURE ee en aa Rn Ne mada luu NA ME onani ant 5 REASSE
6. MBLY PROCEDURES ee ee ne aa abi 8 TES TINC PROCEDUR E se ae nona baba 10 TABLE T TROUBLE SHOOTING GUIDE ee ee en 11 TABLE 2 RECOMMENDED TOOL LI Store ni tenan nalar uan aa ana 12 TABLE 3 RECOMMENDED LUBRICANTS AND CLEANERS oo sess hene aa 13 CLEANING AND LUBRICATION PROCEDURE cece cece tetera etter ee eee aera eae hh nnns nnn natn n nnn nn nn nnn nnne nnns 14 TABLE 4 TOROUVUE SPECIFICA MON LE 15 TABLE EM W EE er ei MR e LE 15 EXPLODED PARTS DRAWING ees pa an ae st ii la aa 16 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 Apeks Marine Equipment Ltd It may not be distributed through the internet or computer bulletin board systems without prior consent in from Apeks Marine Eguipment Ltd 2010 Apeks Marine Equipment Ltd Gauge Console Maintenance Manual AP5929 Issue 1 INTRODUCTION This manual provides prescribed procedures for the correct maintenance and repair of the Apeks Gauge Console Range The procedures outlined within this manual are to be performed only by competent personnel If you do not completely understand all of the procedures outlined in this manual contact Apeks to speak directly with a Technical Advisor before proceeding any further WARNINGS CAUTIONS amp NOTES Pay special attention to
7. aPresb Apeks Insert Logo Pink L aPrsesv JApeks A insert Logo Yeo 8 NA p japsrae APEKSDephGaugelmpeta 18 Q Gauge Consoles Maintenance Manual AP0636 Contents Gauge Depth Gauge Compass Exploded Parts Diagram fg EE Sc e El DI E n n All marked items must be replaced when serviced Tapsras APEKS Contents Gauge Imperial e Psrs Contents Depth Compass Boot 7 AP5709 6 Contents Depth Bezel Green aPBTONP Contents Depth Bezel Pink 8 aPrS99B Aeeke WiserlogoiBla lees JApeks A insert Logo Gree japrsse Apeks A insert Logo Pno aeres Apeks A insert Logo Yellow o AP5706_ APEKS Compass AP5746 APEKS Depth Gauge imperil 19 Notes F TECHNICAL SUPPORT Gauge Consoles MAINTENANCE MANUAL FOR COMPETENT TECHNICIANS Apeks Marine Equpment Ltd Neptune Way Blackburn Lancs England BB1 2BT
8. ble because each Console is built to a high standard of cleanliness using EAN compatible components and lubricants In addition each Gauge design has passed stringent adiabatic compression testing to ensure its safety and compatibility with increased percentages of oxygen If it is your intention to use your new Apeks Nitrox Gauge Console with Nitrox EAN It is imperative that you maintain the internal cleanliness of the Gauge If it is your intention to use the Gauge Console interchangeably with breathing air the breathing air should be oxygen compatible or hyperfiltered where the condensed hydrocarbons do not exceed 0 1 mg m3 Your local authorised Apeks dealer can help you determine whether the breathing air that they provide meets this criterion Standard compressed breathing air meeting the EN 12021 standard often referred to as Grade E in the United States does not necessarily meet this criterion Grade E or EN 12021 breathing air may contain a certain level of hydrocarbons including traces of compressor oils that while not considered harmful to breathe can pose a risk in the presence of elevated oxygen content Passing hydrocarbons through a valve and regulator creates a cumulative effect where the hydrocarbons build up over time along the internal passageways of the equipment this is the same for your gauge too When these hydrocarbons come into contact with high pressure oxygen enriched air they can pose a very real hazard that can lead to
9. erforming any tests involving Compressed air Reattach to the first stage regulator with at least one second stage installed slowly open the cylinder valve holding the Contents Gauge 5 dial face away from your body until the valve is completely open Check Contents Gauge 5 reading matches the pressure contents of the cylinder or test bench Completely Submerge the Gauge Console and first stage in fresh water and check for leaks Do not confuse bubbles from trapped air within the housing with a true air leak If there is an air leak bubbles will come out in a steady constant stream Assuming there are no leaks close the cylinder valve and depressurise the equipment After the system is completely vented ensure the Contents Gauge 5 is reading Zero If readings are inconsistant the Contents Gauge 5 will need to be replaced If a leak is detected note the source of the leak and refer to the troubleshooting table on page 11 for possible corrective actions Check the Compass 9 rotates and tilts correctly is free from oil leaks and the Bezel and ratchet system rotates freely Any damage will require the unit to be replaced This Ends Testing 10 Q aPEKE Maintenance Manual Table 1 Troubleshooting Guide SYMPTOM POSSIBLE CAUSE TREATMENT Tone SI SHENG I rele 1 Open Valve Check fill pressure open i Contents Gauge needle not moving 2 Damaged Blocked Contents or reading incorrectly Gauge 5 2
10. information provided in warnings cautions 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 product or render the product unsafe if instructions are not followed correctly are used to emphasise important points tips and reminders SCHEDULED SERVICE Itis recommended that the Apeks Gauge Consoles should be rinsed in fresh water after use the operation of the Contents Gauge and Compass should be checked before each dive If a fault or leak occurs this document illustrates the steps required to service and rectify any faults However If at all unsure about the correct functioning of the Apeks Gauge Console then it must be officially inspected immediately Q Gauge Consoles Maintenance Manual An Official Inspection consists of Testing instructions see page 10 Checking that all parts are assembled correctly and that no parts are loose A visual inspection of the High Pressure Hose 2 looking for wear or damage and checking the general condition especially around the ferrules A visual inspection of the HP Hose 2 Gauges 5 10 and Compass 9 for damage Leaks and checking the general condition Check the Gauges 5 and 10 needles point to Zero when not in use Check the
11. n prescribed in this manual using a calibrated torque wrench WARNING Once the Contents Gauge 5 has been used with Standard breathing Gas the gauge cannot be used for Oxygen Levels above 21 unless the breathing air is oxygen compatible or hyperfiltered where the condensed hydrocarbons do not exceed 0 1 mg m3 GENERAL CONVENTIONS Unless otherwise instructed the following terminology and techniques are assumed 1 When instructed to remove unscrew or loosen a threaded part turn the part anti clockwise 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 below if possible or use a brass aluminium or plastic O Ring removal tool Avoid using hardened steel picks as they may damage O Ring sealing surfaces 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 a protrusion Grab O Ring or insert O Ring tool at protrusion 4 The following acronyms are used throughout the manual HP is High Pressure PN is Part Number 5 Numbers in parentheses reference the key numbers on the exploded parts schematics For example in the statement remove O ring 3 from the number 3 is the key number to the Nipple O Ring DISASSEMBLY PROCEDURES NOTE Before performing any disassembly refe
12. r 7 tothe 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 brass or aluminium O Ring removal tool PN AT54 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 damaged the part must be replaced with new DO NOT use a dental pick or any other steel instrument Gauge Consoles Maintenance Manual APEKS Gauge Console Range AP0633 Single Contents Gauge AP0634 Contents Gauge with Compass m a AP0635 Contents Gauge and Depth Gauge AP0636 Contents Gauge Depth Gauge and Compass Gauge Consoles Maintenance Manual Bezel 7 separated from the boot 6 Depth Gauge 10 removed from Bezel 7 LA M The APEKS Gauge Console range share identical parts and are assembled and disassembled in the l i m same sequence additional parts Colours differentiate 2 Pull the Contents Gauge Assembly clear of the boot the various models for ease of writing this manual 6 AP0636 Model has been chosen as this contains the full compliment of components Removal of the Bezel 1 Peelthe boot
13. sto Lube MCG 111 All O Ring seals Apeks Marine Equipment Ltd Lubricant PN AP1495 or Lubrication Technologies 310 Morton Street Jackson OH 45640 USA 800 477 8704 CAUTION Silicone rubber reguires no lubrication or preservative treatment DO NOT apply grease or spray to silicone rubber parts eg Diaphragm Exhaust Valves Doing SO may cause a chemical breakdown and premature deterioration of the material Biox Biological immersion fluid for Solent Divers Ltd Cleaning agent reusable stainless steel and brass 122 128 Lake Rd Portsmouth parts Hants PO1 4HH White distilled vinegar 100 gr Acid bath for reusable stainless Household grade Cleaning agent steel and brass parts CAUTION Do not use muriatic acid for the cleaning of any parts Even if strongly dilutec 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 Cleaning agent solution for plastic and rubber CAUTION Do not clean the inside of the Contents Gauge 5 Once the Contents Gauge 5 has been used with standard breathing Air it cannot be used for Oxygen levels greater than 21 13 A PEI Consoles Maintenance Manual Cleaning amp Lubrication Procedure General Cleaning of all Parts 1 Both the Nipple 4 and the Hose 2 can be placed in an
14. tion according to the procedures outlined in Cleaning amp Lubrication on page 14 1 Replace O Ring 1 on HP Hose 2 2 Replace the two O Rings 3 on the Nipple 4 3 Torgue HP Hose nut to 14Nm or 10 3 Ibs ft 4 5 6 T Push replacement HP Hose 2 if reqiured Through Boot 6 as shown above Pull Contents Gauge assembly part way through Boot 6 PP Align Depth Gauge 10 recess Green Arrow with Pip Red Arrow on Bezel 7 Test location by gently twisting Depth Gauge 10 in the Bezel 7 No movement should occur Gauge Consoles Maintenance Manual REASSEMBLY OF THE COMPASS 8 Place Bezel 7 over Contents Gauge 5 1 Align Compass 9 Lug Red Arrow with Boot recess Green Arrow 9 Place Bezel 7 nose first into the boot 6 Checking the location as shown by the above red arrow 2 Align Compass lubber line Red Arrow with Boot Detail Green Arrow Left Hand Configuration Shown and push Compass 9 into Boot 6 10 Push the boot 6 over the Bezel 7 11 Check the Bezel 7 is fitted correctly into the boot 6 This Ends Reassembly Compass 9 Central Configuration 9 Q Gauge Consoles Maintenance Manual Gauge Console Tests WARNING Compressed air can be highly explosive and is dangerous if misused Ensure cylinder valve is opened slowly Use Eye and Ear Personal Protective Equipment when p
15. tsBoot APS7O2G ContensBezelGren APS702P ContensBezelPink S AP5702NP Contents Bezel Nitrox Green S 8 AP759008 Apeks A Insert Logo Black oJaprs96 6 Apeks A Insert Logo Green 0000 APz590P jApeks A metlogo Pin 000000000 AP7596Y Apeks A Insert Logo Yelow 16 Q Gauge Consoles Maintenance Manual AP0634 Contents Gauge Compass Exploded Parts Diagram x All marked items must be replaced when serviced O Rin Thermoplastic HP Hose 800mm Long O Ring Nipple 1AP5745 APEKSContentsGaugelmperiad S 6 AP5731 ContentsCompassBoot APS702G ContentsBezelcren 0 1AP5702P ContensBezelPink S 8 AP7596B Apeks A InsertLogo ch AP7590G Apeks A Insert Logo Green 1 AP7590P L peks A Insert Logo nk AP7590 Y Apeks A Insert Logo Yellow 9 Japan APEKS Compass 17 A PEI Consoles Maintenance Manual AP0635 Contents Gauge Depth Gauge Exploded Parts Diagram All marked items must be replaced when serviced Tapsras APEKS Contents Gauge Imperlal e asoa Contents Depth Boot AP5703 6 Contents Depth Bezel Green L aPSTONP Contents Depth BezelPink a aPr99B Apets Ar insert Logo Black aeree JApeks A Insert Logo Gree L
16. ultrasonic cleaning bath containing an appropriate cleaning solution such as Biox 2 All plastic and rubber components such as Bezel Compass Depth Gauge and Boot must be cleaned in soapy water 3 The components should be cleaned for 6 minutes depending upon their condition Longer cleaning times may be used if required 4 Rinse the components in warm fresh water 5 The components should then be blown dry or left to dry naturally WARNING DO NOT allow any cleaning fluid or water to enter the Contents Gauge This component must be wiped clean with a lint free cloth WARNING Once the Contents Gauge 5 has been used with Standard breathing Gas the gauge cannot be used for Oxygen Levels above 21 unless the breathing air is oxygen compatible or hyperfiltered where the condensed hydrocarbons do not exceed 0 1 mg m3 The Contents Gauge 5 cannot be re cleaned using any type of oxygen cleaning method Lubrication and Dressing 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 Enriched Air Nitrox Oxygen Use Your Apeks Nitrox Gauge Console has been prepared for use with Enriched Air Nitrox EAN and 100 Oxygen This is possi
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