Service Manual
Contents
1. 41532 LP air nozzle Parts drying N A Magnifier w illumination Sealing surface inspection N A Ultrasonic cleaner 60HZ 1 3 amp Brass stainless steel parts cleaning Apeks Regulator Service and Repair Manual Lubricant Cleaner Christo Lube Chemical Bath Solution Liquid dishwashing detergent diluted with warm water TABLE 2 LUBRICANT AND CLEANER Recommended Type MCG 111 Chromesafe 50 50 mix distilled white vinegar and water Joy Application All O rings threaded metal parts as indicated Chrome plated brass brass and stainless steel parts Chrome plated brass brass and stainless steel parts General cleaning solution degreaser for plastic and rubber parts leak detection Source Lubrication Technologies 310 Morton Street Jackson OH 45640 800 477 8704 Sea Quest Aqua Lung America P N 0201 05 Local grocery stores Local grocery stores DO NOT use muriatic acid for the cleaning of any parts Muriatic acid even when strongly diluted can harm chrome plating and may leave a residue that is harmful to O ring seals and other parts Aerosol spray silicone should be avoided because 1 common aerosol propellants may attack plastic and rubber parts and 2 because only a slight amount of silicone remains after the solvent evapo rates and provides no lasting benefit tion of the material Silicone rubber requires no lu2. tioned inside the retaining tabs on either side see Fig 14 15 While holding the valve module securely seated inside the case fit Figure 14 the O ring 4 down over the threaded inlet of the valve spindle Correct Index of Valve Spindle w Case 14 Apeks Regulator Service and Repair Manual 16 17 18 19 20 21 22 23 24 Fit either the spacer or the large diameter end of the heat exchanger item 3 over the threaded inlet of the spindle and then thread the retaining nut 2 clockwise by hand onto the spindle until it is finger snug Check again to ensure that the valve module is held secure inside the case with the flange and lever arms fitted inside the retain ing tabs Then apply a torque wrench with 46 socket to tighten the retaining nut or the hex fitting of a newer revision spacer heat ex changer to a torque measurement of 50 inch lbs Check the height of the lever to ensure that it stands perfectly level with the rim of the case with a slight freeplay that does not exceed 1 0 mm If necessary apply a 5mm hex key to adjust the seat crown as needed to raise or lower the lever until it is level with the case rim Install the exhaust valve diaphragm 12 into the box bottom by gen tly pulling the stem through the hole in the center of the support spokes until the barb has passed through and is securely seated against the opposite side Gently turn the diaphragm outside the case to
3. damage to the seating flange requiring replacement of the case Do not use a tool to remove the exhaust tee Doing so may cause Remove the exhaust valve diaphragm 12 from the case Discard and do not reuse Carefully snip the mouthpiece clip 15 and remove the mouth piece 14 from the case 11 Inspect the mouthpiece to ensure it is free of any tears or cuts that may cause leakage of water into the second stage or other discomfort Discard the mouthpiece or set it aside to be reused depending on its condition To remove the case cover mate the two pins of the case cover tool P N AT31 into the case cover with the opening aligned over the APEKS logo at one o clock see Fig 1 While holding the tool pressed inward and securely engaged turn the case cover counter clockwise to loosen and remove NOTE The TX100 requires a different case cover tool P N AT42 which can be mated into any two opposing slots 6 The purge button can be removed if cleaning or replacement is nec essary by flexing two opposing arms inward while holding the case cover between thumb and forefinger with its underside facing up see Fig 2 Separate the spring from the button and replace the decal with new if needed Apeks Regulator Service and Repair Manual 7 Lift out the diaphragm cover 9 and diaphragm 10 from the case and closely inspect the diaphragm to ensure that it is perfectly round an
4. no fluttering or sticking of the exhalation valve If any of these problems occur refer to Table 3 Troubleshooting This concludes the annual service procedures for Apeks Second Stage Regulators Apeks Regulator Service and Repair Manual 17 TABLE 3 APEKS SECOND STAGE TROUBLESHOOTING SYMPTOM Leakage or freeflow from second stage High first stage intermediate pressure should be 140 5 psi Rubber seating 31 damaged or worn Seat crown 19 incorrectly adjusted lever 22 set too high Seat crown 19 sealing surface damaged Valve spring 28 damaged ACTION REQUIRED Refer to first stage Troubleshoot ing Guide Replace rubber seating Reset crown and perform Final Tuning amp Testing procedures Replace seat crown Replace poppet spring Low purge or excessive work of breathing full cylinder Low intermediate pressure should be 140 5 psi Lever 22 not properly engaged with shuttle valve 30 Seat crown 19 incorrectly adjusted lever 22 set too low Intermediate pressure hose clogged or obstructed Refer to first stage Troubleshoot ing Guide Disassemble and inspect condi tion of shuttle valve and lever Reset crown and perform Final Tuning amp Testing procedures Clean or replace hose External air leakage Intermediate pressure hose loose Immersion Test Seat crown O ring 20 damaged
5. psi Turn the second stage adjustment screw exactly one full turn 360 clockwise Slowly open the air supply valve to fully pressurize the regulator a If airflow can immediately be heard when the regulator is pres surized depressurize and purge the system Disconnect the IP hose and remove the case cover diaphragm cover and diaphragm to re check the height of the lever The lever should be set at a height level with the rim of the case with approximately 1 0 mm freeplay see Fig 16 If the lever is set too low or too high apply a 5mm hex key through the inlet to adjust the crown seat either counter clockwise to raise or clockwise to lower the lever When the lever is set correctly re install the diaphragm diaphragm cover and case cover and connect the IP hose to the second stage 6 When no airflow can be heard after the regulator has been pressur ized slowly depress the purge button to verify whether a strong air flow can be initiated when the button has traveled no more than 2mm If a strong purge cannot be initiated by depressing the purge button a maximum distance of 2mm it will be necessary to adjust the seat crown slightly counter clockwise Excessive travel of the purge button indicates that the lever is set too low 7 Depress the purge button sharply several times to ensure that leakage or freeflow does not occur If a slight leak occurs after sharply purging the secon
6. those that are being reused to ensure that each part is clean and free of any contamination corrosion or blemish Before performing any reassembly it is important to inspect all 4 AI O rings should be replaced at every servicing New O rings should be inspected for contamination and or imperfections and lightly dressed with a thin film of approved lubricant prior to installation See Lubricant and Cleaner Table 2 Do not use any petroleum based lubricants or products or any aerosol silicone sprays on any part of Sea Quest Apeks regulators The petro leum base or propellant gas may attack or weaken plastic or rubber parts Refer to Table 2 for a list of approved lubricants Apeks Regulator Service and Repair Manual 11 5 In addition to the O rings the following parts should be routinely replaced at the time of servicing e Exhaust Valve Diaphragm 12 e Rubber Seating 31 e Mouthpiece Clip 15 All O rings and the above mentioned routine replacement parts are included in the Overhaul Service Kit P N APO219 The following parts should be closely inspected for the damage listed below Close inspection is best accomplished by using strong magni fication under bright lighting Lever 22 Compare with new to inspect for bending or distortion Valve Spring 28 Inspect for signs of permanent corrosion includ ing pitting or cracks in the surface of the metal Seat
7. with a magnifier to ensure it is not dam aged bent or corroded If any signs of damage or corrosion are found discard the spring and do not reuse Using a fingernail remove the rubber seat 31 and the small O ring 29 from the shuttle valve Discard both the seat and O ring and do not reuse Do not use a metallic instrument or any other tool to remove the seat or the O ring Doing so may damage the shuttle valve which could result in a leak if the damage is undetected and the shuttle valve is not re placed 17 18 Closely inspect the condition of the shuttle valve to check for any signs of damage especially at the ears which engage with the le ver Set the shuttle valve aside if it is found to be in reusable condi tion or discard and replace it with new if damage is present While holding the spindle secure apply a 5mm hex key to the head of the seat crown 19 inside the threaded inlet Turn the crown coun terclockwise to disengage its threads Because the seat crown is O ring sealed it will not freely exit the valve spindle after it has been unthreaded The following step must be performed correctly in order to remove the crown without damaging its delicate sealing surface 19 20 21 When the seat crown has been unthreaded from the valve spindle carefully insert the pin of the Seat Extraction Tool through the oppo site end of the valve spindle and
8. Case 11 damaged Tighten to 40 inch lbs at female second stage fitting Disassemble and replace O ring Disassemble and replace case Water entering second stage Hole in mouthpiece 14 Demand diaphragm 10 damaged Exhaust valve diaphragm 12 damaged Venture lever O ring 13 dirty damaged or worn Case 11 damaged Check exhaust valve sealing surface Valve spindle O ring 4 damaged Replace mouthpiece Replace demand diaphragm Replace exhaust valve diaphragm Disassemble and replace O ring Disassemble and replace case Disassemble and replace O ring Recommended treatments which require disassembly of the regulator must be performed during a complete overhaul according to the prescribed procedures for scheduled annual service Do not attempt to perform partial service For assistance with a problem not described here contact a Sea Quest Technical Advisor 18 Apeks Regulator Service and Repair Manual REGULATOR REPAIR AND REPLACEMENT PARTS APEKS SECOND STAGES Item Description Part Item Description Part 1 Deflector AP2037 14 Comfo Bite Mouthpiece 109438 2 Nut TX100 AP2031 S 15 Mouthpiece Clip 104913 Nut TX50 40 T20 AP2031 16 Exhaust Tee AP2040 3 Heat Exchanger TX100 AP5013 S 17 Venturi Lever TX100 AP5339 Heat Exchanger TX50 40 AP5013 Venturi Lever TX50 40 T20 AP2039 Spacer T20 AP5003 18 Spring Pin AP1151 Heat Ex
9. Crown 19 Inspect the cone area for nicks scratches pitting or any defects in the plating Pay particular attention to the sealing edge of the cone Shuttle Valve 30 Inspect for scratches or other damage particu larly at the groove which holds the small O ring and around the ears Demand diaphragm 10 Inspect for tears or pinholes To detect pinholes hold diaphragm up to a light source as you gently stretch the diaphragm Inspect the round plastic diaphragm plate for any evidence of damage Mouthpiece 14 Inspect for cracking or tears or any excessive wear especially around the bite tabs Case 11 Inspect for any indication of cracks or thread damage Closely examine the seating ledge which indexes with the poppet housing to ensure it is free of any distortion or other damage If any of the listed parts show any damage they must be replaced with new Check all metal parts for excessive wear or corrosion Check all metal sealing surfaces which make contact with O rings for any signs of contamination and or imperfections that may cause leakage past the O ring seal Examine all chrome plated surfaces for any evidence of peeling or flaking of the chrome plating Inspect all threads for gall ing cross threading or damage to the chrome plating If any parts show damage or excessive wear they must be replaced with new 12 Apeks Regulator Service and Repair Manual REASSEMBLY PROCEDURES ad d Before performing any rea
10. brication or preservative treatment DO NOT apply silicone grease or spray to silicone rubber parts Doing so will cause a chemical breakdown and premature deteriora Apeks Regulator Service and Repair Manual Figure 1 Case Cover Tool Alignment Figure 2 Removing Purge Button DISASSEMBLY PROCEDURES Before performing any disassembly refer to Table 4 which references all mandatory replacement parts These parts must be replaced with new and must not be reused under any cir cumstances regardless of the age of the regulator or how much use it has received since it was last serviced To prevent damage to critical sealing surfaces use only a plastic or brass O ring removal tool P N 9440 22 when removing O rings Once an O ring sealing surface has been damaged the part must be replaced with new in order to prevent the possibility of leakage DO NOT use a dental pick or any other type of steel instrument While holding the retaining nut 2 secure at the second stage inlet fitting with an 11 6 open end wrench apply a second lA6 open end wrench to the female fitting of the LP hose 16 Turn the fitting counter clockwise to loosen and remove the hose from the second stage Remove the O rings from the hose and discard Set the hose aside While holding the case 11 secure remove the exhaust tee 16 by firmly pulling one side off and then the other serious
11. ch Threaded TX50 40 AP5002 19 Seat Crown AP2033 Heat Exch Threaded TX100 AP5013 20 O ring AP1154 Spacer Threaded T20 AP5003 21 Valve Spindle TX100 AP2028 S 4 O ring AP1267 Valve Spindle TX50 40 T20 AP2028 Decal TX100 AP5015 22 Lever AP2035 Decal TX50 AP5004 1 23 O ring AP1267 Decal TX40 AP5004 2 24 Plug TX100 50 40 AP2030 Decal T20 AP5004 3 25 Adjusting Screw TX100 AP2029 2S 6 Purge Button AP2053 Adjusting Screw TX50 AP2029 7 Spring AP2020 Adjusting Screw TX40 T20 AP2029 1 8 Case Cover TX100 AP5326 26 O ring AP1409 Case Cover TX50 40 T20 AP2026 27 Counter Balance Cylinder AP2038 9 Diaphragm Cover AP2025 28 Valve Spring AP2021 10 Diaphragm AP2023 29 O ring AP2041 11 Case AP5001 30 Shuttle Valve AP2036 12 Exhaust Valve Diaphragm AP1429 31 Rubber Seating AP2034 13 O ring AP1438 n s Overhaul Service Kit APO219 Items in bold are included in the Overhaul Service Kit Apeks Regulator Service and Repair Manual 19 Apeks Second Stages Schematic NOTE Apeks has recently introduced a new heat exchanger and spacer which feature a 6 threaded fitting and do not require a hex nut item 2
12. d free of any tears deterioration or other damage If deterioration or damage is found discard the diaphragm and do not reuse 8 Turn the adjusting screw 25 completely out counter clockwise until it stops either by hand for models TX100 and TX50 or with the use of a 5mm hex key for models TX40 and T20 see Fig 3 This will hold the retaining pin 18 in place when the valve module is removed from the case 9 Apply an 11 16 open end or box wrench to the retaining nut 2 and turn the nut counter clockwise to loosen and remove from the threaded Figure 3 inlet portion of the spindle Remove either the heat exchanger or Romovin g Adjusting Screw TX40 T20 spacer item 3 which will slide off freely after the retaining nut has been removed More recent models may contain a threaded heat exchanger or spacer which do not require a separate retaining nut 10 While holding the case secure and the lever 22 completely depressed press against the threaded inlet as needed until the valve spindle can be grasped from the opposite side Firmly grasp the end of the spindle or the external adjusting screw and pull the entire valve assembly straight out of the case see Fig 4 Remove and discard the O ring 23 Sn i from inside the case if it did not fall off the end of the spindle Figure 4 Removing Valve Module CAUTION Do not attempt to remove the valve module assembly from the case without first holdi
13. d stage it will be necessary to adjust the seat crown slightly clockwise being careful to adust only as far as needed to create a seal between the seat crown and rubber seating without raising the lever too high 8 Move the venturi lever to the MAX position and depress the purge button sharply This should initiate a strong continuous freeflow that can be eliminated by turning the venturi lever back to the MIN position 16 Apeks Regulator Service and Repair Manual 9 To test the setting of the seat crown turn the second stage adjustment screw completely out counter clockwise to initiate a slight flow of air and then slowly turn it back in clockwise to verify that the airflow has stopped completely before it has been turned 1 full turn If more than 1 turn is required to shut off the airflow it will be necessary to readjust the crown as described in step 5 10 When all adjustments have been satisfactorily performed apply a torque wrench with 1 6 crow foot to tighten the IP hose fitting to a torque measurement of 40 inch lbs 3 EXTERNAL LEAK TEST 1 After disconnecting the regulator from the flow bench connect to a scuba cylinder filled to approximately 3 000 psi Open the cylinder valve to repressurize the regulator and submerge the entire system in a test tank of clean water 2 Observe any bubbles arising from the submerged regulator over a one minute period The recommended time is nece
14. e inlet side of the box bottom and pull the clamp sufficiently snug Snip the extra length with a small pair of scissors or wire cutters This concludes the reassembly of the second stage Refer directly to the following section titled_Final Adjustment amp Testing Apeks Regulator Service and Repair Manual Figure 15 Venturi Lever MIN Setting ne a Lever set correctly case rim Lever set too low R case rim ja E if Zero free movement Lever set too high ma a ies o ie case rim Figure 16 Relationship between seat crown and lever height adjustment FINAL ADJUSTMENT AND TESTING PROCEDURES Prior to adjusting and testing the Apeks second stage regulator the accompanying first stage must be correctly serviced adjusted to a stable intermediate pressure of 140 psi and fully tested Refer to the corre sponding first stage service procedures before attempting to perform the adjustment and testing of the second stage Thread the male fitting of the IP hose into the preferred low pressure port of the first stage and apply a torque wrench with 1 46 crow foot to tighten to 40 inch pounds 2 Turn the second stage adjustment screw completely out counter clock wise and set the venturi lever to the MIN position see Fig X Connect the first stage to a filtered air source of 3 000
15. followed correctly Indicates any situation or technique that may result in potential damage to the product or render the product unsafe if instructions are not followed cor rectly Is used to emphasize important points and tips GENERAL PROCEDURES MAINTENANCE SCHEDULES Regulators are subjected to a variety of environmental el ements that over time can affect the performance of the product As an Authorized Sea Quest Apeks Dealer you are advised to inform your staff and customer that Sea Quest Apeks regulator require complete servicing at least once a year Under certain circumstances a complete ser vicing is required every 3 6 months Some of these cir cumstances are e Frequent or improper use e Inadequate routine freshwater rinsing e Regulator use in dirty or polluted waters e Rental use e Regular use in chlorinated pool water Recommended maintenance schedules are based on aver age use under normal conditions and assume that recom mended preventative maintenance and storage procedures have been followed as outlined in the Sea Quest Apeks owner s manuals Advise the customer that any adjustments or servicing on Sea Quest Apeks regulators must be performed by Sea Quest or by an Authorized Sea Quest Apeks Dealer that has attended a Sea Quest authorized service seminar INITIAL INSPECTION AND PRE TEST Prior to beginning the servicing of the regulator a pre
16. is seated against the opposite end and then slowly release the valve lever to prevent it from springing up Postale Sean rows Be careful not to turn the external adjusting screw while installing the wwe venturi lever onto the valve spindle It is very important to keep the screw turned completely out counter clockwise in order to hold the retaining pin in place a 12 Install the O ring 20 onto the seat crown 19 and carefully insert the threaded end of the crown into the inlet end of the valve spindle Gently press it in further with the blunt end of the seat extraction tool P N 1094 36 until it stops see Fig 12 13 Apply a 5mm hex key to the head of the seat crown and turn the crown clockwise to engage the threads Continue turning the crown Figure 13 clockwise only until the lever begins to drop slightly Installing Valve Module 14 Orient the case with the exhaust valve facing down at 6 o clock While holding the lever depressed guide the inlet end of the valve spindle through the opening in the right side of the case and into the opening on the opposite side until the lever can stand up see Fig 13 Check to ensure that the venturi lever is correctly aligned to fit in its groove outside the case and the valve lever is facing straight up Carefully guide the valve spindle completely to the left until the flange is seated flush against the inside of the case and the arms of the lever are posi
17. liminary inspection and pre test of the entire breathing sys tem is recommended This will help the repair technician identify any problems that may affect the second stage Preliminary inspection should include e First stage inlet filter If the first stage inlet filter is discolored the entire regulator should be completely ser viced Deposits of rust red powder or aluminum oxide gray powder on the filter may indicate that water has entered the SCUBA cylinder and caused internal cylinder corrosion The customer should be notified that their SCUBA cylinder s may be in need of visual inspection cleaning and testing Advise your customers to regularly inspect the inlet filter for any discoloration or corrosion e High pressure HP and low pressure LP hoses Inspect the hoses carefully for any evidence of cracking tearing or excessive abrasion of the outer rubber cover ing Remove all of the hose protectors and examine the area around the metal fittings for any damage to the hose Inspect the fittings for signs of excessive corrosion 4 Apeks Regulator Service and Repair Manual e All chrome plated parts Inspect for any excessive cor rosion indicating weak or absent chrome plating Also look for any signs of peeling or flaking of the chrome plating e Regulator pre test A regulator pre test should include all tests outlined in the test section for each regulator A pre test will assist the technician in determi
18. ng the lever depressed Doing so may cause serious damage to the case lever or shuttle valve which will require their re placement 11 Remove the venturi lever 17 from the case if it remained inside when the valve assembly was removed or hold the lever depressed to re move it from the spindle see Fig 5 Remove and discard the O ring 13 12 While holding the valve spindle secure and horizontal with the lever facing down turn the adjusting screw slightly clockwise to allow the retaining pin 18 to fall out Set the pin aside If the retaining pin does not easily fall out of the valve spindle Figure 5 Removing Venturi Lever after the adjusting screw has been turned slightly clockwise it may be necessary to press it out using the pin of the Seat Extraction Tool P N 1094 36 13 Continue to hold the valve spindle secure and turn the adjusting screw counter clockwise until it has disengaged from the threads of the spindle Remove and discard the O ring 25 14 While holding the valve spindle vertical with the inlet end facing up lift the lever up to allow the shuttle valve 30 and counter balance cylinder 27 to fall out of the valve spindle see Fig 6 Separate these items from the spring 28 between them Figure 6 Removing Yoke Connector Apeks Regulator Service and Repair Manual Figure 7 Removing Seat Crown 15 16 Closely examine the spring
19. ning if there are any specific performance deficiencies not mentioned by the customer INFREQUENTLY USED REGULATORS Do not assume that the regulator is in good condition be cause of infrequent use or because it has been in storage Deterioration of the O rings and corrosion can still occur under these circumstances WORK AREA amp REQUIRED TOOLS Servicing and repair of the regulator should be carried out in a clean well lighted work area As each regulator is dis assembled all parts should be kept separate from parts of other regulators Some special tools are required for proper disassembly and reassembly Please see Table 1 page 5 for a list of these tools O RING REMOVAL When removing O rings care must be taken to not damage the regulator surfaces in contact with the O rings Tools used to remove O rings must not have any sharp edges or points that could scratch metal sealing surfaces Sea Quest strongly recommends that all O ring removal tools should be made of either brass or plastic LUBRICATION O rings should be lubricated with an approved compound please refer to Table 2 for proper lubricants O rings should be lubricated only with a very light film of grease Do not use spray aerosol lubricants under any circumstances The aerosol propellant may damage the plastic and rubber com ponents of the regulator and the lubricant will quickly evaporate providing little or no lasting benefit Do not use any pet
20. position the rib perfectly horizontal Then carefully snip off the excess mate rial of the stem inside the case with a small pair of scissors Install the exhaust tee 16 onto the case by fitting 1t over one upper corner of the seating flange and then stretching it over the other Firmly press the lower portion of the tee onto the flange until it is completely seated Install the diaphragm 10 into the case with its raised center facing up and check to ensure it is evenly seated onto the shoulder at the base of the threads Place the diaphragm cover 9 over the diaphragm with the support cone facing up and press it down to ensure that it seated evenly on all sides If the purge button 6 was disassembled from the case cover 8 fit the spring 7 over the four tabs of the purge button with the smaller diameter end facing down Then position the purge button inside the front of the case cover so that the logos on the decal and the cover are correctly aligned with each other Press the purge button into place so that all four mating tabs are seated inside of the case cover Mate the case cover onto the case and turn it clockwise by hand until snug Apply the case cover tool P N AT31 or AT42 to tighten it further until the purge button logo is properly aligned Install the mouthpiece 14 onto the box bottom and lightly fasten a clamp 15 onto the groove of the mouthpiece Turn the clamp so that the locking tab is facing toward th
21. rch and development Apeks has utilized proven materials and design to maximize reliability and performance This manual is intended only as a guide for the experi enced repair person that has completed a Sea Quest Apeks service and repair seminar It is not intended to educate inexperienced repair personnel or the consumer in all as pects of Apeks regulator repair Sea Quest Apeks repair seminars are available periodically to Authorized Sea Quest Dealers Servicing and repair at the repair shop level mainly involves cleaning inspection adjustment and re placement of worn parts If you have any questions on any of the procedures in spections or tests please contact Sea Quest at 877 253 3483 SAFETY PRECAUTIONS This manual provides step by step instructions for the dis assembly inspection cleaning reassembly and testing of the Apeks second stage regulator It is recommended that all steps are followed in the order given Read each sec tion completely PRIOR to beginning work described in that section This will familiarize the repair technician with important precautions to take during each service pro cedure Pay close attention to all WARNINGS CAUTIONS and NOTES that are intended to draw your attention to items of importance Definition of Warnings Cautions and Notes Indicates a procedure or situation that may result in serious injury or death for either the technician or the user if instructions are not
22. re 9 4 Install the O ring 23 onto the grooved flange of the valve spindle 21 e 5 If the lever 22 was removed lay the valve spindle lengthwise with the threaded inlet facing to the right 3 o clock and the outlet port facing toward 6 o clock see Fig 8 While holding the lever stand ing up perpendicular to the spindle insert one arm into one of the square holes that are located near the flange and then hold it securely in place while rotating the lever slightly over the spindle until the other arm fits into the opposite square hole Closely examine the shape and position of the lever to ensure that the arms have not be come stretched or bent during installation 6 While holding the lever in place stand the valve spindle vertically with the male threaded inlet end facing down and positioned so that the lever faces to the right While holding the shuttle valve and spring by the counterbalance cylinder align the shuttle valve above the spindle so that the two retaining ears which engage the arms of the lever are facing directly to the left opposite of the lever see Fig 9 7 Lift the lever completely up and hold it against the valve spindle Then drop the shuttle valve and counterbalance cylinder straight down inside the barrel of the spindle while being careful to avoid disturbing the alignment of the shuttle valve see Fig 10 Slowly lower the Figure 10 Installing Shuttle Valve Step 2 Apeks Regulator Ser
23. roleum based lubricants or products or any aerosol sprays to lubricate or clean any part or component of Apeks regulators The petroleum base or propellant gas may attack or weaken the plastic or rubber parts Refer to Table 2 for approved lubricants Apeks regulators are intended for use in water tempera tures warmer than 45 F 7 C Colder water may cause regulators to be more sensitive to a freeflow condition and can lead to a situation that requires an appropriate response to prevent serious injury or death Users of Sea Quest regulators are advised to ensure that they are adequately trained to deal with a regulator in a freeflow condition or an out of air emergency before attempting to dive in a cold water environment Apeks Regulator Service and Repair Manual 5 TABLE 1 RECOMMENDED TOOLS APEKS SECOND STAGES Sea Quest Part No Description Application 5116236 Seal seat extractor Removal installation of seat crown AT31 Case Cover Tool TX50 40 T20 Removal installation of case cover AT42 Case Cover Tool TX100 Removal installation of case cover N A 5mm hex key amp hex key socket Removal installation of blanking plugs N A 11 16 open end wrench hex socket Removal installation of LP hose retaining nut N A 0 120 inch lbs torque wrench Small fittings 1116 10 I P test gauge Intermediate pressure testing 9440 22 O ring tools O ring removal amp installation
24. sealfuest Apeks Second Stage Regulator Service amp Repair Manual for Authorized Sea Quest Service Centers 2000 Sea Quest Inc Contents A Introductions isecen onene aoon r ooer teste tient socle tie ssciss O Safety PT CAUTIONS a til este ie dede eh ice ins dents ete a eee ide tete ans ete ts General Procedures sicsccccssesesaseisccasicesedeasaieccuccbcsbesssedececcadedeteSeadecescecadussededeodcccdetessadeccesedcadedssesedeescdsdodedsaseessecso Maintenance Schedules ER en re Ce ea tid Seo RE Re nc ne rake 3 Initial Inspection and Pre Test a A Re nas AP nn 3 a A SIA 4 Work Area amp Reguired Toolsi RAS Us ne ae A NN en 4 OO RC 1015 7 RRR RS a ne 4 E 4 Table t Recommended Tod vns Table 2 Lubricant and Cleaner ici Disassembly Procedures nac ad Cleaning amp Inspection Procedures ssesssesssecssooesoossoosssoeessesssoossoossoosesoesssesssoossoossoosssosessesssoesssssssossssssssse LO Reassembly Procedures AAA O L2 Final Adjustment and Testing Procedures sscssscccssscsscssccssssccscscesscsssscsessscessssecssssscscssecsssssssssseees LS External Leak Cited SR ER ee eo 16 Subjecive Breathing Testi afta as nn 16 Table 3 Troubl sh00ting sise seen lancer dai 7 Repair Replacement Part caciones LO Sehematie DEA need nine nine sine ne ie n e eee etat ent LO Apeks Regulator Service and Repair Manual INTRODUCTION Apeks regulators are the product of many years of resea
25. ssary due to slower bubble formation that occurs in smaller leaks Bubbles indicate a leak which requires that the system must be disassembled at the source to check sealing surfaces assembly sequence and component posi tioning in order to correct the problem s Bubble streams will indicate the source ofthe leak Before dis assembling to correct any leaks rinse the entire regulator thor oughly with fresh water and blow out all residual moisture with filtered low pressure 50 psi air Disassemble and remedy the problem referring to Table 1 Troubleshooting SUBJECTIVE BREATHING TEST 1 While the regulator is connected to a cylinder containing 3 000 psi and pressurized turn the second stage adjustment knob completely out counterclockwise to the full positive position and verify that a slight leak of airflow is present 2 Slowly turn the adjustment knob in clockwise to verify that the air flow stops between 2 1 turn 3 Turn the adjustment knob completely in clockwise and depress the second stage purge to ensure that an adequate volume of air needed to clear the second stage flows through the mouthpiece 4 Turn the adjustment knob back to 2 1 turn negative and breathe from the second stage A properly serviced and adjusted regulator should deliver air upon deep inhalation without excessive inhalation effort freeflow or fluttering of the second stage diaphragm When ex haling there should be
26. ssembly it is important to inspect all parts both new and those that are being reused to ensure that T every part and component is perfectly clean and free of any 4 dust corrosion or blemishes Before dressing each O ring with Christo Lube check to ensure it is clean supple and y free of any blemish Figure 8 Installing Lever Arm Use only genuine Apeks parts subassemblies and components when LE ever assembling any Apeks product DO NOT attempt to substitute an Apeks part with another manufacturer s regardless of any similarity in shape size or appearance Doing so may render the product unsafe and could result in serious injury or death 1 Install the O ring 26 into the groove on the small end of the adjust ing screw 25 and set the adjusting screw aside 2 Install a new rubber seat 31 into the shuttle valve 30 by pressing the stem inward until the lip of the seat is seated evenly on all sides Next install the small O ring 29 onto the opposite end of the shuttle valve 3 Fit one end of the spring 28 over the open end of the counterbalance cylinder 27 and then insert the stem of the shuttle valve into the opposite end While holding these items together press the counter 1 balance cylinder and shuttle valve together compressing the spring slightly so that the counterbalance cylinder seals over the small O ring on the stem of the shuttle valve ts Figu
27. through the opening in the center of the crown Gently pull the crown out and remove and discard the O ring 20 See Fig 7 Closely examine the seat crown with the use of magnifier checking for any scoring nicks or other damage to the polished sealing sur face If damage is found discard the crown and do not attempt to reuse If it is in reusable condition set it aside on a soft surface to prevent damage to the sealing surface Remove and discard the O ring 23 from the valve spindle Do not attempt to remove the lever from the valve spindle un less it is suspected to be damaged If removal is necessary the lever should automatically be discarded and replaced with new due to the damage that may result in the process of re moving it 22 To remove the lever hold one arm pressed against the side of the valve spindle while pulling the other arm out of the opposite side When it has disengaged from the valve spindle pull the other arm out Discard the lever and do not reuse This concludes the disassembly procedures 10 Apeks Regulator Service and Repair Manual CLEANING amp INSPECTION PROCEDURES 1 All parts should be cleaned first in a warm not over 120 F mild soap and water solution Use a soft nylon bristle brush to help remove any excess or loose contamination After an initial warm water and soap cleaning all parts should be thoroughly rinsed in clean fresh water and dried
28. vice and Repair Manual 13 lever until the shuttle valve drops slightly while viewing its position through the outlet port of the spindle see Fig 11 Then raise the lever halfway up until it is perpendicular to the valve spindle 8 Being careful to avoid disturbing the engagement of the lever with the shuttle valve lay the valve spindle horizontal with the lever fac ing up While holding the spindle secure mate the adjusting screw into the open end of the spindle and hold it pressed inward while turning it clockwise until the threads are engaged Watch to ensure that the lever rises initially as the adjusting screw is installed into the valve spindle If the lever does not rise the arms are not properly engaged with the shuttle valve Disassemble and repeat steps 6 8 before proceeding Figure 11 Installing Shuttle Valve Step 3 9 Insert the retaining pin 18 into the valve spindle near the grooved flange Hold it centered in place and then turn the adjusting screw completely out counter clockwise until it stops This will hold the pin securely in place to prevent it from falling out while installing the valve module into the case 10 Install the O ring 13 onto the venturi lever 17 11 While holding the valve lever depressed against the spindle fit the venturi lever over the threaded inlet with the plastic lever facing to ward the adjusting screw Gently pass it over the spindle until it
29. with filtered low pressure 30 psig air After an initial cleaning in warm soap and water solution metal parts should be cleaned in an ultrasonic cleaner using the appropriate ultrasonic clean ing solution see Lubricant and Cleaner Table 2 moved before cleaning in an ultrasonic cleaner or chemical bath Be sure all O rings and other rubber or plastic parts are re Cleaning solutions may damage these components 2 Ifan ultrasonic cleaner is not available metal parts can be cleaned by soaking the metal parts in a chemical bath solution of Chromesafe see Lubricant and Cleaner Table 2 and agitating gently for 3 4 min utes Cleaning of metal parts can also be done by soaking in a mild acetic solution distilled white household vinegar for 10 15 minutes plated parts Never clean parts for longer than specified by the manufacturer of the solution used After completion of clean ing in any solution thoroughly rinse parts with clean fresh water and blow dry with low pressure 30 psig air Only brass plated brass and stainless steel parts should be immersed in chemi cal cleaning solutions Use hand and eye protection when handling chemical cleaning solu tions Cleaning times in excess of those recommended may damage 3 After cleaning all parts should be thoroughly rinsed in fresh water and dried with filtered low pressure 30 psig air parts both new and
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