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Cressi-sub 2nd Stage Ellipse Balanced Repair And Maintenance Instructions
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Cressi-sub 2nd Stage Ellipse Balanced Repair And Maintenance Instructions

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nd
2
stage Ellipse
Balanced
Regulators repair and maintenance
January 2009
Rev. ELL.BAL/B
Ed. C /12
1

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Summary of Contents for Cressi-sub 2nd Stage Ellipse Balanced

  • Page 1 stage Ellipse Balanced Regulators repair and maintenance January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 2 EXCLUSIVELY by an authorized Cressi-Sub center. If the information provided in this document is unclear or not fully intelligible, • please contact Cressi-sub before proceeding with any disassembly or maintenance procedures. Before proceeding, Cressi-sub recommends that you read the following document •...
  • Page 3 • To prevent any assembly errors when performing maintenance and/or repairs, we recommend using all the replacement parts provided by Cressi-Sub in every operation. • Pay special attention to the recommendations provided in the margin of the figures that show the various sequences of equipment maintenance and/or repair in order to avoid any problems that could result in an accident.
  • Page 4 stage Ellipse Balanced: spare parts Regulators repair and maintenance Ellipse Balanced 2° stage (HZ 820080) ANNUAL REPLACEMENT KIT CHART (Real Size) January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 5 • Code Nr. HZ 820080 (Real Size) Go back to •Use only original Cressi-sub spare parts •Note: it is recommended to carry out a complete servicing of the regulator yearly or more frequently in case of intensive use. January 2009 Rev.
  • Page 6 Balanced Regulators repair and maintenance • Annual replacement • Cressi-Sub recommends complete regulator maintenance at least once a year, or more frequently in the case of particularly intense use. • Maintenance must include replacement of all components provided in the annual equipment maintenance kit.
  • Page 7 Users must never perform maintenance themselves; all maintenance must be performed EXCLUSIVELY by an authorized Cressi-Sub center. • You can find your authorized Cressi-Sub center by asking your dealer, or Cressi Sub S.p.A. itself by sending an e-mail to: info@cressi-sub.it •Use only original Cressi-sub spare parts January 2009 Rev.

  • Page 8: Special Tools

    stage Ellipse Balanced Special tools Regulators repair and maintenance January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 9 To replace the O-ring correctly, press its sides to create a bulge inside which to insert the round pointed tool, as shown in the pictures; • Attention: USE ONLY ORIGINAL CRESSI-SUB SPARE PARTS January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 10 stage Ellipse Balanced Regulators repair and maintenance • Remove the low pressure hose • Use a 0,75 in. and a 0,67 in. spanner to remove the low pressure hose, holding the lock nut steady with the former and unscrewing the hose with the latter;...
  • Page 11 stage Ellipse Balanced: disassembling Regulators repair and maintenance 0,15 in. Allen wrench HZ 810077 •Cam-lock – Disassembling the regulator • Insert a 0,15 in. Allen wrench into the cam-lock seat, press gently and turn by 90 degrees anticlockwise. The inner spring will push the key outwards, and you will be able to take it out easily.
  • Page 12 stage Ellipse Balanced: disassembling Regulators repair and maintenance • After removing the cam-lock key, press with your fingers the main cap of the baffle, and open it outwards as shown in the picture. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 13 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 820072 • Open the cap, holding the regulator casing in your hand, and remove the soft cap (button), the diaphragm ring and the diaphragm. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 14 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 810077 HZ 820074 HZ 820072 HZ 820073 January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 15 stage Ellipse Balanced: disassembling Regulators repair and maintenance O,75 in. HZ 820050 • Use a 0,75 in. spanner to remove the regulator lock nut. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 16 stage Ellipse Balanced: disassembling Regulators repair and maintenance • Lower the lever (phase 1), then take out the 2 stage whole device out of the regulator casing (phase 2), as shown in the picture. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 17 stage Ellipse Balanced: disassembling Regulators repair and maintenance OR = HZ 820051 • Remove the valve O-ring out of its seat January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 18 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 820078 • Remove the baffle out of the regulator casing, pressing its sides as shown in the picture. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 19 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 810074 • Remove the exhaust valve out of its seat. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 20 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 820064 • Use a 0,15 in. Allen wrench to unscrew the setting white screw placed inside the adjustment knob, and remove the metal knob cover, as shown in the picture. January 2009 Rev.
  • Page 21 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 820065 • Insert bird beak pliers into the knob opening and remove the clip out of its seat, as shown in the picture. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 22 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 820061 • Unscrew the knob fully and take it out of the valve body. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 23 stage Ellipse Balanced: disassembling Regulators repair and maintenance • Remove the knob O-ring out of its seat. OR = HZ 820060 January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 24 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 820063 HZ 709011 Brugola Ch.4 • Use a 0,15 in. Allen wrench to fully unscrew the setting screw lying inside the setting knob (phase 1); • Now use the tool HZ 709011 to remove the screw out of the knob: push it in the direction shown by the picture, to overcome the friction induced by the O-ring onto the knob side (phase 2);...
  • Page 25 stage Ellipse Balanced: disassembling Regulators repair and maintenance Use the tool HZ 709011 to remove the piston including spring and balancing chamber out of the valve body, as shown in the picture; NOTE: push with a certain amount of strength to overcome the friction induced by the balancing chamber O-ring onto the valve body side, until the whole valve comes out.
  • Page 26 stage Ellipse Balanced: disassembling Regulators repair and maintenance Use a screwdriver to fully unscrew the adjustable nozzle. It will be shown later how to remove it out of its seat. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 27 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 810094 HZ 709011 • Remove the nozzle out of the regulator valve body using the tool HZ 709011 (designed to prevent the edge from being damaged) as shown in the picture; •...
  • Page 28 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 820058 HZ 820055 OR = HZ 820059 OR = HZ 820057 HZ 820056 HZ 820049 • Remove the 2 stage piston pad, the piston spring and the balancing chamber out of their seat. •...
  • Page 29 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 820067 • Levering on their sides, lift and remove the upper mask hookings out of the casing, as shown in the picture. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 30 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 820076 Use a 0,08 in. pin pusher to remove the cap titanium upper pin out of its seat: please push in the direction shown by the picture. January 2009 Rev. ELL.BAL/B Ed.
  • Page 31 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 820075 • Remove the upper mask out of its seat as shown in the picture. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 32 stage Ellipse Balanced: disassembling Regulators repair and maintenance HZ 820066 HZ 820068 OR = HZ 820069 • Remove the flow deviator out of it seat as shown in the picture. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 33 stage Ellipse Balanced: components Regulators repair and maintenance Titanium lock nut Upper mask Titanium cap + upper titanium pin Flow deviator + OR Cap button Camlock Button ring Baffle cap + lower titanium pin Diaphragm Valve nozzle Balancing chamber Adjustment knob stage casing + O-ring + O-ring clip...
  • Page 34 stage Ellipse Balanced: assembling Regulators repair and maintenance • After replacing and lubricating its O-ring, insert the flow deviator into it seat as shown in the picture. HZ 820067 January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 35 stage Ellipse Balanced: assembling Regulators repair and maintenance • Place the upper mask onto the 2 stage casing, then press its sides to hook it to the casing as shown in the picture. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 36 stage Ellipse Balanced: assembling Regulators repair and maintenance HZ 820076 • Insert the upper pin into the cap in the direction shown in the picture. • Place the cap hookings into their seats in the 2 stage casing, as shown in the picture. January 2009 Rev.
  • Page 37 stage Ellipse Balanced: assembling Regulators repair and maintenance • Seat one side of the regulator case onto a hard surface, as shown in the picture; • Now hold the case in one hand firmly and tap with a plastic hammer on the upper pin to push it into the corresponding seat in the second stage case, as shown in the picture;...
  • Page 38 stage Ellipse Balanced: assembling Regulators repair and maintenance • Insert the eshaust valve, taking care to place correctly the shaft into its seat, by pulling it from the inside of the regulator. HZ 810074 January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 39 stage Ellipse Balanced: assembling Regulators repair and maintenance • Check the piston hole is NOT blocked with impurities. • Insert the fresh pad pushing it into its seat in the piston. Please note the two bulges on HZ 820055 its shaft, which allow its full HZ 820056 connection with the piston.
  • Page 40 stage Ellipse Balanced: assembling Regulators repair and maintenance OR = HZ 820054 • While inserting the assembled valve, as will be described on next page, please pay attention to hold its fulcrum as shown in the picture (feet downwards with respect to the lever). •...
  • Page 41 stage Ellipse Balanced: assembling Regulators repair and maintenance • Raising the lever, insert the assembled valve inside its body, as shown in the picture. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 42 stage Ellipse Balanced: assembling Regulators repair and maintenance • Check the lever works perfectly by pressing it more HZ 820053 times: it has to swing freely and go back every time to its vertical position automatically. January 2009 Rev. ELL.BAL/B Ed.
  • Page 43 stage Ellipse Balanced: assembling Regulators repair and maintenance OR = HZ 820062 HZ 820063 HZ 820061 OR = HZ 820060 • After replacing and greasing the O-ring, turn the setting screw into its seat using a 0,15 in. Allen wrench with a certain amount of strength to overcome the friction induced by the O-ring onto the knob side;...
  • Page 44 stage Ellipse Balanced: assembling Regulators repair and maintenance • Push the adjustment knob into its seat, overcoming the friction induced by the O-ring on the valve body side. • Screw the knob including the screw into the valve body, paying particular attention to line up the plastic thread perfectly with the metal one of the valve body: do not insert the knob inclined in order not to damage the plastic connecting thread.
  • Page 45 stage Ellipse Balanced: assembling Regulators repair and maintenance • After screwing the adjustment knob for some turns, insert the clip straight side into the hole placed on the left of the knob opening, just exactly as shown in the picture. HZ 820065 January 2009 Rev.
  • Page 46 stage Ellipse Balanced: assembling Regulators repair and maintenance HZ 820065 • Push the clip until its straight side comes out of the opposite hole on the knob. • In such way the clip bent side will be automatically placed perfectly into its seat on the knob, as shown in the picture.
  • Page 47 stage Ellipse Balanced: assembling Regulators repair and maintenance • After placing the adjustment knob clip into its seat, fully unscrew the knob thread corresponding with the clip. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 48 stage Ellipse Balanced: assembling Regulators repair and maintenance • Replace and lubricate the nozzle O-ring. • Screw the nozzle for some turns into the valve body keeping the 2 stage lever pressed, to prevent the sharp edge from damaging the piston pad.
  • Page 49 stage Ellipse Balanced: assembling Regulators repair and maintenance • After replacing and properly lubricating the knob O-ring, lower the lever (1) and introduce (2) the regulator mechanism into the casing, exactly as shown in the picture. January 2009 Rev. ELL.BAL/B Ed.
  • Page 50 stage Ellipse Balanced: assembling Regulators repair and maintenance OR = HZ 820051 HZ 820050 • Replace and lubricate the valve body O-ring, then place it into its seat as shown in the picture; • After screwing it, a tooth placed on the closing side of the titanium lock nut will put the O-ring correctly into its seat on the 2 stage.
  • Page 51 stage Ellipse Balanced: assembling Regulators repair and maintenance • Use a 0,75 in. spanner to screw the titanium lock nut. • Check the lever is in parallel to the casing. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 52 stage Ellipse Balanced: assembling Regulators repair and maintenance HZ 820078 • Assemble the second stage baffle, inserting and pushing it into the seats in the casing as shown in the picture. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 53 stage Ellipse Balanced: assembling Regulators repair and maintenance HZ 820073 HZ 820072 • Place the diaphragm onto the ring as shown in the picture; • Now check their correct coupling, as shown in the picture. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 54 stage Ellipse Balanced: assembling Regulators repair and maintenance • Insert the ring including the correctly placed diaphragm into the second stage case, making sure all the ring vertices line up perfectly with the case, as shown in the picture. January 2009 Rev.
  • Page 55 stage Ellipse Balanced: assembling Regulators repair and maintenance • While holding the ring in your hand tightly, pull gently the diaphragm plate outwards, to check its perimeter sits perfectly in the regulator case. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 56 stage Ellipse Balanced: assembling Regulators repair and maintenance HZ 820074 Insert the button into the ring, making sure all the ring teeth connect with the corresponding holes in the button. The picture show how they are correctly coupled. January 2009 Rev.
  • Page 57 stage Ellipse Balanced: assembling Regulators repair and maintenance January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 58 stage Ellipse Balanced: assembling Regulators repair and maintenance • Bend the swinging cap towards the exhaust valve seat. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 59 stage Ellipse Balanced: assembling Regulators repair and maintenance • When closing it, make sure the teeth shown in the picture are free to teeth lie and rotate only in their seats. These latter serve also as closing fulcrum of the cap. FULCRI (SEDI) January 2009 Rev.
  • Page 60 stage Ellipse Balanced: assembling Regulators repair and maintenance • Keep rotating the swinging cap until the regulator is fully closed. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 61 stage Ellipse Balanced: assembling Regulators repair and maintenance • Press the baffle main cap (grey in the picture) and close the regulator. • It will be fully locked after inserting the safety cam- lock key. January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 62 stage Ellipse Balanced: assembling Regulators repair and maintenance • Place the “Cam-lock” as shown in the picture, insert an Allen wrench into its seat and press gently, while turning by 90 degrees clockwise. • The “Cam-lock” inner spring will push the key into its position to lock the regulator, as shown in the picture.
  • Page 63 stage Ellipse Balanced: assembling Regulators repair and maintenance HZ 820064 • Insert the knob metal part into its seat. • NOTE: push it with a certain strength in order to place it correctly in its seat. January 2009 Rev. ELL.BAL/B Ed.
  • Page 64 stage Ellipse Balanced: setting Regulators repair and maintenance Ellipse Balanced second stage setting: valve nozzle setting (page 66) • Screw the second stage to the setting gauge (HZ 710011) connected with a middle pressure hose to a correctly set MC9 first stage (10 bars - 200 bars tank) ; •...
  • Page 65 stage Ellipse Balanced: setting Regulators repair and maintenance • Ellipse Balanced second stage setting: lever height setting • Since the setting screw has been adjusted during the assembly phases (page 43) and the valve nozzle has been correctly set, the regulator is now set; •...
  • Page 66 stage Ellipse Balanced: setting Regulators repair and maintenance 10 bar HZ 710011 Fully open January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 67 stage Ellipse Balanced: checking Regulators repair and maintenance •After setting the regulator, keep it pressurized with a properly set 1 stage MC9, and carry out following final checking: •Put the second stage gently under water with its mouthpiece upwards and its Venturi checking lever in the position Dive “+”, without letting water enter the mouthpiece;...
  • Page 68 2°stadio Ellipse Balanced: Service records Regulators repair and maintenance Download January 2009 Rev. ELL.BAL/B Ed. C /12...
  • Page 69 2°stadio Ellipse Balanced: Service records Regulators repair and maintenance Download Tab Maintenance / Service Record January 2009 Rev. ELL.BAL/B Ed. C /12...