Balanced Diaphragm First Stage Manual
Contents
1. 12 FINAL ASSEMBLY AND TESTING 12 TABLE 1 TROUBLESHOOTING 14 TABLE 2 REQUIRED TOOLS 14 EXPLODED PARTS DIAGRAM 15 3 BEFORE STARTING WARNING This manual is not a training document It is meant to be a guide for experienced technicians who have also received factory training at a Cressi sanctioned repair seminar Do not attempt to repair this or any regulator without the proper train ing Before starting Cressi recommends that you read through the entire manual to familiarize yourself with all the required tools and techniques Use this manual as a guide during the servicing process to avoid missing any critical steps Make sure the work area is clean and that you work over a cushioned work surface so critical parts do not get damaged Pay close attention to all warnings and cautions as they will alert you to any potential hazard that may cause damage or injury Also pay attention to the notes as they provide important tips and reminders DISASSEMBLY CAUTION The following steps require that the first stage be secured in a vise Never secure the first stage directly in the vise as it will dam2. 13 4 Dry off the first stage Blow out any moisture in the dust cap with low pressure air Place the dust cap over the inlet fitting and tighten the yoke screw to secure the dust cap in place Balanced Diaphragm First Stage Service Manual 14 TABLE 2 REQUIRED TOOLS Tool Description Used for 1 One inch open end wrench Removing yoke retainer 24 2 Needlenose pliers Removing filter retaining clip 22 3 O ring tool Removing O rings 4 Adjustable spanner wrench Removing installing spring retainer 2 5 3 8 7 16 vise mounting tool Mounting first stage into vise 6 4mm hex wrench Removing installing all port plugs 7 6mm hex wrench Removing installing adjustment screw 1 8 Torque Wrench Tightening yoke retainer 24 9 1 inch crows foot Used with torque wrench TABLE 1 TROUBLESHOOTING Problem Cause Solution Air leak from spring retainer a Spring retainer 2 not tight a Tighten spring retainer b Diaphragm sealing area damaged b Replace body 12 c Diaphragm 5 worn or damaged c Replace diaphragm I P Creep a HP seat 13 worn or damaged a Replace HP seat b HP seat sealing surface damaged b Replace body 12 c O ring 17 worn or damaged c Replace O ring d Backup ring 18 worn or damaged d Replace backup ring e Balance chamber scratched internally e Replace balance chamber 19 15
3. 2500 to 3000 psi Crack open the relief valve on the test gauge and slowly open the cylinder valve After the cylinder valve is fully open close the test gauge relief valve The intermediate pressure IP should be 140 5 psi 4 If the IP does not fall within this range use a 6mm hex wrench to turn the adjustment screw 22 and adjust the IP Turning clockwise in creases IP turning counterclockwise decreases IP After making an adjustment cycle the regulator by purging the second stage several times and reread the IP After IP is set continue to observe it to make sure IP remains constant FINAL ASSEMBLY AND TESTING 1 Close the cylinder valve and purge the air from the regulator system Remove the first stage from the cylinder and remove the second stage and test pressure gauge and the port plugs if necessary 2 Install the customer s second stages inflator hose s and pressure gauge back into the first stage using the same configuration as when you received the regulator in for service 3 Reattach the first stage to the cylinder and slowly open the cylinder valve to pressurize the regulator Dip the entire first stage into a water bath and watch for leaks Any streaming bubbles means there is a leak somewhere Note the location of the leak and refer to the trouble shooting guide for possible remedies If there are no leaks close the cylinder valve purge the regulator and remove from the valve
4. Balanced Diaphragm First Stage Service Manual Copyright 2002 Cressi sub Revised 3 2002 Balanced Diaphragm First Stage Service Manual 2 Contents BEFORE STARTING 3 DISASSEMBLY 3 PARTS CLEANING AND LUBRICATION 7 CLEANING METAL PARTS 7 CLEANING COMBINATION METAL PLASTIC PARTS 7 CLEANING PLASTIC ONLY PARTS 7 LUBRICATION 7 Types of Lubricant 7 O rings 8 Threaded parts 8 REASSEMBLY 8 ADJUSTMENT PROCEDURE
5. EXPLODED PARTS DIAGRAM Key Description 1 Adjustment Screw 2 Spring Retainer 3 Main Spring 4 Spring Pad 5 Diaphragm 6 Pin Support 7 Pin 8 O ring LP Port x3 9 Port Plug LP x3 10 Port Plug HP x2 11 O ring HP Port x2 12 Body 13 HP Seat 14 Sleeve HP seat 15 Spring HP seat Key Description Parts in bold are to replaced during each overhaul 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 16 Sleeve Balance Chamber 17 O ring 18 Backup Ring 19 Balance Chamber 20 Spring Balance Chamber 21 Filter 22 Retaining Clip 23 Yoke 24 Yoke Retainer 25 Yoke Screw 26 O ring 27 Dust Cap 29 O ring 30 Filter PROFESSIONAL UNDERWATER EQUIPMENT 1 Charles Street Westwood NJ 07675 Tel 800 338 9143 Fax 800 493 2680
6. O ring from each port plug and discard Figure 13 Remove port plugs with 4mm hex wrench 7 PARTS CLEANING AND LUBRICATION CLEANING METAL PARTS 1 Wash all the metal parts in a hot soapy water solution Use a soft bristle toothbrush to clean the threads and remove any flaky corrosion 2 After washing in the hot soapy water rinse all the parts in fresh water 3 Place the metal parts in an ultrasonic cleaner with an appropriate clean ing solution Avoid using harsh acids such as muriatic acid in ultrasonic cleaners Clean the parts for 5 to 15 minutes depending on the amount of corrosion 4 Remove the parts from the ultrasonic cleaner and rinse them in fresh water Blow dry the parts using low pressure filtered air CLEANING COMBINATION METAL PLASTIC PARTS Some parts have plastic and metal molded together such as the yoke screw 26 In general avoid cleaning these parts in an ultrasonic cleaner with an acidic cleaning solution Doing so may chemically attack the plastic The yoke screw threads may be held in the ultrasonic cleaner but do not submerge the plastic yoke knob 1 Wash the parts in a hot soapy water solution Use a soft bristle tooth brush to clean the threads and remove any flaky corrosion 2 After washing in the hot soapy water rinse all the parts in fresh water 3 Blow dry the parts using low pressure filtered air CLEANING PLASTIC ONLY PARTS Avoi
7. age the body Instead thread a vise mounting tool into one of the HP ports located closest to the yoke and tighten the mounting tool in the vise Vise mounting tools are available from third party accessory companies or you can use the following homemade tool Thread a high pressure adapter 3 8 female to 7 16 male onto an expired CO2 cartridge Screw the cartridge into the HP port on the first stage Mount the CO2 cartridge in the vise DO NOT thread the CO2 cartridge without the adapter into a LP port If the threads of the CO 2 cartridge break off it will ruin the first stage body 1 Mount the first stage adjust ment screw facing upward into a vise as described in the caution above see figure 1 Using a 6mm hex wrench unscrew and remove the ad justment screw 1 Remove the main spring 3 Figure 1 Mount first stage in vise and remove adjustment screw Balanced Diaphragm First Stage Service Manual 4 2 Place the two pins of an adjustable face spanner wrench into the two holes in the spring retainer 2 as shown in figure 2 Rotate counter clockwise and remove Lift out the spring pad 4 CAUTION DO NOT attempt to pry out the diaphragm Doing so will damage the sealing area underneath the diaphragm caus ing the regulator to leak when pressurized 3 Attach an air nozzle to a low pres sure source 25 to 30 psig If any of the first stage ports are open plug th
8. cessary Balanced Diaphragm First Stage Service Manual 10 6 Turn the regulator over Insert the pin 7 into the small hole located in the center of the first stage body figure 26 Place the pin support 6 onto the pin figure 27 Press the pin support a few times It should have a smooth springy feel Pin Figure 26 Install pin Figure 27 Install pin support 7 Press a new diaphragm 5 into the first stage Using your finger work the edges of the diaphragm into place so it is evenly seated in the groove below the threads figure 28 Place the spring pad 4 in the middle of the diaphragm figure 29 and place the main spring 3 onto the spring pad figure 30 Figure 28 Install diaphragm Figure 29 Place spring pad in center of diaphragm Figure 30 Place main spring onto spring pad 8 Thread the spring retainer 2 onto the first stage body until handtight figure 31 Thread the adjustment screw 1 into the spring retainer and tighten using a 6mm hex wrench figure 32 Tighten the adjust ment screw until it is flush with the end of the spring retainer Figure 31 Thread spring retainer onto body until handtight Figure 32 Screw in adjustment screw until flush with spring retainer 11 9 Place the yoke 23 over the first stage inlet figure 33 Thread the retain ing nut 24 wrench flats facing upward onto the first stage inlet unt
9. d placing plastic parts in an ultrasonic cleaner with an acidic cleaning solution To properly clean plastic parts perform the same steps listed above LUBRICATION Types of Lubricant Cressi recommends using only food grade silicone grease or more prefer ably Christo lube MCG 111 CAUTION DO NOT use spray silicones as the aerosol propellants may chemically attack the rubber compound Balanced Diaphragm First Stage Service Manual 8 O rings All O rings should be treated with a thin film of lubrication Do not over lubricate the O rings with large amounts of grease Simply place a small amount of grease between your thumb and forefinger and run the O ring between them Threaded parts You may lightly lubricate first two threads As you tighten parts together the lubricant will spread to the other threads REASSEMBLY 1 Slide a new HP seat sleeve 14 over a new HP seat 13 as shown in figure 14 Make sure it is pressed all the way onto the seat figure 15 Figure 14 Install sleeve onto HP seat Figure 15 Make sure sleeve captures entire plastic disk 2 Pass the seat spring 15 over the shaft of the HP seat and press it onto the backside of the seat sleeve figure 16 Press the balance chamber sleeve 16 into the other end of the spring figure 17 Insert this assembly into the first stage body HP seat first as shown in figure 18 Figure 16 Install seat spring Figure 17 Pres
10. em with spare port plugs leaving one of the low pressure LP ports open Make sure the dust cap 27 is in place and secured with the yoke screw While keeping a finger over the diaphragm insert the air nozzle into the open LP port and add a quick blast of LP air The diaphragm 5 will partially pop out as shown in figure 3 Completely remove the diaphragm by lifting it out with your fingers Figure 3 Remove diaphragm with a short blast of low pressure air Figure 2 Remove spring retainer 4 Lift out the pin support 6 and pin 7 as shown in figures 4 amp 5 Figure 4 Remove the pin support Figure 5 Remove the pin 5 5 Loosen the vise and turn the regulator so the yoke screw 25 is facing upward Tighten the vise so the first stage is secure Unscrew the yoke screw from the yoke 23 and remove the dust cap 27 from the yoke screw Remove the O ring 26 located on the outside of the dust cap 6 Using a large adjustable wrench or 1 inch wrench unscrew the yoke retainer 24 as shown in figure 6 and remove the yoke 23 Remove the first stage from the vise and work over the work bench Figure 6 Remove yoke retainer CAUTION The parts underneath the filter are under spring tension Keep pressure applied to the filter when removing the retaining clip to prevent parts from ejecting from the first stage and causing injury Figure 7 Remove filter retaining clip and f
11. il hand tight figure 34 Figure 33 Place yoke onto first stage body Figure 34 Thread yoke retainer onto inlet boss 10 Thread the vise mounting tool back into one of the high pressure ports Mount the first stage into a vise with the yoke facing upward Attach a 1 inch crows foot to a torque wrench Tighten the retaining nut to 20 foot pounds figure 35 Figure 35 Tighten retainer to 20 foot pounds 11 Loosen the vise and turn the regulator over so the spring re tainer is facing upward Using the adjustable face spanner wrench tighten the spring retainer until it stops figure 36 Figure 36 Tighten spring retainer with adjustable face spanner wrench until it stops Balanced Diaphragm First Stage Service Manual 12 12 Place a new o ring 26 onto the dust cap 27 Pass the loop of the dust cap over the yoke screw threads Thread the yoke screw into the yoke ADJUSTMENT PROCEDURE 1 Install new O rings 8 amp 11 on the LP and HP port plugs Install only two LP port plugs and both HP port plugs Leave the other two LP ports open for the testing procedure to follow 2 Attach a second stage to one of the open LP ports This will act as an over pressure valve in case of a high pressure leak Attach a LP test gauge 0 400 psi to the other open LP port Note A test gauge with a relief valve is highly recommended 3 Attach the first stage to a fully charged cylinder
12. ilter Figure 8 Remove balance chamber spring 7 Using needlenose pliers squeeze the inside legs of the retaining clip 22 while at the same time keeping downward pressure against the filter 21 as shown in figure 7 Slowly relax the pressure against the filter and remove the retaining clip Lift out the spring 20 as shown in figure 8 Balanced Diaphragm First Stage Service Manual 6 8 Turn the first stage over so the balance chamber 19 slides partially out Grab it with your fingers and remove it from the first stage figure 9 If the balance chamber stays inside the first stage you may gently grasp it with needlenose pliers and remove it from the first stage Using an O ring tool remove the O ring 17 and backup ring 18 located inside the balance chamber see figure 10 Figure 9 Remove balance chamber Figure 10 Remove O ring and backup ring from balance chamber 9 Turn over the first stage The high pressure seat assembly 13 14 spring 15 and balance chamber sleeve 16 will come out as one assembly see figure 11 Separate the HP seat and balance chamber sleeve from the spring Remove the seat sleeve 14 from the HP seat 13 as shown in figure 12 Figure 11 Remove HP seat assembly Figure 12 Separate parts HP Seat HP Seat Sleeve HP Seat Spring Balance Chamber Sleeve 10 Using a 4mm hex wrench remove all the port plugs see figure 13 Remove the
13. s balance chamber sleeve into spring Figure 18 Install assembly into first stage body 9 3 Install a new backup ring 18 and lubricated O ring 17 into the balance chamber 19 as shown in figures 19 amp 20 Insert the balance chamber assembly into the balance chamber sleeve as shown in figure 21 Figure 19 Install backup ring Figure 20 Install O ring Figure 21 Install balance chamber into sleeve 4 Place the balance spring 20 onto the balance chamber figure 22 Set the filter 21 on top of the spring with the cup of the filter facing upward as shown in figure 23 Figure 22 Install balance spring on top of balance chamber Figure 23 Place filter cup facing upward onto spring 5 Grasp the inner legs of the retaining clip 22 with needlenose pliers and squeeze the legs together Align the outer edges of the retaining clip and filter Press down on the filter with the tips of the needlenose pliers to compress the springs figure 24 It may be necessary to press one side of the retaining clip into the first stage using your finger or a small dowel When the retaining clip is in place release the pressure on the needle nose pliers Inspect the retaining clip to make sure it is properly seated all the way around the groove figure 25 Figure 24 Install filter retaining clip Figure 25 Inspect retaining clip to make sure it is properly seated Press down on clip if ne
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