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Tabata Tusa BCU-174 Service Manual

Active purge assist bcj power inflator
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SERVICE MANUAL
BCU-174 (APA)
Active Purge Assist BCJ Power Inflator
Volume I

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Summary of Contents for Tabata Tusa BCU-174

  • Page 1 SERVICE MANUAL BCU-174 (APA) Active Purge Assist BCJ Power Inflator Volume I...

  • Page 2: Table Of Contents

    Hoses & Rubber Components Troubleshooting Guidance Troubleshooting DISASSEMBLY/ASSEMBLY Disassembly Procedure, BCU-163 Disassembly Procedure, BCU-162 General Cleaning Methods Repair & Replacement Schedule Assembly Procedure, BCU-162 Assembly Procedure, BCU-163 SPECIFICATION Torque Specifications Performance Specifications TABATA Co., WORLDWIDE Contact Details V1.0 – 7.14.2010...

  • Page 3: Igeneral Information

    TUSA regulator repair. This manual is intended for use only in connection with the TUSA Regulator Repair course as prescribed by Tabata Co., Ltd and is not meant for general distribution. Accordingly, Tabata Co., Ltd makes no representations or warranties of any kind concerning the techniques or procedures contained within this manual.

  • Page 4: Repair Guidline

    BCU-174 (APA) SCHEMATIC DIAGRAM BCU-162 (APA) ANNUAL REPLACEMENT - V1.0 – 7.14.2010...

  • Page 5: Bcu-162 Schematic Parts List

    BCU-174 (APA) SCHEMATIC PARTS LIST BCU-162 (APA) ANNUAL TORQUE ITEM No. PART No. DESCRIPTION QTY. OVERHAUL N•m BCU-162-010 INFLATE BUTTON ASSY ● O-RING BCU-162-020 INFLATE SPRING ● O-RING BCU-162-040 SPRING BASE BCU-162-130 EXHAUST SPRING BCU-162-110 EXHAUST BUTTON BCU-162-140 EXHAUST BUTTON COVER BCU-162-160 MOUTHPIECE BCU-162-200...

  • Page 6: Bcu-163 Schematic Diagram

    BCU-174 (APA) SCHEMATIC DIAGRAM BCU-163 (APA) ANNUAL REPLACEMENT - V1.0 – 7.14.2010...

  • Page 7: Bcu-163 Schematic Parts List

    BCU-174 (APA) SCHEMATIC PARTS LIST BCU-163 (APA) TORQUE ITEM ANNUAL N・ｍ PART No. DESCRIPTION QTY. OVERHAUL BCU-163-020 OPEV VALVE CAP BCU-163-030 OPEV SPRING BCU-163-040 VALVE PLATE BCU-163-050 OPEV VALVE BCU-163-060 VALVE BASE BCU-163-160 GUIDE PIN ● O-RING BCU-163-150 OPEV BODY ASSY. BCU-163-090 WIRE TOP RETAINER ●...

  • Page 8: Tools Required

    Vice are considered standard workshop tools and may not be listed. All tools pictured below are available from local sources and Tabata except special tools. Special tools are designed exclusively for TUSA SCUBA equipment; they are available from the TUSA Factory Service Departments only using the indicated item number.

  • Page 9: General (User) Recommended Maintenance

    BCU-174 (APA) GENERAL CARE GUIDELINES Tusa recommends to all Authorized Dealers that they take individual time with each customer to explain and demonstrate the following simple steps for care and maintenance of the Buoyancy Compensator Jacket. This will help to ensure the following goals: •...

  • Page 10: Determining Service Intervals

    BCU-174 (APA) DETERMINING SERVICE INTERVALS TUSA recommends that the servicing of dive equipment be done on an annual basis or before any extended trip. Equipment being used for rental, training or any technical diving may require more frequent service intervals. Most components in the BCU-174 have very high-expected usable life.

  • Page 11: Inspection Techniques And Troubleshooting

    BCU-174 (APA) INSPECTION TECHNIQUES We encourage the service technician to develop good habits and practice in inspection techniques during service and overhaul. Observing the exterior condition of the Power Inflator can offer clues on what may be found during overhaul. Finding sand or salt deposits on the exterior crevices between mating parts may indicate a Power Inflator that is not properly maintained by the customer.

  • Page 12: Troubleshooting Guidance

    BCU-174 (APA) TROUBLESHOOTING GUIDANCE Prior to troubleshooting the BCU-174 (APA) we recommend you become familiar with the operation and design by reading Sections 2.0 and 5.0 through to 6.0. You will find that a good basis and understanding of the Power Inflator function which will benefit your repair and servicing abilities.

  • Page 13: Vdisassembly/Assembly

    BCU-174 (APA) DISASSEMBLY PROCEDURE BCU-174 (APA) Prior to disassembly, record the results of the preliminary inspection and the in water test. Remember to retain any o-rings, filters or other components that are to be replaced in case the customer requests to view the parts. For replacements, that were part of the Warranty scheme annual service, it is no longer necessary to return these parts to your TUSA factory distributor (Check with your regional distributor for details).
  • Page 14 BCU-174 (APA) 5.0.3 BCU-163 Disassembly Using a suitable Pin Wrench, remove the OPEV Valve Cap (1). Rotate Cap counter clockwise to remove. Remove the OPEV Spring (2), Valve Plate (3) and the OPEV Valve (4). 5.0.4 BCU-163 Disassembly Push upward on the Valve Base (5) from the bottom side of the OPEV Body Assy.
  • Page 15 BCU-174 (APA) 5.0.6 BCU-163 Disassembly Now that the Wire Assy. (37) is free, pull it from the OPEV Body Assy. (8) and remove the Wire Top Retainer (9). Remove the O-ring (7). Set aside the OPEV Body Assy. (8) and Wire Top Retainer (9) for cleaning.
  • Page 16 BCU-174 (APA) 5.1.2 BCU-162 Disassembly Extract the Piston (32) from the Piston Housing (35) by pulling it outward using a pair of soft tip needle nose pliers. NOTE: Show caution, do not scar or damage the Piston (32) WARNING A damaged Piston (32) can not be repaired, it must be replaced 5.1.3 BCU-162 Disassembly Using a 7/32”...
  • Page 17 BCU-174 (APA) 5.1.5 BCU-162 Disassembly Begin disassembly of the Quick Body (10) by removing the Inflator Plug (26) with a 1/2” wrench Remove the Plug O-ring (23) 5.1.6 BCU-162 Disassembly Remove the Exhaust Button Cover (8) using the ST-004-89 (TUSA Mask/Multi tool).
  • Page 18 BCU-174 (APA) 5.1.8 BCU-162 Disassembly Remove the Exhaust Axle Chamber assembly (24), Exhaust Stem (19) and the Piston Chamber (29). 5.1.9 BCU-162 Disassembly Disassemble the Exhaust Axle Chamber (24) using a pair of needle nose pliers to extract the Exhaust Axle (21) by gently pulling outward.
  • Page 19 BCU-174 (APA) 5.1.11 BCU-162 Disassembly Remove the Inflate Plug (15) using a coin (Nickel or Quarter). Remove the Inflate Plug O-ring (16). 5.1.12 BCU-162 Disassembly Using a 5/32” socket, remove the Inflate Poppet (17). Remove the Inflate Poppet O-ring (18). O-ring (18) 5.1.13 BCU-162 Disassembly Remove the Inflate Button (1) and Inflate...
  • Page 20 BCU-174 (APA) 5.1.14 BCU-162 Disassembly Using a 4” screw driver inserted in the open end of the Quick Body (10) locate the slot of the Purge Stem (28). While pressing the Purge Button (14) in, unscrew the Purge Stem (28) and remove.

  • Page 21: General Cleaning Methods

    BCU-174 (APA) GENERAL CLEANING METHODS Authorized TUSA Service and Repair technicians shall heed all warnings on the service and cleaning of all plastic parts in order to prevent failures. The design and performance of Power Inflators has advanced significantly within the past 10 years. Advances in materials have led to the use of engineered plastic polymers and thermoplastic resin alloys replacing traditional metal components.

  • Page 22: Repair & Replacement Schedule

    BCU-174 (APA) REPAIR AND REPLACEMENT SCHEDULE The following repair and replacement schedule is recommended for the BCU-174 (APA). Tusa recommends that all manufacturing specification are following when replacing soft seals and seat, also according to service use and cycle life of the regulator as discussed in Section 3.0 Annual service requires replacement of all item listed at a minimum of 1 year and 6 months or more for regulators in rental or commercial applications.

  • Page 23: Assembly Procedure, Bcu-162

    BCU-174 (APA) ASSEMBLY PROCEDURE BCU-162 (APA) 5.4.1 BCU-162 Assembly Check the Ring Clip on the Wire Assy. (37) to be sure that it is holding firmly in place. Retainer (36) Slide the Wire End Retainer (36) onto the Ring Clip Wire Assy.
  • Page 24 BCU-174 (APA) 5.4.4 BCU-162 Assembly Install new O-rings (25 & 31) onto the Piston (32). Attach the Wire Assy. (37) to the Piston (32) using the Cord Retainer (33). Tighten the Cord Retainer (33) clockwise using a 7/32” wrench. 5.4.5 BCU-162 Assembly Gently push the Piston (32) into the Piston Housing (35).
  • Page 25 BCU-174 (APA) 5.4.7 BCU-162 Assembly Place a new O-ring (13) onto the Purge Button (14). Place the Purge Spring (12) into the Purge Button (14). 5.4.8 BCU-162 Assembly Load the Stem Guide (11) into the Quick Body (10). The narrow end heads into Quick Body (10) first.
  • Page 26 BCU-174 (APA) 5.4.10 BCU-162 Assembly Place a new O-ring (2) onto the shaft of MT-1A W the Inflate Button (1). Place Inflate Spring (3) onto the Inflate Button (1). Install the Inflate Button Assy. (1,2 and 3) into the Quick Body (10). 5.4.11 BCU-162 Assembly Place a new O-ring (18) onto the Inflate Poppet (17).
  • Page 27 BCU-174 (APA) 5.4.13 BCU-162 Assembly Prepare the Exhaust Stem (19) with a MT-4A Y new O-ring (20). Fit a new O-ring (2) to the Exhaust Axle (21). Prepare the Exhaust Axle Chamber (24) with new O-rings (25 & 23). 5.4.14 BCU-162 Assembly Load the Exhaust Axle Spring (22) into the Exhaust Axle Chamber (24).
  • Page 28 BCU-174 (APA) 5.4.16 BCU-162 Assembly Slide the Piston Chamber (29) attached to the Wire Assy. (25, 31-37) into the Quick Body (10) with the largest opening lined up with the hole for the Exhaust Axle Chamber (24) Align holes 5.4.17 BCU-162 Assembly Through the Exhaust Axle Chamber hole in the Quick Body (10), load the Exhaust Stem (19) with the narrowest end heading...
  • Page 29 BCU-174 (APA) 5.4.19 BCU-162 Assembly Place a new O-ring (4) over the Exhaust Stem (19). Then place the Spring Base (5) over the Exhaust Stem (19). Be sure that the spring capture is facing 5.4.20 BCU-162 Assembly Place Inflate Spring (3) onto the Spring Base (5).

  • Page 30: Assembly Procedure, Bcu-163

    BCU-174 (APA) ASSEMBLY PROCEDURE BCU-163 (APA) 5.5.1 BCU-163 Assembly Slide the Spring Sleeve back into the Inflate Hose (11) exposing the Wire Assy. (37). Place the Wire Top Retainer (9) onto the Wire Assy. (37). The hollow end of the Wire Top Retainer (9) should be facing the Inflate Hose (11).
  • Page 31 BCU-174 (APA) 5.5.4 BCU-163 Assembly Position the Wire Assy. (37) into the slot of the Valve Base (5). Push Guide Pins (6) into place capturing the Wire Assy. (37). 5.5.5 BCU-163 Assembly Rotate Valve base (5) 180° and push it into the OPEV Body Assy.
  • Page 32 BCU-174 (APA) 5.5.7 BCU-163 Assembly Position the slot on the post of the Valve Plate (3) into the Valve Base (5) capturing the Wire Assy. (37) 5.5.8 BCU-163 Assembly Place the OPEV Spring (2) onto the Valve Plate (3). Place the OPEV Valve Cap (1) on top of the OPEV Spring (2).

  • Page 33: Specification

    BCU-174 (APA) TORQUE SPECIFICATIONS The following specifications are to meet upon assembly of the BCU-174 (APA). Torque and Pressure conversions: Movement of force 10.2 kgf cm 1 Nm Movement of force 1 Nm 8.85 Ib in 0.7375 Ib ft ITEM NO. DESCRIPTION TORQUE Inflate Plug...

  • Page 34: Tabata Co., Worldwide

    BCU-174 (APA) CONTACT DETAILS Tabata, Co. Worldwide contact details TABATA CO., LTD. JAPAN 1-3-17, Higashikomagata, Sumida-ku, Tokyo, Japan 130-0005 TEL +81(03)-3624-2816 / FAX +81(03)-3623-9902 www.tusa.net TABATA U.S.A. INC. 2380 Mira Mar Ave., Long Beach, CA 90815, U.S.A. TEL +1(562)-498-3708 / FAX +1(562)-498-1390 www.tusa.com...

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