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Apollo A-102 1ST STAGE Disassembly

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A-102 1ST STAGE
DISASSEMBLY

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Summary of Contents for Apollo A-102 1ST STAGE

  • Page 1 A-102 1ST STAGE DISASSEMBLY...
  • Page 2 FEATURES FEATURES Balanced Diaphragm type 1st stage. 2 x HP port. - 7/16” NF 4 x LP port. - 3/8” NF • Lightweight and compact • Symmetrical service ports...
  • Page 3 TOOLING REQUIREMENTS TOOLING REQUIREMENTS • 12” adjustable wrench • Apollo wrench No. 155610 • 3/16” & 5/8” Allen key (wrench) • Snap ring (circle) pliers • O ring pick • Fine tweezers • Nylon dowel - 10mm dia. • Small screw driver. (blunt edges) •...
  • Page 4 DISASSEMBLY DISASSEMBLY Remove the yoke screw. To support the 1st stage fit the 7/16” threaded rod to a HP port and hold the rod in a suitable vice. Use a 12” adjustable wrench, undo the yoke retainer. The retainer is removed counter-clockwise.
  • Page 5 DISASSEMBLY DISASSEMBLY Remove the yoke and yoke retainer. Strip the yoke retainer ready for cleaning and inspection. Remove the yoke bolt o ring.
  • Page 6 DISASSEMBLY DISASSEMBLY Carefully remove the filter retaining ring. Remove and discard the filter.
  • Page 7 DISASSEMBLY DISASSEMBLY Fit the Apollo adjusting wrench to the body cap. Use a 12” adjustable wrench, undo and lift off the body cap to expose the adjusting assembly. (Turn anti-clockwise to undo)
  • Page 8 DISASSEMBLY DISASSEMBLY Lift off the teflon washer and place to one side. Lift out the adjusting screw and guide nut.
  • Page 9 DISASSEMBLY DISASSEMBLY Separate the screw and nut. (the screw is left hand thread) Next lift out the LP spring and the spring pad.
  • Page 10 DISASSEMBLY DISASSEMBLY Install the Apollo adjusting wrench. Engage the pins in the diaphragm retainer. Use the 12” adjustable wrench and undo the diaphragm retainer turning counter clock-wise.
  • Page 11 DISASSEMBLY DISASSEMBLY Lift out the diaphragm retainer. Carefully remove the diaphragm washer.
  • Page 12 DISASSEMBLY DISASSEMBLY Place a low pressure air nozzle against one of the LP ports, use air pressure to lift the diaphragm off its seat. Apply pressure gently, and place a rag over the top of the body to prevent the diaphragm from being blown out and possibly causing an injury.
  • Page 13 DISASSEMBLY DISASSEMBLY Lift out the pushrod assembly and place to one side. The HP module is removed next. Use a wide blade screw driver to avoid damaging the groove. NOTE: If the HP module is tight and appears to be locked in position, refer to HP Module Technical Update for the correct removal procedure.
  • Page 14 DISASSEMBLY DISASSEMBLY Place the HP module on a solid surface as shown. Exert a downward pressure with your thumb or finger while engaging the circlip pliers to the retaining ring. While compressing the retaining ring gradually reduce the downward pressure. The HP assembly should now disengage the module…...
  • Page 15 DISASSEMBLY DISASSEMBLY Using a curved o ring picker, carefully pick up the o ring and remove from the chamber and discard. After removing the o ring check the teflon back up ring for damage. Any signs of damage (scoring etc) is cause for rejection, in this case a new balance chamber must be fitted.
  • Page 16 A-102 1ST STAGE INSPECTION & ASSEMBLY...

  • Page 17: Inspection And Cleaning

    INSPECTION & CLEANING INSPECTION & CLEANING A quick check of parts to be reused is carried out prior to cleaning. This will ensure you do not clean obviously defective parts. All metal parts are cleaned using white vinegar. The vinegar may be diluted using water, however diluting usually only means a longer soak period before the parts are clean.
  • Page 18 INSPECTION & CLEANING INSPECTION & CLEANING Check the HP seat knife edge orifice (cone) for damage prior to assembly. The pushrod assembly must be inspected for corrosion on the shaft, also any bending of the shaft. If any damage is noted replace the shaft. All threads are checked for damage, look for peeling chrome and damage caused by crossed threads.
  • Page 19 INSPECTION & CLEANING INSPECTION & CLEANING Rubber parts o rings etc. which are going to be reused should be washed in warm water and detergent. After washing all o rings are to be carefully inspected for damage or distortion. If the HP seat is to be reused for a repair (replace for a service) carefully inspect the rubber face for ANY defects.
  • Page 20 ASSEMBLY ASSEMBLY The lubrication of parts, o rings and threads, for Apollo regulators is carried out using either Christo-lube or Silicone grease. NOTE: The use of Christo-lube throughout the regulator DOES NOT constitute a regulator approved for use with Nitrox or O2 enriched Breathing Air.
  • Page 21 ASSEMBLY ASSEMBLY HP module sub assembly Replace the balance chamber o ring by using your fine tweezers as shown. Be sure to fit the o ring between the white teflon back up ring and the brass washer. The o ring must sit between the two parts, not on top of the brass washer.
  • Page 22 ASSEMBLY ASSEMBLY Next place the HP spring onto the seat. Place the balance chamber onto the spring, the side with the o ring facing the seat and spring.
  • Page 23 ASSEMBLY ASSEMBLY Sit the retaining ring on top of the assembly. Ensure all parts are centred or you will have difficulty compressing the assembly and installing the retaining ring. Compress the HP assembly and install the retaining ring.
  • Page 24 ASSEMBLY ASSEMBLY Check to ensure the retaining ring is located correctly in its groove. CAUTION When inspecting the retaining ring for security, be sure to wear eye protection and never point the assembly directly at your face. Lubricate and install the o ring to the HP module groove.
  • Page 25 ASSEMBLY ASSEMBLY Lightly lubricate the o ring on the HP module, lubricate the threads very lightly (if at all) and install the module assembly. Using a thick bladed screw driver, screw the module into position. DO NOT tighten down hard. Tighten until the module bottoms and then back out approximately 1/64 of a turn.
  • Page 26 ASSEMBLY ASSEMBLY Install the pushrod assembly. Be sure the pushrod engages the centre of the HP seat. Depress the assembly several times with your thumb to test the movement of the seat assembly. Next install the diaphragm. Bend between thumb and forefinger to make the installation easier.
  • Page 27 ASSEMBLY ASSEMBLY Use your nylon drift (or your finger) to push the diaphragm flat all the way around against the inner shoulder. The diaphragm washer is placed on top of the diaphragm.
  • Page 28 ASSEMBLY ASSEMBLY The spring pad is dropped through the retainer. Ensure the flat side is down, recessed side up. Lightly lubricate both ends of the spring and then install onto the spring pad.
  • Page 29 Christo-lube or silicone grease and install the retainer. The retainer must be finally tensioned using a spanner with the Apollo tool. Tighten sufficiently to ensure no leakage of air from under the diaphragm, but not so tight as to crush the diaphragm.
  • Page 30 ASSEMBLY ASSEMBLY Lightly lubricate the thread of the adjusting shaft and screw onto the nut. (left hand thread) Screw the nut onto the shaft until almost touching. Ensure the recess side is facing the spring.
  • Page 31 ASSEMBLY ASSEMBLY Place the teflon washer onto the adjusting shaft nut. Place the body cap over the spring adjusting assembly. Hand tighten.
  • Page 32 ASSEMBLY ASSEMBLY Tighten the body cap using the Apollo adjusting wrench. Slightly more than hand tight is sufficient. Sit the filter into the yoke retainer. Coarse or rough side of the filter faces up.
  • Page 33 ASSEMBLY ASSEMBLY Install the retaining ring. Ensure the retaining ring is seated correctly in its groove. Lightly lubricate the yoke retainer o ring and fit to its groove. Examine this o ring carefully before reusing. Any signs of distortion or damage is cause for rejection.
  • Page 34 ASSEMBLY ASSEMBLY NOTE: DO NOT lubricate the yoke retainer thread. A small drop of ‘Loctite 243’ can be applied to the thread. This will ensure the yoke does not come loose during service. Place the yoke and retainer assembly into position.
  • Page 35 12” adjustable wrench. Lightly lubricate and install the yoke screw. (not shown) Attach the Apollo low pressure test gauge to a low pressure port. Fit the 1st stage to a source of high pressure air. Eg; a full tank.
  • Page 36 ASSEMBLY ASSEMBLY The Apollo test gauge has a bleed screw, this should be slightly open when turning the air on. Once the system is pressurised tighten the bleed screw. NOTE: Ensure all the ports are blanked to carry out the adjustments.
  • Page 37 ASSEMBLY ASSEMBLY Use the Apollo adjusting wrench to set the intermediate pressure. Use the two small pins to turn the adjusting screw. Turn clockwise to increase pressure, counter clockwise to decrease the pressure. When decreasing pressure remember to open and close the bleed screw to obtain the correct pressure reading.
  • Page 38 ASSEMBLY ASSEMBLY The first stage is now ready for service. A final check for leakage can be carried out after the installation of the 2nd stage and any accessories. (BC hose etc.)