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Genesis Scuba Atlas Service & Repair Manual

Second stage
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Atlas & Yukon
(Part Numbers GRXXX & )
Second Stage
S
& R
ERVICE
EPAIR
G
UIDE

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Summary of Contents for Genesis Scuba Atlas

  • Page 1 Atlas & Yukon (Part Numbers GRXXX & ) Second Stage & R ERVICE EPAIR UIDE...

  • Page 2: Table Of Contents

    Section 5 – Reassembly Procedures ........24 General Guidelines ..............24 Section 6 – Final Testing Procedures ........ 28 Table 2 – Troubleshooting Guide ........32 Schematic & Parts List – Atlas Second Stage....33 Schematic & Parts List – Yukon Second Stage ....35...

  • Page 3: Introduction

    When performing service, whether it is a routine overhaul or a repair of a specific problem, it is important to understand how the regulator is designed and how it operates. An illustrated explanation of the Atlas/Yukon second stage design is provided on the following page. EAN/ Nitrox Service Genesis regulators can be upgraded for use with oxygen enriched air (EAN/ Nitrox) not to exceed 40% oxygen content.

  • Page 4: Function & Design

    (4), which is designed to minimize exhalation resistance while keeping the case internally dry in all positions. (Atlas only - not shown) A dive/pre-dive switch can be set to minimize or boost peak venturi airflow, according to the diver's preference.

  • Page 5: Section 1 - Facility Requirements

    Genesis specialty tools that are required to perform service for the Atlas and Yukon second stages are pictured on the following page. Copyright ©2001 Liberty Group...
  • Page 6 Table 1 – Recommended Equipment and Suppliers Table 1 – Recommended Equipment and Suppliers The specialty tools shown below can be purchased directly from Genesis Scuba. For other items needed to outfit your store's service facility, we recommend the following suppliers: Peter Built Co.

  • Page 7: Section 2 - Preliminary Inspection

    Service & Repair Manual Preliminary Inspection Preliminary Inspection s e c t i o n s e c t i o n External Inspection 1. Closely examine the conical filter of the first stage to check for any signs that contaminants have entered the system, including sea water, rust, or aluminum oxide.

  • Page 8: Section 3 - Disassembly Procedures

    Atlas & Yukon Second Stage Disassembly Procedures Disassembly Procedures s e c t i o n s e c t i o n General Guidelines Prior to performing any disassembly, check to ensure that the service facility is well equipped with all the tools and parts needed to perform a complete service from start to finish.
  • Page 9 Service & Repair Manual CAUTION: Whenever possible, use only plastic or brass O- ring tools for removing O-rings in order to prevent damage to the sealing surface. Steel instruments, such as dental picks, can easily damage the sealing surface of a softer brass part, causing irreparable leakage and requiring the part to be replaced with new.
  • Page 10 Identify the side of the Rim Clamp that contains the larger diameter shoulder, which is designed to hold the Atlas/ Yukon cover ring. Place the Rim Clamp between the jaws of a bench mounted vise with the larger diam- eter side facing straight up, and the split edge parallel with the vise jaws (see Fig.
  • Page 11 Service & Repair Manual CAUTION: Do not over-tighten the vise. Doing so may permanently distort or fracture the cover ring and the case, requiring their replacement. c. When the cover ring is held secure, firmly grasp the second stage with both hands and rotate the second stage counter-clockwise in a level direction above the clamp (see Fig.
  • Page 12 Atlas & Yukon Second Stage 19. Using the O-ring pick that is provided in the Select Kit, lightly pierce the center of the LP seat(8) and pull it out of the head of the poppet. Discard the seat and do not attempt to reuse.
  • Page 13 23. Gently press upward against the base of the dive/ pre- dive switch inside the mouthpiece tube, and pull it out from Fig. 11 – Atlas Retaining Ring Removal the opposite side to remove it from the case. Squeeze the...

  • Page 14: Section 4 - Cleaning Procedures

    Atlas & Yukon Second Stage Cleaning Procedures Cleaning Procedures s e c t i o n s e c t i o n Acidic Cleaning Procedure (For Equipment Used With Compressed Air) Introduction This procedure provides complete instructions for cleaning reusable, non-wearing components and parts of regulators and valves used with standard Grade E compressed air.
  • Page 15 Genesis Scuba recommends Lawrence Factor Wash (LFW™) to be used exclusively for the acid bath cleaning of all non-wearing metal parts.
  • Page 16 Atlas & Yukon Second Stage CAUTION: Harsh acids, such as muriatic acid, may cause damage to parts and must be strictly avoided. Undiluted white vinegar, although less ™ effective, is the only recommended substitute for LFW STEP 4 – Neutralizing Bath: Thoroughly mix 8 cup sodium bicarbonate (baking soda) with one quart fresh tap water in a clean container.

  • Page 17: Ean/Nitrox Cleaning Procedure

    EAN/Nitrox Cleaning Procedure (For Equipment Used With Oxygen Enriched Air) Introduction Genesis Scuba regulators may be upgraded for dedicated use with mixtures of oxygen enriched air (EAN/Nitrox), not exceeding 40% oxy- gen. This upgrade must only be performed by an Authorized Genesis...
  • Page 18 Final Inspection (direct light, ultraviolet, and wipe test) NOTE: Although second stage components are not usually exposed to high pressure oxygen enriched air, Genesis Scuba recommends that the same cleaning and assembly procedures be followed for the complete regulator. This prevents the possibility of cross contamination, and guar- antees the integrity of the complete system.
  • Page 19 Service & Repair Manual NOTE: All tools and fixtures, including the ultrasonic cleaner well, must be kept completely clean of any contaminants. For this reason, a sepa- rate set of clean tools should be used for the reassembly of enriched air equipment, different from those used for normal air equipment.
  • Page 20 Atlas & Yukon Second Stage 1. Place the parts inside a clean dip basket and lower the basket into the tank of a separate ultrasonic cleaner which contains an approved aqueous cleaning solution. (Refer to Table 1 for an approved and recommended solution, and follow the manufacturer’s instructions for...
  • Page 21 WARNING: Do not attempt to use individually ordered spare parts as a substitute for those packaged in kit form directly from Genesis Scuba. Doing so will render the product incompatible for use with enriched air, and may seriously jeopardize the safety of the diver.
  • Page 22 Atlas & Yukon Second Stage LOW PRESSURE HOSE ASSEMBLIES 1. Ultrasonically clean both hose fittings by dipping only the hose ends in the LFW ™ acid bath, and rinse thoroughly in distilled water. 2. Inspect each fitting to ensure that all scale and corrosion is removed, and re-clean if necessary, using a small nylon brush.
  • Page 23 Service & Repair Manual Set the O-rings aside on a perfectly clean surface that is covered with cellophane. Do not use lubricant that appears to be contaminated with any particulate matter or other foreign debris. CAUTION: The use of aerosol spray or petroleum based lubricants must be strictly avoided.

  • Page 24: Section 5 - Reassembly Procedures

    Atlas & Yukon Second Stage Reassembly Procedures Reassembly Procedures s e c t i o n s e c t i o n General Guidelines Refer to the schematic parts list, that highlights automatic replacement parts (ARP) which should be discarded and replaced with new during reassembly.
  • Page 25 Doing so may render the product unsafe, and could result in serious injury or death. Atlas Second Stage Only (Yukon proceed to Step 5) 1. Install the O-ring(11b) onto the dive/ pre-dive switch(11c). 2. Mate the flat vane of the dive/ pre-dive switch into the case(11) above the mouthpiece tube, and position the indicator pin above the curved recess.
  • Page 26 Atlas & Yukon Second Stage 7. Fit the LP seat(8) into the head of the poppet(9) with the smooth side facing out. Ensure that it is seated flush with the inner rim of the poppet. DO NOT use adhesive. 8. Stand the Poppet Drive Tool (provided in the Genesis Poppet Tool Kit –...
  • Page 27 Service & Repair Manual 16. Apply a medium blade screwdriver to engage the slotted head of the orifice, and turn it clockwise approximately 5 full revolutions. Then, grasp the screwdriver by the shaft, rather than the handle, for best sensitivity of touch. Con- tinue turning the orifice very slowly while closely observing the locknut on the end of the poppet (see Fig.

  • Page 28: Section 6 - Final Testing Procedures

    Atlas & Yukon Second Stage Final Testing Procedures Final Testing Procedures s e c t i o n s e c t i o n CAUTION: If the regulator has been upgraded for use with EAN/ Nitrox, it is important to pressurize and flow test the regulator using only hydrocarbon-free gas.
  • Page 29 Service & Repair Manual 4. Ensure that all the first stage ports are sealed, and connect the first stage with a filtered gas supply of 2,500-3,000 psi. Slowly open the supply valve to pressurize the regula- tor. Listen to verify that a leak can be heard from the second stage valve, and proceed to step 6.
  • Page 30 Atlas & Yukon Second Stage end wrench to remove the inlet fitting with orifice from the second stage. Be careful to protect the exposed sealing edge of the orifice. d. Fasten the Poppet Drive Tool (PN 20-640-100) onto the second stage inlet, and engage the driver with the head of the poppet.
  • Page 31 Disinfect the mouthpiece, and dry the regulator completely with a clean towel. This completes the overhaul service procedures for the Atlas/Yukon Second Stage Regulator Copyright ©2001 Liberty Group...
  • Page 32 Do not attempt to perform partial service if the regulator shows any signs of use. For additional troubleshooting assistance, contact your Genesis Scuba distributor. Copyright ©2001 Liberty Group...

  • Page 33: Schematic & Parts List Atlas Second Stage

    Ref # PN *ARP Description ..PK040 Annual Service Kit 12 ..G4485-07 Mouthpiece, Black ..GXXXX Atlas Second Stage, Assembled 13 ..G5234 Exhaust Tee 14 ..G1978-07 Tie-Strap 1 ..G5240 Cover Ring 15 ..G6326 Exhaust Valve 2 ..
  • Page 34 NOTES...

  • Page 35: Schematic & Parts List - Yukon Second Stage

    Ref # PN *ARP Description ..PK040 Annual Service Kit 15 ..G6326 Exhaust Valve ..GXXXX Atlas Second Stage, Assembled 16 ..G5241 Case Plug 17 ..G2-016 O-ring 1 ..G5240 Cover Ring 18 ..G5256 Retaining Ring 2 ..

This manual is also suitable for:

Yukon

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