BalancedPistonFirstStage537 KBytes
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1. male onto an expired CO cartridge Screw the cartridge into the HP port on the first stage Mount the CO cartridge in the vise DO NOT thread the CO cartridge without the adapter into a LP port If the threads of the CO cartridge break off it will ruin the first stage body Balanced Piston First Stage Service Manual 5 Mount the first stage into a vise as described in the caution above Using a large adjustable wrench or 1 inch crows foot unscrew the inlet fitting 28 as shown in figure 1 Separate the inlet fitting from the yoke 25 and spacer 24 Leave the first stage mounted in the vise Figure 1 Remove the inlet fitting 6 Using a pair of needlenose pliers squeeze the two legs of the filter retaining clip 31 together and remove the clip see figure 2 Turn the inlet fitting over and let the filter 30 drop out into your hand Remove the inside O ring 29 located underneath where the filter was and remove the outer O ring 27 Figure 2 Remove the filter retaining clip located above the threads 7 Using a side spanner wrench remove the piston chamber 6 by hooking the wrench into one of the holes and turning the chamber counterclock wise see figure 3 Figure 3 Remove piston chamber Lift out the main spring 11 e eeeeee QO Carefully remove the piston 10 from the piston chamber see figure 4 Take special care not to drop the piston as it may damage the end tha2. blade screwdriver Piston installation guide Torque Wrench 6mm hex key 1 inch crows foot Used for Removing inlet fitting 28 Removing filter retainer 31 adjustment pins 18 Removing O rings Removing installing piston chamber 6 Mounting first stage into vise Removing installing all port plugs Removing installing swivel retainer 8 adjustment screw 22 HP plug 21 Removing installing retaining ring 13 Installing piston 10 Tightening swivel retainer 8 inlet fiting 28 Used with torque wrench Used with torque wrench EXPLODED PARTS DIAGRAM Key Description Swivel LP Port Plugs O ring 4 Swivel O ring Spacer Piston Chamber Washer Swivel Retainer Piston O ring O D Jo om PAWN o 21 CS Key Description 10 Piston 11 Main Spring 12 Spring Support 13 Retaining Ring 14 Backup Ring 15 O ring 16 HP port Plugs 17 O ring 2 18 Adjustment Pins 19 O ring 20 HP Seat 21 HP Plug 22 Adjustment Screw 23 Rubber Cap 24 Spacer 25 Yoke 26 Yoke Knob 17 l Key Description 27 O ring 28 Inlet Fitting 29 O ring 30 Filter 31 Filter Retainer 32 Dust Cap 40 Body DIN Fitting 33 O ring 34 Filter Body 35 Handwheel 36 O ring 37 Din Fitting 38 O ring 39 Dust Cap Parts in bold are to replaced during each overhaul Gessi sub Balanced Piston First Stage Service Manual A e Qcesst sub PROFESSIONAL UN
3. 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 1 Remove any hoses attached to the first stage using the appropriate sized wrench Note Hose servicing is covered in the Airtech and Airplus Second Stage Repair Manual 2 Using a 4mm hex wrench remove the remaining port plugs 2 amp 16 Remove and discard the O ring 3 amp 17 on each port plug Unscrew the yoke knob 26 Unweave the dust cap 32 from the yoke Using an O ring tool remove the O ring located in the face of the dust cap if equipped AA 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 damage the body Instead thread a vise mounting tool into the HP port marked 300 bar 4000 psi 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
4. Copyright 2002 Cressi sub Gessi sub Service Manual Balanced Piston First Stage Revised 3 2002 Balanced Piston First Stage Service Manual Contents BEFORE STAR TING eege te kis b atab oeil an Sot an kk ko ke ea ai 3 DISASSEMBLY EE 3 PARTS CLEANING AND LUBRICATION see EEEEEEEEEEERREREEER KREE KEEN e 5 CLEANING ME TAL TA RE 5 CLEANING COMBINATION METAL PLASTIC PARTS ecceeeeeeeeeeeeeeeeeneeeeeeeeeeeeees 5 CLEANING PEASTIG ONIY PARTS et e Ge 6 URR CAT ON een Een 6 TV DOS OF EEN 6 ela EE 6 TUM CAGCO ANS w win be E A dad 6 Adjustment OWNS e eae eae ated erated a kak Perea mea Pare bah on fok ae enan e a aa e 6 REASSEMBL EE 7 ADJUSTMENT PROCEDURE ki kika nan kek a kk kk n no a ek n a n 8 FINAL ASSEMBLY AND TESTING ccceceeeeeeeeeeesneeeeeeeeeeeeeeseeeseeeeneesenees 9 FOO DESCHIDNOM E E1210 H 10 abet etc stad eege ee Eeer 10 TABLE 1 TROUBLESHOOTING e kaki kk ks n san vot ewod kte gonon oka ki kaka kone mes 10 TABLE 2 REQUIRED TOOLS enee ege Eeer 10 EXPLODED PARTS DIAGRAM ae onikonn ak saa onn kaooiaiaos sen kk nos pakin sonn den kk kad sake son 11 Qeessi sub eeeeeee Q BEFORE STARTING 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
5. DERWATER EQUIPMENT 1Charles Street Westwood NJ 07675 Tel 800 338 9143 Fax 800 493 2680
6. O ring into the dust cap 32 Weave the dust cap onto the yoke Screw the yoke knob 26 into the yoke Qeessi sub 15 ADJUSTMENT PROCEDURE 1 Install new O rings 3 amp 17 on the LP and HP port plugs Install only two LP port plugs 2 and both HP port plugs 16 Leave the other two LP ports open for the testing procedure to follow 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 Attach the first stage to a fully charged cylinder 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 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 increases IP turning counterclockwise decreases IP After making an adjustment cycle the regulator by purging the second stage several times and recheck the IP After IP is set continue to observe it to make sure IP remains con stant 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 por
7. Use a soft bristle toothbrush to clean the threads and remove any flaky corro sion After washing in the hot soapy water rinse all the parts in fresh water Place the metal parts in an ultrasonic cleaner with an appropriate cleaning 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 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 Blow dry the parts using low pressure filtered air CLEANING PLASTIC ONLY PARTS Avoid 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 Ch
8. on guide Figure 27 Piston installation guide Figure 28 Installing piston assembly Install a vise mounting tool into one of the HP ports and mount the first stage in a vise Hook the side spanner wrench into one of the holes on the piston chamber and tight the chamber until it stops metal meets metal as shown in figure 29 Figure 29 Tighten piston chamber with side spanner wrench Loosen the vise and turn the first stage so the high pressure end is facing upward Install a new O ring 19 into the body see figure 30 use your finger to press it all the way down and make sure it is laying flat Examine the new HP seat 20 to see which side has the conical shaped indent Press the HP seat into the HP plug 21 with conical indent facing out see figure 31 Screw the plug into the first stage body Using a 6mm hex wrench tighten the plug until it stops see figure 32 Figure 30 Install HP O Figure 31 Install HP seat Figure 32 Install HP plug ring with conical side facing out with 6mm hex wrench CQessit sub 13 10 Liberally lubricate the three adjustment pins 18 and insert them into the three holes in the first stage body see figure 33 Place the rubber cap 23 onto the end of the first stage body see figure 34 Thread the adjustment screw 22 into the first stage body and tighten with a 6mm hex wrench see figure 35 Figure 33 Install Figure 34 Install rubber Figure 35 Install adjustment pin
9. risto lube MCG 111 CAUTION ZAN DO NOT use spray silicones as the aerosol propellants may chemically attack the rubber compound O rings All O rings should be treated with a thin film of lubrication Do not over lubri cate 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 Adjustment pins Lubricate the three adjustment pins 18 with a light film of grease 10 Balanced Piston First Stage Service Manual REASSEMBLY 1 Install a new lubricated O ring 4 onto the swivel 1 as shown in figure 17 Place the spacer ring 5 onto the tapered side of the piston chamber 6 as shown in figure 18 Press the swivel 1 into the piston chamber Place the washer 7 into the bottom of the piston chamber see figure 19 Place swivel retaining nut 8 onto a 6mm hex wrench and thread the retaining nut into the swivel see figure 20 Figure 17 Install new O ring Figure 18 Install spacer onto onto swivel tapered side of piston chamber Figure 19 Install retainer Figure 20 Install retainer with washer 6mm hex wrench Screw a vise mounting tool into one of the LP ports and secure the swivel into a vise Attach a 6mm hex key to a torque wrench and tighten the retaining nut to 20 foot pounds
10. s cap adjustment screw 11 Install a new O ring 29 into the inlet fitting Using your finger press the O ring into the groove located inside the inlet fitting and make sure it is seated evenly see figure 36 Install a new lubricated O ring 27 onto the inlet fitting just above the threads see figure 37 filter Orii Figure 36 Install filter O ring Figure 37 Install inlet fitting O ring 12 Insert the filter 30 conical end first into the face of the inlet fitting see figure 38 Compress the filter retainer 31 and insert it into the inlet fitting Use a small dowel to work the retainer into place see figure 39 Inspect the retainer to make sure it is captured all the way around the perimeter Figure 38 Install filter into inlet Figure 39 Use a dowel to ensure fitting retaining clip is securely in place 14 Balanced Piston First Stage Service Manual 13 14 Pass the threaded end of the inlet fitting through the yoke 25 and through the flat side of the spacer 24 as shown in figure 40 With the spacer straddling the body thread the inlet fitting into the body Attach a 1 inch crows foot to a torque wrench and tighten the inlet fitting to 20 foot pounds see figure 41 Remove the first stage from the vise and remove the vise mounting tool Figure 40 Pass inlet fitting through yoke and spacer Figure 41 Torque inlet fitting to 20 foot pounds If equipped install a new
11. see figure 21 Remove the vise mounting tool Set the assembly aside Figure 21 Torque retainer to 20 foot pounds Ctessi sub 11 Install a new lubricated O ring 15 into the hole for the piston shaft just below the threads Place the backup ring 14 on top of the O ring see figure 22 Use a small dowel to gently press these two parts so that they lay flat Using a thin wide bladed tool a common butter knife works well thread the retaining ring 13 into the body until it stops see figure 23 F GAN KANN ing Oring Figure 22 Install shaft O ring followed Figure 23 Install retainer by back up ring Install the spring support 12 open side facing out into the first stage body see figure 24 Place the main spring 11 into spring support see figure 25 Figure 24 Install spring support Figure 25 Install main spring Install a new lubricated O ring 9 on the piston head Liberally lubricate both sides of the piston head Press the piston head all the way into the piston chamber see figure 26 Figure 26 Press piston into piston chamber 12 Balanced Piston First Stage Service Manual Carefully insert the piston installation guide tapered tip first into the body as shown in figure 27 Pass the piston shaft through the center of the spring into the piston installation guide as shown in figure 28 Compress the spring and thread the piston chamber onto the body Remove the installati
12. t seals against the HP seat Remove the O ring 9 located on the piston head Remove the first stage body from the vise but leave the mounting tool in place Tap the first stage against the work bench until the spring support 12 falls out see figure 5 Figure 5 Remove spring support Using a thin wide bladed tool a common butterknife works well un screw the retaining ring 13 as shown in figure 6 Using an O ring tool carefully lift out the washer 14 and O ring 15 as shown in figure 7 Figure 6 Remove retainer Figure 7 Remove back up ring and O ring Balanced Piston First Stage Service Manual 12 Loosen the vise and turn the first stage body so the adjustment screw 22 is facing upward Using a 6mm hex wrench remove the adjust ment screw as shown in figure 8 Remove the rubber cap 23 as shown in figure 9 N Figure 8 Remove adjustment screw Figure 9 Remove rubber cap 13 Using a 6mm hex wrench un screw the high pressure plug 21 as shown in figure 10 Ch Figure 10 Remove HP plug WARNING When blowing out the high pressure seat with an air nozzle hold the plug just above the workbench with the seat facing down Make sure the seat cannot fly out of the plug causing injury 14 The high pressure seat 20 fits tightly in the high pressure plug therefore it should be removed with a quick blast of pressurized air To do this insert a pressur ized air noz
13. t plugs if necessary Install the customer s second stages inflator hose s and pressure gauge back into the first stage using the same configuration as when you re ceived the regulator in for service Reattach the first stage to the cylinder and slowly open the cylinder valve to pressurize the regulator Dip the entire first stage into a bucket of water and watch for leaks Any streaming bubbles means there is a leak some where Note the location of the leak and refer to the troubleshooting guide for possible remedies If there are no leaks close the cylinder valve purge the regulator and remove from the valve 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 16 Balanced Piston First Stage Service Manual TABLE 1 TROUBLESHOOTING a O ring 4 worn or damaged a Replace O ring a Piston O ring 9 damaged b Piston sealing surface damaged c Piston shaft O ring 15 damaged a HP Seat 20 damaged or worn b Piston sealing edge damaged a Replace O ring b Replace Piston c Replace O ring a Replace seat b Replace piston TABLE 2 REQUIRED TOOLS Tool Description 1 ON SONS saan 10 11 12 One inch open end wrench or crows foot Needlenose pliers O ring tool Side spanner wrench 3 8 7 16 vise mounting tool 4mm hex wrench 6mm hex wrench Wide
14. zle into the hex hole of the high pressure plug Slowly introduce air into the hex hole to push the HP seat out of the plug see figure 11 Figure 11 Blow HP seat with air nozzle 15 Remove the O ring 19 located inside the body see figure 12 Figure 12 Blow HP O ring 16 Remove the three IP adjustment pins 18 by pushing the pins flush to one side of the body and grasp ing the exposed end with needlenose pliers see figure 13 Figure 13 Remove adjustment pins 17 Thread a 3 8 inch vise mounting tool into one of the LP swivel ports Mount the swivel into a vise with piston chamber facing upward Using an 6mm hex wrench remove the swivel retaining nut 8 as shown in figure 14 Using an O ring tool lift out the washer 7 as shown in figure 15 Figure 14 Remove swivel retainer Figure 15 Remove swivel washer 18 Separate the swivel 1 from the piston Balanced Piston First Stage Service Manual chamber 6 and remove the spacer ring 5 as shown in figure 16 Remove the swivel O ring 4 Figure 16 Separate swivel from piston chamber and remove spacer THIS ENDS DISASSEMBLY PARTS CLEANING AND LUBRICATION CLEANING METAL PARTS CAUTION U Keep the piston separate from the other parts while clean ing If the end of the piston is damaged it will not be able to seal against the HP seat and the piston will have to be replaced Wash all the metal parts in a hot soapy water solution
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