Apeks Egress Manual de usuario
EGRESS
SECOND STAGE
REGULATOR
TECHNICAL SUPPORT
APEKS MARINE EQUIPMENT LTD, NEPTUNE WAY, BLACKBURN, LANCASHIRE. BB1 2BT
MAINTENANCE MANUAL
FOR
AUTHORISED TECHNICIANS
Document No. AP5832
Issue 5
16/02/2011
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Change
No.
Change
Request No.
Description & Comments: Change Date New Issue No. Changed
By:
Approved
By:
1116 0247 Add details of new O ring pick and reduce the
torque setting of the spindle from 5 Nm to 3
Nm.
16/02/11 06 RH ACD
AMENDMENTS RECORD:
Amendments and approval of this document can only be carried out by the relevant people listed on the Approved list of signatures, which
is listed in the Apeks Quality Manual. To instigate a change, a Task / Change request form, (Form No. ‘DESI/10002’), must be completed
and passed to the relevant person(s) for approval which are listed on the Approved List of Signatures. When approval has been granted and
recoreded this table can then be completed and the document up issued.
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Contents
COPYRIGHT NOTICE................................................................................................................................................................ 3
INTRODUCTION ........................................................................................................................................................................ 3
WARNINGS, CAUTIONS & NOTES ......................................................................................................................................... 3
SCHEDULED SERVICE ............................................................................................................................................................. 3
GENERAL GUIDELINES ........................................................................................................................................................... 3
GENERAL CONVENTIONS....................................................................................................................................................... 4
DISASSEMBLY PROCEDURES ................................................................................................................................................ 4
REASSEMBLY PROCEDURES.................................................................................................................................................. 7
FINAL TESTING ....................................................................................................................................................................... 10
TABLE 1 - TROUBLSHOOTING GUIDE.................................................................................................................................11
TABLE 2 - RECOMMENDED TOOL LIST.............................................................................................................................. 12
TABLE 3 - RECOMMENDED LUBRICANTS AND CLEANERS ........................................................................................ 13
CLEANING AND LUBRICATION PROCEDURE .................................................................................................................. 14
TABLE 4 -TORQUE SPECIFICATIONS .................................................................................................................................. 15
TABLE 5 - TEST BENCH SPECIFICATIONS ......................................................................................................................... 15
EXPLODED PARTS DRAWING............................................................................................................................................... 16
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An Ofcial Inspection consists of:
1. A pressurised immersion test of the entire unit to
check for air leakage.
2. Checking for stable medium pressure that is within
the acceptable range.
3. Checking for opening effort that is within the
acceptable range.
4. Checking for smooth operation of the control knob
and venturi switch (if tted.)
5. A visual inspection of any lters for debris or
discoloration.
6. A visual inspection of the exhaust valve(s) to see
that they are in good condition and that it is seating
against a clean and undamaged surface.
7. A visual inspection of the mouthpiece looking for
tears or holes and checking the general condition.
8. Pulling back hose protectors and checking that the
hoses are secure in the hose crimps.
If a regulator fails steps 1,2,3 or 4 the entire regulator
should be serviced. If a regulator fails 5,6 or 7 it will be up
to the technician’s discretion whether or not a full service
is required. Failure of step 8 requires replacement of the
hose.
GENERAL GUIDELINES
1. In order to correctly perform the procedures outlined
in this manual, it is important to follow each step
exactly in the order given. Read over the entire
manual to become familiar with all procedures and
to learn which specialty tools and replacement parts
will be required before commencing disassembly.
Keep the manual open beside you for reference while
performing each procedure. Do not rely on memory.
2. All service and repair should be carried out in a work
area specically set up and equipped for the task.
Adequate lighting, cleanliness, and easy access to
all required tools are essential for an efcient repair
facility.
3. During disassembly, reusable components should
be segregated and not allowed to intermix with
nonreusable parts or parts from other units. Delicate
parts, including inlet ttings and valve seats which
contain critical sealing surfaces, must be protected
and isolated from other parts to prevent damage
during the cleaning procedure.
4. Use only genuine Apeks parts provided in the 2nd
stage service kit (AP0219). DO NOT attempt to
substitute an Apeks part with another manufacturer’s,
regardless of any similarity in shape or size.
5. Do not attempt to reuse mandatory replacement
parts under any circumstances, regardless of the
amount of use the product has received since it was
manufactured or last serviced.
6. When reassembling, it is important to follow every
torque specication prescribed in this manual,
using a calibrated torque wrench. Most parts are
made of either marine brass or plastic, and can be
permanently damaged by undue stress.
COPYRIGHT NOTICE
This manual is copyrighted, all rights reserved. It may not,
in whole or in part, be copied, photocopied, reproduced,
translated, or reduced to any electronic medium or machine
readable form without prior consent in writing from Apeks
Marine Equipment Ltd. It may not be distributed through the
internet or computer bulletin board systems without prior
consent in from Apeks Marine Equipment Ltd.
©2004 Apeks Marine Equipment Ltd.
Egress Maintenance Manual
(AP5832 Issue 1)
INTRODUCTION
This manual provides factory prescribed procedures for
the correct maintenance and repair of the Apeks Egress. It
is not intended to be used as an instructional manual for
untrained personnel. The procedures outlined within this
manual are to be performed only by personnel who have
received factory authorized training through an Apeks Service
& Repair Seminar. If you do not completely understand all
of the procedures outlined in this manual, contact Apeks to
speak directly with a Technical Advisor before proceeding any
further.
WARNINGS, CAUTIONS & NOTES
Pay special attention to information provided in warnings,
cautions, and notes that are accompanied by one of these
symbols:
WARNIN G S indicate a procedure or situation
that may result in serious injury or death if
instructions are not followed correctly.
CAUTIONS indicate any situation or technique
that will result in potential damage to the
product, or render the product unsafe if
instructions are not followed correctly.
NOTES are used to emphasise important points, tips,
and reminders.
SCHEDULED SERVICE
It is recommended that the Apeks Egress second stage
regulator should be serviced annually regardless of usage.
However, If at all unsure about the correct functioning of the
Apeks Egress, then it must be ofcially inspected immediately.
All service and inspection details need to be documented
in the Regulator Service Record in the back of the Owner’s
Manual to keep the Limited Lifetime Warranty in effect.
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GENERAL CONVENTIONS
Unless otherwise instructed, the following terminology and
techniques are assumed:
1. When instructed to remove, unscrew, or loosen a
threaded part, turn the part anti-clockwise.
2. When instructed to install, screw in, or tighten a
threaded part, turn the part clockwise.
3. When instructed to remove an ‘O’ Ring, use the pinch
method (see gure below) if possible, or use a brass,
aluminium or plastic ‘O’ Ring removal tool. Avoid using
hardened steel picks, as they may damage ‘O’ Ring
sealing surfaces. All ‘O’ Rings that are removed are
discarded and replaced with brand new ‘O’ Rings.
1. Whilst holding the Inlet Fitting (12) stationary with a
19mm spanner turn the hose swivel anti-clockwise
using an 11/16” spanner. Taking care not to scratch the
‘O’ Ring grooves, remove the ‘O’ Rings from both the
inside of the hose swivel and from the male end of the
hose.
4. The following acronyms are used throughout
the manual: MP is Medium Pressure; HP is High
Pressure; PN is Part Number.
5. Numbers in parentheses reference the key numbers
on the exploded parts schematics. For example, in
the statement, “...remove ‘O’ ring (4) from...”, the
number 4 is the key number to the Spring Carrier ‘O’
Ring.
DISASSEMBLY PROCEDURES
NOTE: Before performing any disassembly, refer
to the exploded parts drawing, which references all
mandatory replacement parts. These parts should
be replaced with new, and must not be reused under
any circumstances - regardless of the age of the
regulator or how much use it has received since it
was last serviced.
CAUTION: Use only a plastic, brass or aluminium
‘O’ Ring removal tool (PN AT79) when removing
‘O’ Rings to prevent damage to the sealing surface.
Even a small scratch across an ‘O’ Ring sealing
surface could result in leakage. Once an ‘O’ Ring
sealing surface has been damaged, the part must be
replaced with new. DO NOT use a dental pick, or
any other steel instrument.
Pinch Method
Press upwards on
sides of ‘O’ Ring to
create a protrusion.
Grab ‘O’ Ring or
insert ‘O’ Ring tool
at protrusion.
2. Pull back the two hose
protectors and inspect
the hose crimps.
If either crimp is
damaged or the hose
is pulling out of the
crimp then the hose
must be replaced.
3. Using the Egress Locking Ring Tool (AT62) unscrew the
front locking ring (19) and remove the front cover (18).
NOTE: Ensure that tool is aligned with both locking
ring and front cover before unscrewing.
Removal of hose
Removal of diaphragm
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4. Using the reverse side
of the Egress Locking
Ring Tool (AT62),
fully unscrew the inner
locking ring (17).
5. Carefully lift out
Friction Ring (16) and
Diaphragm (15).
6. Using a 19mm ring
spanner, unscrew the
Inlet Fitting (12).
7. Using a 5mm Allen Key and by screwing clockwise
remove the Valve Seat (9) from the Inlet Fitting (12).
8. Remove the ‘O’ Rings
(10 & 11) from the
both the Valve Seat
and the Inlet Fitting.
9. Withdraw and lift the
Spindle Assembly (2-8)
out of the Case (1).
11. Whilst the Shuttle Valve (6) is held compressed into the
Spindle Body (2), remove the Lever (8) by sliding out the
lever feet one at a time.
12. Carefully remove the Shuttle Valve Assembly (3-7) from
the Spindle Body (2) and separate the Spring Carrier (3), the
Valve Spring (5) and the Shuttle Valve (6).
Removal of valve assembly
10. Whilst pressing down the lever (7) screw the 9/16” UNEF
Handle Tool (AT48) into the Spindle Body (2), just enough
to drop the lever.
NOTE:The tool should
not be screwed in too
tightly, as this could
damage the rubber seat
(7) on the shuttle valve.
This is only to relieve
the spring tension on
the leaver for removal.
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14. To remove the Exhaust Gate (14) insert a 3mm
screwdriver into the holes on the bottom of the Exhaust
Gate and carefully push out the tabs in turn. Then simply
lift the top edge of the Exhaust Gate out the Case.
15. In turn, fold back the edges of each of the Exhaust Valves
(13) and inspect underneath. The seating surfaces should
be clean and free of damage. Inspect the Exhaust Valves.
They should be supple and have well dened edges. If
they look undamaged then there is no need to remove
them and they may be reused. If there is any sign of
deterioration they must be replaced.
16. Using side cutters, snip the Zip Tie (22). Remove and
inspect Mouthpiece (21).
This Ends Disassembly
Before starting reassembly, perform parts cleaning
and lubrication according to the procedures
outlined in ‘Cleaning & Lubrication’ on page 14.
NOTE: If Exhaust Valves (13) are to be removed,
pinch edge of Exhaust Valve and pull tail through hole
in Case (1)
13. Remove the ‘O’ Ring (4) from the Spring Carrier (3) and,
using a ngernail, remove the Rubber Seating (7) from
the end of the Shuttle Valve (6).
Inspection and Removal of Exhaust Valves Removal of mouthpiece
CAUTION: Whilst pushing out tabs, hold a
nger close to the head of the screwdriver
to prevent damaging the Case.
NOTE: It is not always necessary to remove the
Exhaust Gate and the Exhaust Valves. A visual
inspection of the Valves can be made from inside the
case. If the regulator has been leaking or the Exhaust
Gate is damaged then the components should be
removed.
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REASSEMBLY PROCEDURES
1. If the Exhaust Valves (13) were removed, replace by
threading the tails through the retaining holes on the
outside of the Case (1) until the barb engages on the
inside. If valves are new, cut off the excess stem with
side cutters leaving approximately 5mm of the tail
behind.
2. Orientate the Exhaust Gate (14) with the straight
edge to the open side (top) of the Case (1). (Note that
the Exhaust Gate is not symmetrical). Insert the two
tabs into the bottom side of the case rst, then, whilst
squeezing in the sides, clip in the top two tabs.
3. Install a new,
lubricated ‘O’ Ring
(4) onto the Spring
Carrier (3).
5. Fit the Valve Spring (5) over the Spring Carrier (3).
Carefully guide the stem of the Shuttle Valve (6) over
the Spring Carrier (3).
Fitting exhaust valves and exhaust gate
Assembling and tting valve assembly
WARNING: Flooding may occur if the tails of
the valves have not been fully pulled through.
Check that barb has engaged on inside of
case.
CAUTION: Care should be taken. Damage
can occur to the exhaust gate if it is not t
correctly.
NOTE: Check sides have clipped in properly. If they
have not then gate must be removed (according to
Disassembly Procedure 13) then re-installed
CAUTION: Damage to ‘O’ ring can occur
if placed inside the shuttle valve and not
installed onto the spring carrier rst as shown
above.
6. Carefully insert the above Shuttle Valve assembly into the
Spindle Body (2). Leave out the Rubber Seating (7) at this
stage.
7. Screw in the Handle tool (AT48).
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NOTE: If tted correctly the lever should rise when the tool is
removed
9. Install new lubricated ‘O’ Rings (10 & 11) onto the Valve Seat (9)
and the Inlet Fitting (12).
10. Install the Valve Seat (9) into the Inlet Fitting (12), screwing
anti-clockwise with a 5mm Allen Key until it stops.
CAUTION: Ensure that lever is not twisted
and that legs are parallel. Lever should
appear as that shown on the left, not as
shown on the right. If necessary, gently
squeeze legs together to straighten.
NOTE: Lever should face away from spindle
opening as shown below.
CAUTION: Do not tighten
NOTE: Ensure that the Lever has a full range of
movement and does not catch on either the Spindle
Body or the Case.
8. Install Spindle Assembly (2-8) into Case (1).
7. Whilst Shuttle Valve (6) is held in place by the tool, insert
Lever (8) by sliding feet into holes one at a time.
7. Lastly insert the new rubber seat and press it rmly in
place.
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11. Whilst holding the Spindle Assembly (2-8) in place, screw the
Inlet Fitting (12) into the Case using a torque wrench with a
19mm adapter or socket. Tighten to 3 Nm.
12. By turning clockwise, screw in the Valve Seat (9) until the
Lever (8) drops.
NOTE: Top of Lever should be 2mm below the top
of the Case, although the correct lever height can be
checked in step 15
13. Position the Diaphragm (15) in the Case (1), followed by the
Friction Ring (16) . Work edges of Friction Ring into place with
nger so that the Diaphragm sits evenly in the Case.
14. Screw in the Inner Locking Ring (17) using Egress
Locking Ring Tool (AT62) and tighten.
CAUTION: Ensure Diaphragm is seated
correctly and not creased. Creasing may
be caused by excessive tightening. Carry
out suction test by holding thumb over Inlet
Fitting (12) to seal and trying to breathe
through mouthpiece outlet port. No air
should be drawn in.
16. Install Front Cover (18) and screw in Front Locking Ring
(19). Tighten using other side of Egress Locking Ring Tool
(AT62.)
NOTE: Ensure that the ribs on the Front Locking
Ring are aligned correctly with those on the Front
Cover when tightening using locking ring tool.
Fitting Diaphragm
15. At this stage, it is important to check the correct lever
height setting. To do this, connect the Egress second
stage to a medium pressure air supply of 9.5 (±0.5)
bar and pressurise the regulator.
Correct Lever Height Check
CAUTION: Any adjustment should only take
place when regulator is un-pressurised.
15a. With the regulator
pressurised, locate and
press the Egress Locking
Ring Tool (AT62) onto the
top of the Case as shown
right. There should be a
highly audible ow of air
through the mouthpiece
outlet port. If there is no
air ow, the lever is set too
low.
15b. With the same tool
used the opposite
way round, and
located into the Inner
Locking Ring as if
tightening in step 14,
there should not be
an audible ow of air.
If there is an audible
ow of air, the lever is
set too high.
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