Page 15
Disassembly Procedures Removal of hose. • - Retract hose protector. - Use a 5/8” open end wrench.
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Disassembly Procedures Removal and • discard of hose swivel o-ring.
Page 17
Disassembly Procedures Disassembly of cover • assembly. - Unscrew counter clockwise by hand.
Page 18
Disassembly Procedures Note: generally it is unnecessary to disassemble • front cover assembly when performing standard service. Cleaning can be adequately accomplished by rinsing and scrubbing if necessary with a soft brush. However if damage to the cover is observed and it must be disassembled to replace parts, proceed as described.
Page 19
Disassembly Procedures Disassembly of cover • assembly. Tabs - Use cover retainer tool P/N 20-703-100. - Align tab with slots. Slots...
Page 25
Disassembly Procedures Caution: Be sure to use a padded or protected • tool to lift the exhaust cover from the tabs on the housing use of an unprotected tool will damage the exhaust cover and may require replacement of the part.
Page 26
Disassembly Procedures Removal of exhaust • cover. - Carefully insert Pivot down padded bar shaped tool (snap ring pliers P/N 20-101-500). - Gently and carefully pry and lift edge up and away from tab on Pry up housing.
Page 27
Disassembly Procedures Removal of exhaust • cover. Hold first side with thumb - Repeat procedure on opposite side of exhaust cover. - Hold first side with thumb.
Page 28
Disassembly Procedures Removal of exhaust • Slots cover. Tabs - Lift up toward top of housing.
Page 29
Disassembly Procedures Removal of retaining • nut. - Use 3/4” box end wrench.
Page 30
Disassembly Procedures Removal of • retaining nut.
Page 31
Disassembly Procedures Removal of clip. • - Use small flat blade screwdriver.
Page 32
Disassembly Procedures Removal of clip. •...
Page 33
Disassembly Procedures Removal of valve • body. Push threaded end - While lever is depressed. - Push threaded end. While lever is depressed...
Page 34
Disassembly Procedures Removal of valve • body. - As valve body thread pass through housing o-ring will release.
Page 35
Disassembly Procedures Removal of valve • body. - Set valve body aside.
Page 36
Disassembly Procedures Removal of exhaust • valve. - Fold in half and pull while gently pulling tab.
Page 37
Disassembly Procedures Disassembly of valve • body. - Removal of adjustment nut. - Unthread counter clockwise.
Page 68
Cleaning Procedures Thermoplastic, silicone rubber, rubber and anodized • aluminum parts. i.e. diaphragms, adj. knobs static o-rings 2nd stage housing. A. Soak - warm water and liquid dish detergent. B. Scrub - with soft nylon brush. C. Rinse - fresh water. D.
Page 69
Cleaning Procedures Chrome plated brass, stainless steel part and hoses. • A. Degrease - warm water and liquid detergent. B. Rinse - fresh water. C. Soak - vinegar and water solution (50% water) for 30 minutes. D. Rinse - fresh water. E.
Page 72
Inspection Procedures All reusable chrome plated brass and stainless steel parts. • Sealing Surfaces - A. Scratches B. Nicks C. Cuts D. Deformation E. Debris Sealing Surfaces - A. Damage to threads...
Page 73
Inspection Procedures Inspection procedures • - Use magnifier.
Page 75
Lubrication Procedures O-ring lubrication • Use only Christo-Lube 111. • A. General - o-rings in most instances should receive only enough lubrication to ensure they are supple. A light coating of lubrication should present a surface that glistens but without a defined layer of lubrication visible. B.
Page 76
Lubrication Procedures Lubricating procedures. • - Use only Christo-Lube P/N MCG-111.
Page 77
Lubrication Procedures General (left) Ample • (right).
Page 81
Reassembly Procedures Install new amply • lubricated o-ring on orifice.
Page 82
Reassembly Procedures Insert orifice seating • surface end first into threaded end of valve body.
Page 83
Reassembly Procedures Installation of orifice in • valve body using 1/4” wooden dowel. - Push orifice in valve body until it stops.
Page 84
Reassembly Procedures Install ring seal • taper side last over threaded end of valve body.
Page 85
Reassembly Procedures Installation of ring seal. • - Continue to slide ring seal along valve body until up against shoulder of valve body. - Taper surface smallest diameter.
Page 86
Reassembly Procedures Install level saddle. • - Align tab of saddle with notch in valve body. Notch...
Page 87
Reassembly Procedures Installation of lever • Threads against shoulder saddle. - Inspect - tab and notch aligned. - Threads of saddle against shoulder of valve body.
Page 88
Reassembly Procedures Install lever one leg at a • time. - Insert leg in hole in saddle.
Page 89
Reassembly Procedures Installation of lever. • - Inspect - both legs inserted in saddle/body holes.
Page 90
Reassembly Procedures Install amply • lubricated o-ring on thread end of valve body.
Page 91
Reassembly Procedures Installation of o-ring on • valve body. - Inspect - fully seated in groove.
Page 92
Reassembly Procedures Additional lubricant • required in this application to minimize friction allowing the adjustment sleeve to move easily during adjustment procedures.
Page 93
Reassembly Procedures Install adjustment • sleeve thread in place over lever saddle notched end of sleeve facing away from lever.
Page 94
Reassembly Procedures Installation of adjustment • One thread showing sleeve. - Continue to thread over lever saddle until only one thread is visible on lever saddle.
Page 95
Reassembly Procedures Install new • lubricated o-ring on stem.
Page 96
Reassembly Procedures • Installation of o-ring on stem. - Inspect - fully seated in groove.
Page 97
Reassembly Procedures Install stem in • adjustment body. - Use 1/8” hex key.
Page 98
Reassembly Procedures installation of stem in • adjustment body. End of stem - Thread until stem end is sticking out of body.
Page 99
Reassembly Procedures Install new • lubricated o-ring on adjustment body.
Page 100
Reassembly Procedures Installation of o-ring on • adjustment body. - Inspect - fully seated in groove.
Page 101
Reassembly Procedures Install new seat in • end of poppet.
Page 102
Reassembly Procedures Installation of seat in • poppet. - Inspect - properly seated.
Page 103
Reassembly Procedures Install new amply • lubricated o-ring on poppet.
Page 104
Reassembly Procedures installation of o-ring on • poppet. - Inspect - fully seated in groove.
Page 105
Reassembly Procedures Installation of poppet • assembly in valve body. - Mount poppet in end of poppet installation tool P/N 20-706-100. - Note-position of lever contact tabs must be facing down. Lever contact tabs...
Page 106
Reassembly Procedures Installation of • Hold lever 90° with poppet assembly axis of valve body in valve body. Lever contact tabs facing down...
Page 107
Reassembly Procedures Installation of poppet • assembly in valve body. - Continue to insert poppet installation tool until poppet contacts lever. - Lightly push on tool lever should move up and down.
Page 108
Reassembly Procedures Install spring in • valve body.
Page 109
Reassembly Procedures Installation of spring in • valve body. - Inspect - use 1/4” wooden dowel. - Lever still moves up and down.
Page 110
Reassembly Procedures Installation of balance • chamber. - Place lubricant in open end of balance chamber.
Page 112
Reassembly Procedures Installation of balance • chamber in valve body. - Inspect - use 1/4” wooden dowel push dowel lightly to versify lever action.
Page 113
Reassembly Procedures Install adjustment body. • - Thread clockwise just until thread engage.
Page 114
Reassembly Procedures Installation of adjustment • body in valve body assembly. - When threads engage lever should move up.
Page 115
Reassembly Procedures Installation of adjustment • Groove centered in body in valve body hole of valve body assembly. - Use know to continue threading adjustment body just until the groove in adjustment body is centered in the hold of the valve body.
Page 116
Reassembly Procedures Installation of adjustment • body in valve body. - Remove knob and set aside for later installation.
Page 117
Reassembly Procedures Install diverter on valve • body. Rectangular tab - Align rectangular tab in diverter with centered groove of adjustment body in valve body assembly. Centered groove...
Page 118
Reassembly Procedures Installation of • diverter on valve body.
Page 119
Reassembly Procedures Install knob on valve • body.
Page 120
Reassembly Procedures Installation of knob • retainer. - Secure knob to valve body by threading knob retainer in end of knob. - Use 5/32” hex key.
Page 121
Reassembly Procedures Installation of knob • retainer using 5/32” hex key. - Snug finger tight. - Set valve body aside.
Page 131
Reassembly Procedures Installation of retaining • nut. - Thread nut clockwise first by hand.
Page 132
Reassembly Procedures Installation of retaining • nut. - Snug with 3/4” box end wrench.
Page 133
Reassembly Procedures Install exhaust cover. • Tabs - Align slots on top of cover with tabs on shoulder of housing. Slots...
Page 134
Reassembly Procedures Installation of exhaust • cover. - Snap bottom slots of cover over bottom tab on housing. Slots and tabs...
Page 135
Reassembly Procedures Install new • lubricated o-ring on hose swivel.
Page 136
Reassembly Procedures Thread hose swivel • end to valve body first clockwise by hand.
Page 137
Reassembly Procedures Installation of hose. • - Torque hose to 40” lbs using a 5/8” crows foot and torque wrench.
Page 138
Second Stage Regulator Testing Procedures...
Page 139
Second Stage Regulator Testing Procedures 1. Attach partially assembled second stage to a properly • functioning first stage regulator with an intermediate pressure set at 135 ±10 PSI. 2. Rotate the adjustment knob to the full counter clockwise • position. •...
Page 140
Second Stage Regulator Testing Procedures 6. Rotate adjustment sleeve counter clockwise with the • probe until a slight leak is detected. 7. Next, rotate the adjustment sleeve clockwise with the • probe until the leak just stops. • 8. From this position, rotate the adjustment sleeve clockwise through an arc equal in length to one of the slots in the retaining nut.
Page 141
Second Stage Adjustment Procedures Insert a small probe • in the slot of retaining nut to engage one of the linear slots in adjustment sleeve. Rotate sleeve • counter clockwise to create slight leak.
Page 142
Second Stage Adjustment Procedures Next, turn • adjustment sleeve clockwise to just stop leak. Then, continue to • Turn until leak stops turn clockwise in an arc equal in length to one slot in retaining nut.
Page 143
Second Stage Regulator Fine Adjustment Procedures 1. Knob still fully rotated counter clockwise. • 2. Use 1/8” hex key. • • 3. Rotate adjustment stem counter clockwise with 1/8” hex key to create a leak. 4. Rotate adjustment stem clockwise to stop leak. •...
Page 144
Second Stage Regulator Fine Adjustment Procedures • Rotate adjustment stem counter clockwise to create slight leak then turn clockwise to stop leak. - Use 1/8” hex key. Create leak Stop leak...
Page 145
Second Stage Regulator Fine Adjustment Procedures Install diaphragm. •...
Page 146
Second Stage Regulator Fine Adjustment Procedures Install cover assembly • housing. - Thread clockwise to align logo.
Page 147
Second Stage Regulator Fine Adjustment Procedures Note: If installation of cover assembly causes • second stage to leak the lever height may be slightly out of adjustment. Repeat steps that cover adjustment of the adjustment sleeve. Do these steps with the cover in place.
Page 148
Second Stage Regulator Fine Adjustment Procedures Install mouth piece. •...
Page 149
Second Stage Regulator Fine Adjustment Procedures Install tie strap. • - Use tie strap pliers or needle nose pliers. - Trim excess strap.
Page 150
Test Bench Specifications I.P. 135 ±10 PSI. • Control knob turned fully counter clockwise. O.E. no greater than • 1.5” water. Less than 4.0” water • at 15 SCFM.
Page 151
Trouble Shooting PROBLEM CAUSE REMEDY 1. Second stage leaks when 1. a.Orifice not seated on poppet 1. a.Turn air off and back on pressurized. seat. quickly. b. Orifice or orifice o-ring dirty, b. Clean or replace orifice or damaged or worn. orifice o-ring.
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