manual 20-6. 2009. original copywriter 1987. btm17-1. revised 2009 - printed 2010. technical bulletin. the technical assistance department of mares s.p.a. announces a modification to the profile and material of the hp poppet seat used in all of mares mr first stages.
MANUAL 20-6. 2009. original copywriter 1987. BTM17-1. revised 2009 - printed 2010. TECHNICAL BULLETIN. THE TECHNICAL ASSISTANCE DEPARTMENT OF MARES S.P.A. ANNOUNCES A ...
MARES SERVICE MANUAL
2200-069
original copywriter 1987 revised 2009 - printed 2010
TECHNICAL BULLETIN
BTM17-1
RE: NEW HP POPPET SEAT FOR MR FIRST STAGES (CODE: 46186216)
BTM17
THE TECHNICAL ASSISTANCE DEPARTMENT OF MARES S.P.A. ANNOUNCES A MODIFICATION TO THE PROFILE AND MATERIAL OF THE HP POPPET SEAT USED IN ALL OF MARES MR FIRST STAGES. THE CODE FOR THE NEW HP POPPET SEAT HAS NOT CHANGED AND CAN ONLY BE IDENTIFIED BY THE DESCRIPTION BELOW. THE NEW HP POPPET SEAT WAS DESIGNED AND TESTED TO GUARANTEE A GREATER RESISTANCE TO WEAR AND TEAR. THE NEW HP POPPET SEAT SHOULD ONLY BE USED WITH THE TRI-MATERIAL POPPET, (CODE: 46200652) THE NEW HP POPPET SEAT CAN BE EASILY IDENTIFIED BY THE RADIAL THROAT DESIGN UNDER THE SEAT OF THE
O-RING (AS SHOWN IN PICTURE 1 BELOW).
- NEW HP POPPET SEAT -
Old
New
Concentric mark
! WARNING!
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F1-26 1 st S TA G E M R 2 2 N I T R O X 2 0 0 9
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1st STAGE MR22 NITROX 2009
original copywriter 1987 revision 2009 - printing 2010
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CODE
DESCRIPTION
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REF
CODE
DESCRIPTION
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ASSEMBLIES
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ACCESSORIES
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original copywriter 1987 revision 2009 - printing 2010
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original copywriter 1987 revision 2009 - printing 2010
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CODE
DESCRIPTION
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A D F
I * * *
* * *
°°°
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CODE
DESCRIPTION #/.)#!,&),4%2$).#/..%#4/2 302).' &),4%2ST34!'% $534#!0"!2$).#/..%#4/2 /2 /26ITON
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2ING6ITONªST-2
12S "2008" & 12S "2011" INT FIRST STAGE
12S "2008" & 12S "2011" DIN FIRST STAGE
original copywriter 1987 revision 2009 - printing 2010
REGULATORS
12S FIRST STAGE
F11-1
MAINTENANCE PROCEDURE
! WARNING!
ALL MAINTENANCE AND REPAIR PROCEDURES MUST BE PERFORMED BY A MARES AUTHORIZED SERVICE CENTER AND/OR DISTRIBUTOR. THEREFORE, THE INFORMATION PROVIDED BELOW IS INTENDED STRICTLY FOR TECHNICIANS AT SUCH CENTERS.
NOTE ALL OPERATIONS MUST BE CONDUCTED STRICTLY IN THE ORDER DESCRIBED.
NOTE
IN ORDER TO ENSURE ADVANCED PERFORMANCE AND SAFETY DURING USE, AFTER 100 HOURS OF DIVING OR 1 YEAR THE REGULATOR MUST BE CHECKED, AND ITS CRITICAL PARTS MUST BE INSPECTED AND REPLACED IF NECESSARY.
(B-21) #46106221
(B-6) # 46106206
(B-5) # 46106205
(B-14) #46106214
INT
(B-1) 25mm # 46106201
INT
(B-16) 32mm # 46106216
(B-2) 28mm # 46106202
(B-18) 14mm #46106218
Tools needed
· Flathead screwdriver · Compressed air supply circuit or tank (180-200 bar) · nylon brush · O-Ring removal tool · Silicone grease (General Electric Versalube G-322 type) · Compressed air gun (8-10 Bar) · Descaling solution (Deox Extra type) or ultrasound tank · Test Bench or LP pressure gauge to calibrate the
intermediate pressure · Thread compound (Loctite 242 INT connection type -
Loctite 222 type for DIN connection) · 12S 1st stage service kit (code 46200963 INT
46200964 DIN)
(B-13) 10mm #46106213
HEX WRENCH 4mm
B-40 30mm 46200608
CDWRDY
(B-4) 5mm 46106204
DIN
F11-2
12S FIRST STAGE
REGULATORS
DISASSEMBLY
INT
1. Loosen the dust cap ( 24) from the 1st stage, fully unscrewing the yoke knob (25). 2. Remove the hose protection from the body of the 1st stage.
original copywriter 1987 revision 2009 - printing 2010
3. Unscrew the hose (26) using a 14 mm open end wrench (B18). 4. Screw on the disassembly tool (B5) to make it easier to remove the 1st stage from the 3/8 LP port
5. Unscrew the yoke retainer nut (7) using the special 25 mm wrench (B1).
NOTE TO MAKE DISASSEMBLY EASIER, WE RECOMMEND THAT YOU PLACE THE FIRST STAGE IN A BENCH VISE.
6. Using the snap ring pliers (B14), pull out the INT HP chamber nut (10), the snap ring (2), the tapered sintered lter, and the lter spring (61).
original copywriter 1987 revision 2009 - printing 2010
DIN VERSION
REGULATORS
I. Unscrew the DIN OR seat (187) from the DIN tting (48) with a 4 mm Allen wrench.
II. Remove the O-Ring (188) from the OR seat (187).
III. Remove the sintered lter (56) from the DIN connector body (48), turning the rst stage over.
IV. Insert an 5 mm Allen wrench (B4) inside the DIN tting (48) and unscrew it completely.
V. Remove the DIN tting (48) and the DIN ring nut (49).
VI. Remove the O-Ring (171) from the DIN tting body (48).
12S FIRST STAGE
F11-3
F11-4
12S FIRST STAGE
REGULATORS
7. Using a 32 mm open end wrench (B16),(46106216, unscrew the INT HP chamber nut (10) then remove the HP chamber assy (4), poppet spring (8), tri-material poppet (9), and the 32 mm poppet pin (12) from the rst stage.
original copywriter 1987 revision 2009 - printing 2010
8. Extract the O-Ring (6) from the HP housing (4) using a plastic or brass OR removal tool.
! WARNING!
REMOVE THE BACKUP RING (5) FROM THE HP CHAMBER ONLY IF IT IS TO BE REPLACED.
NOTE
DO NOT USE BLADES OR POINTED TOOLS MADE OF STEEL OR OTHER MATERIALS, WHICH CAN SCRATCH THE SURFACES.
original copywriter 1987 revision 2009 - printing 2010
REGULATORS
9. Remove the 2068 O-Ring (83) from the HP chamber nut (10).
12S FIRST STAGE
F11-5
10. Position the special tool (B21) on the 1st stage poppet seat (115) and press lightly then inject compressed air (8-10 bar) through a 3/8 low pressure port.
NOTE
WHEN THE COMPRESSED AIR CAUSES THE POPPET SEAT TO MOVE, REDUCE THE PRESSURE EXERTED ON THE SPECIAL TOOL (B21).
If it is not possible to remove the Poppet Seat (115) in the illustrated way previously it is necessary to use the special utensil special Dismantlement Center 12S (B-41), by inserting it in a hole of low pressure port, and pressing up with it on the Center Valve (115).
46201041 Special 12S Disassembly Tool (B-41) New Tool
F11-6
12S FIRST STAGE
REGULATORS
11. After removing the seat connector (115) from the 1st stage body (1), remove the O-Ring (74).
12. Rotate the rst stage body to remove the cap (157) from it, prying with a flathead screwdriver.
NOTE
BE CAREFUL TO AVOID DAMAGING THE CHROME PLATING ON THE RETAINING NUT (17).
13. Using the Allen wrench (B-13), unscrew the adjusting nut (196) and pull out the spring (16).Unscrew the retaining nut (17) using the 28 mm open end wrench (B2).
14. Use a 4 mm Allen wrench to remove all the low- and highpressure port caps and then remove their O-Rings.
15. Use a 4 mm Allen wrench to remove all the LP (20) and HP (53) port plugs and then remove their O-Rings (19 LP) (52 HP).
original copywriter 1987 revision 2009 - printing 2010
original copywriter 1987 revision 2009 - printing 2010
REGULATORS
12S FIRST STAGE
F11-7
CLEANING AND CHECKS
For routine cleaning of reusable rubber components, wash all parts in a mixture of hot water and mild detergent, scrubbing if necessary with a soft brush. Do not use solvents or acids on rubber components.
NOTE
ACIDS OR OTHER SOLVENTS MAY DAMAGE PLASTIC AND RUBBER PARTS. BEFORE CLEANING METAL COMPONENTS, MAKE SURE THAT ALL SEALS AND OTHER PARTS SUBJECT TO DETERIORATION HAVE BEEN REMOVED.
Chrome-plated brass and stainless steel components can be cleaned using a nylon brush to remove any deposits, by immersing them in a fresh water ultrasound bath, or, if suitable equipment is not available, in a gentle acid solution (Deox Extra type) or white vinegar diluted with hot water. Be sure to rinse all parts in fresh water and dry with a jet of low pressure air at 8-10 bar before proceeding with reassembly.
12S - ROUTINE MAINTENANCE
NOTE
CERTAIN KEY COMPONENTS OF THE FIRST STAGE SHOULD BE REGULARLY REPLACED AT EACH SCHEDULED OVERHAUL.
LISTED BELOW ARE THE COMPONENTS INCLUDED IN THE 12S 1st STAGE SERVICE KIT (CODE 46200963
INT 46200964 DIN) :
12S SERVICE KIT (INT: 46200963 DIN: 46200964) · SNAP RING (only INT conn.) · SINTERED FILTER · BACKUP RING · O-RINGS
3 106 O-RINGS (LP Cap) 2 108 O-RINGS (HP Cap) 1 2012 O-RING (HP housing) 1 2031 O-RING (HP seat connector) 1 2068 O-RING (HP chamber nut) 1 3043 O-RING (for DIN connection only) 1 2037 O-RING (for DIN connection only)
! WARNING!
IF THE SECOND STAGE IS USED FOR DIVES WITH OXYGEN-ENRICHED MIXTURES, STRICTLY FOLLOW ALL THE INSTRUCTIONS PROVIDED IN THIS MAINTENANCE MANUAL IN THE NITROX CHAPTER (EN 13949) BEFORE BEGINNING REASSEMBLY!
NOTE
BEFORE REASSEMBLING, LIGHTLY LUBRICATE ALL THE O-RINGS WITH SILICONE GREASE (TYPE GENERAL ELECTRIC VERSALUBE G-322). LUBRICATION REDUCES THE LIKELIHOOD OF DAMAGE DURING REASSEMBLY
F11-8
12S FIRST STAGE
REGULATORS
REASSEMBLY
16. Place the O-Ring (74) in the MR poppet seat (115) and then correctly position the poppet seat on the special tool (B21).
original copywriter 1987 revision 2009 - printing 2010
17. Pressing gently, push the poppet seat (115) into position in the rst stage body (1).
! WARNING!
TAKE SPECIAL CARE WHEN INSERTING THE POPPET SEAT. MAKE SURE THAT IT IS POSITIONED CORRECTLY ONCE IT ISINSERTED INTO THE HIGH-PRESSURE CHAMBER, WITH THE CONICAL SECTION FACING UPWARD.
18. Insert the O-Ring (83) into the HP chamber nut (10 INT - 192 DIN)
NOTE
WE RECOMMEND THAT YOU PLACE THE O-RING (83) IN ITS SEAT USING A PLASTIC ROD. CHECK THAT IT SITS PROPERLY IN PLACE.
original copywriter 1987 revision 2009 - printing 2010
REGULATORS
19. Insert the backup ring (5) and the O-Ring (6) into the HP housing (4).
12S FIRST STAGE
F11-9
20. Place the complete HP housing (4) inside the HP Chamber Nut (10 INT - 192 DIN). Then position the MR spring (8) and the trimaterial valve (9) over the HP housing.
21. Turn the rst stage (1) over and screw the HP chamber nut into it.
22. Use a 32 mm wrench (B16) to fully tighten the HP nut (10 INT 192 DIN).
NOTE IF USING A TORQUE WRENCH, USE TIGHTENING TORQUE OF APPROXIMATELY 35 N/m.
F11-10
12S FIRST STAGE
REGULATORS
23. Rotate the 1st stage body and insert the 32.5 mm steel pin (12) into the center hole in the 1st stage body (1).
original copywriter 1987 revision 2009 - printing 2010
24. Position the poppet button (13) on the pin (12), and press on it to feel the "response" of the poppet spring.
NOTE FOR THE CWD DRY PROCEDURE, SEE PAGE 16
25. Place the diaphragm (14) in the retaining nut seat (17), making it adhere perfectly to the edges.
NOTE
REINSTALL THE DIAPHRAGM (14) IN THE SAME POSITION FROM WHICH IT WAS REMOVED. NOTE THE IMPRESSION OF THE POPPET BUTTON (13) ON IT.
26. Tighten the retaining nut (17) including the diaphragm (14) to the 1st stage body (1).
original copywriter 1987 revision 2009 - printing 2010
REGULATORS
27. Use a 28 mm wrench (B2) to fully tighten the retaining nut to the 1st stage body.
NOTE USING A TORQUE WRENCH, USE TIGHTENING TORQUE OF APPROXIMATELY 32-35 N/m.
12S FIRST STAGE
F11-11
28. Place the spring base plate (15) in the middle of the diaphragm (14).
29. Position the spring (16) over the spring base plate (15).
30. Screw the adjusting nut (196) 3 4 turns on the retaining nut (17) using a 10 mm Allen wrench (B13).
! WARNING!
DO NOT OVER-TIGHTEN THE ADJUSTING NUT; THIS WILL CAUSE AN INCREASE IN INTERMEDIATE PRESSURE, INTERFERING WITH SUBSEQUENT ADJUSTMENTS.
F11-12
12S FIRST STAGE
REGULATORS
31. Place the cap (157) on the rst stage.
original copywriter 1987 revision 2009 - printing 2010
32. Rotate the 1st stage body and insert the yoke spacer (154).
33. Assemble the lter spring (61) and the sintered lter (22) in the yoke retainer nut body.
34. Using the snap ring pliers (B14), t the snap ring (2) in its position above the sintered lter (22).
NOTE ROTATE THE SNAP RING TO CHECK ITS CORRECT POSITIONING.
NOTE
TO PREVENT THE YOKE RETAINER NUT FROM WORKING LOOSE ACCIDENTALLY, POUR ONE OR TWO DROPS OF THREAD COMPOUND (LOCTITE 242 TYPE) ONTO ITS THREADING.
original copywriter 1987 revision 2009 - printing 2010
REGULATORS
35. Position the yoke (3) with the knob (25) on the rst stage body.
12S FIRST STAGE
F11-13
36. Using the wrench (B1), fully tighten the complete yoke retainer nut (7).
NOTE IF USING A TORQUE WRENCH, USE TIGHTENING TORQUE OF APPROXIMATELY 18-20 N/m.
DIN VERSION
37. Install the O-Ring (171) on the DIN coupling (48).
NOTE
TO PREVENT THE NUT YOKE RETAINER FROM WORKING LOOSE ACCIDENTALLY, PUT ONE OR TWO DROPS OF THREAD COMPOUND (LOCTITE 222 TYPE) AT THE BEGINNING THREADS.
38. Place the DIN ring nut (49) on the DIN chamber nut (192) and then fully tighten the coupling (48).
NOTE IF USING A TORQUE WRENCH, USE TIGHTENING TORQUE OF APPROXIMATELY 18-20 N/m
F11-14
12S FIRST STAGE
REGULATORS
39. Insert the tapered lter (56) into the DIN connector. 40. Position the O-Ring (188) on the OR seat (187).
original copywriter 1987 revision 2009 - printing 2010
41. Screw the O-Ring housing (187) to the DIN tting (48) with a 4 mm Allen wrench and unscrew the disassembly tool (B5) from the rst stage body.
NOTE IF USING A TORQUE WRENCH, USE TIGHTENING TORQUE OF APPROXIMATELY 1.5-2 N/m.
NOTE
CONNECT THE FIRST STAGE TO A FULL TANK (AT LEAST 180 BAR) OR TEST BENCH, AND OPEN THE AIR VALVE SLOWLY TO EXPEL ANY FOREIGN MATTER FROM THE FIRST STAGE.
42. Position the O-Rings (19 - 52) on the caps (20 - 53).
43. Tighten the caps (20 - 53) to the rst stage body (1) using a 4 mm Allen wrench and the flexible hoses in the corresponding ports on the rst stage.
NOTE
FOR CHECKS AND ADJUSTMENTS ON THE FIRST STAGE, CONSULT THE CORRESPONDING SECTION OF THE MAINTENANCE MANUAL : F 7-1 (2008)
original copywriter 1987 revision 2009 - printing 2010
REGULATORS
CWD DRY
a. Place the diaphragm (14) in the CWD Dry body (57), making it adhere perfectly to the edges.
b. Tighten the retaining nut (57) including the diaphragm (14) to the 1st stage body (1). Use a 30 mm wrench (B40) to fully tighten the CWD body (57) to the 1st stage body.
NOTE IF USING A TORQUE WRENCH, USE TIGHTENING TORQUE OF APPROXIMATELY 32-35 N/m.
c. Place the metal spring base plate (194) in the middle of the diaphragm (14).
d. Position the spring (16) over the metal spring base plate (194).
e. Screw the adjusting nut (18) 3 4 turns on the retaining nut (57) using a 10 mm Allen wrench (B13).
! WARNING!
DO NOT OVER-TIGHTEN THE ADJUSTING NUT; THIS WILL CAUSE AN INCREASE IN INTERMEDIATE PRESSURE, INTERFERING WITH SUBSEQUENT ADJUSTMENTS
f. After calibrating the intermediate pressure on the rst stage (9.0-9.4 bar), place the shock ring (190) on the CWD body (57).
! WARNING!
ALL THE OPERATIONS DESCRIBED BELOW MUST BE PERFORMED WITH THE REGULATOR PRESSURIZED!
12S FIRST STAGE
F11-15
F11-16
12S FIRST STAGE
REGULATORS
g. Position the CWD Dry piston inside the CWD Dry body (57).
original copywriter 1987 revision 2009 - printing 2010
h. Arrange the CWD Dry diaphragm (193) over the piston (189) and hold it in place with your nger. i. Tighten the cap (191) to the CWD Dry body (57) and tighten the 10 mm Allen wrench (B13), making sure that the
diaphragm (193) has stayed in place.
NOTE IF USING A TORQUE WRENCH, USE TIGHTENING TORQUE OF APPROXIMATELY 32-35 N/m. NOTE RUN SOME SUPPLY CYCLES FOR A FEW MINUTES. CHECK THE INTERMEDIATE PRESSURE. IT MUST BE
BETWEEN 9.2 AND 9.6 BAR. ADJUST AGAIN IF NECESSARY.
F11-18 12S FIRST STAGE
EROGATORI
Drawing # E112
FIRST STAGE MR12S
original copywriter 1987 revisione 2009 - stampa 2010
UPDATED: 22/12/2008
original copywriter 1987 revision 2009 - printing 2010
REGULATORS
Table # 35
FIRST STAGE MR12S
1 2 S F I R S T S TA G E F11-19
UPDATED : 22/12/2008
REF
CODE
DESCRIPTION
1
46200944 First stage body 12S
2
46185015 Seeger d. Int. 13
3
46185211 Yoke 2000
4
D
Hp chamber
5
46185038 Backup ring 1st stg regulator
6
46110101 OR 2012
6
46110401 OR 2012 viton 006-9707
7
46185212 Nut yoke retainer 1st stage mr12
8
46185011 Spring, 1st stage valve, mr12
9
46200652 Poppet 1° stg tri-material
10
46200940 Connector body int
12
46186214 Pin poppet MR12 32,5 mm
13
46185032 Button, 1st st. Poppet
14
46185022 Diaphragm, 1st stage regulators
15
46185034 Plate spring base
16
46185023 Spring diaphragm 1st stage reg.
17
46200938 Retaining nut 12S
18
46185028 Regulating nut, cwd
19
46110106 OR 106
19
46110402 OR 106
viton 610-9707
20
46185204 Lp plug 3/8", 1st stage, regs.
22
46186202 1st stage filter, regulators
24
46185010 Dust cap
25
46184079 Yoke knob
48
46200934 Connecting plug, din 300 bar 12S
49
46200932 Din 300 bar threaded locking ring
52
46110108 OR 108
52
46110404 OR 108
viton 611-9707
53
46185205 Hp plug 7/16", 1st stage
56
46200948 Filter, din connector, 12S
57
I
Cwd dry 12S body
61
46185013 Spring, filter 1st. Stage
62
46200562 Dust cap 300 bar din connector
REF
CODE
DESCRIPTION
74
46110107 OR 2031
74
46110403 OR 2031 viton 011-9707
83
46110225 OR 2068
83
46110420 OR 2068 viton
115
46186216 Poppet seat mr
148
46184315 Label yoke "en 250"
149
46184316 Oval label
154
46200930 Plastic ring int 12s
157
46200929 Hock cap, 1st stage 12S
171
46110110 OR 2037
171
46200298 OR 2037 viton
187
46200946 O-Ring seat din 12S
188
46110247 OR 3043
188
46200620 OR 3043 viton
189
46200925 Cwd dry 12S piston
190
46200923 Plastic ring cwd dry 12S
191
46200922 Hock cup cwd dry 12S
192
46200942 Conn. Body hp din 12S
193
46200926 Diaphragm, cwd dry 12S
194
46200950 Plate spring base cwd dry
196
46184511 Regulating nut, 1st stage
ASSEMBLIES
A
416209 1st stage assembly 12S (int-din)
D
46185210 Hp housing assy, 1st stage ( 4-5-6 )
D
46186259 Hp housing assy, 1st std (viton o-rings)
F
416807 Din connector 300 12S (48-49-56-62-171-187-188-192)
I
416856 Kit cwd dry 12S
###
46200963 Service kit 1st stg 12S int
###
46200965 Service kit 1st stg 12S int (viton o-rings)
(2-5-6-19-22-52-74-83)
°°°
46200964 Service kit 1st stg 12S din
°°°
46200966 Service kit 1st stg 12S din (viton o-rings)
(5-6-19-52-56-74-83-171-188)
CARBON SECOND STAGE
CARBON SECOND STAGE
original copywriter 1987 revision 2009 - printing 2010
MAINTENANCE PROCEDURES ` TOOLS NEEDED
REGULATORS
! WARNING!
!,,-!).4%.!.#%!.$2%0 !)202/#%$52%3-534"%
0%2&/2-%$"9!!54(/2):%$-!2%3,!"3%26)#%
#%.4%2 $)342)"54/2 /2!!54(/2):%$-!2%3$%!,%2
4(%2%&/2% 4(%).&/2-! 4)/.02/6)$%$"%,/7)3
).4%.$%$342)#4,9&/24%#(.)#)!.3!435#(#%.4%23
NOTE !,,/0%2!4)/.3-534"%#/.$5#4%$342)#4, 9 ).4(%/2$%2$%3#2)"%$
IN ORDER TO ENSURE ADVANCED PERFORMANCE AND SAFETY DURING USE, AFTER 100 HOURS OF DIVING OR 1 YEAR THE REGULATOR MUST BE CHECKED, AND ITS CRITICAL PARTS MUST BE INSPECTED AND REPLACED IF NECESSARY.
· Phillips head screwdriver · Compressed air supply circuit or tank (180-200 bar/
2,646 - 2,940 psi) · Cutting nippers · O-Ring removal tool · Silicone grease (General Electric or Novagard Versilube
G-322L type or equivalent / Nitrox - Christo Lube MCG111) · Compressed air gun (8 -10 Bar/118 -147 psi) · Descaling solution (Deox Extra type or equivalent) and or an
ultrasonic tank · Test Bench · Carbon/Prestige/Rebel 2nd stage maintenance kit (code
46200296 - 46200297 VITON O-RING)
CARBON SECOND STAGE
S13-1
(B-6) # 46106206
(B-17) 17mm (2) # 46106217
(B-18) 14mm #46106218
(B-12) 5.5mm #46106212
(B-4) 5mm #46106204
B-8) 6mm # 46106208
Hex wrench 4mm
S13-2
CARBON SECOND STAGE
REGULATORS
DISASSEMBLY 1. Slide hose protector from body of the 1st stage 2. Unscrew the hose (26) using a 14 mm open end wrench (B18 - 46106218). 3. Slide the 2nd stage side hose cover away from 2nd stage body.
original copywriter 1987 revision 2009 - printing 2010
4. Using the two 17 mm open end wrenches (B17 - 46106217), unscrew the hose from the 2nd stage connector. (need picture)
5. Remove the clamp (43) from the mouthpiece using a cutting nippers or a similar tool.
6. Unscrew the clamp screw (38) with a Phillips head screwdriver and then remove it from the ring clamp (37). 7. Open the ring clamp (37) and pull it off of the second stage case (32).
! WARNING!
'%.4,9302%!$/0%.4(%2).'#,!-04/! 2%!33%-",9
6/)$"%.$).')4 7()#(7),,#/-02/-)3%35"3%15%.4
original copywriter 1987 revision 2009 - printing 2010
REGULATORS
CARBON SECOND STAGE
8. Remove the cover (39) and the diaphragm (36) from the 2nd stage body.
S13-3
9. Remove the exhaust tee (41) from the second stage case (32) by pinching together and pulling off. 10. Gently pull the exhaust valve out of the bottom of 2nd stage case (40). 11. Unscrew the hose connector (28) using a 17 mm open end wrench (B17 - 46106217), and then remove the spacer
ring by pass BK (96).
12. Gently press the demand lever insert assembly into the 2nd stage case, then remove the O-Ring 2068 (83) from its seat in the 2nd stage case (32).
S13-4
CARBON SECOND STAGE
REGULATORS
original copywriter 1987 revision 2009 - printing 2010
13. Position the demand lever connector assembly on the Demand lever assembling tool (B6 - 46106206), and use the Demand lever adjusting tool (B12 - 46106212) to unscrew the demand lever locknut (33) from the demand lever (35). Then remove the washer (34), the poppet assembly pieces (30 + 47 + 92), and the spring (31).
14. Remove the poppet seat (47), pushing slightly on the poppet seat holder (92) in the direction of the threaded stem. Remove the poppet seat holder (92) from the stem of the 2nd stage valve shaft (30).
15. Unscrew the seat connector (21) from the hose connector assembly (28) using a 5 mm hex wrench (B4 - 46106204).
16. Remove the O-Ring 2050 (71) from the hose connector (28), and the O-Ring 2025 (27) from the adjustable poppet seat 2nd stage - (21).
17. Remove the 2nd stage adjustment plug (64) using a 6 mm hex wrench (B8 - 46106208), and remove the O-Ring 2068 (83) from the case plug.
original copywriter 1987 revision 2009 - printing 2010
CLEANING AND CHECKS
REGULATORS
For routine cleaning of reusable rubber, plastic and Carbon components, wash all parts in a mixture of hot water and mild detergent, scrubbing if necessary with a soft brush..
! WARNING!
!#)$3/2/4(%23/,6%.43-!9$!-!'%0,!34)# #!2"/. !.$25""%20!243 "%&/2%#,%!.).'-%4 !,#/-0/.%.43 -!+%352%4(! 4 !,,3%!,3!.$/4(%20 !24335"*%#44/$%4%2)/2! 4)/. (!6%"%%.2%-/6%$
Chrome-plated brass and stainless steel components can be cleaned using a nylon brush to remove any deposits, by immersing them in a fresh water ultrasound bath, or, if suitable equipment is not available, in a gentle acid solution (Deox Extra type) or white vinegar diluted with hot water.Be sure to thoroughly rinse all parts in fresh water and dry with a jet of low pressure air at 8 10 bar / 117 148 psi before proceeding with reassembly.
CARBON - ROUTINE MAINTENANCE
! WARNING!
#%24!).+%9#/-0/.%.43/&4(% .$34!'%3(/5,$"% 2%'5,!2,92%0,!#%$!4%!#(3#(%$5,%$/6%2(!5, "%,/7!2%,)34%$4(%#/-0/.%.43).#,5$%$).4(% !"933#!2"/. .$34 !'%3%26)#%+)4
6)4/./
2).'3
` CARBON/CARBON OCTOPUS 2ND STAGE SERVICE KIT
· DEMAND LEVER LOCK NUT (ref. 33) · 2nd STAGE, RUBBER SEAT (ref. 47) · EXHAUST VALVE 8 (ref. 40) · MOUTHPIECE CLAMP (ref. 43) · O-RINGS :
I. O-RING 106 (ref. 19) II. O-RINGS 2025 (ref. 27) III. O-RINGS 2068 (ref. 83) IV. O-RING 2050 (ref. 51)
CARBON SECOND STAGE
S13-5
S13-6
CARBON SECOND STAGE
REGULATORS
REASSEMBLY
! WARNING!
)&4(%&)23434 !'%)353%$&/2$)6%37)4(/89'%.
%.2)#(%$-)8452%3 &/,,/7!,,4(%).3425#4)/.3 02/6)$%$).-!2%33%26)#%-!).4%.!.#%-!.5!,).4(% .)42/8#(!04%2"%&/2%"%')..).'2%!33%-",9 SPECIAL NOTE: .$34!'%2%'5,!4/2353%$).%52/0%-534"%#,%!.%$ !.$2%!33%-",%$)!7%.34!.$!2$3
NOTE
"%&/2%2%!33%-",).' ,)'(4, 9,5"2)#! 4%!,, 4(%/
2).'37)4(3),)#/.%'2%!3%490%'%.%2!, %,%#42)#/2./6 !'!2$6%23),5"%'
, &/2 .)42/82%!33%-",953%#(2)34/n,5"%-#' ,5"2)#!4)/.2%$5#%34(%,)+%,)(//$/&$!-!'% $52).'2%!33%-",9
18. Install a new exhaust valve (40), carefully pulling its silicone stem through the center hole of the second stage exhaust valve support.
! WARNING!
$/./405,,4//(!2$/.3),)#/.%34%-!34()3-! 9 $!-!'%4(%%8(!5346!,6%
19. Use cutting nippers to cut the silicone stem at approximately half its length.
20. Fit the O-Ring (71) in the seat of the hose connector (28) and fit the O-ring (27) in its place on the 2nd stage adjustable poppet seat (21).
original copywriter 1987 revision 2009 - printing 2010
original copywriter 1987 revision 2009 - printing 2010
REGULATORS
CARBON SECOND STAGE
S13-7
21. Insert and screw the seat connector (21) into the hose connector (28) using the 5 mm hex wrench (B4 - 46106204) until it protrudes about 2.2-2.5 mm).
22. Reassemble the poppet seat holder (92) on the 2nd stage poppet stem (30).Reassemble the rubber poppet seat (47) in the poppet seat holder (92).
23. Place the 2nd stage poppet assembly (30-47-92) together with its spring (31) on the Demand lever assembling tool (B6 - 46106206).
S13-8
CARBON SECOND STAGE
REGULATORS
24. Pressing gently, correctly position the 2nd stage valve and its spring into the demand lever connector (91) and hold it in place.
NOTE
4/%.352%4(! 44(% .$34 !'%0/00%434%- )30/3)4)/.%$#/22%#4, 9).4(%$%-!.$ ,%6%2#/..%#4/2(/,% '%.4, 92/4 !4%4(% #/..%#4/2,%&4!.$2)'(4/.4(%"
4//,
25. Properly position the demand lever (35) with respect to the by-pass hole (VAD) in the metal insert (91) channel.
26. Fit the washer (34) on the poppet stem and tighten the demand lever adjusting nut (33) 7 or 8 full turns using the Demand lever adjusting tool (B12 - 46106212).
NOTE 02%334(%$%-!.$,%6%2!&%74)-%34/ "%352%)4-/6%3&2%%,9).(/53).'
27. Correctly position the demand lever connector assembly (91) in the 2nd stage case (32). Ensure VAD holes are lined up in case.
28. Hold the demand lever connector in place in the second stage case with the B12 - 46106212 Demand lever adjusting tool, insert the O-Ring (83) into the seat between the 2nd stage case and the demand lever connector using the Demand lever assembling tool (B6 - 46106206).
original copywriter 1987 revision 2009 - printing 2010
original copywriter 1987 revision 2009 - printing 2010
REGULATORS
CARBON SECOND STAGE
S13-9
29. Put the spacer ring (96) in place, and then use the 17 mm open-end wrench (B17 - 46106217) to fully lock down the case assembly connector (28) in the 2nd stage case. Press the demand lever a few times to ensure it still moves freely in housing.
NOTE )&53).'!4/215%72%.#( 53%4)'(4%.).'4/215%/&
.M
30. Fit the O-ring (27) in the seat on the swivel coupling of the hose (26). Screw the hose (26) into the case assembly connector (28) using the wrench (B-17).
NOTE )&53).'!4/215%72%.#( 53%4)'(4%.).'4/215%/&
.M
31.Place the O-Ring 106 (19) in the Hose (26) and assemble the hose with the partially finished 2nd stage on the D.F.C. port on the first stage, locking it down with the 14 mm wrench (B-18).
NOTE )&53).'!4/215%72%.#( 53%4)'(4%.).'4/215%/&
.M
S13-10
CARBON SECOND STAGE
REGULATORS
FINAL ADJUSTMENTS
To correctly adjust the regulator:
a. The repair shop should be equipped with a high- and lowpressure compressed air supply.
b. A pressure gauge is required for checking the intermediate pressure (the pressure gauge should have a full scale value of MAX 25 BAR / 350 psi, for greater adjustment accuracy).
c. Screw the intermediate pressure measuring gauge into one of the 3/8" low-pressure ports on the 1st stage, using the wrench (B18 - 46106218).
d. Mount the regulator group on the control valve (of the tank or test bench).
e. Holding down the second stage demand lever, slowly open the tank valve and, slowly release the demand lever.
f. Read the intermediate pressure gauge to check whether the 1st stage pressure is correct. 9.8 - 10.2 bar / 142 148 psi cold water kit installed: 9.2 9.6 bar / 133 139 psi
! WARNING!
4(%&)23434 !'%).4%2-%$)! 4%02%3352%-534"% -%!352%$7(%.4(%2%)3./!)2#/-).'/54/&4(%
.$34!'%&/24(%.%#%33!2 9 1st34!'%!$*534-%.43
2%&%24/4(%#/22%30/.$).'-!2%33%26)#%-!.5!,
IMPORTANT! ALL THE ADJUSTMENTS BELOW MUST BE MADE WITH THE SECOND STAGE CONSISTENTLY SUPPLIED WITH THE CORRECT INTERMEDIATE PRESSURE.
32. Place the 2nd stage diaphragm (36) in the 2nd stage case. 33. Fit the cover (39) on the diaphragm, orienting it the right
way round.
original copywriter 1987 revision 2009 - printing 2010
original copywriter 1987 revision 2009 - printing 2010
REGULATORS
CARBON SECOND STAGE
S13-11
34. Holding the cover in the correct position, insert the ring clamp (37) with the screw eyelets over the second stage case assembly connector.
35. Lock down the clamp screw (38).
! WARNING!
"%&/2%4)'(4%.).'4(%,/#+3#2%7 %.352%4(! 44(%#/-0/.%.43 !.$ !2%/2)%.4%$ #/22%#4,9/.4(%.$34!'%#!3% )./2$%24/02%6%.4-/6).'4(%).(!,!4)/.$)!0(2!'- ).4/ 4(%72/.'0/3)4)/.
36. Working through the hole in the second stage case, use the wrench (B-12 - 46106212) to lock down or back off the demand lever lock nut (32) in order to make final adjustments to the demand lever (35).
! WARNING!
4(%$%-!.$,%6%2)3!$*534%$#/22%#4,97(%.9/5#!.02%334(%052'%"544/./.4(%#/6%2$/7. !"/54MM"%&/2%!)2"%').34/2%,%!3%).!$$)4)/. 4(%3/5.$/&4(%$%-!.$,%6%24/5#().' 4(%-%4!,$)3+/&4(%3%#/.$34 !'%$)!0(2!'-!3)4-/6%34 !00).' 3(/5,$"%!5$)",%7(%.4(% 02%3352):%$3%#/.$34!'%)33(!+%.6)'/2/53,950!.$$/7.
S13-12
CARBON SECOND STAGE
TEST BENCH
original copywriter 1987 revision 2009 - printing 2010
OBJECT: Regulator Test Bench
IMPORTANT INFORMATIONS 4/#(%#+4(%()'(02%3352% -!2%32%#/--%.$3(0!)2"%47%%.
"!2 n 03)
4/#(%#+4(%).4%2-%$)!4%02%3352%)0 /.4(%,0'!5'%!.$!$*534)4)&.%#%33!2 94/$/7.,/!$ 4(%!)2&2/-2%'5,!4/29/5#!.53%4(%h$)3#(!2'%,%6%2v
4!.+02%3352%
)002%3352%
$)3#(!2'%,%6%2
s ).34!,,4(%).(!,).'-/54(0)%#% /.4(%3%#/.$ 34!'%-/54(0)%#%45"%
s 4/#(%#+4(%#2!#+).'%&&/2453).'#/,5-.7!4%2 3%%).&/4!",%
NOTE x4(%#2!#+).'%&&/2 4-534"%2%!$4(% 3!-%-/-%.44(!44(%6!,5%/&).4%2-%$)!4% 02%3352%34!2434/$%#2%!3%x
original copywriter 1987 revision 2009 - printing 2010
2ND STAGE CRACKING EFFORT
TEST BENCH
2° STAGE PRIMARY OCTOPUS
cm of H2O
inch of H2O
NOTE
4//"4!).4(%#2!#+).'%&&/24)3.%##%33!29 4/!$$4(%6!,5%/&#/,5-.7!4%24(!4'/%3 507)4(4(%6!,5%/&#/,5-.7!4%24(!4 '/%3$/7./22%$/5",%/.%/&4(%-
NOTE
3/-%4)-%34(%'2!$5!4)/./&#/,5-.7!4%2 )3!,2%!$92%$/5",%$2%!,CM/. '2!$5!4)/./&#/,5-.7!4%2
s #,/3%4(%4!.+6!,6% !.$$)3#(!2'%4(%2%3)$5!, !)2 "9053().'/.4(%3%#/.$34 !'%"544/.#/6%2 /24(%$)3#(!2'%,%6%2
s #,/3%4(%4%34"%.#(6!,6% !.$4294/).(!,% $)2%#4,9&2/-4(%3%#/.$34!'%7/4(%).(!,).' -/54(0)%#% )./2$%24/$%4%#4,%!+%!'% ).3)$%/&4(%#!3%.
CARBON SECOND STAGE
S13-13
S13-14
CARBON SECOND STAGE
REGULATORS
FINAL ASSEMBLY
37. ss the purge button a few times, and then reassemble the O-Ring (83) on the case plug (64).
38. Use the hex wrench (B8 - 46106208) to fully tighten the case plug assembly (83+64) in the 2nd stage case (32).
! WARNING!
&/2#(%#+3!.$!$*534-%.43/.4(%3%#/.$34 !'% #/.35,44(%#/22%30/.$).'3%#4)/./&4(%-!2%3 3%26)#%-!).4%.!.#%-!.5!,3
39.Assemble the exhaust tee (41) on the support flange on the second stage.
! WARNING!
-!+%352%4(!44(%%$'%/&4(%%8(!5344%%)3#/22%#49, &)44%$/.4(%&,!.'%,)'(4,5"2)#! 4)/.7)4(,)15)$ 3/!0/2$%4%2'%.4&!#),)4!4%3).34!,,!4)/.
40. Carefully assemble the mouthpiece (44), securing it with a new mouthpiece clamp (43).
original copywriter 1987 revision 2009 - printing 2010
AIR CONTROL OCTOPUS
AIR CONTROL OCTOPUS
original copywriter 1987 revision 2009 - printing 2010
MAINTENANCE PROCEDURES
! WARNING!
ALL MAINTENANCE AND REPAIR PROCEDURES MUST BE PERFORMED BY A MARES LAB AUTHORIZED SERVICE CENTER AND/OR DISTRIBUTOR. THEREFORE, THE INFORMATION PROVIDED BELOW IS INTENDED STRICTLY FOR TECHNICIANS AT SUCH CENTERS.
NOTE ALL OPERATIONS MUST BE CONDUCTED STRICTLY IN THE ORDER DESCRIBED.
IN ORDER TO ENSURE ADVANCED PERFORMANCE AND SAFETY DURING USE, AFTER 100 HOURS OF DIVING OR 1 YEAR THE REGULATOR MUST BE CHECKED, AND ITS CRITICAL PARTS MUST BE INSPECTED AND REPLACED IF NECESSARY.
· Small flathead screwdriver · Compressed air supply circuit or tank (180-200 bar/2,646 -
2,940 psi) · Cutting nippers · Plastic or Brass O-Ring removal tool (Pin) · Silicone grease (General Electric Versalube G-322 type/
Christo Lube 111) · Compressed air gun (8-10 Bar / 116 - 145 psi) · Descaling solution (Deox Extra type) or ultrasound tank · Test Bench (code 416920 or code 416922) · Octopus Service kit (code 46201064)
AIR CONTROL
S14-1
(B-6) # 46106206
A-3 13 mm # 46201071
B-18 14 mm #46106248
(B-12) 5.5 mm #46106212
(B-4) 5 mm #46106204
(A-1) # 46201039
(A-4) #46201073
S14-2
AIR CONTROL
original copywriter 1987 revision 2009 - printing 2010
DISASSEMBLY
1. Disconnect the LP hose Quick Coupler (55) from the air control body (218), then remove the Plastic Seeger (208), along with the Inflator Adaptor (189) from the Air Control unit.
2. Remove the clamp (43) from the mouthpiece (44) using cutting nippers or a similar tool.
3. Using a flathead screwdriver, remove the pin-cover (63). Unscrew the cover (204). Remove the diaphragm plastic ring (78) and the diaphragm (36) from the Air Control Body (218).
4. Remove the Retaining Ring (198) from the Male Connector (210) using a screwdriver. 5. Carefully press the Male Connector (210) out of the Main Air Control Body (218).
original copywriter 1987 revision 2009 - printing 2010
6. Using the special A-1 wrench, unscrew the Exhaust Valve Cap (211).
AIR CONTROL
S14-3
7. Remove the Exhaust Valve Seat (220) from the outside by pressing gently on it and then remove the Spacer Ring (222).
8. Remove the exhaust valve (221) and the O-ring (193) from the exhaust valve seat (220).
S14-4
AIR CONTROL
original copywriter 1987 revision 2009 - printing 2010
9. Using the B-18 (14mm) and A-3 (13mm) open end wrenches, carefully unscrew the Male Connector (210) from the Poppet Housing (205).
IMPORTANT INFORMATION! THROUGH SERIAL NUMBER EC10473, MARES ASSEMBLED A POPPET HOUSING (205) THAT REQUIRED A 15 mm WRENCH INSTEAD OF A 14 mm WRENCH AS DESCRIBED IN STEP 9 IN ORDER TO BE REMOVED/REASSEMBLED. 10. Remove the O-Rings (171) from the Male Connector (210). 11. Use the hex wrench (B-4) to fully unscrew the poppet seat (209) from the Poppet Housing (205), then remove the
O-Ring (19).
12. Position the Poppet Housing (205) on the Special Tool (B-6). Using the wrench (B-12), unscrew the demand lever locknut (33), pulling out the demand lever (201) located between the 2 Washers (34), the poppet metal body regs (206), and the spring (207).
13. Remove the rubber seat III (47-46185060) from the 2nd stage poppet.
original copywriter 1987 revision 2009 - printing 2010
CLEANING AND CHECKS
For routine cleaning of reusable rubber and plastic components, wash all parts in a mixture of hot water and mild detergent, scrubbing if necessary with a soft brush.
! WARNING!
ACIDS OR OTHER SOLVENTS MAY DAMAGE PLASTIC AND RUBBER PARTS. BEFORE CLEANING METAL COMPONENTS, MAKE SURE THAT ALL SEALS AND OTHER PARTS SUBJECT TO DETERIORATION HAVE BEEN REMOVED.
Chrome-plated brass and stainless steel components can be cleaned using a nylon brush to remove any deposits, by immersing them in a fresh water ultrasound bath, or, if suitable equipment is not available, in a gentle acid solution (Deox Extra type) or white vinegar diluted with hot water (10-20%). Be sure to thoroughly rinse all parts in fresh water and dry with a jet of low pressure air at 8 - 10 bar / 116 - 145 PSI before proceeding with reassembly.
! WARNING!
CERTAIN KEY COMPONENTS OF THE AIR CONTROL SHOULD BE REGULARLY REPLACED AT EACH SCHEDULED OVERHAUL. BELOW ARE LISTED THE COMPONENTS INCLUDED IN THE SERVICE KIT FOR THE AIR CONTROL OCTOPUS (CODE 46201065):
46185051 46110106 47157984 46185060 46184289
46110110 46110175 46201007 46184006
Demand Lever Locknut OR 106
Mouthpiece clamp Rubber Seat III Pin Cover
OR 2037 (2) OR 2125
Retaining Ring Exhaust valve
AIR CONTROL
S14-5
S14-6
AIR CONTROL
REASSEMBLY
NOTE
BEFORE REASSEMBLING, LIGHTLY LUBRICATE ALL THE O-RINGS WITH SILICONE GREASE (TYPE GENERAL ELECTRIC VERSALUBE G-322 / CHRISTO LUBE 111). LUBRICATION REDUCES THE LIKELIHOOD OF DAMAGE DURING REASSEMBLY.
14. Reassemble the poppet seat (47) in the poppet seat holder (206)
15. Arrange the poppet metal body (206) with the corresponding spring (207) on the special tool (B-6).
16. Pressing gently, correctly position the poppet metal body (206) in the demand lever air control (201).
! WARNING!
TO ENSURE THAT THE 2nd STAGE POPPET STEM IS POSITIONED
CORRECTLY IN THE DEMAND LEVER CONNECTOR HOLE, GENTLY ROTATE THE CONNECTOR LEFT AND RIGHT ON THE B-6 TOOL.
17. Position the one washer (34) only after lightly coating the seat of the Poppet Housing (205) with silicone grease or christo lube 111.
original copywriter 1987 revision 2009 - printing 2010
original copywriter 1987 revision 2009 - printing 2010
AIR CONTROL
S14-7
18. Position the second Washer (34) on the stem of the Poppet Metal Body (206) and tighten the Demand Lever Locknut (33) at least one or two full turns on the Poppet Stem (206).
NOTE MARES RECOMMENDS THAT YOU PLACE THE TWO WASHERS (34) AS SHOWN IN IMAGE A.
Fig. A
19. Lift the special tool (B-6) from the workbench, maintaining pressure on the Poppet Housing (205) in order to make the valve stem (206) stick out as far as possible. Insert the Air Control Demand Lever (201) between the (2) two washers (34).
20. Screw the demand lever locknut (33) approximately 5 full turns using the special wrench (B-12).
S14-8
AIR CONTROL
21. Install the O-Ring (19) in the Poppet Seat (209) and the two O-Rings (171) in the Male Connector (210) - I
22. Place the Poppet Seat (209) on the Male Connector (210) as shown and fully screw them down on the Poppet Housing (205). Then tighten gently using the open end wrenches B-18 and A-3. II-III-IV-V-VI
NOTE IF USING A TORQUE WRENCH, USE TIGHTENING TORQUE OF 6 N/m
original copywriter 1987 revision 2009 - printing 2010
original copywriter 1987 revision 2009 - printing 2010
AIR CONTROL
S14-9
NOTE BEFORE MAKING ANY ADJUSTMENTS, WE RECOMMEND THAT YOU FULLY UNSCREW THE ADJUSTABLE POPPET SEAT (209) INTO THE POPPET HOUSING (205) USING A B-4 HEX WRENCH (I).
23. Turn about ¾ turn on adjustable poppet seat with the B-4 wrench. (II)
24. Insert the full Demand Lever connector inside the Air Control Body (218).
NOTE NOTE THAT THE FLAT SURFACE OF THE POPPET HOUSING (205) MUST BE INSERTED AGAINST THE FLAT SURFACE INSIDE THE AIR CONTROL BODY (218).
25. Carefully put the assembled connector in place using the special B-12 tool and push it into the body.
NOTE BE ESPECIALLY CAREFUL DURING INSERTION TO AVOID DAMAGING THE O-RINGS (171).
NOTE DO NOT FORCE THE DEMAND LEVER, WHICH COULD BEND.
S14-10
AIR CONTROL
26. Use the New Retaining Ring (198) to fasten the connector body to the Air Control Body (218).
27. Place the O-Ring (193) in the seat of the exhaust valve seat (220).
! WARNING!
MAKE SURE THAT THE EXHAUST VALVE (221) IS INSERTED FROM THE CORRECT SIDE INTO ITS SEAT (220).
28. Carefully install a new Exhaust Valve (221), pulling the silicone stem through the central hole in the Exhaust Valve Seat (220).
! WARNING!
IN ORDER TO AVOID DAMAGING THE EXHAUST VALVE, DO NOT
PULL TOO HARD ON THE STEM.
! WARNING!
USE CUTTING NIPPERS TO TRIM THE EXHAUST VALVE TO
APPROXIMATELY 3 mm.
original copywriter 1987 revision 2009 - printing 2010
original copywriter 1987 revision 2009 - printing 2010
29. Position the Spacer Ring (222) with the flat part facing up. 30. Set the Exhaust Valve Seat (220) in the Air Control Body
(218) with the exhaust valve side facing outward and bring it into position, touching the edges of the Valve Seat (220). 31. Screw the Exhaust Valve Cap (211) on to the Air Control Body (218), tightening gently with the A-1 tool. 32. Attach the Hose (55), complete with the Quick Coupler, to the Air Control unit. 33. Screw the hose (55) to an LP port on the 1st Stage Body using a 14 mm open end wrench (B-18).
NOTE IF USING A TORQUE WRENCH, SET A TIGHTENING TORQUE OF 4 - 4.5 N/m
AIR CONTROL
S14-11
S14-12
AIR CONTROL
FINAL ADJUSTMENTS
TO CORRECTLY ADJUST THE REGULATOR: A. The repair shop should be equipped with a high-and low-
pressure compressed air supply. B. A pressure gauge is required for checking the intermediate
pressure (the pressure gauge should have a full scale value MAX 30-40 BAR / 440 - 590 psi, for greater adjustment accuracy).
I. Screw the intermediate pressure measuring gauge into one of the 3/8" low-pressure ports on the 1st stage, using the wrench (B-18).
II. Mount the regulator group on the control valve (of the tank or test bench).
III. Holding down the second stage demand lever, slowly open the tank valve and, almost simultaneously, release the demand lever.
IV. Read the pressure gauge to check whether the 1st stage pressure is correct (9,8 - 10,2 bar / 142 - 148 psi).
! WARNING!
THE FIRST STAGE INTERMEDIATE PRESSURE MUST BE MEASURED WHEN THERE IS NO AIR COMING OUT OF THE
2nd STAGE. FOR ANY NECESSARY 1st STAGE ADJUSTMENTS,
REFER TO THE CORRESPONDING MARES TECHNICAL SERVICE MANUAL.
IMPORTANT INFORMATION! ALL OF THE ADJUSTMENTS DESCRIBED BELOW MUST BE PERFORMED WITH THE AIR CONTROL SUPPLIED WITH THE APPROPRIATE INTERMEDIATE PRESSURE (I.P.).
34. Place the Gauge (A-4) perpendicular to the edge of the second stage case.
35. Tighten or loosen the demand lever locknut (33), using the special wrench (B-12) to correctly adjust the height of the demand lever (201).
! WARNING!
THE DEMAND LEVER IS CORRECTLY ADJUSTED WHEN IT JUST TOUCHES THE GAUGE (A-4) BUT THERE IS NO AIR COMING OUT.
36. Depress and trigger the demand lever a few times. 37. Insert the plastic ring (78) on the diaphragm (36) and place
them inside the Air Control Body (218). 38. Twist the cover (204) until both seats line up (case and
cover) to allow insertion of the Pin Cover (63).
original copywriter 1987 revision 2009 - printing 2010
original copywriter 1987 revision 2009 - printing 2010
AIR CONTROL
S14-13
OBJECT: Regulator Test Bench - Final adjustment
Install the Inhaling Mouthpiece (8) on the second stage mouthpiece tube.
To check the Cracking Effort using Column Water (see info table)
NOTE
...THE CRACKING EFFORT MUST BE READ THE SAME MOMENT THAT THE VALUE OF INTERMEDIATE PRESSURE STARTS TO DECREASE...
AIR CONTROL CRACKING EFFORT
cm of H2O 3.5-4
inch of H2O 1,4-1,6
NOTE NOTE
TO OBTAIN THE CRACKING EFFORT IS NECCESSARY TO ADD THE VALUE OF COLUMN WATER THAT GOES UP WITH THE VALUE OF COLUMN WATER THAT GOES DOWN (OR REDOUBLE ONE OF THEM).
SOMETIMES THE GRADUATION OF COLUMN WATER IS ALREADY REDOUBLED (1 REAL cm = 2 ON GRADUATION OF COLUMN WATER)
Close the Tank Valve, and discharge the residual air, by pushing on the second stage button cover or the Discharge Lever (5)
Close the Test Bench Valve, and try to inhale directly from the second stage (w/o the Inhaling Mouthpiece (8)), in order to detect leakeage inside of the case.
S14-14
AIR CONTROL
OPERATION CONCLUDED
Install the Proper Inflator Adaptor (189) on the Air Control Body (218).
Fasten the Plastic Seeger (208) in place, and then attach the Fastening Sleeve (without spring) on the Air Control Body.
Insert the hose into its Adaptor and apply the Ring clamp / wire tie (42), trimming away the excess.
Connect the Quick Hose Coupler to the Air Control and bring the Hose cover into position. Carefully assemble the mouthpiece (44), securing it with a new mouthpiece clamp (43).
original copywriter 1987 revision 2009 - printing 2010
AIR CONTROL INFLATOR
AIR CONTROL INFLATOR
original copywriter 1987 revision 2009 - printing 2010
MAINTENANCE PROCEDURES
! WARNING!
!,,-!).4%.!.#%!.$2%0 !)202/#%$52%3-534"% 0%2&/2-%$"9!-!2%3,!"!54(/2):%$3%26)#%#%.4%2 !.$/2$)342)"54/24(%2%&/2% 4(%).&/2-! 4)/. 02/6)$%$"%,/7)3).4%.$%$342)#4, 9&/24%#(.)#)!.3 !435#(#%.4%23
NOTE !,,/0%2!4)/.3-534"%#/.$5#4%$342)#4, 9 ).4(%/2$%2$%3#2)"%$
IN ORDER TO ENSURE ADVANCED PERFORMANCE AND SAFETY DURING USE, AFTER 100 HOURS OF DIVING OR 1 YEAR THE REGULATOR MUST BE CHECKED, AND ITS CRITICAL PARTS MUST BE INSPECTED AND REPLACED IF NECESSARY.
· Small flathead screwdriver (Usage Type 322-0.4x2.5) · Pliers (Usage Type 133) · Compressed air supply circuit or tank (180-200 bar) · Cutting nippers · Plastic or Brass O-Ring removal tool (Pin) · Silicone grease (General Electric Versalube G-322 type or
Christo lube 111 (Nitrox)) · Compressed air gun (8-10 Bar) · Descaling solution (Deox Extra type) or ultrasound tank · Test Bench (code 416920 or code 416922) · Inflator Service kit (code 46201064)
AIR CONTROL INFLATOR
S14-17
(B-12) 5.5mm #46106212
(B-17) 17mm (2) # 46106217
(B-18) 14mm #46106218
4mm
(A-1) # 46201039
S14-18
AIR CONTROL INFLATOR
original copywriter 1987 revision 2009 - printing 2010
DISASSEMBLY
1. Disconnect the Quick Coupler from the Hose (55), and, after removing the Plastic Seeger / locking clip (208), the Inflator Adaptor (189) from the Air Control unit.
! WARNING!
4/-!+%4(%3%/0%2!4)/.3%!3)%2 9/5#!.2%-/6%4(%-/54(0)%#% !.$4(%#,!-0 &2/-4(% !)2#/.42/,5.)4/.,92%-/6%4(%#,!-0&2/-4(%-/54(0)%#%)&!2%0,!#%-%.40 !24)3!6!),!",%
2. Remove the exhaust valve cap w/tool (46201039) (New tool)
3. Carefully remove the Exhaust Valve Seat (220) from the outside by gently pulling up on it, and then remove the Spacer Ring (222). Remove the Demand Lever Locknut (33) using the B-12 (5 mm nut driver -46106212) , and remove all the Purge Button components from the Air Control body.
original copywriter 1987 revision 2009 - printing 2010
AIR CONTROL INFLATOR
S14-19
4. Using the special A-1 tool (46201039), unscrew the Inflating Plug (215). 5. Using Pliers, remove the O-Ring Seat (214) from the Air Control Body (218),
and then remove the other components (6, 71, 165, 166).
6. Rotate the Air Control Body and remove the Red Inflating Button (216), gently prying with a flathead screwdriver through the side (Use type 322 - 0.4 x 2.5).
! WARNING!
/.#%4(%).&,!4)/."544/.!33%-",9(!3"%%.2%-/6%$2%&
#/$% )4#!../4"% 2%53%$7(%.4(%5.)4)32%!33%-",%$&)' 9/57),,&).$4(%2%0,!#%-%.40 !24 ).4(% -!).4%.!.#%+)4&)'
7. Lift the O-Ring (54) from Air Control Body (218). 8. Using 2 open-end wrenches (B-17), unscrew the Assembled Quick Connector, female (46201066) from the Hose (55).
S14-20
AIR CONTROL INFLATOR
original copywriter 1987 revision 2009 - printing 2010
9. Using a flathead screwdriver, remove the Snap Ring (3) from its seat. Then remove all remaining components from it. 10. Remove the O-Ring (74) from the Quick Connector Body (192).
11. Remove the first stage connection side (19) and second stage swiveling connector (27) O-Rings from the Hose (55).
original copywriter 1987 revision 2009 - printing 2010
CLEANING AND CHECKS
For routine cleaning of reusable rubber and plastic components wash all parts in a mixture of hot water and mild detergent, scrubbing if necessary with a soft brush.
! WARNING!
!#)$3/2/4(%23/, 6%.43-! 9$!-!'%0,!34)#!.$ 25""%20 !243"%&/2%#,%!.).'-%4 !,#/-0/.%.43 -!+%352%4(!4!,,3%!,3!.$/4(%20!24335"*%#44/ $%4%2)/2!4)/.(!6%"%%.2%-/6%$
Chrome-plated brass and stainless steel components can be cleaned using a nylon brush to remove any deposits, by immersing them in a fresh water ultrasound bath, or, if suitable equipment is not available, in a gentle acid solution (Deox Extra type) or white vinegar diluted with hot water (10-20%). Be sure to thoroughly rinse all parts in fresh water and dry with a jet of low pressure air at 8-10 bar / 116 145 psi before proceeding with reassembly.
! WARNING!
#%24!).+%9#/-0/.%.43/&4(%!)2#/.42/,3(/5,$
"%2%'5,!2,92%0,!#%$! 4%!#(3#(%$5,%$/6%2(!5,
"%,/7!2%,)34%$4(%#/-0/.%.43).#,5$%$
).4(%3%26)#%+)4&/24(%!)2#/.42/,).&,!
4/2
#/$%
Air Control Exploded Diagram
N.
Code Description
/
2ING
/
2ING
/
2ING.ª
$EMAND,EVER,OCKNUT
#LAMP X
/
2ING
/
2ING
/
2ING
/
2ING
#
)NFLATING"UTTON2EDASSEMBLED
AIR CONTROL INFLATOR
S14-21
S14-22
AIR CONTROL INFLATOR
REASSEMBLY
! WARNING!
)&4(%&)23434!'%)353%$&/2$)6%37)4(/89'%.
%.2)#(%$ -)8452%3 342)#4, 9&/,,/7!,,4(%).3425#4)/.3 02/6)$%$).4()3-!).4%.!.#%-!.5!,).4(%.)42/8 #(!04%2%. "%&/2%"%')..).'2%!33%-",9
NOTE
"%&/2%2%!33%-",).' ,)'(4, 9,5"2)#! 4%
!,,4(%/
2).'37)4(3),)#/.%'2%!3%
490%'%.%2!,%,%#42)#6%23!,5"%'
/2
#(2)34/,5"% ,5"2)#! 4)/.2%$5#%34(%
,)+%,)(//$/&$!-!'%$52).'2%!33%-",9
12. Insert the 4 Steel Balls (195) into the Quick Connector Body (192) and then insert the Spring (197), holding the components vertically to keep them inside.
13. Insert the Quick Connector Slider (202) in the correct position over the Spring (197).
14. Fasten the Quick Connector with the Snap Ring (3), holding down the Quick Connector Slider (202).
15. Insert the Quick Connector Shutter (217), including the O-Ring (27) and Conical Spring (196), in the Quick Connector Body (192).
16. Install the O-Rings on the first stage connection side (19) and the second stage swiveling connector (27) on the Hose (55).
NOTE )&53).'!4/215%72%.#( 3%4!4)'(4%.).' 4/215%/&!002/8)-!4%,9.M
17. Using 2 17-mm wrenches (B-17), tighten the Assembled Quick Connector to the Hose (55).
18. Insert the O-Ring 2031 (74) in its seat inside the Quick Connector Body (192), bringing it into place using a pointed plastic or brass tool.
original copywriter 1987 revision 2009 - printing 2010
original copywriter 1987 revision 2009 - printing 2010
AIR CONTROL INFLATOR
S14-23
19. Lubricate and insert the O-Ring (54) in the seat of the Air Control Body (218).
20. Position the O-Ring (53) in the Purge Button seat, and then place the Metal Washer (199) and the Spring (1) on top of it. Insert the Purge Button (203).
21.Rotate the Air Control Body, holding down the Purge Button (203) and insert the LP Inflator Exhaust Diaphragm (194) on the threaded stem of the Purge button.
! WARNING!
-!+%352%4(!44(%,0).&,!4/2%8(!534$)!0(2!'-)3&!#).'4(%2)'(47!950
22. Screw the Demand Lever Locknut (33) onto the LP Inflator Exhaust Diaphragm (194) using the B-12 tool.
NOTE )&53).'!4/215%72%.#( 3%4!4)'(4%.).'4/215%/&.CM
S14-22
AIR CONTROL INFLATOR
original copywriter 1987 revision 2009 - printing 2010
23.Place the Spacer Ring (222) with the flat part facing up. 24. Set the Exhaust Valve Seat (220) in the Air Control Body (218) with the exhaust valve side facing outward and bring
it into position, touching the edges of the Valve Seat (220). 25. Screw the Exhaust Valve Cap (211) onto the Air Control Body (218), tightening gently with the A-1 tool 26. Insert the O-Ring (6) in its seat, and then the Steel Ball (166). Position the O-Ring (71) as shown.
27. Place the O-Ring seat (214) in the correct position. 28.Screw the Inflating Plug (215) snug using the special A-1 tool. 29.Rotate the Air Control Body. Place the Spring (2) inside the Inflation Button assembly (C).
30.Insert the Inflation Button (C), pressing it all the way down until it fastens to the Air Control Body.
! WARNING!
-!+%352%4(! 44(%).&,! 4)/."544/.7 !3).3%2 4%$ #/22%#4,9!.$#(%#+4(! 4)4)3& !34%.%$02%334(% ).&,!4)/."544/.# !&%74)-%34/#(%#+4(!44(%302).' (!34(%#/22%#42%452.-/4)/.
original copywriter 1987 revision 2009 - printing 2010
31. Install the 21-mm Inflator Adaptor (189) on the Air Control Body.
AIR CONTROL INFLATOR
S14-25
32. Fasten the Plastic Seeger (208) in place, and then attach the Fastening Sleeve on the Air Control Body.
33. Insert the hose inside the 21-mm Adaptor (189) apply the Ring clamp 3.6x200 (42), trimming away the excess.
34. Connect the Quick Hose Coupler to the Air Control and bring the Hose cover into position.
35. Screw the Hose (55) to a Low-pressure (LP) port on the 1st stage using a 14-mm open end wrench (B-18). If you removed it previously, install the Mouthpiece (44) with a new Clamp (43).
NOTE )&53).'!4/215%72%.#( 53%4)'(4%.).' 4/215%/&
.M
Slowly open the tank valve, checking for any air leaks. Press the Inflation Button (216) until the BC fully inflates and the overexpansion relief valve opens.
Deflate the BC using the R.E. valve and the Purge Button (203). Repeat this operation a few times to make sure that the Air Control Unit functions properly.
S14-26 A IR CONTROL $2!7).' ./%
REGULATORS
AIR-CONTROL
original copywriter 1987 revisione 2009 - stampa 2010
50$!4%$
original copywriter 1987 revision 2009 - printing 2010
REGULATORS
4ABLE.O
AIR-CONTROL
A I R C O N T R O L S14-27
50$!4%$
N. NO.
CODE
! ! ! !
DESCRIPTION 3PRING$EFLATE"UTTON!)2K 3PRING)NFLATE"UTTON!)2K 3NAP2ING /2 /2 /2 ,OCKNUT $EMAND,EVER 7ASHER $)!0(2!'- .$34!'%2%' #LAMP X -OUTHPIECE#LAMP -OUTHPIECE"+PICS /CTOPUS0LUG (OSE0ROTECTOR 2UBBER3EAT))) /2 /2 (OSE3&8 0IN
#OVER /2 /2 /2 $)!0(2!'-0LASTIC2).' 3PRING)NFLATING6ALVE 3TEEL"ALL 0IN%RGO+ /2 )NFLATOR!DAPTORMM )NFLATOR!DAPTORMM )NFLATOR!DAPTORMM -ETAL0INX -ETAL0INX 1UICK#ONNECTOR"ODY /2
N. NO.
ªªª
! !
CODE
DESCRIPTION
%XHAUST$IAPHRAGM,0)NFLATOR 3TEEL"ALLD #ONICAL3PRING 1UICK#ONNECTOR3PRING 2ETAINING2ING -ETAL7ASHER $EMAND,EVER!IR#ONTROL 1UICK#ONNECTOR3LIDER
0URGE"UTTON3ILVER
#OVER!IR#ONTROL 0OPPET(OUSING 0OPPETMETALBODYREGS 3PRING2EGULATOR 0LASTIC3EGEER 0OPPET3EAT -ALE#ONNECTOR %XAUST6ALVE#AP
/
2INGSEAT )NFLATING0LUG )NFLATING"UTTON2ED 1UICK#ONNECTOR3HUTTER #ORPO!IR#ONTROL %XAUST6ALVE3EAT %XAUST6ALVE 3PACER2ING
ASSEMBLIES
3ERVICE+IT/CTOPUS
3ERVICE+IT)NFLATOR
1UICK#ONNECTOR!SSEMBLED&EMALE
)NFLATING"UTTON2EDASSEMBLED
!DAPTORD!IR#ONTROL
!DAPTORD!IR#ONTROL
copywriter originale 1987 revision 2009 - printing 2010
TECHNICAL BULLETIN )4- 19-1
RE: SPECIAL TOOLS (# 46201041 - # 46201042)
ITM19
IMPORTANT INFORMATION -!2%34%#(.)#!,3500/24!../5.#%34(%).42/$5#4)/./&47/.%730%#)!,72%.#(%33 3434!'% (06!,6%$)3!33%-",94//,"
#/$% !.$ 3434!'%(03%!4#/..%#4/2$)3!33%-",94//, "
#/$%4(%)20520/3%)34/(%,02%-/6%4(%3%4!#/..%#4/2&2/-!,,-!2%3$)!0(2!'- &)23434!'%3 7)4(/54#/-02/-)3).'4(%)2&5.#4)/. %30%#)!,, 97(%.4(%2%!2%3)'.)&)#!.442!#%3 /&3%$)-%.4!4)/. /8)$% !.$/2$%0/3)43/&2534).3)$%4(%()'(02%3352%#(!-"%2
12S HP SEAT CONNECTOR DISASSEMBLY TOOL (B-41)
).3%244(%4//,"
).!,/702%3352%0/2 4!.$53%)44/02 9/544(%(03%!4#/..%#4/2
&)' &)'
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)4- 19-2 TECHNICAL BULLETIN
copywriter originale 1987 revision 2009 - printing 2010
RE: SPECHIAPLSTeOaOt LCSon(n#e4c6to2r01re0m41ov-#a4l 6to2o0l1(0B4-242)
HP SEAT CONNECTOR DISASSEMBLY TOOL (B-42)
).3%244(%4//,"
).4(%#%.42!,0/2 4/.4(%$)!0(2!'-3)$%5.4),9/5&%%,)44/5#(4(%3%! 4 #/..%#4/2&)' 4(%.02%33&)' /.4(%3%!4#/..%#4/25.4),)4#/-%3/54#/-0,%4%,9&)' 6!,6% 02/#%$52%&/24(%-2
6(5"3%2)%3
&)'
&)'
&)'
&)'
copywriter originale 1987 revision 2009 - printing 2010
TECHNICAL BULLETIN )4- 19-3
RE: SPECIAL TOOLS (# 46201041 -#46201042 )
BELOW IS THE VALVE SEQUENCE FOR MR42
).3%244(%4//,"
).4(%#%.42!,0/2 4/.4(%$)!0(2!'-3)$%5.4),9/5&%%,)44/5#(4(%3%! 4 #/..%#4/2&)' 4(%.02%33/.)4&)' 5.4),9/5#/-0,%4%, 92%-/6%4(%3%!4#/..%#4/2
&)'
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&)'
&)'
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