regulator service information
Contents
1. regulator 2nd stage prestige octopus Il Type Demand vahe type Boay Bottom case High impact plastic BK Top cover High impact plastic in 8 colors FPK FYL FOG FGN COBL PL WT BK Mouthpiece Translucent surgical silicone rubber e Exhaust valve Large single silicone vaive Hose length 90cm Standard intermediate pressure 9 8kgficrr prestige octopus Il Product features H Large single exhaust valve system The large silicone single exhaust valve ensures smooth exhalation H Lightweight plastic body and colorful top cover The body is light because it is made of plastic The brightly colored top covers 8 colors fo choose from can be easily seen underwater making them extremely suitable as octopus regulators Volume 5 p 06 regulators accessories low pressure manifold special tools for the regulator required 2B A adjusting wrench B adjusting wrench low pressure Manifold L3 cesigned for 1 2 inch screws Type Direct attachment to the Ist stage low pressure air port For use in conversion of pressurized air flow Converts single port to double port Screw Diameter 1 2 24 UNF Applicable Models For use with the A 103 amp A 105 only C regulator driver This model is identical to the Manifold L 2 except that the screw size is different This model is designed solely for use with the A 105 It is attached to the diagonal low pressure port an2. rapidly open the air stopper or close the tank valve to prevent damage to the L P gauge and L P hose 2 Pressure exceeds specified L P and continues to tise 3 Points to a value that Is different from the setting and stops Inspection Repair 0 The rubber seal on the H P seat is worn out or damaged v lt Replace H P seat gt 0 The O ring in the balance chamber is worn out or damaged v lt Replace O ring ARP 006 gt 0 The teflon washer in the balance chamber has debris deposts or s damaged v lt Replace balance chamber assy gt Won a 102 0 The O ring ARP 017 in the H P module is wom out or damaged v lt Replace O ring ARP 017 gt 0 H P module O ring The rubber seal on the H P seat has damaged 0The rubber seal on the H P seat has debris deposits or is damaged v lt Replace H P seat gt The O ring in the balance chamber has debris deposits of ls damaged v lt Replace O ring ARP 006 gt Mo 102 OThe H P module vatve seat is flawed 7v lt Replace H P module gt Wo 101 105 Q The body valve seat is flawed v lt Replace body gt v Adjust low pressure and set to correct value When adjusting low pressure always attach at least one second stage if replacing the O ring coat with a thin layer of silicone grease on the O ring before installation p 09 Volume 5 regulators E Inspection and repair of air leaks Symptoms 1 Air leakage from
3. Hose Protector When the protector is correctly set in place When the protector is correctly set in place there Is very little chance of cracks occurring in the hose However it is difficult to remove salt from the area and metal corrosion can occur to the hose fitting To prevent corrosion of metal parts remove the protector on a regular basis and check for problems Tne above problems related to the use of a hose protector have been observed In order to prevent cracks in hoses and similar problems Apollo regulator hoses and gauge hoses have been designed with a special outward crimp process for the hose fitting This allows for the use of the unit without a hose protector in most circumstances Any breakdowns or unit problems that are related to the use of a hose protector are not covered by the warranty regulator E Care of the regulator cover etc A regulator maintains proper pressurization levels by adjusting the pressure of the 1st and 2nd stages to surrounding pressure which varies according to depth If a bought regulator cover is attached to the 2nd stage or octopus the performance of the pressure sensor can be reduced In the same way if tape is attached over the pressure sensor holes of the 1st stage or if salt is not properly cleaned out of the unit the pressure sensor can malfunction The result of this is that proper intermediate pressure relative to the depth might not be achieved and a deficiency in air supply
4. The following items should be highlighted in your manual page 38 Items requiring mandatory annual replacement Use Service Kit 163051 key description 09 activated charcoal filter 11 moisturizing pad 30 filter 35 hp seat 33 o ring balance housing Items requiring careful inspection for serviceability before refitting 13 o ring for moisturizer tube ensure the o ring is glued to the tube 27 hp diaphragm special notes All parts must passa visual inspection for serviceability before refitting Adjusting screw 21 and guide nut 22 have a left hand thread Check to ensure that chamber spacer 31 is fitted with the two support legs facing the filter A pollo includes the following items in the a 105 service kit Pinnacle 163051 p 38 key s 9 11 30 33 amp 35 service info 4 2000 maintenance guide for use with Service Manual Vol 5 a 107 1st stage Fora list of features and a description of the a 107 refer to page 4 Factory intermediate pressure 145 psi 7 psi The following items should be highlighted in your manual page 39 Items requiring mandatory annual replacement key description 12 activated charcoal filter 14 moisturizing pad 33 filter 38 hp seat 36 o ring balance housing Items requiring careful inspection for serviceability before refitting 30 hp diaphragm special notes All parts must passa visual inspection for serviceability before refitting Adjusting
5. may result in a very dangerous situation Points to remember when using a 2nd stage If a bought regulator cover is placed on the top of the 2nd stage the pressure sensors of certain models lose efficiency It is very important to remember to remove the cover before entry Points to remember when using a 1st stage Compared to the 2nd stage the water pressure sensor used with the 1st stage is small and complex It is important to explain the functions and maintenance of this component carefully to customers Apollo cannot assume any responsibility for problems related to these areas Water pressure Sensor Volume 5 p 14 regulators 2000 engineering update regulator service periods recommended service periods for regulators It has come to our attention that a number of technicians do not know ordo not adhere to the time frames recommended for having regulators serviced The use of a regulator falls into two basic categories recreational use a regulator used primarily by the sport diver who dives mostly on the weekends periodically during the week and uses the regulator for extended periods only on tnps commercial use a regulator used by an instructor a commercial diver a regulator used in a dive school or for hire situation The following service periodsare recommended by Apollo Service every 12 months after nomal use for recreational diving or before use after prolonged periods of storage Service e
6. prestige balanced ex 2nd stage The following items should be highlighted in your manual page 43 Items requiring mandatory annual replacement key description 21 2 x o rings valve seat ca mier on end of stem Items requiring careful inspection for serviceability before refitting 20 LP seat in end of stem 17 valve cone check tip for damage 18 o ring valve cone 14 demand lever distortion 13 diaphragm 37 exhaust valve special notes All parts must passa visual inspection for serviceability before refitting The adjustable orifice haschanged on this unit compared to the earlier prestige 2nd stage An in line adjusting tool isnow required to complete the tuning operation The balance housing is threaded onto the adjusting shaft this is difficult to remove although it will screw together easily for replacement Do not remove the balance cylinder unless it is damaged this can be safely acid cleaned while in position The adjusting knob 23 should be tumed counter clockwise all the way out until it stops and then tumed back clockwise 1 2 to 1 tum before commencing to adjust the orifice When dismantling the adjusting shaft 33 from adjusting nut 30 the shaft hasa left hand thread This thread should be well lubricated during reassemble to maintain free movement between service periods The latest 2nd stage housing has two design changes 1 The diaphragm cover lock is now an integrated part of the cover
7. reduced to the level at which there is little noticeable breathing resistance Fluctuations in pressurization levels resulting from changes in internal tank pressure measured on land Unbalanced piston type Tank Pressure kg cm Pressure kg cm Maximum Pressure Difference kg cm 4 LP 4 LP Figure 1 Operational Principles of the Balanced Piston Type Volume 5 regulators 01 p general design of Ist stage regulator i EN 5 E Features of the unbalanced diaphragm type Compated to the piston type the diaphragm type has a complex composition that involves many components However the level of precision required of the components of this type is not as high as that of the piston type so unit cost prices are lower A major advantage of this type is that the pressurization level can be easily adjusted In the unbalanced type as the remaining tank pressure decreases the pressurization level increases As a result breathing resistance is particularly strong at the beginning of a dive Fluctuations in pressurization levels resulting from changes in internal tank pressure measured on land Unbalanced diaphragm type Tank Pressure kg cm Pressure kg crn Maximum Pressure Difference kg cm 10 0 3 3 fluctuation rate about 40 gr ea E Features of the balanced diaphragm type Like the unbalanced diaphragm type the 1st stage allows for easy ad
8. remove any rinse water from inside pressurizing the regulatorand purging with air will be more efficient Store your regulator in a dry area away from damp fuels paint and thinners and remember cockroaches eat silicone mouthpieces exhaust valves and diaphragms CARRYING OUT THE ABOVE PROCEDURES WILL PROVIDE PEAK PERFORMANCE FROM ONE SERVICE PERIOD TO THE NEXT service info 2 2000 maintenance guide for use with Service Manual Vol 5 a 101 1st stage Fora list of features and a description of the a 101 refer to page 3 Factory intermediate pressure 145 psi 7 psi The following items should be highlighted in your manual page 37 Items requiring mandatory annual replacement key ription 20 filter 23 o ring balance housing 25 hp seat Items requiring careful inspection for serviceability before refitting 17 hp diaphragm special notes All parts must passa visual inspection for serviceability before refitting Adjusting screw 11 and guide nut 12 have a left hand thread Check to ensure that chamber spacer 21 is fitted with the two support legs facing the filter A pollo includes the following items in the a 101 service kit Pinnacle 163050 p 37 key s 20 23 amp 25 service info 3 2000 maintenance guide for use with Service Manual Vol 5 a 105 1st stage Fora list of features and a description of the a 105 refer to page 4 Factory intermediate pressure 145 psi 7 psi
9. the body cap Common for all models 2 Air leak from filter cap base A 105 only 3 Air leakage from tip of fitter cap A 105 only 4 Air leak from yoke attachment base A 102 only regulator maintenance Ist stage maintenance Inspection Repair Insufficient tightened diaphragm retainer v lt Re tighten with special tool A gt 0 H P diaphragm is damaged 0 The contact face of the body wih the H P diaphragm is damaged v lt Replace the defective diaphragm and recheck for leakage gt lt lf the problem is with the body replace the body gt 4 Orting ARP 025 wom or damaged 0 The body cap C or the contact face of the filter case with the O ring is dirty or damaged v lt If the cause is in the O ring remove deposits or replace if damaged gt lt Metal parts with any scratches or dents should be replaced gt Very slight flaws can be smoothed out with sandpaper grade 1 000 0 O ring ARP 022 wom or damaged 0 Filter case or O ring contact face of cap W has deposits or is damaged v lt f the cause is in the O ring remove deposits or replace if damaged gt lt Metal parts with any scratches or dents should be replaced gt Very slight flaws can be smoothed out with sandpaper grade 1000 0 The copper gasket is damaged or has deposits The yoke retainer or body surface contacting the copper gasket is damaged or has deposits v lt Thoroughly remove ali deposits Replace the copp
10. the diver breathes The diver consequently could have difficulty breathing comfortably The LPs ae less pressure the carnier spring exerts P ae A the easier breathing willbe We have therefore designed a balance chamber for the other side of the valve seat the side which Is subjected to air pressure The balanced type 2nd stage uses thie machanien to reduce the pressure the canter spring exerts Balance chamber Volume 5 p 02 regulators regulator 1st stage a 101 a 101 Type Balanced Diaphragm No of Ports 1 H P 7 16 5 L P 3 8 intermediate Pressure Value When tank pressure is 200 kg cm 9 8kg cm 0 5kg cm with external adjustment control Total Weight 680 g Product features BB Lightweight and compact This model has the same stable regulation feature as the A 105 Itis a lightweight compact regulator Furthermore the yoke screw is large and easy to use E Simple low pressure adjustments made from exterior a 102 a 102 Type Balanced diaphragm No of Ports 2 H P 7 16 symmetrical positioning 4 L P 1 2 symmetrical positioning symmetrical positioning Intermediate Pressure Value When tank pressure is 200 kg cm 9 Bkg cmet 0 5kg cm with external adjustment control Total Weight 930 g Product features E Lightweight and compact A simple and compact design has been achieved The newly designed yoke handle has been ma
11. amaged in any way change parts 4 Problem in the balance chamber for balanced type Consult No 1 above first for checking then No 2 for making adjustment E Checkpoints to verify there is no leakage to the main unit Checkpoints 1 Exhaust valve function reduced by deterioration deformation or debris Inspection Repair 0 If leak is traced to exhaust valve replace valve v Thoroughly remove all debris 2 Damaged or dirty O ring ARP 015 damaged or dirty contact surface on demand valve housing bonnet or bottom case gt Replace O ring if the problem lies there v Replace parts if O ring contact surface Is damaged gt Replace O ring v Replace parts if O ring contact surface Is damaged 3 O ring S 8 is deformed damaged or dirty damaged or dirty contact surface on adjusting shaft and or bonnet 4 Holes In the diaphragm Replace parts When replacing the O ring coat the new O ring with a thin layer of silicone grease before installation Volume 5 p 11 regulators regulator maintenance regulator maintenance E Inspection and repair of free flows The most frequent problem with a regulator is free flowing When free flowing occurs with the 2nd stage although the cause is generally thought to be the 2nd stage itself that is not always the case Because there can be some causes other than the 2nd stage please
12. d an additional port can be attached This additional port converts the flow of pressurized air and lies parallel to the 2nd stage main hose D yoke retainer wrench E circlip pliers Volume 5 p 07 regulators regulation regulator adjustments a a E 1st stage adjustments E 2nd stage adjustments 1st stage low pressure adjustments 2nd stage low pressure adjustment The low pressure value of the Prestige A 101 is set at 9 8 After adjusting the 1st stage low pressure value or after kg cm Connect a low pressure gauge to the L P port with verifying that the value reads as designated adjust the 2nd the 2nd stage connected and open up the relief valve in stage pressure direction 1 as shown in the illustration below First rotate the adjustment knob from the fully open position Open the valve slowly and while watching the low pressure turning it one half turn clockwise towards close Also move gauge needle slowly close the relief valve Purge two or the Turbo Stream knob to a position half way between MAX three times at the 2nd stage and MIN When the tank pressure Is at 100 to 200 kg crre the low Next move the valve cone back and forth toward and away pressure value should be at 9 8 kg cm from the valve seat until the position ensures that free flow air leakage stops At the same time verify that the demand lever has no slack If it does that means the parts are not coordinating well together and that the va
13. d into the guide nut as far as possible E Disassembly and assembly of H P seat side For the A 102 After you have finished disassembly of the body cap side as previously explained use screwdriver 1 special tool C shown on page 7 to remove the H P module assembly from the body To do this first remove tne C ring shown below with C ting snap ring pliers IN special tool E on page 7 then remove the balance chamber H P spring and H P seat located in the H P module lt Re assembly gt Replace the parts in the H P module following the reverse order to that explained above Make sure the C ring fits snugly into the H P module groove Next insert the bush lot assembly into the middle of the H P seat Secure it with your ES finger and verify H P seat movement For the A 101 and A 105 A For complete disassembly first disassemble the body dlanco chamber cap side as explained above If you plan to inspect onty the H H P seat side without HP spring disassembling the body cap ES side first loosen the adjusting HPseat NSA screw completely SY Then remove the C ting on NSA top of the air port with C ring BeOS snap ring pliers IN special too gt E on page 7 Watch for parts O ring i that the H P spring might push out After removing the C ring remove the filter guide retainer balance chamber H P spring and H P seat lt Re assembly gt To re assemble the H P seat b
14. de larger to fit the divers hana assuring ease of use E Symmetrical service ports The symmetrically positioned service ports allow you to connect your gauges and low pressure hoses on either the left or the right as you wish E Simple low pressure adjustments made from exterior Volume 5 p 03 regulators regulator Ist stage a 105 E Moisturizing device if possible divers would prefer the air supplied to them to be moist and clean When a cylinder is being charged the compressed air is temporarily heated Afterward the air is cooled and the moisture present is separated out in the form of water droplets Generally atmospheric air contains about 40 70 moisture while pressurized air of 1 3 moisture results in extremely dry air When this dry air is breathed in and then breathed out the moisture content in the exhaled air can be measured to about 80 Because this moisture is drawn from the lungs and circulatory system divers get dry throats in addition to an increased possibility of decompression illness due to a detrimental effect on the ability to dissipate bubbles in the circulatory system caused by a lack of moisture in the lungs The A 105 adds an appropriate amount of moisture to the dry air coming from a tank to supply moist and clean air a 105 to the diver Type Balanced Diaphragm E Effects of moisturizing device and air purifier No of Ports 1 H P 7 16 1 Prevention of decompression sickness whic
15. e sure to insert the spring pin protruding from the inside of the body into the center opening of the H P seat only when disassembling the H P seat side Also be sure to replace the guide retainer correctly with top side at top Reassemble all parts and finally secure with the C ring MAKE SURE THE C RING FITS SNUGLY INTO THE GROOVE OF THE H P MODULE C ring Filter side Guide retainer Balance chamber HP spring HP seat Volume 5 p 13 regulators precautions when using regulator 2S ee eS ee H Care of the hose protector There are some cases in which hose breakdowns have been traced to problems with a hose protector attached to a regulator hose or gauge hose The hose protector is made from soft material Therefore when it is attached in the proper way in the proper piace it performs correctly However when it is put in place or used in the wrong way there is a possibility of the following types of breakdowns occuring The protector comes off from the hose fitting Under this circumstance the hose protector becomes rigid and is not able to bend easily with the hose Tne most common hose problem involves cracks in the hose attaching component hose at the brass parts The hose protector is designed to prevent this sort of problem from occuring However if the hose protector moves away from the hose fitting it loses its protective function and actually can cause damage to the hose Junction Holder
16. er gasket if defective or damaged gt Very slight flaws can be smoothed out with sandpaper grade 1000 0 For 1993 and later models 0 The O ting ARP 01 1 of the yoke retainer is wom or damaged v lt Replace the O ring gt Yoke Retainer Wrench Volume 5 p 10 regulators regulator maintenance 2nd stage maintenance E Free flows First check the air pressure in the 1st stage to verify it is at the designated level If free flow continues after adjustment check and repair as explained below Checkpoints 1 Is the top of the valve cone or valve seat dirty or damaged Inspection Repair 0 Thoroughly clean and inspect the valve cone and seat Repiace if parts ore damaged Gradually tighten the valve cone in a counterclockwise direction until the free flow stops and set it at that position CAUTION Do NOT over tighten the valve cone or the demand lever will lower and the diaphragm will not function Stop the valve cone at the point where the free flow stops NEVER tighten beyond this point 2 Is the valve cone in the proper position 0 Check the valve seat carrier O ting 2 places and remove any debris sand salt etc If the O ring is worn or warped install a new one 3 Problem with the carier O ring for balanced type 0 Clean away any debris sand salt etc from the balance chamber seal surface If the interior surface is d
17. ge Fora list of featuresand a description of the prestige 2nd stage referto pages2 amp 5 The following items should be highlighted in your manual page 42 Items requiring mandatory annual replacement key description 18 valve seat Items requiring careful inspection for serviceability before refitting 15 valve cone check tip fordamage 14 demand lever distortion 13 diaphragm 35 exhaust valve special notes All parts must passa visual inspection for serviceability before refitting It is suggested to check the diaphragm cover lock and if the lock is the early type screw with plastic lug ensure the thread isnot stripped It issuggested although not mandatory that the screw assembly be replaced with the new metal lock 9 The adjusting knob 23 should be tumed counter clockwise all the way out until it stops and then tumed back clockwise 1 tum before commencing to adjust the orifice When dismantling shaft 31 from nut 28 the shaft hasa left hand thread Thisthread should be well lubricated during reassemble to maintain free movement between service periods Check to ensure that a liberal quantity of silicone is applied to the threads of the adjusting shaft 31 during reassemble Apollo includes the following items in the prestige standard 2nd stage service kit Pinnacle 163053 p 42 key s 3 4 18 20 amp 27 service info 8 2000 maintenance guide for use with Service Manual Vol 5
18. h is due to lack 2 L P 1 2 of moisture in the air supply e Intermediate Pressure Value 2 Clean air during a dive When tank pressure is 200 kg cm 3 Decrease in post diving fatigue or exhaustion ee ae oe 4 Pressure equalization becomes easier n ment contr wim extemal GauSImenicontol 5 internal tank rust oils and odors are removed Total Weight 1005 g The psychological influence which the effects provided in Fitter Device Activated Charcoal Filter the examples above have on diving a sport which is e Moisturizing Device W sponge Filter Moisturizing Tube strongly affected by the mental and emotional state of the diver cannot be discounted Product features E Simple low pressure adjustments made from exterior W Air purifier A tank may contain rust and corrosion In addition to the debris that may enter when a tank is being filled or charged In general the fitter set in the 1st stage port is designed to handle high pressure air and cannot filter out the smaller molecules of rust iron or small particles of debris The A 105 attachments fitter out the debris through the activated charcoal fitter installed in the low pressure port Any breathing resistance Is compensated for by the larger surface area of the fitter which also acts as a deodorizer Activated Charcoal Filter Moisturizing Device Composition of the Clean Air a 105 a 105 Construction Diagram Volume 5 p 04 regulators regulator 2nd stage pre
19. it is not removable To remove the front cover depress the lock with a jewelers screw driver 2 The exhaust cover is removable via a bayonet fitting depress the lock and tum a quarter of a tum to remove the cover This cover is now interchangeable with the ecodiver exhaust covers A pollo includes the following items in the prestige balanced 2nd stage service kit Pinnacle 163056 p 43 key s 3 4 16 21 amp 28 service info 9 2000 maintenance guide for use with Service Manual Vol 5 ecodiver 2nd stage The following items should be highlighted in your manual page 44 Items requiring mandatory annual replacement key description 22 2 x o rings valve seat ca mier on end of stem Items requiring careful inspection for serviceability before refitting 21 LP seat in end of stem 23 valve cone check tip for damage 24 o ring valve cone 13 demand lever distortion 12 diaphragm 25 exhaust valve special notes All parts must passa visual inspection for serviceability before refitting The adjustable orifice haschanged on this unit compared to the earlier prestige 2nd stage An in line adjusting tool isnow required to complete the tuning operation Assembly and tuning proceduresare located on the back of this page A pollo includes the following items in the ecodiver balanced 2nd stage service kit Pinnacle 163054 p 44 key s3 4 15 17 amp 22 service info 10
20. justments to the pressurization level and unit cost prices are lower Furthermore since it is designed so that there is almost no influence from the remaining pressure high degree of stability in the 1st stage is ensured and supply pressure is not affected Fluctuations in pressurization levels resulting from changes in internal tank pressure measured on land Balanced diaphragm type Tank Pressure kg cm Pressure kg cm Maximum Pressure Difference kg cry 200 760_ 100 0 9 4 9 5 9 6 9 6 0 2 fluctuation rate under about 2 HP Figure 2 Operational Principles of the Balanced Diaphragm Type regulator general design of 2nd stage regulator E 2nd Stage The 1st stage decompresses air Apollo products decompress air to 9 8 cr The 2nd stage takes this air and decompresses it further to the pressure best suited to the depth the diver is at It supplies this air only in the amount the diver needs at any specific moment First principle of 2nd stage operation When the diver is not breathing the carrier spring acts on the pressure of air being sent through the L P hose stopping leakage in the 2nd stage The force exerted by the carrier spring is determined by the air pressure made in the 1st stage Apollo s 2nd stage has been designed to adjust air pressure to a standard of 9 8 kg cm When the diver starts breathing again air pressure in the 2nd stage becomes lower than the ambient press
21. lve cone is not set in the right position Inspect each part and adjust the air pressure once more When the iow pressure is not at the specified value Adjust the pressure with the adjusting screw on the bottom of the regulator body A special tool see page 7 is necessary for tuming the adjusting screw As shown in Figure 5 when the adjusting screw Is turned clockwise the pressure increases Similarly when the screw is turned counterclockwise the pressure decreases Adjust the pressure to 9 8 kg cm After you have set the pressure to this value release air a few times using the 2nd stage purge button then verify that pressure has stabilized Lever does not budge easily Volume 5 p 08 regulators regulator maintenance Ist stage maintenance E Inspection and repair of the 1st stage First measure the low pressure from the 1st stage Set a low pressure gauge onto the low pressure port and open the relief valve in direction 1 as shown in the illustration right side This is to prevent damage to the low pressure gauge and hoses in the event of damage to the high pressure seot by directing the flow of high pressure toward the L P port Open the valve and while watching the needle of the low pressure gauge siowly close the relief valve in direction 2 as shown in the illustration right side Note the movement of the pressure gauge needle Symptoms 1 Rapidly rises above 15 kg cm In this case
22. re the module is the next part to be removed and the module has thread lock take a nylon drift 1 2 diameter x 5 long place the 1st stage on a solid surface and position the nylon drift on top of the hp module Then using a small engineers hammer firmly tap the module This has the effect of breaking the thread lock and the module can now be removed using normal force CAUTION DO NOTUSE a metal drift use only nylon ora hard wooden dowel the module is manufactured from brass which is quite soft so using a metal drift can damage the housing service info 6 2000 maintenance guide for use with Service Manual Vol 5 a 102 1st stage Fora list of features and a description of the a 102 refer to page 3 Factory intermediate pressure 145 psi 7 psi The following items should be highlighted in your manual pages 40 amp 41 Items requiring mandatory annual replacement key description 11 filter 26 o ring balance housing 28 hp seat Items requiring careful inspection for serviceability before refitting 20 hp diaphragm special notes All parts must pass a visual inspection for serviceability before refitting Adjusting screw 14 and guide nut 15 have a left hand thread A pollo includes the following items in the a 102 service kit Pinnacle 163050 pp 40 amp 41 key s 11 26 amp 28 service info 7 2000 maintenance guide for use with Service Manual Vol 5 prestige standard 2nd sta
23. regulator general design of Ist stage regulator E Regulator A regulator is important for easy breathing underwater It supplies pressurized air from the tank to the diver after decompressing it to the pressure suitable for the depth the diver is at matching the ambient pressure It also makes sure air is supplied onty in the amount the diver needs at any specific moment and in a way easy to inhale For these reasons the regulator is very important Handle the regulator with care it shouid not be subjected fo large shocks or treated roughly in any way Wash thoroughly with fresh water after use to remove any debris and all salt Salt and small objects are the cause of ftee flows and thorough washing cuts down on these and other problems Overhaul and inspect the regulator once a year or after every 100 dives whichever comes first E Regulator elements Regvicret lsisiage Ist Low Air depressurization Pressure _ sutrounding pressure LP ee 2E mOge 2nd depressurization High Air Pressure E Types of 1st stage construction The Ist stage depressurizes the higher tank pressure and sends air of a suitable pressure to the 2nd stage Two different types a Unbalanced piston type called a standard piston type A Piston Type b Balanced piston type a Unbalanced diaphragm type B Diaphragm Type 4 b Balanced diaphragm type are available The intermediate pressure of the balanced
24. screw 24 and guide nut 25 have a left hand thread Check to ensure that chamber spacer 34 is fitted with the two support legs facing the filter A pollo includes the following itemsin the a 107 service kit Pinnacle 163052 p 39 key s 12 14 33 36 amp 38 service info 5 e apollo 2000 engineering update a 102 hp module problem Some difficulty is being experienced by some technicians with disassembly of the HP module in the a 102 regulator Refer to the drawing on page 40 or 41 of the service manual volume 5 causes Although the hp module is not over tightened during the assembly at manufacture after a period of use it is possible for the module to experience thread lock Supply pressure inside the module exerts a considerable force trying to push the module from the 1st stage body In some cases this causes the thread to lock up If salt water is allowed to enterthe 1st stage through the filter this can find its way into the hp module threads causing thread lock due to salt build up remedy One remedy is very simple ensure you use the corect size tool to remove the module a standard screw driver will not engage the slot in the module without causing damage to the slot A numberof units have been retumed to Apollo with this slot badly damaged If you are using the correct tool and the module is still too tight to move the following procedure can be used After dissembling the 1st stage to the point whe
25. stige 2nd stage prestige 2nd stage Type Demand valve type adjusting mechanism with Turbo Stream flap breathing resistance adjustment design Demand valve adjustment design Boay Bottom case High impact plastic BK Top cover High impact plastic in 8 colors FPK FYL FOG FGN COBL PL WT BK Mouthpiece Translucent surgical silicone rubber Exhaust valve Large single silicone valve L P hose 2nd main 70cm Octopus 90cm Standard intermediate pressure 9 8kgficm Product features E Turbo stream flap breathing resistance adjustment design mechanism A turbo stream flap breathing resistance adjustment valve has been Installed in front of the mouth piece so that the inhalation resistance level can be controlled By using this with the demand valve adjuster it is all the more suited to meet the breathing patterns of each diver E Demand valve adjusting mechanism The inhalation resistance can be adjusted through the demand valve adjuster without disassembly of the regulator Turn the adjusting knob on the side of the body to obtain the desired inhalation resistance E Large single exhaust valve system The large silicone single exhaust valve ensures smooth exhalation E Lightweight plastic body and colorful top cover The body is light because it is made of plastic The brightly colored top covers with 8 colors to choose from can be easily seen underwater Volume 5 p 05 regulators
26. type remains roughly the same regardless of the amount of remaining tank pressure However the intermediate pressure of the unbalanced type is greatly influenced by the amount of pressure remaining in the tank Changes in intermediate pressure have a direct effect on breathing resistance E Features of the unbalanced standard piston type Since the unbalanced piston type is composed of relatively few parts it experiences few breakdowns However due to its design intermediate pressure is subject to influence from the amount of remaining pressure in the tank As the amount of remaining tank pressure decreases the intermediate pressure level decreases as well increasing breathing resistance The reason for this is that the influence of the remaining tank pressure is absorbed by the piston Fluctuations in pressurization levels resulting from changes in internal tank pressure as observed on land Unbalanced piston type Tank Pressure kg cm Pressure kg cm Maximum Pressure Difference kg cm 7 fluctuation rate about 30 E Features of the balanced piston type Like the unbalanced piston type the Ist stage is composed of relatively few parts and experiences few breakdowns Furthermore compared to the unbalanced piston this unit is designed with a structure that reduces the direct influence of remaining tank pressure on Internal pressurization Intermediate pressure fluctuations have been
27. ure so the diaphragm is pushed downward This results in the demand lever opening the vaie thereby supplying air to match the divers needs Even when the diver stops breathing air at intermediate pressure passes through the open vaie and the diaphragm displaced by ambient pressure retums to its original position The carrier spring then closes the valve Second principle of 2nd stage operation When a dive is begun pressure outside the 2nd stage increases meaning a relative decrease in air pressure within the 2nd stage As a result the diaphragm is pushed downward and air flows as described immediately above Air flows out until air pressure in the 2nd stage reaches the same pressure as the ambient pressure Then the diaphragm returns to its original position When the diver surfaces air pressure in the 2nd stage increases and excess air is expelled through the exhaust valve So even when a diver moves from one level to another the 2nd stage supplies air at a pressure suitable to the depth The diaphragm which senses air pressure in the 2nd stage plays an important role The opening in the top cover through which water is removed is also important as it transmits exterior pressure to the diaphragm in the 2nd stage Do not use regulator covers sold by other companies lil Principles of the balanced type The carier spring exerts pressure to prevent air leakage A different LP pressure is exerted by the valve tying to open when
28. use the following flow chart to identify the problem Checking and repairing free flows Checking the Ist stage Checking the low pressure with a OK ist stage OK Checking the 2nd stage Check each part repair p See section on inspection and maintenance of the 2nd Stage OK Seems OK but free flows Figure 4 p 12 Volume 5 regulators regulator maintenance regulator maintenance E Disassembly and assembly of 1st stage When you want to inspect important parts such as the H P seat balance chamber H P diaphragm and bush lot assembly use the following order E Disassembly of body cap side all models 1 First completely loosen the adjusting screw then remove the body cap with the pressure adjustment wrench and the cap wrench special tools A shown on page 7 Then remove the parts shown in section A below 2 Section B of diagram on tight Next remove the diaphragm retainer with the adjustment wrench special tool then remove the diaphragm washer and H P diaphragm The H P diaphragm is inserted tightly so pull it up with a small pointed instrument Be careful not to scratch surfaces of the H P diaphragm or the inner body 3 Section C of diagram on right Finally remove the bush lot assembly and check Important Notes The adjusting screw and guide nut are reverse threaded When re assembling first make sure the adjusting screw is screwe
29. very 6 months for commercial use or after using in contaminated waters note Service means canying out the procedures laid down and recommended by Apollo at technical workshops and seminars service info 1 e apollo 2000 engineering update regulator washing methods routine washing after use The following procedures should be recommended to your customers for washing their equipment after use and also for washing rental equipment after use 1 After completing the check that the dust cap is dry before fitting to the regulator blow dry using cylinder air if necessary Fit to regulator Before canying out the washing procedure make sure the dust cap is fitted that it is fitted the corect way up DO NOTdepress the purge button during the washing procedure After EVERY dive the regulator should be soaked in fresh water preferably wam Allow enough time for any salt deposits to soften After the salt has softened it must be flushed away by rinsing under running water again wam water works better than cold To be effective direct the water into the ambient sensing chamber of the first stage as well as washing extemally The second stage should be flushed both intemally and extemally Do not depress the purge button If the button is accidentally depressed during washing the regulator must be fitted to a cylinder pressurized and purged until all moisture is blown from the regulator Shake the 1st and 2nd stagesto help
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