AirTechSecondStage681 KBytes
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1. 5 10 Using a 3 4 wrench unscrew the retaining nut 18 as shown in figure 6 Figure 6 Remove retaining nut with 3 4 inch wrench 11 While looking at the valve body through the front of the second stage slide the valve body from left to right about a 1 2 and lift out the valve body alignment key 20 as shown in figure 7 Figure 7 Remove alignment key 12 Press the lever 21 against the valve body and slide the valve body out of the second stage housing see figure 8 Figure 8 Depress the lever and slide the valve body out of the second stage 13 Grasp the venturi channel 13 with your fingers and pull it straight out of the second stage see figure 9 Figure 9 Remove venturi channel Air Tech Second Stage Service Manual 6 14 Fit the adjustment knob 34 back onto the adjustment screw and thread the retaining screw 35 back into the adjustment screw see figure 10 Turn the adjustment screw counterclockwise several times to disengage the threads Because the adjustment screw is O ring sealed it will not freely exit the valve body therefore firmly grasp the adjustment knob and pull the adjustment screw out of the valve body see figure 11 Figure 10 Temporarily reinstall adjustment knob Figure 11 Unscrew adjustment knob to disengage threads then pull straight out 15 Remove the retaining nut and knob from the adjustment screw Re mo2. 16 TABLE 1 TROUBLESHOOTING 18 TABLE 2 REQUIRED TOOLS 18 EXPLODED PARTS DIAGRAM 19 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 1 Using a 9 16 wrench unscrew the second stage hose from the first stage Remove the O ring from the end of the hose 2 While holding the retaining nut 18 with a 3 4 19mm wrench unscrew the swivel hose fitting using an 11 16 wrench see
3. Figure 35 Install venturi channel 14 Orient the second stage so the front is facing you While depressing the lever insert the threaded end of the valve body into the second stage from right to left see figure 36 Continue pressing the valve body into place until about half of the squared section is still visible see figure 37 Place the two legs of the retaining key 20 around the squared section and press it into place until the wings are against the plastic see figure 38 Press the valve body all the way into the second stage until it is stopped by the retaining key Figure 36 Depress lever and insert valve body Figure 37 Leave half of the squared section visible Figure 38 Install the retaining key over squared section Air Tech Second Stage Service Manual 14 Notch 15 Thread the retaining nut 18 onto the end of the valve body until finger tight Attach a 3 4 crows foot or socket to a torque wrench and tighten the retaining nut to 50 inch pounds see figure 39 Figure 39 Install retaining nut and torque to 50 inch pounds 16 Install a new lubricated O ring 19 onto the adjustable orifice 17 Insert the threaded end of the adjustable orifice into the end of the valve body see figure 40 Using a medium blade screwdriver press the orifice all the way into the valve body and start turning it clockwise see figure 41 As you turn in the orifice watch the lever
4. damaged a Replace O ring b O ring 16 worn or damaged b Replace O ring Second stage leaks air a Adjustable orifice 17 damaged a Replace adjustable orifice b LP seat 24 Damaged or worn b Replace seat Hard to breathe a Adjustable orifice too tight a Back out adjustable orifice TABLE 2 REQUIRED TOOLS Tool Description Used for 1 9 16 open end wrench Removing hose 14 2 3 4 open end wrench Removing retaining nut 18 3 Side cutters Removing mouthpiece clamp 9 4 Phillips screwdriver Removing installing exhaust tee screw 7 5 O ring tool Removing O rings 6 2 medium blade screwdrivers Removing adjustable orifice 17 Clip 10 7 Small wooden dowel Removing adjustable orifice 17 8 Torque Wrench Tightening retaining nut 18 Hose swivel 9 9 16 crows foot Used with torque wrench 10 3 4 crows foot Used with torque wrench 11 In line adjustment tool Adjusting second stage 12 3mm hex wrench Removing adjustment knob screw 35 13 Circlip pliers Removing installing circlip 33 19 EXPLODED PARTS DIAGRAM Key Description 1 Retaining Ring Assy 2 Front Cover 3 Diaphragm 4 Second Stage Body 5 Exhaust Valve 6 Exhaust Tee 7 Retaining Screw Exhaust Tee 8 Mouthpiece 9 Clamp 10 C Clip 11 O ring 12 Flow Control Knob 13 Venturi Channel 14 Hose 15 O ring Hose Swivel 1
5. 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 Figure 21 Install C clip REASSEMBLY 1 Install a new lubricated O ring 11 onto the flow control knob 12 Insert the flow control knob into the second stage body 4 and press down so that the groove for the retaining clip is visible in the mouth piece opening 2 Hold the second stage body with the flow control knob facing down ward One side of the retaining clip 10 has a sharp edge the other side has a rounded edge Set the retaining clip into the mouthpiece opening with rounded edge against the second stage housing and the open side against the flow control knob Using your finger or a flat blade screwdriver press the retain ing clip against the flow control knob until it snaps into place figure 21 Move the flow control knob back and forth to ensure that it operates smoothly 3 Insert the stem of a new exhaust valve 5 through the center hole in the exhaust port on the outside of the second stage housing 4 as shown in figure 22 Grasp the stem with your fingers and pull it until the barb pops through figure 23 Figure 22 Install ex
6. 6 O ring Adjustable Orifice 17 Adjustable Orifice 18 Retaining Nut Key Description 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 28 29 30 31 32 34 35 33 19 O ring Valve Body 20 Retaining Key 21 Lever 22 Valve Body 23 O ring Valve Body 24 Low Pressure Seat 25 Poppet 26 O ring Poppet 27 Spring 28 Balance Chamber 29 Metal Disk 30 O ring Adjustment Screw 31 Adjustment Screw 32 O ring Adjustment Screw 33 C Clip Adjustment Screw 34 Adjustment Knob 35 Retaining Screw Adjustment Knob Air Tech Second Stage Service Manual PROFESSIONAL UNDERWATER EQUIPMENT 1 Charles Street Westwood NJ 07675 Tel 800 338 9143 Fax 800 493 2680
7. Air Tech Second Stage Service Manual Copyright 2002 Cressi sub Revised 3 2002 Air Tech Second Stage Service Manual 2 Contents BEFORE STARTING 3 DISASSEMBLY 3 PARTS CLEANING AND LUBRICATION 9 CLEANING METAL PARTS 9 CLEANING PLASTIC ONLY PARTS 9 LUBRICATION 9 Types of Lubricant 9 O rings 10 Threaded parts 10 REASSEMBLY 10 ADJUSTING THE SECOND STAGE 15 FINAL REASSEMBLY
8. When the orifice starts pressing against the low pressure seat the lever will start to drop As soon as it drops stop turning the adjustable orifice Figure 40 Install adjustable orifice into valve body Figure 41 Tighten adjustable orifice until lever starts to drop 17 Place the knob 34 onto the adjustment screw Thread the retaining screw 35 into the end of the adjustment screw and tighten with a 3mm hex wrench 15 ADJUSTING THE SECOND STAGE A medium pressure air supply of 135 5 is required to properly adjust the second stage Make sure the first stage that you are using is properly ad justed before performing the second stage adjustments Please refer to the appropriate Cressi first stage repair manual for proper first stage adjustment procedures The first stage should be attached to a fully charged cylinder 2500 to 3000 psi The use of an in line adjustment tool is required to tune the regulator The in line tool is available from other 3rd party suppliers ADJUSTING THE SECOND STAGE WITH AN IN LINE ADJUSTMENT TOOL 1 Screw the threaded end of the second stage hose into the first stage Using an 11 16 wrench tighten the hose until snug Pull back the adjust ment wheel of the in line tool and thread the in line tool into the second stage inlet fitting Thread the swivel end of the second stage hose onto the in line tool until finger tight 2 Turn the adjustment knob count
9. al Unless the lever 21 is damaged it is not nec essary to remove it However if the lever needs to be removed gently spread the two legs and remove it from the valve body 21 Separate the poppet 25 and balance chamber 28 by pulling them in opposite directions see figure 17 Remove the spring 27 Using your fingernail pry the low pressure seat 24 from the end of the poppet see figure 18 Remove the small O ring 26 from the end of the poppet Figure 17 Separate poppet from balance chamber Figure 18 Remove LP seat from end of poppet Air Tech Second Stage Service Manual 8 22 Using a medium blade screwdriver rotate the retaining clip 10 so the open side of the clip faces the mouthpiece opening Lay the sec ond stage body on the workbench with the mouthpiece opening facing upward Using a second flat blade screwdriver press the two legs of the retaining clip and pop it off the flow control knob 12 as shown in figure 19 Figure 19 Push on both legs of the c clip to remove This ends disassembly Figure 20 Remove flow control knob 23 Lift the flow control knob 12 out of the second stage body figure 20 Remove the O ring 11 from the flow control knob 9 PARTS CLEANING AND LUBRICATION CLEANING METAL PARTS CAUTION Keep the adjustable orifice 17 separate from the other parts while cleaning If the sealing
10. erclockwise until it is all the way out then turn it clockwise a half turn 3 Slowly open the cylinder valve and pressurize the regulator When the regulator pressurizes the lever will drop 4 Press the handwheel of the in line tool inward until it stops Rotate the handwheel until the in line tool engages the screwdriver slot in the ad justable orifice Slowly rotate the handwheel counterclockwise until there is an audible air leak Once the leak is heard turn the handwheel clock wise until the leak stops then an additional eighth turn 5 Turn the adjustment knob counterclockwise until it stops You should be able to hear a slight leak Turn the adjustment knob back in a half turn the leak should stop 6 Close the cylinder valve and purge the regulator by pressing the lever Pull back on the in line tool handwheel and unscrew the in line tool from the second stage Unscrew the hose from the in line tool Air Tech Second Stage Service Manual 16 1 Note the two notches at the top and bottom of the diaphragm 3 These notches mate with two tabs inside the second stage housing see figure 42 On the backside of the dia phragm is a metal strike plate With the strike plate facing the lever place the diaphragm into the second stage housing Notch Tab Figure 42 Align notches in diaphragm with tabs in housing 2 Orient the front cover so the purge button logo is properly a
11. figure 1 Using a brass or plastic O ring pick remove the O ring 15 located inside the hose swivel Figure 1 Removing the hose Air Tech Second Stage Service Manual 4 3 Using side cutters snip the mouthpiece clamp 9 Pull the mouth piece 8 off the second stage body 4 4 Using a Phillips screwdriver remove the exhaust tee retaining screw 7 as shown in figure 2 5 To remove the exhaust tee 6 place your thumb on the top corner of the exhaust tee and press downward Figure 2 Removing the exhaust tee screw Figure 3 Press down on top corner of exhaust tee to remove 6 Remove the exhaust valve 5 by grasping it with your thumb and forefinger and pulling it straight out 7 Remove the front cover by grasping the retaining ring 1 with your fingers and turning it counterclockwise Separate the front cover 2 from the retaining ring Lift out the diaphragm 3 Figure 4 Remove retaining screw with 3mm hex wrench 9 To remove the circlip 33 you must turn the adjustment screw so one of the flat edges is facing the two eyelets on the circlip Using a pair of circlip pliers contract and remove the circlip see figure 5 8 Turn the adjustment knob clock wise until it stops Using a 3mm hex wrench remove the adjust ment knob retaining screw 35 as shown in figure 4 Remove the adjustment knob 34 Figure 5 Remove circlip flat edge
12. haust valve Figure 23 Pull barb all the way through 11 4 Install new lubricated O rings 19 amp 23 onto the valve body 22 as shown in figure 24 Figure 24 Install valve body O ring Install O rings 5 Note Perform this step only if lever was removed during disas sembly One side of the valve body has a machined flat surface With the machined flat surface facing upward gently spread the legs of the lever 21 and insert the feet of the lever into the two side holes in the valve body see figure 25 machined flat surface Figure 25 Install lever 6 Press a new low pressure seat 24 into the end of the poppet 25 as shown in figure 26 Install a new lubricated O ring 26 onto the stem of the poppet figure 27 Figure 26 Install LP seat into poppet Install O ring Figure 27 Install poppet O ring 7 Press the spring 27 onto the balance chamber 28 Pass the poppet stem through the spring and press it into the balance chamber see figure 28 Figure 28 Install spring onto balance chamber press poppet into balance chamber Air Tech Second Stage Service Manual 12 8 Install two new lubricated O rings 30 amp 32 onto the adjustment screw see figure 29 Figure 29 Install adjustment screw O rings Install O rings 9 With the feet of the poppet face down away from the lever see figure 30 sl
13. ligned Align the notches in the front cover with the tabs in the second stage figure 43 While holding the front cover down with your thumb screw the retaining ring onto the second stage housing Figure 43 Align notches in front cover with tabs in housing Notch Tab 3 Hang the exhaust tee 6 from the top edge of the flange see figure 44 Press on the bottom of the exhaust tee until it snaps into place Figure 44 Hang exhaust tee on top edge of flange Hang tee from this ledge Hang tee from this ledge 4 Using a Phillips screwdriver install the exhaust tee retaining screw 7 FINAL REASSEMBLY 17 This ends reassembly and testing Note Do not install the mouthpiece at this time if you will be performing bench tests 5 Install the mouthpiece onto the 2nd stage body Secure the mouth piece with a new clamp 12 The clamp s locking tab should be posi tioned on the hose side of the mouthpiece Using side cutters trim the clamp so it is flush with the locking tab 6 Thread the hose swivel onto the inlet fitting until finger tight Attach an 11 16 crows foot to a torque wrench While holding the inlet fitting with a 3 4 19mm wrench tighten the hose swivel to 40 inch pounds Air Tech Second Stage Service Manual 18 TABLE 1 TROUBLESHOOTING Problem Cause Solution Air leak at hose swivel a O ring 15 worn or
14. owly drop the pop pet assembly low pressure seat side first into the valve body poppet feet point down lever faces upward Figure 30 Install poppet assembly into valve body 10 Drop the metal disk 29 into the end of the valve body making sure it lays flat against the balance chamber see figure 31 Slowly press the adjustment screw into the valve body see figure 32 As you insert the adjustment screw the lever will pop up Continue to press the adjustment screw into place until the outer O ring is no longer visible You will hear a click sound meaning that the poppet has cleared the lever feet Place the knob onto the end of the adjustment screw and turn clockwise until it stops Figure 31 Install metal disk Figure 32 Press adjustment screw into valve body 13 12 Place the circlip 33 onto a pair of circlip pliers Orient the two eyelets so they are facing one of the flat edges on the adjustment screw Compress the circlip pass it over the adjustment screw and install it into the end of the valve body see figure 33 Make sure the circlip is positioned in the groove all the way around see figure 34 Turn the adjustment knob in and out to ensure it operates smoothly flat edge faces eyelets Figure 33 Install circlip into valve body Figure 34 Inspect circlip to make sure it is properly seated 13 Slide the venturi channel 13 back into the slot as shown in figure 35
15. surface is damaged the part will have to be replaced 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 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 1 Wash all the plastic 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 Blow dry the parts using low pressure filtered air 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 continued Air Tech Second Stage Service Manual 10 O
16. ve the two O rings 32 amp 30 from the adjustment screw 16 Underneath the adjustment screw is a metal disk 29 This disk should freely fall out of the valve body If it doesn t gently tap the end of the valve body against the work bench until the disk falls out see figure 12 Figure 12 Remove metal disk 17 Insert a small dowel or 3mm hex wrench through the threaded end of the valve body 22 and press out the poppet assembly 24 28 as shown in figures 13 amp 14 Figure 13 Push against poppet assembly Figure 14 Poppet assembly removed from valve body 7 CAUTION Take special care when removing the adjustable orifice so the sealing edge is not damaged Place the orifice on a cushioned surface while disassembling the remainder of the second stage Keep it away from the edge of the work bench so it doesn t fall to the floor and become damaged 18 Using a medium blade screwdriver unscrew the adjustable orifice 17 about 6 to 7 turns see figure 15 Because the adjustable orifice is O ring sealed it will not freely exit the valve body therefore insert a wooden dowel in the opposite end of the valve body and push out the adjustable orifice see figure 16 Figure 15 Unscrew the adjustable orifice to disengage threads Figure 16 Push out adjustable orifice with small wooden dowel 19 Remove the two O rings 19 amp 23 from the valve body 20 This step is option
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