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Splash Atlantis R10 Service Manual

1st stage
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R10 1st Stage
Service Manual
PATRIOT AS103

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Summary of Contents for Splash Atlantis R10

  • Page 1 R10 1st Stage Service Manual PATRIOT AS103...
  • Page 2 PATRIOT 1ST STAGE Balanced Regulator 1ST STAGE • Maximum working pressure 3500psi (232 bar) • Low pressure port swivel assembly for versatile positioning • Intermediate pressure output balanced piston • 135-145PSI • Four 3/8-24 UNF-2B intermediate pressure ports • Two 7/16-20 UNF-2B high pressure port •...

  • Page 3: Specifications

    SPECIFICATIONS PINNACLE AS-103 AIR FLOW 33 cu. ft. (935 liters/min). @ 1 atmosphere INHALATION RESISTANCE 0.9” -2.0” (2.3 - 5.08 cm) w.c. @ 1 atmosphere EXHALATION RESISTANCE 0.6” (1.52 cm) w.c. max. @ 1 atm. RECOMMENDED LUBRICANT LTI Christo-Lube 111® PINNACLE FIRST STAGE REGULATOR TYPE balanced Piston Regulator - swivel...
  • Page 4 ANNUAL SERVICE REPLACEMENT PARTS: 790482...
  • Page 5 2-112-02 O-RING DIN ONLY 2-019-01 O-RING...
  • Page 6 SERVICE KIT LIST 790482 PART NO DESCRIPTION Q'TY 2-010-02 O - RING PISTON/BODY 2-022-01 O - RING PISTON TOP 2-019-01 O - RING CAP/LP PORT SWIVEL 3-903-01 O - RING LP PORT OR ATLANTIS LP HOSE 3-904-01 O - RING HP PORT OR ATLANTIS HP HOSE 2-014-02 O - RING...
  • Page 7 Torque Specifications: Description Item # Torque 120-140 in/lbs (13.56-15.82 N.M) DIN HOUSING 16-18 ft/lb (21.70-24.41 N.M) YOKE RETAINER 23-25 ft/lb (31.19-33.90 N.M) DIN RETAINER 120-130 In/lb (13.56-14.69 N.M) Port Plugs 18,20 35-40 In/lbs (3.96-4.52 N.M) Hose inlet end 2-3 ft/lb (3-4 Nm) Hose outlet end 2-3 ft/lb (3-4 Nm)
  • Page 8 SERVICE PROCEDURES FOR THE AS-103 Before you begin disassembly of the regulator, test the first and second stages for output pressures and leakage. Pre-testing in this way will help the technician to pinpoint any specific problems requiring repair.
  • Page 9 SERVICE PROCEDURES FOR THE AS-103 The work area must be clean and well lit, with clean compressed air available to blow sand and dirt from parts.
  • Page 10 PATRIOT 1ST STAGE ANNUAL SERVICE KIT HANDLE BAR 6" & 8" ADJUSTABLE WRENCH - HOSE 4MM HEX BIT SOCKET (ALLEN KEY) = PORT PLUGS PIN SPANNER (RING SPANNER) = CAP 1/4" HEX BIT SOCKET (ALLEN KEY) = HP SEAT RETAINER 8MM HEX BIT SOCKET (ALLEN KEY) = SWIVEL SEAT RETAINER 1.7MM DRILL BIT = SEAT PISTON BULLET...
  • Page 11 Use the 6” and 8” adjustable wrenches to loosen the hose nut from the PORT of the 1st stage. Remove the hose assembly from the second stage. Inspect the hose assembly for any cuts or cracks, especially on the hose at the metal ferrules.
  • Page 12 Put the body into the fixture block or clamp carefully in a soft-jawed bench vise. Use 1" HEX SOCKET to loosen and remove the yoke retainer (3) , the dust cap (6) and saddle (7). Remove the yoke knob assembly (1) from the yoke (2). remove the inlet filter (4) and the filter O-ring (5).
  • Page 13 Use a 4MM HEX BIT SOCKET to remove all port plugs (21, 23) from the body. Discard the port plug O-rings. (20, 22)
  • Page 14 Screw the STAINLESS HANDLE BAR into the HP port. Put the body into the fixture block or on the table. Use the PIN SPANNER to remove the Cap (17) from the Body (8).
  • Page 15 Remove any Spacer(s) (10, 12), the Spring (11) and the Piston (13) from the Cap. Remove and discard the O-rings (14) from the piston. Remove and discard the O-rings (9) from the body. Whenever possible, try to remove the O-rings by pinching them with the fingers and rolling them out of the groove.
  • Page 16 WARNING If a sharp pick is used to remove the O-rings, it should be made from soft brass, not steel. ANY scratches left in the groove when removing O-rings will cause leaks (bubbling out of the Cap ambient pressure ports) and the piston or body will have to be replaced to stop these leaks.
  • Page 17 Put the body into the fixture block again with the hp seat cap (27) facing up. Use a 1/4" HEX BIT SOCKET to remove the seat cap (27).
  • Page 18 Remove the Seat (26) from the seat cap (27) by pushing it out with a 1.70MM DRILL BIT or pneumatic pressure with air. Place one end of the drill bit on a flat hard surface. Lower the large end of the seat cap over the drill bit until the flat end of the drill bit rests against the back side of the Seat.
  • Page 19 Remove the o-ring (25) from the body (8). Remove the o-ring (33) and style cap (24).
  • Page 20 Screw the STAINLESS HANDLE BAR into the lp port swivel. Use an 8mm BIT SOCKET to remove the swivel retainer (15) and swivel washer (16) .Remove and discard the o-ring (18) from the cap (17).

  • Page 21: Handling Tips

    5.2.2 Don’t expect your cleaning solution to do all the work in a matter of seconds. If the solution cleans extremely rapidly, it is probably too strong and is etching the finish on the parts. Use a wooden or plastic Cleaning and Inspection of the 1st Stage stick or a soft bristle brush to help get rid of the thickest deposits.
  • Page 22 Remove the regulator parts from the cleaning solution. Rinse with clean fresh water, then blow internal passageways dry with clean, dry compressed air.
  • Page 23 Inspect all O-ring grooves for scratches or wear. If the regulator was leaking air because of scratches or wear, replace the parts. If some corrosion deposits persist, carefully wipe them away with a plastic scrubbing cloth or plastic or wooden dowel. Blow any resulting dust out of the regulator parts.
  • Page 24 Closely examine the sealing cones (orifices) in the piston (13) where the Seat (26) and the Piston seal.
  • Page 25 Place the HP Seat (26) on a clean flat surface and press the seat cap (27) stem straight over the seat until the new seat is installed into the end of the HP Seat Cap.
  • Page 26 Install the pre-lubricated O-rings (14) onto the piston and O-ring (9) into the body (8) and o-ring (18) onto the cap (17) . Put the swivel washer into place on the cap (17) and insert the swivel retainer (15) into the cap(17) and then screw to the LP swivel with the cap assembly.
  • Page 27 Carefully guide the large end of the Piston into the Cap until it bottoms. Use a gentle rocking motion if necessary to move the Piston into the Cap, but do not cock it at too severe an angle since this may cause the Piston to gouge the sealing surface of the Cap.
  • Page 28 Support the Body (8) so that the Cap threaded end is facing up. Use the same number of Shims (12, 10) that were installed in the Spring Cavity when you took the AS-103 apart. If there was one shim, it goes on the Body side of the Spring (9). If there were two Shims, install one at each end of the Spring.
  • Page 29 Lubricate the threads on the Cap (17) with grease. Put the Cap with its Piston (13) installed over the Spring and Shim sitting in the cavity of the body and screw them together as far as you can by hand. (Photos shown without cap for ease of view).
  • Page 30 Screw STAINLESS HANDLE BAR into HP port. Put the body into the fixture block or on the table. Use PIN SPANNER AND HOLD SOCKET to snug the Cap (17) onto the body with 120- 140 in/lbs (13.56-15.82 N.M) of torque.
  • Page 31 Put the style cap (24) onto the body (8). Install the pre-lubricated O-ring (33) into the style cap and o-ring (25) onto the body. Screw the seat cap assembly to the body. Tighten the HP seat cap (27) with a 1/4” HEX BIT SOCKET, follow the Torque Specifications. (13.5-15.5 Nm)
  • Page 32 Install the yoke retainer (3) into the yoke (2). Install the saddle (7) and the dust cap (6) onto the yoke.
  • Page 33 Install the new inlet filter (4) and filter O-ring (5) into the yoke retainer (3).
  • Page 34 Place the body carefully into a fixture so that the yoke retainer is facing up.
  • Page 35 Tighten the yoke retainer (3) with a 1" HEX SOCKET to 23-25 ft/lb (31.19-33.90 N.M).
  • Page 36 Install new O-rings (20,22) from the kit onto port plugs (21,23) and install the port plugs into the appropriate ports. Use the 4MM HEX BIT SOCKET to tighten port plugs to 35-40 In/lbs (3.96-4.52 N.M).
  • Page 37 Install yoke knob (1) onto the yoke.
  • Page 38 SET-UP AND TESTING THE FIRST STAGE Install an intermediate pressure test gauge with over-pressure release valve into one of the low-pressure ports of the first stage, or a functional 2nd stage into another low pressure port. Plug any remaining open outlet ports with suitable port plugs.
  • Page 39 Turn the air tank ON SLOWLY while listening for any unusual air leaks. If any are heard, turn the air off immediately and determine the source of the leak. If no leaks are found, watch the intermediate pressure gauge reading rise. It should stop before 150 psi (10.2 bar).
  • Page 40 If the in-line pressure gauge continues to rise above 150 psi (10.2 bar), turn the air supply off immediately and inspect the regulator to determine the cause.
  • Page 41 Depress the 2nd stage purge cover fully, then release it several times to clear particles from the regulator, and to work the internal parts into place.
  • Page 42 The pressure range for AS-103 Regulators at 3000 psi inlet pressure is 130-150 psi ( 9-10.2 bar). Add Shims (12) in either side of the spring (9) to raise the intermediate pressure. Remove Shims to lower the pressure. The pressure increase per shim is not linear due to the rate of the spring, so no specific increase per shim can be given.