Table of Contents
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Table of Contents
Related Manuals for Deep 6 SCUBA
Summarization of Contents
Introduction to Deep6 Regulators
Service Training Requirement
Manual is for trained divers only, emphasizing the need for formal training by Deep6 or equivalent.
Service Interval and Safety Information
Service Interval and Maintenance Schedule
Details the recommended service interval of 2 years or 200 dives and annual inspection requirements.
Safety Cautions and Warnings
Explains symbols for caution, warning, and specification, emphasizing safety and proper procedure.
Understanding Schematics
Explains how numbered parts on schematics relate to manual text and part ordering.
Guide to Using the Service Manual
Provides advice on printing pages and navigating the manual for efficient service.
General Service Considerations
Oxygen Service and Clean Air
Details requirements for oxygen service, including Modified Grade E air and avoiding hydrocarbons.
Tool and Workspace Cleanliness
Emphasizes maintaining clean tools and non-porous work surfaces, especially for oxygen service.
Shop Environment and Lint-Free Cloths
Stresses a dust-free environment and using lint-free cloths for cleaning parts.
Using Pressurized Air Safely
Warns about risks of pressurized air for drying, including part loss and subcutaneous gas injection.
Printing Manual Schematics and Quick Reference
Recommends printing schematics and quick reference sections for easier service.
Part Matching and Work Area Management
Ensures all parts are matched to the service kit and removed from the work area after use.
Service Specifications and Warnings
Torque Specifications and Lubrication
Mandates measured torque for components and warns against over/under-torquing.
Thread Lubrication Warnings
Warns against lubricating threads unless specified, as it can double axial load and cause failure.
Handling Sensitive Components
Highlights sensitive parts like HP seat, volcano orifice, and second stage orifice that require careful handling.
Understanding IP Drift and Creep
Explains IP drift and creep, their causes, and how they indicate potential issues.
Pre-Service Inspection and Testing Importance
Emphasizes the criticality of pre-service inspection and testing for proper diagnosis.
Service Timing and Dive Safety
Advises against last-minute servicing and recommends testing equipment after service.
Pre-Service Inspection and Testing Procedures
Exterior Inspection and IP Cap Check
Inspect regulator exterior for damage and check for looseness in the IP cap.
Hose and O-ring Inspection
Check hose guards for corrosion and ensure hoses and o-rings are properly seated.
First Stage Filter Inspection
Inspect the sintered metal filter for signs of verdigris or rust, indicating salt water entry.
Hose Integrity Check
Examine hoses for cracks and ensure they are rigid, checking for rotation at swaged ends.
Second Stage Leak Check
Check for leaks by inhaling from the second stage with the dust cap, identifying potential causes.
SPG Inspection
Inspect the SPG dial face for damage and check for smooth rotation on the hose.
Intermediate Pressure (IP) Measurement Setup
Connect an IP gauge to the BCD hose and prepare to pressurize the regulator set.
Monitoring Intermediate Pressure
Observe IP gauge for lockup, drift, or creep, and be ready to depressurize if needed.
First Stage Tank Connection Check
Check for looseness in the first stage connection to the tank (yoke or DIN).
General Leak Detection
Perform a general check for leaks by listening, feeling, and looking for air escaping.
Second Stage Cracking Effort Measurement
Measure the force required to initiate airflow from the second stage.
Second Stage Breathing and IP Fluctuation
Observe IP fluctuation during gentle breathing to ensure proper performance.
Pre-Service Inspection and Testing Procedures
IP Drop During Purge Check
Monitor IP drop during a purge to identify potential issues like filter blockage or friction.
Submersion Leak Check
Immerse the regulator in water to check for leaks from connections or internal components.
SPG Face Water Intrusion Check
Inspect the SPG face for signs of water intrusion after submersion.
Defect Listing for Service
Compile a list of all identified defects to be addressed in subsequent service steps.
First Stage Service: Disassembly Overview
First Stage Disassembly Steps
Detailed steps for disassembling the Deep6 Signature first stage, starting with hose removal.
Environmental Cap Removal
Instructions for removing the environmental cap using a hook spanner and maintaining pressure.
Environmental Seal and Transpiston Removal
Remove the environmental seal and the Transpiston from the first stage body.
Securing Body and Releasing Spring Tension
Mount the regulator body in a vise and release spring tension on the diaphragm clamp.
First Stage Service: Disassembly Procedures
Diaphragm Clamp Removal
Loosen and remove the diaphragm clamp, carefully separating it from the regulator body.
Diaphragm Removal Techniques
Details methods for safely removing the diaphragm, using air pressure or a dowel.
Diaphragm Removal with Air Pressure
Safely remove the diaphragm using 40psi air pressure, with precautions for parts.
Valve Lifter Removal
Invert the regulator to collect the valve lifter, cautioning against manual extraction.
First Stage Service: Yoke and DIN Disassembly
Yoke/DIN Retainer Removal Preparation
Explains the challenge of removing retainers due to salt crystal impregnation and preparation.
Removing Remaining Port Plugs
Remove any remaining LP and HP port plugs using a hex key and vise tool.
Securing Body for Yoke/DIN Removal
Secure the regulator body in a vise for retainer removal, using padding to protect the finish.
Yoke Retainer Removal
Detailed steps to remove the yoke retainer using a socket, extension, and breaker bar or wrench.
O-ring Removal Warning
Warns against using metal picks for o-ring removal to prevent leaks.
Yoke Filter and O-ring Removal
Remove the filter and o-ring from the yoke retainer using a wooden dowel.
DIN Retainer and Housing Removal
Remove the DIN retainer and housing using a hex key and appropriate wrench.
First Stage Service: DIN Disassembly Details
DIN Wheel and Housing Removal
Remove the DIN wheel and housing, noting the need for specific socket modification for removal.
DIN Housing Socket Modification
Explains how to modify a socket to avoid damaging the DIN housing flats during removal.
Custom Tool for DIN Housing Removal
Suggests grinding a socket's chamfer off for better engagement with DIN housing flats.
Alternative Tools for DIN Housing Removal
Discusses using open end wrenches or crowfoot attachments as alternatives for DIN housing removal.
DIN Housing Removal Procedure
Details the process of removing the DIN housing using an open end wrench or socket.
DIN Filter and O-ring Removal
Remove the filter and o-ring from the DIN housing using a thin dowel.
First Stage Service: IP Cap and Balance Plug Disassembly
IP Cap Removal Preparation
Mount the regulator in a vise and use a hook spanner to loosen the IP cap.
Diaphragm Removal if Stuck
Provides a method to remove the diaphragm using a dowel if it remains stuck after IP cap removal.
IP Cap O-ring Removal
Remove the 2-024 o-ring from the regulator body using a thin pick.
IP Cap and Swivel Retainer Disassembly
Steps to disassemble the IP Cap, including removing the swivel retainer and thrust washer.
Swivel Retainer and O-ring Removal
Remove the swivel retainer, thrust washer, and o-rings from the IP cap.
Balance Plug and O-ring Removal
Loosen the balance plug and remove its o-rings, warning against using ball-end hex keys.
First Stage Service: Balance Plug Assembly Disassembly
Balance Plug Unscrewing
Unscrew the balance plug from the regulator body while maintaining upward pressure.
Balance Plug Assembly and HP Seat Removal
Remove the balance plug assembly, spring, and HP seat, emphasizing careful handling.
Balance Chamber O-ring Removal and HP O-ring
Remove o-rings from the balance chamber, warning against damaging the HP o-ring land.
Loosening Frozen Threads
Ultrasonic Cleaning for Frozen Threads
Discusses ultrasonic cleaning as a method to loosen frozen threaded parts.
Acid Bath Soaking for Frozen Threads
Explains using an acetic acid bath to dissolve corrosion and loosen threads.
Cold Soaking for Frozen Threads
Describes cold soaking to contract metal parts and aid in loosening frozen threads.
Percussive Force for Frozen Threads
Suggests using percussive force to shatter crystals that lock threaded parts.
WD-40 and Time for Frozen Threads
Recommends using WD-40 or Liquid Wrench and allowing time for capillary action.
Cosmetic Damage from Frozen Thread Techniques
Notes that cosmetic damage may occur when using techniques to loosen frozen threads.
Importance of Regular Service
Highlights the benefit of regular service to prevent issues like frozen threads.
First Stage Parts Cleaning Procedures
Part Matching Before Cleaning
Match all replacement parts to their old equivalents before proceeding with cleaning.
Protecting Sensitive Parts During Cleaning
Warns against contact of HP seat, o-ring lands, and volcano cone with metal parts during cleaning.
Standard vs. Oxygen Service Cleaning
Distinguishes between standard and oxygen service cleaning, emphasizing higher standards for oxygen.
Oxygen Cleaning Course Recommendation
Recommends formal training for oxygen cleaning service if contemplating use above 40%.
Mandatory Oxygen Service Requirements
Lists mandatory requirements for oxygen service, including gloves, lubricants, work area, and air.
Suitability for Air/EAN Below 40%
States that if oxygen service requirements aren't met, the regulator is only suitable for air or EAN below 40%.
Oxygen Cleaning Process Steps
Outlines the multi-step process for oxygen cleaning, including washes, rinses, and testing.
First Stage Parts Cleaning Details
Detergent Wash Procedure
Details the detergent wash process, including agitation, scrubbing, and segregation of parts.
Alkaline Degreasing for Oxygen Service
Explains the mandatory alkaline degreasing step for oxygen-cleaned equipment.
Warm Acid Wash Procedure
Describes the warm acid wash using vinegar solution to remove corrosion.
Acid Wash Effectiveness and Alternatives
Discusses limitations of vinegar wash and mentions phosphoric acid as a more aggressive alternative.
Neutralizing and Final Rinse
Neutralize parts with a sodium bicarbonate solution and rinse thoroughly.
Post-Cleaning Inspection
Inspect parts under light for dust, corrosion, or oils, returning to previous steps if contamination is found.
Hydrocarbon Contamination Testing
Test parts for residual hydrocarbons using ultraviolet light and water sheeting tests.
First Stage Parts Cleaning Testing
Water Sheeting and Bubble Test
Perform water sheeting and bubble tests to detect hydrocarbon contamination.
Repeat Cleaning if Contamination Found
If hydrocarbon residue is found, repeat the cleaning process.
Passing Cleaning and Testing Requirements
States that passing all tests means parts are safe for oxygen service if lubricants are oxygen-safe.
Recommended Cleaners and Equipment
Lists examples of suitable cleaners and equipment for servicing Deep6 regulators.
First Stage Reassembly Preparation
Workspace Setup for Reassembly
Prepare the workspace with tools, cleaned parts, gloves, and reassembly layout.
O-ring Duro Differences
Highlights differences between duro 70 and duro 90 o-rings and their specific uses.
O-ring Placement Warning
Warns about incorrect placement of soft o-rings potentially causing major gas leaks.
Attention to Detail in Reassembly
Emphasizes the importance of paying attention to detail and following reassembly steps precisely.
Valve Lifter Installation
Install the valve lifter into the center hole of the regulator body.
Diaphragm Installation and Seating
Install the diaphragm, ensuring it is correctly seated and warning against lubricating it.
Gathering Diaphragm Clamp Components
Collect the parts needed for the diaphragm clamp assembly: spring pad, washers, spring, adjuster, and clamp.
First Stage Reassembly: Diaphragm Clamp
Spring Adjuster and Washer Installation
Lubricate and thread the spring adjuster into the diaphragm clamp, then install washers and spring.
Spring Pad and Washer Placement
Place the spring pad on top of the main spring inside the diaphragm clamp.
Diaphragm Clamp Assembly Installation
Thread the diaphragm clamp assembly into the regulator body, warning against lubricating clamp threads.
Mounting for Diaphragm Clamp Tightening
Mount the regulator in a vise with the diaphragm clamp facing up for tightening.
Diaphragm Clamp Tightening Procedure
Use a hook spanner to tighten the diaphragm clamp, warning against slipping.
Applying Torque to Diaphragm Clamp
Hold the hook spanner firmly and tighten the diaphragm clamp clockwise.
Diaphragm Clamp Tightening Specification
Specify torque limit or metal-to-metal contact for tightening the diaphragm clamp.
First Stage Reassembly: Balance Plug Assembly
Spring Adjuster Final Turns
Add three more turns clockwise to the spring adjuster to center the lift pin.
Collecting Balance Plug Assembly Components
Gather components for the balance plug assembly: plug, o-rings, spring, and HP seat.
Balance Plug O-ring Installation
Lubricate and install the 3-905 o-ring on the balance plug, checking for twists.
HP O-ring Installation in Balance Plug
Lubricate and install the Teflon HP o-ring (#18) into the balance plug, ensuring proper seating.
HP Seat and Spring Installation
Install the seat spring and HP seat into the balance plug, taking care not to scratch.
HP Seat Assembly Insertion into Regulator Body
Insert the HP seat assembly into the regulator body by hand, carefully aligning the valve lifter pin.
First Stage Reassembly: Balance Plug and Turret
Securing Balance Plug Assembly
Thread the balance plug assembly into the regulator body and tighten with a hex key.
Balance Plug Tightening Fixture
Secure the regulator body in a vise for tightening the balance plug assembly.
Balance Plug Torque Specification
Torque the balance plug to 80 in-lb using a 4mm straight shaft hex key.
Spring Adjuster Adjustment for Initial Pressure
Unscrew the spring adjuster one turn to set initial intermediate pressure.
Collecting Turret Assembly Components
Gather components for the turret assembly: retainer, washer, IP cap, o-rings, and swivel turret.
Turret O-ring Installation
Lubricate and install the o-rings onto the swivel turret.
Swivel Washer and Retainer Placement
Place the thrust washer in the IP cap and hold the swivel retainer in place.
Swivel Turret Installation
Thread the swivel turret onto the retainer and secure the turret assembly in a vise.
Swivel Retainer Torque Specification
Torque the swivel retainer to 150 in-lb using an 8mm socket hex bit.
IP Cap and Turret Assembly Installation
Install the IP cap with the turret onto the regulator body.
First Stage Reassembly: Yoke and DIN Assembly
IP Cap Tightening Procedure
Use a hook spanner to tighten the IP cap until firm metal-to-metal contact is achieved.
IP Cap Metal-to-Metal Contact
Tighten the IP cap until firm metal-to-metal contact is achieved between parts.
Yoke Assembly Preparation
Prepare for yoke assembly with gloves and gather necessary parts.
Yoke Retainer, Filter, and O-ring Assembly
Assemble the yoke retainer, filter, and sealing o-ring.
Yoke Assembly to Regulator Body Attachment
Attach the yoke assembly to the regulator body, warning against lubricating threads.
Yoke Assembly Safety Check
Ensure the sealing o-ring is trapped before turning the yoke assembly over.
Yoke Assembly Securing for Torquing
Mount the regulator horizontally in a vise for torquing the yoke retainer.
Yoke Retainer Torque Specification
Torque the yoke retainer to 230 in-lb in a single smooth motion.
Yoke Dust Cap and Knob Installation
Thread the dust cap onto the yoke knob and install the knob into the yoke.
Yoke Port Plug Installation
Install lightly lubricated o-rings on port plugs and thread them into the HP and LP ports.
First Stage Reassembly: DIN Assembly Details
DIN Assembly Preparation
Prepare for DIN assembly with gloves and gather necessary parts.
DIN Housing, Filter, and O-ring Assembly
Assemble the DIN housing, filter, and sealing o-ring.
DIN Housing to Regulator Body Attachment
Attach the DIN housing to the regulator body, warning against lubricating threads.
DIN Assembly Safety Check
Ensure the sealing o-ring is trapped before turning the DIN assembly over.
DIN Assembly Securing for Torquing
Mount the regulator horizontally in a vise for torquing the DIN housing.
DIN Housing Torque Specification
Torque the DIN housing to 230 in-lb in a single smooth motion.
DIN Wheel and Retainer Assembly
Assemble the DIN wheel, o-ring, and retainer into the DIN housing.
DIN Retainer Torque Specification
Torque the DIN retainer to 80 in-lb using a 6mm Hex socket.
Ball-End Hex Key Warning for DIN Retainer
Warns against using ball-end hex keys for DIN retainer torque due to potential damage.
DIN Port Plug Installation
Install lightly lubricated o-rings on port plugs and thread them into the HP and LP ports.
First Stage Tuning Procedures
First Stage Tuning Precheck
Perform precheck by opening tank valve and observing IP gauge, addressing initial issues.
Initial IP Range and Stabilization
Discusses initial IP range (0-50 psi) and how to stabilize it by cycling the second stage.
Intermediate Pressure Adjustment (Low Tank)
Adjust IP to ~120 psi, then to 138 psi at 500 psi tank pressure, using small increments.
Fine-Tuning IP to 138 psi
Fine-tune IP to 138 psi using 1/12 turn increments, cycling the second stage.
Adjusting IP Counterclockwise
Describes how to adjust IP counterclockwise if an overshoot occurs, using small increments.
Intermediate Pressure Confirmation (High Tank)
Confirm IP at 3000 psi, ensuring it's within specification and checking for IP Creep.
First Stage Tuning and Final Checks
Addressing Persistent IP Creep
True IP Creep requires disassembly and component replacement.
Post-Break-in IP Readjustment
Explains how IP may change after break-in and how to readjust it if necessary.
Environmental Seal Installation and Final Testing
Install the environmental seal with the regulator pressurized and perform final tests.
Preparing for Environmental Seal Installation
Leave the first stage pressurized and remove the hex key.
Transpiston Installation
Install the Transpiston into the hex broach of the regulator body.
Environmental Seal Installation
Install the environmental seal, ensuring it is centered and noting potential IP rise.
Environmental Cap Installation
Lubricate and screw on the environmental cap by hand, tightening firmly.
Post-Installation Seal Check
Depressurize, check seal shape, repressurize, and confirm static IP.
Dynamic IP Drop and Purge Test
Confirm dynamic IP drop during breathing and purging is within limits.
Final Submersion Leak Test
Immerse the pressurized first stage in water to check for leaks.
Final IP Specification
Specifies static IP range (125-145 psi) and the absence of IP Creep.
SPG and High Pressure Hose Service
SPG Removal from Console
Remove the SPG from its console boot, possibly using hot soapy water.
SPG Spool Removal
Remove the spool from the gauge or hose nut, using a tool if heavily corroded.
SPG Spool O-ring Removal
Remove the two o-rings from the SPG spool using a pick.
SPG O-ring Removal Technique
Use a pick parallel to the o-ring and avoid digging to prevent damaging the land.
Spool Corrosion Removal and Oxygen Use
Clean spool corrosion with vinegar and notes on using with high pressure oxygen.
Contaminated HP Hose Warning
Warns that contaminated HP hoses cannot be oxygen cleaned and must be replaced.
SPG and HP Hose Thread Corrosion
Notes that thread corrosion is usually not necessary to remove as it's outside the sealing area.
Cleaning Thread Corrosion on HP Hose
Details a technique to clean thread corrosion on HP hoses using tape and vinegar.
SPG and HP Hose Service Details
SPG Thread Corrosion and Bore Cleaning
Discusses gauge thread corrosion and warns against cleaning the bore to prevent debris issues.
Cleaning Thread Corrosion on SPG
Details a technique to clean thread corrosion on SPG ends using tape and vinegar.
SPG Spool O-ring Lubrication and Selection
Lubricate and select the correct o-ring (70 or 90 duro) for the SPG spool.
SPG Spool O-ring Installation
Installs the o-ring onto the SPG spool using a padded surface.
SPG Assembly and Connection Tightening
Insert the spool into the gauge and thread the gauge onto the hose, tightening with two wrenches.
HP Hose O-ring and Protection
Install a lubricated o-ring on the HP hose end, using a hose bullet for protection.
Low Pressure Hose Service
Low Pressure Hose First Stage End O-ring Removal
Remove the 2-011 o-ring from the first stage end of the hose using a pick.
Low Pressure Hose Second Stage End O-ring Removal
Remove the o-ring from the second stage end of the hose, detailing pick usage and alternatives.
Low Pressure Hose Vinegar Soak and Neutralization
Soak hose ends in vinegar solution and neutralize with baking soda solution.
Low Pressure Hose Oxygen Cleaning
Immerse hoses in detergent for oxygen cleaning, repeating filling and draining.
Low Pressure Hose Final Rinse
Rinse the interior of the hose thoroughly with clean water.
Drying Low Pressure Hose with Air
Dry the hose interior using intermediate pressure air, warning to maintain control of the hose end.
Low Pressure Hose Cleanliness Inspection
Inspect for contamination by blasting air through the hose onto a cloth.
Low Pressure Hose O-ring Installation
Install new lubricated o-rings on both ends of the low pressure hose.
BCD Hose Service
BCD Hose First Stage End O-ring Removal
Remove the 2-011 o-ring from the first stage end of the BCD hose.
Schrader Valve Removal from BCD Hose
Unscrew the Schrader valve from the BCD hose, noting difficulty with corroded ends.
Schrader Valve Cleaning and Replacement
Remove, clean, or replace the Schrader valve, using vinegar soak if corroded.
BCD Hose End O-ring Removal
Remove the sealing o-ring from the BCD hose end, warning about pick usage to avoid land damage.
BCD Hose Cleaning and Inspection
Clean the BCD hose using the low pressure hose method and inspect for contamination.
BCD Hose O-ring Installation
Install a new lubricated o-ring into the BCD hose end, detailing tool use and paper wad method.
BCD Hose O-ring Size Considerations
Suggests substituting a 3-903 o-ring if the fitting doesn't lock easily.
BCD Hose Final Lubrication
Lubricate ball bearing holes and install the first stage end o-ring.
Second Stage Service: Disassembly Overview
Second Stage Disassembly Steps
Detailed steps for disassembling the Deep6 Signature second stage.
LP Hose and Heat Sink Nut Removal
Remove the LP hose, using a wrench to hold the heat sink nut if necessary.
Faceplate and Thrust Washer Removal
Unscrew the faceplate and remove the thrust washer, if present.
Diaphragm Seal Break and Removal
Break the diaphragm seal and lift it free, warning against using sharp tools.
Heat Sink Nut Loosening
Loosen the heat sink nut, but do not remove it completely yet.
Heat Sink Nut Complete Removal
Completely remove the heat sink nut and set it aside.
Adjustment Knob Unscrewing
Unscrew the adjustment knob to its stop, and prepare to pull the barrel assembly.
Barrel Assembly Removal
Depress the lever and pull the deflector and barrel assembly from the case.
Second Stage Service: Knob and Barrel Disassembly
Case O-ring Removal
Remove the 2-014 o-ring from the case recess.
Deflector and Barrel Assembly Removal
Slide the deflector assembly off the barrel and separate the o-ring.
Pin Removal Preparation
Prepare a surface to catch loose parts and identify the pin adjacent to the adjustment knob.
Pin Release from Adjustment Knob
Loosen the adjustment knob to allow the pin to fall out, with methods for stuck pins.
Complete Adjustment Knob Removal
Unscrew the adjustment knob completely, noting it may require gentle pulling.
Balance Cylinder and Main Spring Removal
Remove the balance cylinder and main spring if they drop out.
Adjustment Knob Plug Removal
Lever the plug out of the adjustment knob using a blunt brass pick.
Adjustment Knob O-ring Removal
Remove the 2-011 o-ring from the adjustment knob and other o-rings from the plug.
Second Stage Service: Poppet Assembly Removal
Turbine Piston Design Features
Highlights the Turbine Piston for improved airflow, safety, and continuous engagement.
Piston Head and Lever Foot Comparison
Compares piston head width to lever foot space, illustrating the necessary spread for poppet removal.
Zip-Tie Method for Lever Spread
Use a zip-tie to spread the lever feet for poppet assembly removal.
Zip-Tie Loop Formation
Form a large loop with the zip-tie and thread it through the lever.
Zip-Tie Snugness and Lever Spread
Fold the lever down to ensure the zip-tie is snug, providing the required lever spread.
Poppet Assembly Drop Free
Tilt the barrel to allow the poppet assembly to drop free, with methods for stuck assemblies.
Second Stage Service: Poppet and Lever Disassembly
Optional Lever Removal for Stuck Poppet
Optional steps to remove the lever completely if the poppet assembly remains stuck.
Poppet Assembly Disassembly
Disassemble the poppet assembly, setting aside the main spring and balance cylinder.
Low Pressure Seat and O-ring Removal from Turbine Piston
Remove the low pressure seat and o-rings from the Turbine Piston shaft.
Lever Leg Inspection
Inspect the lever legs to confirm they are parallel and square to the cross-bar.
Lever Feet Inspection and Shape
Inspect lever feet for symmetry and warns against re-bending levers.
Contacting Deep6 for Lever Replacement
Instructs users to contact Deep6 for lever replacement if shape is compromised.
Second Stage Service: Orifice and Exhaust Valve
Orifice Loosening Procedure
Loosen the orifice completely by unscrewing it counterclockwise.
Orifice Removal with Dowel
Push the orifice out of the barrel using a wooden dowel, checking for obstructions.
Mouthpiece Zip-Tie and Removal
Cut the mouthpiece zip-tie and remove the mouthpiece.
Exhaust Cover Removal
Push the exhaust cover tab to pop it free, warning against excessive force.
Exhaust Valve and Case Inspection
Inspect the exhaust valve and case for damage or debris.
Optional Exhaust Valve Removal
Optional steps to remove the exhaust valve, recommending against reusing removed valves.
Second Stage Component Inspection
Orifice Knife Edge Inspection
Inspect the orifice knife edge for catches or irregularities that may impair sealing.
Diaphragm Integrity Check
Stretch the diaphragm to check for pinholes, discarding if any are found.
Mouthpiece Inspection
Flex the mouthpiece wings to check for cuts or holes.
Lever Alignment and Binding Check
Confirm lever sides are parallel and feet are aligned, checking for binding against the barrel.
Second Stage Case Inspection
Carefully inspect the case for any cracks under bright light.
Second Stage Parts Cleaning for Oxygen Use
Details cleaning procedures for second stage parts, noting similarities and differences with first stage.
Cleaning Second Stage Plastic Parts
Plastic parts require only gentle detergent cleaning and thorough rinsing.
Cleaning Second Stage Metal Parts
Metal parts like barrel, lever, and orifice need full cleaning techniques; others need basic cleaning.
Inspection After Oxygen Cleaning
Refers to pages 22-23 for inspection techniques after oxygen cleaning.
Second Stage Initial Reassembly
Second Stage Reassembly Layout
Lay out cleaned parts according to the reassembly layout photo for organized assembly.
O-ring Lubrication Guidelines
Use a thin film of lubricant on o-rings; excess lube attracts grit.
Low Pressure Seat and Turbine Piston Assembly
Press the low pressure seat into the Turbine Piston shaft, ensuring proper seating.
Turbine Piston O-ring and Balance Cylinder Assembly
Lubricate and assemble the o-rings and balance cylinder onto the Turbine Piston.
Bounce Test for Balance Cylinder Seal
Perform a bounce test to confirm the balance cylinder seals with the Turbine Piston.
Plug and Adjustment Knob Assembly
Install unlubricated o-rings into the plug and insert the plug into the adjustment knob.
Adjustment Knob O-ring Installation
Lubricate and place the 2-011 o-ring on the end of the adjustment knob.
Orifice O-ring and Installation
Install the orifice o-ring and screw the orifice into the barrel, avoiding contact with the knife edge.
Orifice Seating and Backout
Seat the orifice fully into the barrel, then unscrew it exactly three full turns.
Second Stage Initial Reassembly: Poppet and Lever
Barrel O-ring Installation
Install a lubricated 2-015 o-ring over the barrel end and into its land.
Lever Reinstallation Procedure
Steps for reinstalling the lever, ensuring legs are parallel and do not bind.
Poppet Assembly and Main Spring Reassembly
Separate the balance cylinder from the Turbine Piston and reassemble with the main spring.
Zip-Tie Insertion for Lever Positioning
Insert the zip-tie between the lever leg and barrel to assist with positioning.
Zip-Tie Loop Placement
Create a large loop with the zip-tie and slide it over the barrel.
Lever and Zip-Tie Positioning for Assembly
Position the lever flat against the barrel with the zip-tie held at a right angle.
Poppet Assembly Insertion with Zip-Tie Support
Insert the poppet assembly into the barrel while holding the zip-tie, pushing the balance cylinder.
Lever Spring Action Check
Check if the lever springs up as the balance cylinder is pushed, indicating correct pressure.
Second Stage Initial Reassembly: Knob and Deflector
Troubleshooting Lever Rise Issues
Provides strategies for fixing lever rise issues, including using a thicker zip-tie or reassembling the lever.
Adjustment Knob and O-ring Installation
Insert the adjustment knob and thread it into the barrel, ensuring proper o-ring alignment.
Final Adjustment Knob Tightening
Continue screwing the knob in until the pin hole is clear.
Pin Installation and Adjustment Knob Binding
Insert the pin symmetrically and unscrew the adjustment knob until it binds against the pin.
Deflector O-ring Installation
Install the 2-019 o-ring onto the deflector.
Deflector Installation and Alignment
Slide the deflector onto the barrel, ensuring proper alignment and seating of the lever and pin.
Second Stage Initial Reassembly: Cover and Barrel
Optional Exhaust Valve Installation
Optional steps to install a new exhaust valve, including cutting the spindle.
Exhaust Cover Installation
Hook and press the exhaust cover into the case until it locks.
Barrel Assembly Insertion into Case
Slide the barrel assembly into the case, guiding it carefully and controlling the lever.
Second Stage O-ring and Heat Sink Nut Installation
Install the second stage o-ring and thread the heat sink nut onto the barrel.
Heat Sink Nut Torque Specification
Torque the heat sink nut to 35 in-lb, warning against overtightening.
Orifice Adjustment for Valve Sealing
Adjust the orifice clockwise to seal the valve against lung pressure.
Second Stage Final Reassembly and Tuning
Connecting Components for Tuning
Connect the first stage, inline adjuster, and second stage for tuning.
Initial Orifice Sealing and Adjustment
Pressurize the system, seal the orifice, and unscrew it until it leaks, then retighten.
Orifice Adjustment for Lever Height
Adjust the orifice to achieve proper lever height, aiming for ~120 psi or 5 minutes on the clock.
Diaphragm Seating and Fit Check
Set the diaphragm carefully, ensuring a perfect fit in the case groove.
Diaphragm Fit Warning
Warns that a small diaphragm may not engage properly and could become dislodged, posing a fatal risk.
Checking for Diaphragm Dangle
Check for diaphragm dangle or lifting due to lever arms, which may require orifice adjustment.
Diaphragm Edge Fit Verification
Verify diaphragm fit by checking thread count where edges meet the case.
Adjusting Orifice for Diaphragm Seating
Adjust orifice in 1/12 turn increments if diaphragm is held up, depressing lever during adjustments.
Second Stage Final Reassembly and Tuning Details
Resizing Stored Diaphragms
Optional steps to resize a stored diaphragm by stretching it to achieve full diameter.
Thrust Washer and Faceplate Installation
Seat the thrust washer and install the faceplate, ensuring proper orientation.
Faceplate Installation Technique
Start faceplate attachment by unscrewing slightly to prevent cross-threading.
Faceplate Lubrication and Threading
Apply lubricant to faceplate threads and screw it onto the assembly.
Depressurizing and Inline Adjuster Removal
Depressurize the system and remove the inline adjuster.
Hose Inlet Leak Check
Check the hose inlet for leaks by inhaling gently from the mouthtube.
Leak Check After Hose Reattachment
Repressurize and check for leaks by listening or submerging the second stage.
Troubleshooting Second Stage Leaks
Troubleshoot leaks by reattaching the adjuster, repressurizing, and making fine adjustments.
Transition to Cracking Effort Adjustment
Indicates that cracking effort is the final adjustment needed.
Setting Second Stage Cracking Effort
Cracking Effort Note on Smooth Orifices
Notes that smooth orifice edges tolerate low cracking effort but can cause freeflow.
Cracking Effort Specification
Specifies the minimum cracking effort range (1.0-1.4 inches of water).
Measuring Cracking Effort with Magnehelic/Manometer
Describes how to measure cracking effort using a magnehelic or manometer.
Magnehelic Cracking Effort Measurement Technique
Inhale gently from the mouthpiece to note the magnehelic value when IP first drops.
Initial Cracking Effort Reading
Note the valve opening value and adjust orifice if less than 0.9".
Rechecking Cracking Effort After Orifice Adjustment
Recheck cracking effort after orifice adjustment; troubleshoot if still below 0.9".
Knob Adjustment for Diving Use
Always dive with the knob adjusted to at least the minimum cracking effort value.
Measuring Cracking Effort with Water Immersion
Describes measuring cracking effort using water immersion as an alternative to magnehelic.
Water Immersion Setup and Procedure
Pressurize the system, submerge horizontally, and note the IP drop point.
Water Immersion Freeflow Warning
Warns that rapid submergence can cause a full-on freeflow.
Water Immersion Cracking Effort Reading
Note the valve opening value; adjust orifice if less than 0.9".
Second Stage Cracking Effort Tuning and Discussion
Troubleshooting High Cracking Effort
Refers to troubleshooting if minimum cracking effort with knob fully out exceeds 1.4 inches of water.
Checking Maximum Cracking Effort
Fully screw in the adjustment knob and recheck cracking effort to confirm it won't open below 1.7 inches of water.
Storage Recommendation for Adjustment Knob
Store the second stage with the adjustment knob fully out to reduce wear on the LP seat.
Attaching Hose to Second Stage
Attach the hose to the second stage using two wrenches.
Low Pressure Hose Nut Torque Specification
Torque the low pressure hose nut to 35 in-lb.
Discussion of Cracking Effort Limits
Explains the importance of minimum cracking effort limits and potential consequences of incorrect settings.
Lever Height and Cracking Effort Example
Illustrates normal lever height vs. a low lever height due to weak spring and orifice adjustment.
Addressing Weak Spring Force
Suggests adding a shim or replacing the spring to address weak spring force.
First Stage Troubleshooting Guide
IP Drift (Less Than 8 psi)
Troubleshoots IP drift less than 8 psi, citing new HP Seat or cycle regulator.
IP Drift (Greater Than 8 psi)
Troubleshoots IP drift greater than 8 psi, citing debris or damaged components.
Intermediate Pressure Creep
Troubleshoots IP creep, citing damaged components or o-rings and recommending replacement.
Low Intermediate Pressure Issues
Troubleshoots low IP, citing spring adjuster, mainspring, or gas flow issues.
IP Drop During Purge Check Failure
Troubleshoots significant IP drop during purge, citing tank valve, filter, or component friction.
Environmental Seal Bulging
Troubleshoots environmental seal bulging, recommending reinstallation or replacement.
Bubbles at Hose or Port Plugs
Troubleshoots bubbles at connections, recommending tightening fittings or replacing o-rings.
Bubbling at IP Cap to Body Joint
Troubleshoots bubbling at IP cap joint, recommending tightening or replacing IP cap o-ring.
Bubbling at Diaphragm Clamp Joint
Troubleshoots bubbling at diaphragm clamp joint, recommending tightening or diaphragm replacement.
Bubbling at Tank Connection
Troubleshoots bubbling at tank connection, recommending retainer tightening or o-ring replacement.
Regulator Movement on Tank
Troubleshoots regulator movement, recommending retainer tightening or replacement.
Bubbling at Tank Connection to Body
Troubleshoots bubbling at tank connection, recommending retainer tightening or o-ring replacement.
Second Stage Freeflow Issues
Troubleshoots second stage freeflow, citing high IP, damaged orifice, or worn LP seat.
Second Stage Zero Flow
Troubleshoots zero flow, citing tank off, clogged filter, or low IP.
Second Stage Troubleshooting Guide
Poor Air Delivery Issues
Troubleshoots poor air delivery, citing adjustment knob, low IP, or debris in valve assembly.
Regulator Breathes Wet
Troubleshoots wet breathing, citing low cracking effort, defective exhaust valve, or damaged o-rings.
Low Cracking Effort (< 0.9")
Troubleshoots low cracking effort, citing weak poppet spring or scratched orifice.
High Cracking Effort (> 1.4")
Troubleshoots high cracking effort, citing scratched orifice or indented LP seat.
Low Maximum Cracking Effort (< 1.7")
Troubleshoots low maximum cracking effort, citing weak poppet spring or indented LP seat.
Lever Position Below Case Rim
Troubleshoots lever position, citing scratched orifice, indented LP seat, or weak spring.
Quick Reference: First Stage Disassembly
First Stage Disassembly Steps Summary
Summarizes key steps for first stage disassembly, from hose removal to balance plug assembly.
Quick Reference: First Stage Reassembly
Summarizes key steps for first stage reassembly, from valve lifter to port plugs.
Quick Reference: Second Stage Disassembly
Second Stage Disassembly Steps Summary
Summarizes key steps for second stage disassembly, from hose removal to exhaust valve.
Quick Reference: Second Stage Initial Reassembly
Summarizes initial reassembly steps for the second stage, from parts layout to orifice seating.
Quick Reference: Second Stage Final Tuning
Summarizes final reassembly and tuning steps, including lever height and cracking effort.
First Stage Service Kit Components
DIN First Stage Service Kit Components
Lists and illustrates the specific components included in the DIN first stage service kit.
Yoke First Stage Service Kit Components
Notes that there are no unique service kit items for the Yoke first stage.
Common First Stage Service Kit Components
Illustrates and lists common components for both DIN and Yoke first stage service kits.
IP Compartment Components
Details components related to the IP compartment, such as diaphragm and antifriction washer.
HP Compartment Components
Details components related to the HP compartment, such as the filter.
IP Cap/Turret Components
Details components related to the IP Cap/Turret, such as o-rings and swivel thrust washer.
Port Plug Components
Details the various port plugs included in the service kit.
Second Stage Service Kit Components
Poppet Assembly Service Kit Components
Lists components for the poppet assembly, including seat, o-rings, and piston.
Orifice Service Kit Components
Details the o-ring for the orifice.
Barrel Assembly Service Kit Components
Lists components for the barrel assembly, including o-rings.
Deflector Service Kit Components
Details the o-ring for the deflector.
Plug Service Kit Components
Details the o-rings for the plug.
Appendix A: Faceplate Disassembly and Reassembly
Faceplate Disassembly Steps
Steps for disassembling the faceplate components, including cover retainer and purge cover.
Faceplate Component Cleaning
Clean faceplate components in soapy water, rinse, and air dry; avoid ultrasonic cleaning.
Faceplate Reassembly Steps
Steps for reassembling the faceplate, including trim ring, purge cover, and cover retainer.
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