dacor repair manual volume three - … usa 02.pdf · 2007-08-15 · dacor repair manual volume...

DACOR REPAIR MANUALVOLUME THREE

INDEX

LASTREVISION NOTES

LASTREVISION NOTES

INTRODUCTIONGENERAL INFORMATION 1-1 1999DACOR TECHNICAL MANUAL 1-1 1999IMPORTANT! 1-1 1999IMPORTANT! 1-1 1999SERIAL NUMBERS 1-1 1999WARRANTY 1-1 1999ROUTINE MAINTENANCE 1-1 1999SERVICE CENTER OVERHAUL 1-2 1999GENERAL OVERHAUL

General Information 1-2 1999O-RING TABLE 1° STAGES 1-3 2002 NEWO-RING TABLE 2° STAGES - INFLATORS 1-4 2002 NEWO-RING TABLE H.U.B. - HOSES - MANIFOLDS -ORAL INFLATOR - DEPTH GAUGE 1-5 2002 NEWO-RING TABLE H.U.B. AIR TRIM -PNEUMATICAL INFLATOR -PNEUMATICAL DUMP VALVES 1-6 2002 NEW

1. FIRST STAGE REGULATORSD16 FIRST STAGE• D16 SCHEMATIC AND PARTS LIST 1-1 1999• D16 TABLE 1-1.1 2002 NEW• DISASSEMBLY 1-2 1999• DIN VERSION / DISASSEMBLY 1-6 1999• CLEANING 1-6 1999• INSPECTION 1-6 1999• REASSEMBLY 1-7 1999• DIN VERSION / REASSEMBLY 1-8 1999• ADJUSTING THE INTERMEDIATE PRESSURE

ON THE FIRST STAGE D16 1-10 1999• PROCEDURE FOR ADJUSTING

THE INTERMEDIATE PRESSURE 1-10 1999• A.E.R. 1-12 1999• COLD WATER DIVING 1-12 1999• INSTRUCTION FOR INSTALLING THE A.E.R. KIT 1-13 1999• FIRST STAGE D16 TROUBLESHOOTING 1-16 1999

D12 FIRST STAGE• D12 SCHEMATIC AND PARTS LIST 1-1 1999• D12 TABLE 1-1.1 2002 NEW• DISASSEMBLY 1-2 1999• DIN VERSION / DISASSEMBLY 1-3 1999• CLEANING 1-6 1999• INSPECTION 1-7 1999• REASSEMBLY 1-8 1999• DIN VERSION / REASSEMBLY 1-9 1999• ADJUSTING THE INTERMEDIATE PRESSURE

ON THE FIRST STAGE D12 1-10 1999• PROCEDURE FOR ADJUSTING

THE INTERMEDIATE PRESSURE 1-10 1999• A.E.R. 1-11 1999• COLD WATER DIVING 1-11 1999• INSTRUCTION FOR INSTALLING THE A.F.K. KIT 1-12 1999• FIRST STAGE D12 TROUBLESHOOTING 1-15 1999

D2 FIRST STAGE• D2 SCHEMATIC AND PARTS LIST 1-1 1999• D2 TABLE 1-1.1 2002 NEW• DISASSEMBLY 1-2 1999• DIN VERSION 1-5 1999

• CLEANING / INSPECTION 1-6 1999• REASSEMBLY 1-7 1999• REASSEMBLY 1-7 1999• DIN VERSION 1-8 1999• ADJUSTING OF THE INTERMEDIATE PRESSURE1-9 1999• FIRST STAGE D2 TROUBLESHOOTING 1-10 1999

D20 FIRST STAGE• D 20 DRAWING 1-1 2002 NEW• D 20 METAL TABLE 1-1.1 2002 NEW• D 20 GOLD TABLE 1-1.2 2002 NEW• DISASSEMBLY 1-2 2002 NEW• DIN VERSION / DISASSEMBLY 1-3 2002 NEW• CLEANING 1-6 2002 NEW• INSPECTION 1-7 2002 NEW• REASSEMBLY 1-8 2002 NEW• DIN VERSION / REASSEMBLY 1-9 2002 NEW• ADJUSTING THE INTERMEDIATE PRESSURE

ON THE D20 FIRST STAGE 1-10 2002 NEW• PROCEDURE FOR ADJUSTING

THE INTERMEDIATE PRESSURE 1-10 2002 NEW• A.E.R. 1-11 2002 NEW• COLD WATER DIVING 1-11 2002 NEW• INSTRUCTION FOR INSTALLING THE A.E.R.KIT 1-12 2002 NEW• FIRST STAGE D20 TROUBLESHOOTING 1-15 2002 NEW

2. SECOND STAGE REGULATORSBTD 1 FURY SECOND STAGE • DACOR TECHNICAL BULLETIN

AND INFORMATION 1-1 2001

FURY SECOND STAGE• FURY SCHEMATIC AND PARTS LIST 1-1 1999• FURY DRAWING 1-1.1 2002 NEW• FURY TABLE 1-1.2 2002 NEW• DISASSEMBLY 1-2 1999• CLEANING / INSPECTION 1-4 1999• REASSEMBLY 1-5 1999• ADJUSTMENT AND FINAL ASSEMBLY 1-8 1999• ADJUSTMENT PROCEDURE / PROCEDURE A 1-8 1999• PROCEDURE B 1-9 1999• FINAL CHECKS AND ADJUSTMENTS 1-10 1999• FURY SECOND STAGE TROUBLESHOOTING 1-12 1999

FURY ADJ SECOND STAGEBTD 1 FURY ADJ SECOND STAGE• DACOR TECHNICAL BULLETIN


FURY ADJ SECOND STAGE• FURY ADJ SCHEMATIC AND PARTS LIST 1-1 1999• FURY ADJ DRAWING 1-1.1 2002 NEW• FURY ADJ TABLE 1-1.2 2002 NEW• DISASSEMBLY 1-2 1999• CLEANING / INSPECTION 1-4 1999• REASSEMBLY 1-5 1999• ADJUSTMENT AND FINAL ASSEMBLY 1-8 1999• ADJUSTMENT PROCEDURE 1-8 1999• ASSEMBLY OF THE EXTERNAL

ADJUSTMENT SYSTEM 1-9 1999• FINAL ASSEMBLY 1-10 1999• FINAL CHECKS AND ADJUSTMENTS 1-11 1999• FURY ADJ 2° STAGE TROUBLESHOOTING 1-13 1999


INDEX

LASTREVISION NOTES

LASTREVISION NOTES

VIPER TEC - VIPER SECOND STAGEBTD 3 VIPER – VIPER TEC• MODIFICATION REGARDING THE NBS SYSTEM

ON ALL VIPER-VIPERTEC REGULATORS 1-1 2001• FIG.1 AND FIG.2A 1-2 2001• FIG.2B AND FIG.2C 1-3 2001

VIPER SECOND STAGES• VIPER TEC SCHEMATIC AND PARTS LIST 1-1 1999• VIPER TEC DRAWING 1-1.1 2002 NEW• VIPER TEC TABLE 1-1.2 2002 NEW• VIPER SCHEMATIC AND PARTS LIST 1-2 1999• VIPER DRAWING 1-2.1 2002 NEW• VIPER TABLE 1-2.2 2002 NEW• VIPER AMERICA DRAWING 1-2.3 2002 NEW• VIPER AMERICA TABLE 1-2.4 2002 NEW• VIPER METAL - VIPER GOLD DRAWING 1-2.5 2002 NEW• VIPER METAL TABLE 1-2.6 2002 NEW• VIPER METAL - VIPER GOLD DRAWING 1-2.7 2002 NEW• VIPER GOLD TABLE 1-2.8 2002 NEW• DISASSEMBLY 1-3 1999• CLEANING / INSPECTION 1-5 1999• REASSEMBLY 1-6 1999• ADJUSTMENTS 1-10 1999• ADJUSTING THE DEMAND LEVER 1-11 1999• FINAL CHECKS AND ADJUSTMENTS 1-11 1999• VIPER TEC - VIPER - OCTOPUS VIPER

SECOND STAGE TROUBLESHOOTING 1-14 2002 NEW

CLASSIC SECOND STAGE• CLASSIC DRAWING 1-1 2002 NEW• CLASSIC TABLE 1-1.1 2002 NEW• DISASSEMBLY 1-2 2002 NEW• CLEANING 1-4 2002 NEW• INSPECTION 1-4 2002 NEW• REASSEMBLY 1-5 2002 NEW• PROCEDURE FOR ADJUSTING THE

DEMAND LEVER 1-7 2002 NEW• FINAL CHECKS AND ADJUSTMENTS 1-8 2002 NEW• CLASSIC 2°STAGE TROUBLESHOOTING 1-10 2002 NEW

CLASSIC PRO SECOND STAGE• CLASSIC PRO DRAWING 1-1 2002 NEW• CLASSIC PRO TABLE 1-1.1 2002 NEW• DISASSEMBLY 1-2 2002 NEW• CLEANING 1-2 2002 NEW• INSPECTION 1-3 2002 NEW• REASSEMBLY 1-3 2002 NEW• ADJUSTMENTS AND FINAL ASSEMBLY 1-6 2002 NEW• FINAL CHECKS AND ADJUSTMENTS 1-7 2002 NEW• CLASSIC PRO SECOND STAGE

TROUBLESHOOTING 1-9 2002 NEW

EAGLE DPD - EAGLE - EAGLE OCTOPUS SECOND STAGE• EAGLE DPD DRAWING 1-1 2002 NEW• EAGLE DPD TABLE 1-1.1 2002 NEW• EAGLE DRAWING 1-1.2 2002 NEW• EAGLE TABLE 1-1.3 2002 NEW• DISASSEMBLY 1-2 2002 NEW• CLEANING 1-4 2002 NEW• INSPECTION 1-5 2002 NEW

• REASSEMBLY 1-5 2002 NEW• ASSEMBLING THE DEMAND LEVER /

METHOD "A" 1-6 2002 NEWMETHOD "B" 1-9 2002 NEW

• FINAL ASSEMBLY 1-10 2002 NEW• FINAL ADJUSTMENTS 1-11 2002 NEW• FINAL CHECKS AND ADJUSTMENTS 1-14 2002 NEW• EAGLE / EAGLE DPD SECOND STAGES

TROUBLESHOOTING 1-16 2002 NEW

3. JACKETS INFLATORBTD 2 PULSE INFLATOR• PULSE INFLATOR SCHEMATIC

AND PARTS LIST 1-1 2001• DACOR TECHNICAL BULLETIN


PULSE INFLATOR• PULSE INFLATOR SCHEMATIC

AND PARTS LIST 1-1 1999• PULSE INFLATOR TABLE 1-1.1 2002 NEW• DISASSEMBLY OF THE INFLATOR 1-2 1999• DISASSEMBLY OF THE INFLATOR BODY 1-2 1999• DISASSEMBLY OF EXHAUST BUTTON 1-3 1999• DISASSEMBLY OF THE R.E. VALVE 1-4 1999• CLEANING / INSPECTION 1-4 1999• REASSEMBLY 1-5 1999• ASSEMBLY OF THE EXHAUST BUTTON 1-5 1999• ASSEMBLY OF THE INFLATION BUTTON 1-7 1999• ASSEMBLY OF THE R.E. VALVE 1-7 1999• ASSEMBLY OF CORRUGATED HOSE 1-7 1999• ASSEMBLY OF CORRUGATED HOSE

ON THE BC VEST 1-7 1999• FINALS CHECKS 1-8 1999• PULSE INFLATOR TROUBLESHOOTING 1-9 1999

4. INTEGRATED SYSTEM H.U.B.• DACOR H.U.B. SCHEMATIC AND PARTS LIST 1-1 2001• DACOR H.U.B. TABLE 1-1.1 2002 NEW• EVOLUTION H.U.B. DRAWING 1-1.2 2002 NEW• EVOLUTION H.U.B. TABLE 1-1.3 2002 NEW• PNEUMATIC DUMP VALVE H.U.B.

SCHEMATIC AND PARTS LIST 1-2 2001• PNEUMATIC EXHAUST VALVE H.U.B. DRAWING 1-2.1 2002• PNEUMATIC EXHAUST VALVE H.U.B. TABLE 1-2.2 2002 NEW• PNEUMATIC CONTROL H.U.B. SCHEMATIC

AND PARTS LIST 1-3 2001• PNEUMATIC INFLATOR ASSEMBLY

A.T. DACOR TABLE 1-3.1 2002 NEWDISASSEMBLIES• DISASSEMBLY OF THE 1ST STAGE

FROM INTEGRATED SYSTEM 1-4 2001• DISASSEMBLY OF H.U.B. BAG 1-4 2001• DISASSEMBLY OF 4-WAY MANIFOLD 1-4 2001• DISASSEMBLY OF BACKPACK 1-4 2001• DISASSEMBLY OF 7-WAY MANIFOLD 1-5 2001• DISASSEMBLY OF TANK SUPPORT PLATE 1-5 2001• DISASSEMBLY OF MECHANICAL

OVERPRESSURE VALVES 1-6 2001• DISASSEMBLY OF INFLATING ORAL PIPE 1-6 2001• DISASSEMBLY OF H.U.B. PNEUMATIC SYSTEM 1-7 2001• DISASSEMBLY OF PNEUMATIC CONTROL 1-7 2001


INDEX

LASTREVISION NOTES

• DISASSEMBLY OF PNEUMATIC DUMP VALVES EXTERNAL BEZEL 1-8 2001

• DISASSEMBLY OF PNEUMATIC SYSTEM INTERNAL SUPPORTS FROM BAG 1-8 2001

• DISASSEMBLY OF BOTTOM PNEUMATIC DUMP VALVE INTERNAL SUPPORT 1-9 2001

• DISASSEMBLY OF TOP PNEUMATIC DUMP VALVE INTERNAL SUPPORT 1-9 2001

CLEANING 1-10 2001INSPECTION 1-10 2001• PNEUMATIC CONTROL 1-10 2001• PNEUMATIC VALVES 1-11 2001• 7-WAY MANIFOLD/HOSES 1-12 2001• 4-WAY MANIFOLD 1-12 2001• ORAL PIPE 1-13 2001• OVERPRESSURE VALVE 1-13 2001REASSEMBLY 1-14 2001• PNEUMATIC SYSTEM REASSEMBLY 1-14 2001• REASSEMBLY OF INTERNAL SHEATHING OF

INTEGRATED SYSTEM 1-14 2001• REASSEMBLY OF INTERNAL SUPPORT OF

PNEUMATIC CONTROL 1-14 2001• REASSEMBLY OF INTERNAL SUPPORT OF

TOP PNEUMATIC DUMP VALVE 1-15 2001• REASSEMBLY OF INTERNAL SUPPORT OF

BOTTOM PNEUMATIC DUMP VALVE 1-15 2001• REASSEMBLY OF PNEUMATIC DUMP VALVES

EXTERNAL BEZEL 1-16 2001• REASSEMBLY OF PNEUMATIC CONTROL BODY 1-17 2001• REASSEMBLY OF PNEUMATIC CONTROL 1-18 2001• REASSEMBLY OF BAG 1-19 2001• REASSEMBLY OF INFLATION PIPE 1-19 2001• REASSEMBLY OF MECHANIC

OVERPRESSURE VALVES 1-19 2001• REASSEMBLY OF TANK PLATE SUPPORT 1-20 2001• REASSEMBLY OF 7-WAY MANIFOLD SYSTEM1-21 2001• REASSEMBLY OF TANK PLATE SUPPORT

+ 7-WAY MANIFOLD ON INTEGRATED SYSTEM 1-22 2001• REASSEMBLY OF BACK PACK 1-23 2001• REASSEMBLY 4-WAY MANIFOLD AND

SECONDS STAGES 1-24 2001• REASSEMBLY OF 1ST STAGE 1-25 2001TESTS 1-26 2001• TEST OF PNEUMATIC SYSTEM 1-26 2001• A) PNEUMATIC CONTROL BODY 1-26 2001• B) PNEUMATIC DUMP VALVES 1-26 2001• TEST OF BAG 1-26 2001• C) MECHANICAL OVERPRESSURE VALVES 1-26 2001• D) BAG 1-27 2001• TEST OF INTEGRATED SYSTEM ASSEMBLY 1-27 2001• TEST OF DISTRIBUTORS / HOSES 1-28 2001• F) DISASSEMBLY 1-28 2001• G) REASSEMBLY 1-28 2001

O-RING REFERENCE CHART

REPAIR PROCEDUREPAGE

1-3

INTRODUCTION

O-Ring reference chart 06/02

Geared for the Environment ® DACOR REPAIR MANUAL - VOLUME THREE

FIRST STAGES

O-RING TYPE - REFERENCE

2012 - 46110101

106 - 46110106

108 - 46110108

115 - 46110117

2068 - 46110225

2100 - 46110224


2018 - 46110203

2031 - 46110107

2037 - 46110110

2043 - 46110215

2050 - 46110211

3118 - 46110176



1-4

INTRODUCTION


DACOR REPAIR MANUAL - VOLUME THREE Geared for the Environment ®

SECOND STAGES

INFLATORS


2012 - 46110101

106 - 46110106

2043 - 46110215

2062 - 46110220

2125 - 46110175


2025 - 46110205

2037 - 46110110

2050 - 46110211

3043 - 46200218

2068 - 46110225


106 - 46110106

2-109 - 46110241

3043 - 46200218


2031 - 46110107

2056 - 46110210



1-5

INTRODUCTION



H.U.B. - HOSES / MANIFOLDS

H.U.B. ORAL INFLATOR

DEPTH GAUGE


2-003 - 46110242

2025 - 46110205

2031 - 46110107

2043 - 46110215


106 - 46110106

108 - 46110108

114 - 46110114


3100 - 47110271


2056 - 46110210


108 - 46110108


2-003 - 46110242



1-6

INTRODUCTION



H.U.B. AIR TRIM - PNEUMATICAL INFLATOR

H.U.B. AIR TRIM - PNEUMATICAL DUMP VALVES


3X1 - 46110265

2015 - 46110102

106 - 46110106

3231 - 46110265


2007 - 46110213

2050 - 46110211

3156 - 47110270


3231 - 46110265


3X1 - 47110272

2015 - 46110102

2037 - 16110110

D 16 FIRST STAGEPAGE

1-1.1REPAIR PROCEDURE

First StageRegulators

06/02

.oN.feR edoC noitpircseD .oN.feR edoC noitpircseD

1 A ydobegatsTS1 17 11201164 0502RO

2 51058164 31.D.tnIgnirpanS 17 31401164 7079-410notiV0502RO

3 30078164 ekoY 47 70101164 1302RO

4 D rebmahc.P.H 47 30401164 7079-110notiV1302RO

5 83058164 gnirpukcaB 57 61268164 rotcennoctaeS

6 10101164 2102RO 67 01268164 gnirpsrebmahc.P.H

6 10401164 7079-600notiV2102RO 97 F gnihsubrecapsrotcennocNID

7 14268164 tunreniaterekoY 08 60268164 daehgard-itnA

8 11058164 gnirpsteppoP 18 80268164 gulptroP

9 20058164 teppopegatSts1 701 31078164 rekcitsbonkekoY

21 41268164 nipteppoP 011 21078164 pactsuD

31 23058164 nottubteppoP 351 67101164 8113RO

41 22058164 mgarhpaiD 451 61078164 rotcennocydobekoyrocaD

51 43058164 etalpesabgnirpS 551 51078164 gulpdellirdegatSts1

61 32058164 gnirpsmgarhpaiD

71 01548164 tungniniateR SEILBMESSA

81 11548164 tunretsujdagnirpS

91 60101164 601RO A 53278164 61DylbmessaegatSts1

91 20401164 7079-016notiV601RO A >93278164< NID61DylbmessaegatSts1

02 40258164 gulptroPFNU"8/3 D 95268164 notiV)6-5-4(ylbmessarebmahc.P.H

22 20268164 retlifderetnisderepaT D 01258164 )6-5-4(ylbmessarebmahc.P.H

32 71101164 511RO F 909634 notiVRAB003NIDylbmessArotcennoC

32 60401164 7079-416notiV511RO )97-17-86-26-65-94-84-32(

42 11078164 pactsuD F 509634 notiVRAB002NIDylbmessArotcennoC

52 70078164 bonkekoYrocaD )97-17-86-26-65-94-84-32(

84 F ydobrotcennocNIDRAB003 I 309634 TIK.R.E.A61D

94 F RAB003)NID(tungnirgnikcolB *** 42278164 TNI61DtikecivresegatSts1

84 F ydobrotcennocNIDRAB002 )47-17-25-32-22-91-6-5-2(

94 F RAB002)NID(tungnirgnikcolB *** 52278164 NID61DtikecivresegatSts1

25 80101164 801RO )47-17-86-65-25-32-91-6-5(

25 40401164 7079-800notiV801RO *** 62278164 notiV61Degatsts1tikecivreS

35 50258164 gulpgnisolcFNU"61/7.P.H )47-17-25-32-22-91-6-5-2(

65 35038164 9.DretlifrotcennocNID *** 72278164 notiVNID61Degatsts1tikecivreS

75 I ydob.R.E.A )47-17-86-65-25-32-91-6-5(

85 10358164 mgarhpaid.R:E.A

95 I gnirgnikcol..R.E.A SETON

16 31058164 gnirpsretliF)47(ROeht)52278164dna42278164.doc(tiKehtnI

notiVnioslasitaesteppopehtfo26 31038164 pactsudrotcennocNID

86 25038164 9.DrotcennocNIDrofgnirpslanogatneP

TableNo. 1

Drawing reference No.: 1Table updated on: 30/10/2001D 16 FIRST STAGE


D 12 FIRST STAGEPAGE



06/02


1 A ydobegatsts1 25 80101164 801RO

2 51058164 31.D.TNIgnirpanS 25 40401164 7079-116notiV801RO

3 30078164 ekoY 35 50258164 gulptropPH"61/7

4 D rebmahc.P.H 75 I ydob.R.E.A

5 83058164 gnirpukcaB 85 10358164 mgarhpaid.R:E.A

6 10101164 2102RO 95 I tungniR

6 10401164 7079-600notiV2102RO 26 31038164 pactsudrotcennocNID

7 21258164 tunreniaterekoY 47 70101164 1302RO

8 11058164 gnirpsevlav21RM 47 30401164 7079-110notiV1302RO

9 20058164 teppopegatsts121RM 57 61268164 taesteppopegatsts1

21 30368164 nipteppop21V 701 31078164 rekcitsbonK

31 23058164 nottubteppoP 011 21078164 pactsuD

41 22058164 mgarhpaiD

51 43058164 etalpesabgnirpS SEILBMESSA

61 32058164 gnirpsmgarhpaiD

71 01548164 tungniniateR A 63278164 21DylbmessaegatSts1

81 11548164 tunretsujdagnirpS A >04278164< RAB003NID21DylbmessaegatSts1

91 60101164 601RO D 01258164 )6-5-4(ylbmessarebmahc.P.H

91 20401164 7079-016notiV601RO D 95268164 notiV)6-5-4(ylbmessarebmahc.P.H

02 40258164 gulptroPFNU"8/3 F 809634 2D/21D/02DnotiVRAB003ylbmessarotcennocNID

22 41058164 retlifderetniS )26-15-05-94-84-32(

32 71101164 511RO F 409634 2D/21D/02DnotiVRAB002ylbmessarotcennocNID

32 60401164 7079-416notiV511RO )26-15-05-94-84-32(

42 11078164 pactsuD I 309634 21Dtik.R.E.A

52 70078164 tunekoy21RM *** 02278164 NID/TNI21Dtikecivresegatsts1

84 F RAB003)NID(ydobrotcennoC )47-25-05-32-22-91-6-5-2(

94 F gnirgnikcoldedaerhtRAB003NID *** 12278164 notiVNID/TNI21DtikecivreS

84 F RAB002)NID(ydobrotcennoC )47-25-05-32-22-91-6-5-2(

94 F gnirgnikcoldedaerhtRAB002NID

05 30201164 8102RO SEIROSSECCA

05 90401164 7079-800notiV8102RO

15 F RAB003)NID(gnilpuocrotcennoC ---- 75297164 rotcennocekoyNID/TNI.LPC

15 F RAB002)NID(gnilpuocrotcennoC ---- 06297164 daerhtNIDlanretxegulptroP

TableNo. 2

Drawing reference No: E 2Table updated on: 30/10/2001D 12 FIRST STAGE


D 2 FIRST STAGEPAGE



06/02


1 A ydobegatsts1 16 31058164 gnirpsretliF

2 51058164 31.DgnirpanS 26 31038164 pactsudrotcennocNID

3 30078164 ekoY 28 12268164 rehsawgnirpS

7 21258164 tunreniaterekoY 48 82268164 ydobnotsiP

8 02268164 gnirpsnotsiP 58 75078164 detsalb-dnas2Dpactsudegatsts1

91 60101164 601RO 68 42201164 0012RO

91 20401164 7079-016notiV601RO 68 91401164 7079-220notiV0012RO

02 40258164 gulptroPFNU"8/3 88 32268164 taesnotsiP

22 41058164 retlifderetniS 98 45348164 2DlebalegatsTS1

32 71101164 511RO 701 31078164 rekcitsbonkegatsts1

32 60401164 7079-416notiV511RO 851 01078164 pactsuD

42 11078164 pactsuD

52 70078164 bonkekoY SEILBMESSA

84 F RAB003)NID(ydobrotcennoC

94 F gnirgnikcoldedaerhtRAB003NID A 03100264 2DylbmessaegatSts1

84 F RAB002)NID(ydobrotcennoC F 809634 2D/21D/02DnotiVRAB003ylbmessarotcennocNID

94 F gnirgnikcoldedaerhtRAB002NID )26-15-05-94-84-32(

05 30201164 8102RO F 409634 2D/21D/02DnotiVRAB002ylbmessarotcennocNID

05 90401164 7079-800notiV8102RO )26-15-05-94-84-32(

15 F RAB003)NID(gnilpuocrotcennoC *** 33100264 tikecivresegatsts1NID/TNI

15 F RAB002)NID(gnilpuocrotcennoC )88-68-25-05-32-22-91-2(

25 80101164 801RO *** 43100264 tikecivresegatsts1notiVNID/TNI

25 40401164 7079-116notiV801RO )88-68-25-05-32-22-91-2(

35 50258164 gulptropFNU"61/7.P.H

TableNo. 3

Drawing reference No.: E 3Table updated on: 30/10/2001D 2 FIRST STAGE



SECTION 1

FIRST STAGE REGULATOR

D 20FIRST STAGE


1-1

D 20 FIRST STAGE


06/02


DrawingNo. E 4

Drawing updatedon: 30/10/2001D 20 - D20 GOLD FIRST STAGE


1-1.1

D 20 FIRST STAGE


06/02


TableNo. 5

Drawing reference No.: E 4Table updated on: 30/10/2001D 20 METAL FIRST STAGE


1 A ydobegatsts102D 26 31038164 )NID(pactsuD

2 51058164 31.D.TNIgnirpanS 07 12200264 pacnoitcetorpegatsts102D

3 07268164 ekoY 27 51201164 3402RO

4 D rebmahc.P.H 27 51401164 7079-310notiV3402RO

5 83058164 gnirpukcaB 47 70101164 1302RO

6 10101164 2102RO 47 30401164 7079-110notiV1302RO

6 10401164 7079-600notiV2102RO 57 61268164 taesteppopegatsts1



9 20058164 teppopegatsts121RM 701 31078164 rekcitsbonK

21 30368164 nipteppop21V 841 51348164 rekcits"rab002-052-NE"

31 23058164 nottubteppoP 351 92201164 8113RO

41 22058164 mgarhpaiD 861 98100264 gnilpuocleviws02D

51 43058164 etalpesabgnirpS 961 29100264 nipgnikcolleviws02D

61 32058164 gnirpsmgarhpaiD 071 93200264 elddasgnilpuocleviwS

71 01548164 tungniniateR 171 01101164 7302RO

81 11548164 tungnitsujdagnirpS 171 89200264 notiV7302RO

91 60101164 601RO

91 20401164 7079-016notiV601RO SEILBMESSA

02 40258164 gulptropFNU"8/3

22 41058164 retlifderetniS A 58200264 egatsts102D.LPC

32 71101164 511RO A >48200264< RAB003NIDegatsts102D.LPC

32 60401164 7079-416notiV511RO D 01258164 )6-5-4(ylbmessarebmahc.P.H

42 11078164 pactsuD D 95268164 notiV)6-5-4(ylbmessarebmahc.P.H

52 70078164 tunekoy21RM F 809634 2D/21D/02DnotiVRAB003ylbmessarotcennocNID

84 F RAB003)NID(ydobrotcennoC )26-15-05-94-84-32(

94 F RAB003)NID(gnirgnikcoldedaerhT F 409634 2D/21D/02DnotiVRAB002ylbmessarotcennocNID

84 F RAB002)NID(ydobrotcennoC )26-15-05-94-84-32(

94 F RAB002)NID(gnirgnikcoldedaerhT I 709634 tik.R:E.A02D

05 30201164 8102RO *** 18200264 NID/TNIdloG02D/02Dtikecivresegatsts1

05 90401164 7079-800notiV8102RO )171-351-38-47-27-25-05-32-22-91-6-5-2(

15 F RAB003)NID(gnilpuocrotcennoC *** 08200264 notiVNID/TNIdloG02D/02DtikecivreS

15 F RAB002)NID(gnilpuocrotcennoC )171-351-38-47-27-25-05-32-22-91-6-5-2(

25 80101164 801RO

25 40401164 7079-116notiV801RO SEIROSSECCA

35 50258164 gulptrop"61/7PH

75 I ydob.R.E.A ---- 75297164 rotcennocekoyNID/TNI.LPC

85 10358164 mgarhpaid.R.E.A ---- 06297164 daerhtNIDlanretxegulptroP

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1-1.2

D 20 FIRST STAGE


06/02



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TableNo. 6

Drawing reference No.: E 4Table updated on: 30/10/2001D 20 GOLD FIRST STAGE

D 20 FIRST STAGE

DISASSEMBLY

1. Using a 14 mm open-end wrench (B-18) unscrew the hose from the 1st Stage.2. Using a 6 mm hex wrench (B-8), unscrew the D20 swivel locking pin (169), to release the D20 swivel coupling (168)

and the D20 rotation stop coupling (170).3. Pull out the locking pin (169) from the swivel coupling (168).4. Remove O-Ring (83) from the D20 rotation stop coupling (170), remove O-Rings (83) from the D20 swivel coupling

(168), and remove O-Ring (171) and O-Rings (72) from the D20 swivel locking pin (169).5. Screw the first stage disassembly tool (B-5) into a low pressure port (3/8").6. Using a small flat head screwdriver, remove the protection cap (70).7. Using the special tool (B-1) back off the yoke retainer nut (7), thereby releasing the yoke (3) and the yoke knob (25).

(Fig. 1)

FIG. 1


1-2

D 20 FIRST STAGE


06/02


DIN VERSION

DISASSEMBLY:(instead of step 7)A. Using the 6-mm hex wrench (B-8), unscrew the DIN connector coupling (51) and remove O-Rings (23) and (50) from it.B. Remove the threaded locking ring (49).C. Using the 28-mm open end wrench (B-16), unscrew the DIN connector body (48) and remove O-Ring(23).8. Remove the O-Ring(153) from the 1st Stage body.9. Using the snap ring pliers (B-14), remove the following from the 1st stage body (1): the snap ring (2), the sintered

filter (22), the HP chamber assembly (4+5+6), the spring (8), the poppet (9) and the poppet pin (12). (Fig. 2).

FIG. 2

10.Remove the O-Ring(6) from the HP chamber.

11.Position the special tool (B-21) on the 1st Stage poppet seat (75) and exert a slight pressure on it. Supply withcompressed air (110 p.s.i. - less than 7 BAR) through a low pressure port. (Fig. 3)

WARNING ��DO NOT ATTEMPT TO REMOVE THE POPPET SEAT USING SHARP OR POINTED TOOLS; SCRATCHES ON THE SURFACE OF THE SEATMAY RESULT IN MALFUNCTION.

WARNING ��WHEN THE COMPRESSED AIR CAUSES THE POPPET SEAT TO MOVE, REDUCE THE PRESSURE EXERTED ON THE SPECIAL TOOL (B-21).

WARNING ��REMOVE THE BACKUP RING (5) FROM THE HP CHAMBER (4) ONLY IF IT NEEDS TO BE REPLACED.


1-3

D 20 FIRST STAGE


06/02


FIG. 3

12.Remove the poppet seat (75) from the 1st Stage body and remove the O-Ring(74).13.Using the 10-mm hex wrench (B-13) back off the adjusting nut (18) and remove the spring (16). (Fig. 4)

FIG. 4


1-4

D 20 FIRST STAGE


06/02


14.Back off the retaining nut (17) using the 28-mm open end wrench (B-2) and remove the spring base plate (15). (Fig. 5).

FIG. 5

15.Supply compressed air (110 p.s.i. - less than 7 bar) through a low pressure port (3/8") and remove the diaphragm(14) and the poppet button (13).

WARNING ��DO NOT ATTEMPT TO REMOVE THE DIAPHRAGM USING SHARP OR POINTED TOOLS; SCRATCHES ON THE SURFACE OF THEDIAPHRAGM OR IN THE FIRST STAGE BODY SEAT MAY RESULT IN AIR LEAKS.

WARNING ��TO FACILITATE REMOVING THE DIAPHRAGM, IT IS RECOMMENDED TO CLOSE OFF (FOR EXAMPLE USING A FINGER) THE INLET TOTHE HIGH PRESSURE CHAMBER (FIG. 6)


1-5

D 20 FIRST STAGE


06/02


FIG. 6

16.Unscrew the high (53) and low (20) pressure port plugs from the 1st stage body, removing their respective O-Rings(52) and (19).

17.Unscrew the disassembly tool (B-5) from the 1st stage body.

CLEANING

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 to clean the rubber components. Chrome platedbrass and stainless steel parts can be cleaned with an ultrasonic cleaner in fresh water or, if the necessary equipmentis not available, in a mild acid solution (for example white vinegar, diluted with hot water as necessary). Make sure thatall components have been rinsed and dried before proceeding with reassembly.

WARNING ��ACIDS OR OTHER SOLVENTS MAY DAMAGE PLASTIC AND RUBBER PARTS. BEFORE CLEANING THE PLASTIC PARTS BE SURE TOREMOVE ANY SEALS OR OTHER MATERIALS SUBJECT TO DETERIORATION.

WARNING ��WHEN WORKING WITH ANY KIND OF ACID, WEAR ADEQUATE PROTECTIVE GEAR FOR EYES AND SKIN.


1-6

D 20 FIRST STAGE


06/02


INSPECTION

Certain key components of the first stage should be regularly replaced at each scheduled overhaul. In addition,considering their low cost, it is recommended to replace all the O-Rings.The components that it is recommended to replace are the following:

If these components are not replaced, they should at least be inspected with a jeweler's magnifying glass for thefollowing defects.

DO NOT USE PARTS WITH THE FOLLOWING DEFECTS:

Snap rings (2) Check for distortion, cracking or damaged edges. It is recommended to replacethese components at each overhaul

Sintered filter (22) Check for the presence of sedimentation or rust: rust deposits may indicatecorrosion of the air tanks. Inspect for any cracks

1st Stage poppet (9) Check for cuts, burrs or abrasion of the rubber and separation of the rubber fromthe poppet body. Make sure that the hole through the poppet stem is notobstructed by foreign bodies

HP chamber (4) Inspect the interior for any foreign matter or particlesBackup ring (5) Make sure that it is correctly positioned inside the HP chamber, and inspect its

surface for deformations or foreign particlesO-Rings Check for cuts, deformation or foreign particles. The presence of any of these

defects may result in leakage1st Stage Diaphragm (14) Check for splitting, cuts, tears or major surface deformations1st Stage Body (1) Check for chips and/or scratches on the diaphragm sealing surfaces, the port

plug seats and the poppet seat housingPoppet seat (75) Check for chipping, scratches and/or foreign particles on the sealing surface

and in the O-Ring seat

O-Ring seats Inspect all metal surfaces in contact with the O-Rings or other seals, and checkfor scratches, chipping, deteriorated plating or foreign particles

Springs Check for any split, deformed or broken coilsThreaded components Check that all threads are clean and undamaged

WARNING ��FOR THOROUGH CLEANING OF THE FIRST STAGE POPPET SEAT IT IS POSSIBLE TO USE A SLIGHTLY ABRASIVE ERASER.

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gniR-OgnittifNID )32( 2 71101164.doc 60401164notiV.doc


1-7

D 20 FIRST STAGE


06/02


REASSEMBLY

Before reassembling, lightly lubricate all the O-Rings with silicone grease (type General Electric Versalube G 322 orequivalent). Lubrication reduces the likelihood of damage during reassembly.

1. Screw the disassembly tool (B-5) into a low pressure port (3/8").2. Reassemble the O-Ring(74) on the poppet seat (75).3. Correctly position the poppet seat on the special tool (B-21).4. Exerting a slight pressure, push the poppet seat into position in the first stage body. (Fig. 7).

FIG. 7

5. Correctly position the first stage poppet (9) on the poppet seat.6. Place the spring (8) on top of the poppet.7. Fit the backup ring (5) (if it was disassembled) and the O-Ring(6) in the HP chamber (4).8. Position the HP chamber assembly (4-5-6) on top of the spring.9. Position the sintered filter (22) on the Hp chamber.

10.Using a pair of snap ring pliers (B-14), tighten the snap ring (2) and position it above the filter; use a finger tosimultaneously press on the snap ring and filter to perfectly position the snap ring inside the groove of the first stagebody.

NOTE ROTATE THE SNAP RING TO CHECK ITS CORRECT POSITIONING

WARNING ��IF THE FIRST STAGE IS USED FOR DIVING WITH OXYGEN-RICH MIXTURES, IT MUST BE PERFECTLY CLEANED AND FREE OF ANYRESIDUAL SILICONE OR OTHER IMPURITIES. VITON O-RINGS MUST BE LUBRICATED WITH SPECIAL OXYGEN-COMPATIBLE GREASE.DO NOT USE SILICONE GREASE!


1-8

D 20 FIRST STAGE


06/02


11.Position the O-Ring(153) in its seat in the 1st Stage body.12.Position the yoke (3) with the knob (25) on the 1st Stage body (1).13.Using the special tool (B-1) lock down the yoke retainer nut (7).

DIN VERSION

REASSEMBLY:(instead of steps 11 and 12)

D. Position the O-Ring(23) in the seat on the DIN connector body (48).E. Screw the DIN connector body (48) onto the first stage body, locking down fully with the tool (B-16).F. Correctly position the threaded locking ring (49) on the first stage.G. Fit the O-Rings (23) and (50) on the DIN connector coupling (51).H. Using the 6-mm hex wrench (B-8) lock down the DIN connector coupling onto the first stage body.

14. Insert the poppet pin (12) in the center hole of the first stage body.15.Place the poppet button (13) on the pin.

NOTEPRESS THE POPPET BUTTON A FEW TIMES TO CHECK ITS MOVEMENT AND THE CORRECT POSITIONING OF THE POPPET ON THE FIRST STAGE

16. Install the first stage diaphragm (14), positioning it correctly in its seat.17.Position the spring base plate (15) on the diaphragm.18.Lightly lubricate the sealing edge of the retaining nut (17) and screw it into the first stage body, locking it down fully

with the wrench (B-2).

NOTEIF A TORQUE WRENCH IS USED, USE A TORQUE SETTING OF APPROXIMATELY 3 - 3.5 kg/m (APPROX. 30 - 35 N/m).

19.After having lightly lubricated the ends of the spring (16), center it on the base plate.20.Using the 10-mm hex wrench (B-13), lock down the adjusting nut (18) through 2-3 turns into the retaining nut.21.Fit the protection cap (110).22.Unscrew the disassembly tool (B-5).23.Fit O-Ring (83) on the rotation stop coupling (170), O-Rings (83) on the swivel coupling (168), and O-Ring (171) and

O-Rings (72) on the locking pin (169).24.Position the rotation stop coupling (170) on the first stage body.25.Position the swivel coupling (168) on the rotation stop coupling (170).26. Insert the locking pin (169) in the swivel coupling (168) and lock it down fully against the body using a 6-mm hex

wrench.27.Place the respective O-Rings (52) and (19) on the high (53) and low (20) pressure port plugs.28.Screw the high and low pressure port plugs (53) and (20) into the ports on the first stage body.29.Using the 14-mm open end wrench (B-18) screw the hose into the swivel coupling (168).

WARNING ��TO PREVENT THE DIN CONNECTOR BODY (48) AND THE DIN CONNECTOR COUPLING (48) FROM ACCIDENTALLY WORKING LOOSE,APPLY ONE OR TWO DROPS OF THREAD COMPOUND (TYPE LOCTITE 242 E) ON THE BASE OF THEIR THREADS. DO NOT APPLY THETHREAD COMPOUND (LOCTITE 242 E) ON THE O-RINGS.

IMPORTANT ��TO PREVENT THE YOKE RETAINER NUT FROM ACCIDENTALLY WORKING LOOSE DURING USE, APPLY A FEW DROPS OF THREADCOMPOUND (TYPE LOCTITE 242 E) ON THE THREAD ITSELF.


1-9

D 20 FIRST STAGE


06/02


ADJUSTING THE INTERMEDIATE PRESSURE

To obtain a correct adjustment of the intermediate pressure:A. The system used must have both a high and low pressure air supply.B. It is necessary to have a pressure gauge for checking the intermediate pressure (the pressure gauge should have a

full scale value MAX 30 - 40 BAR).

(Tab. A)

(Tab. B)

PROCEDURE FOR ADJUSTING THE INTERMEDIATE PRESSURE

1. Screw the intermediate pressure measuring gauge (cod. 46106252) into one of the 3/8" low pressure ports, usingthe special tool (B-18).

2. Using the wrench (B-18), apply the hose with the partially assembled second stage to the port D.F.C. (swivel).3. Mount the regulator group on a tank.4. Holding down the second stage demand lever, slowly open the tank valve and, almost simultaneously, release the

demand lever.5. Read the value of the first stage adjustment on the pressure gauge, and proceed as follows (Fig. 6):

a) If the first stage adjustment is higher than the required value (see table), use the wrench (B-13) to slowly backoff the adjusting nut (18) until the specified value is obtained.

NOTEWHENEVER THE INTERMEDIATE PRESSURE IS REDUCED, IT IS NECESSARY TO VENT THE EXCESS AIR IN ORDER

TO OBTAIN A CORRECT READOUT OF THE NEW VALUE.

b) If the first stage adjustment is lower than the required value (see table), slowly lock down the adjusting nut untilthe specified value is obtained.

6. Operate the second stage demand lever a few times, and check that the first stage adjustment remains constant.7. After completing the second stage adjustments, remove the pressure gauge and screw on the corresponding port

plug.

WARNING ��DO NOT SUBMERGE THE INTERMEDIATE PRESSURE MEASURING GAUGE.

TIK.R.E.AHTIWERUSSERPETAIDEMRETNIEGATSTSRIFFOELBAT

LEDOM .I.S.PERUSSERP RABERUSSERP

02D 631-031 4.9-0.9

SERUSSERPETAIDEMRETNIEGATSTSRIFFOELBAT

LEDOM .I.S.PERUSSERP RABERUSSERP

02D 251-241 2.01-8.9


1-10

D 20 FIRST STAGE


06/02


A.E.R.COLD WATER DIVING KIT FOR

DACOR DIAPHRAGM REGULATORSALL ENVIRONMENT REGULATOR (A.E.R.)

COLD WATER DIVING

According to the CEN EN 250: 2000 standard, water is considered to be cold at a temperature below 10°C.

When diving in cold water conditions, parts of the regulator may be subject to "icing" phenomena. The factors affectingthe likelihood of ice forming inside and on the regulator are: the external ambient temperature, the water temperature,the temperature of the air in the tanks (and hence the exposure time of the tanks to the cold before the dive). whetherthe dive is in fresh or seawater, the moisture content of the air in the tanks, the quantity of air delivered by the regulatorduring the dive and the breathing frequency.

In particular, for cold water conditions observe the following precautions:1. Take a course to learn cold water diving techniques.2. Refill the air tanks only at filling stations equipped with an efficient filtering and moisture removal system.3. When preparing for a cold water dive, keep the tanks and regulator in a place that is sheltered from the cold until just

before starting the dive.4. Open the tank control valve for one or two seconds to make sure there are no water droplets or small ice crystals.

Also check the inlet opening of the regulator.5. In the event of repetitive dives, take particular care to ensure that the regulator is perfectly dry before starting the

second dive.6. Avoid breathing from the regulator outside the water.7. As much as possible, try to prevent water from entering inside the second stage during the dive.8. Never operate the purge button when not underwater.9. Use the purge button as little as possible. In any case, never hold it down for more than 2 or 3 seconds consecutively;

pressing it for longer may cause the formation of ice.10.Try to breathe normally, to minimize the cooling effect produced by the higher air velocity during overbreathing.

WARNING ��BECAUSE NO REGULATOR CAN BE COMPLETELY GUARANTEED AGAINST FREEZING OF THE SECOND STAGE UNDER ALL THEAFORESAID CONDITIONS, EVEN DACOR REGULATORS FITTED WITH THE AER KIT MAY BE SUBJECT TO "ICING" PHENOMENA WHICHCAN INTERFERER WITH THEIR CORRECT OPERATION. THIS MAY RESULT IN SERIOUS INJURY. THEREFORE, TO MINIMIZE THEPOTENTIAL HAZARDS, IT IS ESSENTIAL TO BE ADEQUATELY TRAINED IN THE PREVENTION AND HANDLING OF THE PROBLEMSWHICH MAY ARISE FROM A REGULATOR SUBJECT TO "ICING" PHENOMENA.

WARNING ��ATTEMPTING TO DIVE IN COLD WATER CONDITIONS (10°C OR BELOW) WITHOUT ADEQUATE TRAINING MAY RESULT IN SERIOUSINJURY. BEFORE DIVING IN COLD WATER, IT IS ADVISABLE TO TAKE A SPECIAL TRAINING COURSE UNDER THE SUPERVISION OF ACERTIFIED DIVING INSTRUCTOR.

WARNING ��THE INSTALLATION OF THE A.E.R. KIT MUST BE CARRIED OUT AT AN AUTHORIZED DACOR SERVICE CENTER BY A TECHNICIANTRAINED IN THE SERVICING OF REGULATORS, IN ACCORDANCE WITH THE INSTRUCTIONS PROVIDED HERE. DACORRECOMMENDS PERFORMING A COMPLETE OVERHAUL OF THE REGULATOR BEFORE INSTALLING THE A.E.R. KIT.


1-11

D 20 FIRST STAGE


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INSTRUCTION FOR INSTALLING THE A.E.R. KIT

To facilitate the disassembly operations, the technician is advised to disassemble the hoses connected to the First Stageports and replace them with the corresponding port plugs.1. Screw the first stage disassembly tool (B-5) into a low pressure port (3/8").2. After removing the protection cap (110), use the hex wrench (B-13) to unscrew the adjusting nut (18) and pull out

the spring (16).3. Unscrew the retaining nut (17) using wrench (B-2) and remove the spring base plate (15).

4. Position the spring base plate (15) on the diaphragm (14).5. Lightly lubricate the sealing rim of the A.E.R. body (57) and screw it onto the first stage body, locking it down firmly

with the wrench (B-16).

NOTEIF A TORQUE WRENCH IS USED, USE A TORQUE SETTING OF APPROXIMATELY 3 - 3.5 kg/m (APPROX. 30 - 35 N/m).

6. After having lightly lubricated the ends of the spring (16), center it on the base plate (15).7. Using the hex wrench (B-13), lock down the A.E.R. adjusting nut (18) through 2-3 turns into the A.E.R. body. (57).

NOTEDO NOT OVERTIGHTEN THE ADJUSTING NUT; THIS INCREASES THE INTERMEDIATE PRESSURE AND INTERFERES WITH THE SUBSEQUENT ADJUSTMENTS.

8. Unscrew the disassembly tool (B-5).9. Screw the intermediate pressure measuring gauge (cod. 106252) into one of the 3/8" low pressure ports, using the

special wrench (B-18).10.Using the wrench (B-18), screw the hose with the second stage into the swivel coupling (168).11.Remove the cover (39) from the second stage case (follow the instructions provided in the manual for the regulator

model in question).12.Mount the regulator group on the control valve (of a tank or Test Bench).13.Holding down the second stage demand lever, slowly open the tank valve and, almost simultaneously, release the

demand lever.14.Read the first stage adjustment on the pressure gauge, and proceed as follows:

a. If the adjustment is higher than the required value (see table in the "First Stage Adjustments" manual), slightlyback off the adjusting nut (16) using wrench (B-13) until the specified adjustment is obtained.

NOTEWHENEVER THE INTERMEDIATE PRESSURE IS REDUCED, IT IS NECESSARY TO VENT THE EXCESS AIR IN ORDER TO OBTAIN

A CORRECT READING OF THE NEW VALUE.

b. If the adjustment is lower than the required value (see table in the "First Stage Adjustments" manual), slowly lockdown the adjusting nut, until the specified adjustment is obtained.

15.Operate the second stage demand lever a few times, and check that the first stage adjustment remains constant16.After having completed the second stage adjustments, (follow the instructions provided in the manual of the regulator

in question), remove the pressure gauge and the second stage, replacing them with port plugs.17.Remove the first stage from the control valve.18.Close the first stage air inlet with the dust cap (24).19.Slightly tilt the first stage (5° - 10°).20.Slowly fill the A.E.R. body (57) up to about 3 mm from the upper edge, using the silicone oil provided in the kit.

WARNING ��DACOR RECOMMENDS CLEANING THE DISASSEMBLED COMPONENTS TO REMOVE ANY TRACES OF RUST OR FOREIGNPARTICLES, FOLLOWING THE INSTRUCTIONS PROVIDED IN THE SERVICE MANUALS.


1-12

D 20 FIRST STAGE


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21.Hold the first stage vertically and turn it 2/3 times to eliminate any bubbles trapped in the threads or in the coils ofthe spring.

22.Fit the A.E.R. diaphragm (58) inside the A.E.R. body. (57) orienting it correctly (with the edge facing upward) on theseat of the A.E.R. body (See Fig. 8).

NOTEWHEN THE DIAPHRAGM IS CORRECTLY FITTED IN THE A.E.R. BODY, IT SHOULD BE COMPLETELY IMMERSED THE SILICONE OIL.

FIG. 8

23.Press the center of the diaphragm (58) slightly to expel any air bubbles.

24.Correctly lock down the ring (59) against the body, using the special wrench provided in the kit.25.Empty the excess oil.

WARNING ��DO NOT USE SHARP OBJECTS TO PRESS ON THE DIAPHRAGM.TO CHECK THAT THE DIAPHRAGM DOES NOT ADHERE BY SUCTION TO THE SIDES OF THE A.E.R. KIT BODY, SLIGHTLY LIFT THEEDGE OF THE A.E.R. DIAPHRAGM, TAKING CARE NOT TO ALLOW ANY AIR TO ENTER.


1-13

D 20 FIRST STAGE


06/02


26.Rinse the first stage in fresh water.

27.Using the wrench (B-18), screw the hose with the second stage into the swivel coupling (168).28.Screw the intermediate pressure measuring gauge (cod. 106252) into one of the 3/8" low pressure ports, using the

special tool (B-18).29.Mount the regulator group on the control valve (of a tank or test bench).30.Check that the previously adjusted intermediate pressure has not changed.

31.Disassemble the group from the tank, replacing the LP pressure gauge (106252) and any port plugs with thecorresponding hoses removed previously.

WARNING ��A VARIATION OF 0.1 - 0.2 BAR IN THE INTERMEDIATE PRESSURE IS ACCEPTABLE.IF THE VARIATION IS GREATER, IT IS NECESSARY TO REPEAT THE A.E.R. KIT INSTALLATION PROCEDURE.TO OBTAIN A CORRECT READING OF THE INTERMEDIATE PRESSURE, DO NOT PRESS ON THE A.E.R. DIAPHRAGM.

WARNING ��DO NOT DIRECT STRONG JETS OF WATER (FOR EXAMPLE FROM A HOSE) ONTO THE A.E.R. DIAPHRAGM.


1-14

D 20 FIRST STAGE


06/02


D 20 FIRST STAGE TROUBLESHOOTING


1-15

D 20 FIRST STAGE


06/02


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1-16

D 20 FIRST STAGE


06/02



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02D

)1 erusserpetaidemretnIhgihoot

)1 erusserpetaidemretniehttsujdA

)2 degamadteppopegatStsriF )1 ecalpeR

)3 taesteppopevitcefeD )1 taesehtecalperronaelC

)2 gniR-OehtecalpeR

)4 rebmahcPHevitcefeD )1 gniR-OehtecalpeR

)2 gnirpukcabehtecalpeR

)3 taesPHehtecalperronaelC

FURY SECOND STAGE PAGE


Second StageRegulators

06/02


DrawingNo. E 22

Drawing updatedon: 15/02/2001FURY SECOND STAGE

FURY SECOND STAGEPAGE



06/02

DACOR REPAIR MANUAL - VOLUME THREEGeared for the Environment ®

TableNo. 107

Drawing reference No.: E 22Table updated on: 30/10/2001FURY SECOND STAGE


91 60101164 601RO 46 76268164 gulptropretsujdA

91 20401164 notiV601RO 66 02201164 2602RO

12 32068164 taesteppopegatSdn2 66 71401164 notiV2602RO

62 26078164 esohwolfihyruF 27 51201164 3402RO

62 07078164 esohwolfihwolleyyruF 27 51401164 notiV3402RO

72 50201164 5202RO 87 42248164 gnirreniatermgarhpaiD

72 11401164 notiV5202RO 38 52201164 8602RO

03 91248164 metsteppopegatsdn2 38 02401164 notiV8602RO

13 75058164 gnirpsteppopegatSdn2 78 33248164 rotcennocsseccaretsujdA

23 95078164 yruFesacegatsts1 09 22248164 gnirrecapS

33 15058164 reveLtun.xiF 19 81248164 rotcennoctropreveL

43 94058164 rehsawegatsdn2 29 02248164 ydobteppopegatsdn2

53 40158164 DWCreveldnameD 361 60000264 rotcennocylbmessaesaC

63 52248164 mgarhpaidraludoM

04 60048164 evlavtsuahxeegatsdn2 SEILBMESSA

14 66268164 eettsuahxeegatsdn289

34 48975174 parts8.4x002kcalB G 059634 ylbmessaegatsdn2yruF

44 68058164 )SG(eceiphtuomkcalB 93 75278164 revocylbmessayruF

54 16078164 rotcetorpesohegatsdn2yruF 93 95278164 revocylbmessawolleyyruF

64 41078164 rotcetorpesohegatsts1rocaD *** 92278164 tikecivresegatsdn2yruF

74 26048164 taesteppoP )38-27-66-74-34-04-33-92-72-91(

45 09068164 paceceiphtuomsupotcO *** 93100264 tikecivresegatsdn2xortiN

36 59000264 nipkcoldetalp-lekciN )38-27-66-74-34-04-33-92-72-91(

FURY ADJ SECOND STAGE PAGE



06/02


DrawingNo. E 23

Drawing updatedon: 15/02/2001FURY ADJ SECOND STAGE

FURY ADJ SECOND STAGEPAGE



06/02


TableNo. 108

Drawing reference No.: E 23Table updated on: 30/10/2001FURY ADJ SECOND STAGE


91 60101164 601RO 09 22248164 gnirrecapS

12 32068164 taesegatSdn2 19 81248164 rotcennoctropreveL

62 96078164 esohwolfrepusJDAyruF 29 02248164 ydobteppopegatsdn2

72 50201164 5202RO 521 58648164 eerttnemtsujdA

03 91248164 .metsteppopegatsdn2 621 52336134 netStnemtsujdarewop-gnirpS

13 75058164 gnirpS 721 68648164 gnihsubtsujdA

23 66078164 JDAyruFesacegatsts1 821 48648164 ydobretsujdA

33 15058164 tunreveldnameD 921 88648164 gulptropretsujdA

43 94058164 rehsawegatsdn2 031 76078164 bonkretsujdA

53 40158164 DWCreveldnameD 131 69648164 9867INU8x3mswercS

63 52248164 mgarhpaidraludoM 231 51201164 3402RO

04 60048164 evlavtsuahxeegatSdn2 431 78648164 nipretsujdA

14 66268164 eettsuahxeegatsdn289 951 55078164 rekcitsporD

34 48975174 parts8.4x002kcalB 361 60000264 rotcennocylbmessaesaC

44 68058164 )SG(eceiphtuomkcalB

54 16078164 rotcetorpesohegatsdn2yruF SEILBMESSA

64 41078164 rotcetorpesohegatsts1rocaD

74 26048164 taesteppoP B 159634 ylbmessaegatsdn2JDAyruF

36 59000264 nipkcoldetalp-lekciN 93 85278164 revocylbmessaJDAyruF

66 02201164 2602RO *** 82278164 tikecivresegatsdn2JDAyruF

87 42248164 gnirreniatermgarhpaiD )231-38-66-74-34-04-33-92-72-91(

38 52201164 8602RO


SECTION 2

SECOND STAGE REGULATOR

VIPER SECOND STAGES

VIPER SECOND STAGES PAGE



06/02


DrawingNo. E 25

Drawing updatedon: 24/05/2001VIPER TEC SECOND STAGE

VIPER SECOND STAGESPAGE



06/02


TableNo. 110

Drawing reference No.: E 25Table updated on: 30/10/2001VIPER TEC SECOND STAGE


91 60101164 601RO 59 C niprotcelfedelibomceTrepiV

91 20401164 notiV601RO 69 45078164 gnirreniaterssapybneerG

12 32068164 taesteppopegatsdn2 69 53078164 gnirreniaterssapybyarG

62 73078164 esohwolFrepuSFNU8/3 401 13078164 rekcitslavomm52ceTrepiV

72 50201164 5202RO 041 40078164 swercsrevoc4A-5897NID5x2M

72 11401164 notiV5202RO 141 92078164 revocceTrepiVlairetam-owT

82 28248164 rotcennocylbmessaesaC 241 90078164 mgarhpaidlavorepiV

03 91248164 .metsteppopegatsdn2 341 57101164 5212RO

13 95058164 gnirpsteppoP 341 03401164 notiV5212RO

23 C esacxortiNceTrepiV 441 52078164 tropevlavtsuahxerepiV

23 C esacceTrepiV 541 32078164 dirgtsuahxeyarG

33 15058164 tunreveldnameD 151 80078164 rehsaw5.0x5x8.1

43 94058164 rehsawreveL 251 50078164 rehsawtalf5.4D2956INU

53 72078164 reveldnameddetaoc-nolfeT 661 97100264 laripscinoC

04 63200264 evlavtsuahxE

24 C rotcelfedeliboM SEILBMESSA

34 48975174 parts8.4x002kcalB

44 68058164 eceiphtuoM B >73278164< ylbmessaegatsdn2ceTrepiV

54 63078164 rotcetorpesohegatsdn2 C >05100264< esacegatsdn2.F.PCETREPIV

64 41078164 rotcetorpesohegatsts1rocaD )59-24-23(

74 26048164 taesteppoP C >94100264< esacegatsdn2.F.PXNCETREPIV

17 11201164 0502RO )59-24-23(

17 31401164 notiV0502RO *** 22278164 egatsdn2repiV/ceTrepiV.tik.vreS

38 52201164 8602RO )341-38-17-74-34-04-33-72-91(

38 02401164 notiV8602RO *** 32278164 egatsdn2xNrepiV/xNceTrepiV.tik.vreS

19 33078164 rotcennoctropreveL )341-38-17-74-34-04-33-72-91(

29 12248164 ydobteppopegatsdn2


1-2.1 REPAIR PROCEDURE


06/02


DrawingNo. E 24

Drawing updatedon: 24/05/2001VIPER SECOND STAGE

VIPER SECOND STAGES

1-2.2 REPAIR PROCEDURE


06/02


PAGE

TableNo. 109

Drawing reference No.: E 24Table updated on: 30/10/2001VIPER SECOND STAGE


91 60101164 601RO 19 33078164 rotcennoctropreveL

91 20401164 notiV601RO 29 12248164 ydobteppopegatsdn2

12 32068164 taesteppopegatsdn2 69 45078164 gnirreniaterssapybneerG

62 34078164 esohwolF-iHkcalbrocaD 69 08248164 gnirreniaterssapybkcalB

62 44078164 esohwolf/ihsupotcowolleY 69 83078164 gnirreniaterssapybwolleY

72 50201164 5202RO 401 23078164 rekcitslavomm5.71ceTrepiV

72 11401164 notiV5202RO 041 40078164 swercsrevoc4A-5897NID5x2M

82 28248164 rotcennocylbmessaesaC 141 82078164 revocrepiVwolleY

03 91248164 .metsteppopegatsdn2 141 03078164 revocrepiVkcalB

13 95058164 gnirpsteppoP 241 90078164 mgarhpaidlavorepiV

23 02078164 esacrepiV 341 57101164 5212RO

23 91078164 esacsupotcorepiV 341 03401164 notiV5212RO

23 15078164 esacrepiVxortiN 441 52078164 tropevlavtsuahxerepiV

23 05078164 esacsupotcoxortiNrepiV 541 22078164 dirgtsuahxekcalB

33 15058164 tunreveldnameD 541 42078164 dirgtsuahxewolleY

43 94058164 rehsawreveL 151 80078164 rehsaw5.0x5x8.1

53 72078164 reveldnameddetaoc-nolfeT 251 50078164 rehsawtalf5.4D2956INU

04 63200264 evlavtsuahxE 661 97100264 laripscinoC

34 48975174 parts8.4x002kcalB

44 68058164 eceiphtuoM SEILBMESSA

54 63078164 rotcetorpesohegatsdn2

64 41078164 rotcetorpesohegatsts1rocaD B 83278164 ylbmessaegatsdn2repiV

74 26048164 taesteppoP *** 22278164 egatsdn2repiV/ceTrepiV.tik.vreS

17 11201164 0502RO )341-38-17-74-34-04-33-72-91(

17 31401164 notiV0502RO *** 32278164 egatsdn2xNrepiV/xNceTrepiV.tik.vreS

38 52201164 8602RO )341-38-17-74-34-04-33-72-91(

38 02401164 notiV8602RO




06/02


DrawingNo. E 24

Drawing updatedon: 13/11/2001VIPER AMERICA SECOND STAGE




06/02


TableNo. 111

Drawing reference No.: E 26Table updated on: 02/05/2002VIPER AMERICA SECOND STAGE


91 60101164 601RO 59 C niprotcelfedelibomceTrepiV

91 20401164 notiV601RO 69 71200264 gnirreniaterssapybneerG

12 32068164 taesteppopegatsdn2 401 13078164 rekcitslavomm52ceTrepiV

62 73078164 esohwolFrepuSFNU8/3 041 40078164 swercsrevoc4A-5897NID5x2M

72 50201164 5202RO 141 18200264 revocaciremArepiVlairetam-owT

72 11401164 notiV5202RO 241 90078164 mgarhpaidlavorepiV

82 28248164 rotcennocylbmessaesaC 341 57101164 5212RO


13 95058164 gnirpsteppoP 441 52078164 tropevlavtsuahxerepiV

23 C esacaciremArepiV 541 32078164 dirgtsuahxeyarG

33 15058164 tunreveldnameD 151 80078164 rehsaw5.0x5x8.1

43 94058164 rehsawreveL 251 50078164 rehsawtalf5.4D2956INU

53 72078164 reveldnameddetaoc-nolfeT 661 97100264 laripscinoC


24 C rotcelfedeliboM SEILBMESSA

34 48975174 parts8.4x002kcalB

44 71078164 eceiphtuoM B 73278164 ylbmessaegatsdn2aciremArepiV

54 63078164 rotcetorpesohegatsdn2 C 05100264 xobegatsdn2.F.PaciremArepiV

64 41078164 rotcetorpesohegatsts1rocaD )59-24-23(

74 26048164 taesteppoP C 94100264 xobegatsdn2.F.PXNaciremArepiV

17 11201164 0502RO )59-24-23(

17 31401164 notiV0502RO *** 22278164 tikecivresegatsdn2rotalugerrepiV

38 52201164 8602RO )341-38-17-74-34-04-33-72-91(

38 02401164 notiV8602RO *** 32278164 tikecivresegatsdn2rotalugerXNrepiV


29 12248164 ydobteppopegatsdn2




06/02


Drawing No. E 21

Drawing updatedon: 28/12/2000VIPER METAL - VIPER GOLD SECOND STAGE




06/02


TableNo. 105

Drawing reference No.: E 21Table updated on: 30/10/2001VIPER METAL SECOND STAGE


91 60101164 601RO 29 12248164 ydobteppopegatsdn2

91 20401164 notiV601RO 59 C niprotcelfedelibomceTrepiV

12 32068164 taesteppopegatsdn2 69 71200264 gnirreniaterssapyB

62 55200264 esohwolFrepuSlateMrepiV 401 13078164 rekcitslavomm52ceTrepiV




03 91248164 metsteppopegatsdn2 341 57101164 5212RO


23 C esaclateMrepiV 441 52078164 tropevlavtsuahxerepiV

33 15058164 tunreveldnameD 541 22078164 dirgtsuahxekcalB




24 C rotcelfedeliboM 761 81200264 3403RO

34 48975174 parts8.4x002kcalB

44 71078174 eceiphtuoM SEILBMESSA

54 63078164 rotcetorpesohegatsdn2

74 26048164 taesteppoP ylbmessaegatsdn2lateMrepiV

17 11201164 0502RO B 19200264 esacegatsdn2.F.PLATEMREPIV

17 31401164 notiV0502RO C 88200264 )59-24-23(

38 52201164 8602RO tikecivresegatSdn2lateMrepiV

38 02401164 notiV8602RO *** 22278164 )341-38-17-74-34-04-33-72-91(

19 33078164 rotcennoctropreveL




06/02


Drawing No. E 21

Drawing continuedfrom previous tableVIPER METAL - VIPER GOLD SECOND STAGE




06/02


TableNo. 106

Drawing reference No.: E 21Table updated on: 30/10/2001VIPER GOLD SECOND STAGE



91 20401164 notiV601RO 59 C niprotcelfedelibomceTrepiV

12 32068164 taesteppopegatsdn2 69 52200264 gnirreniaterssapyB

62 55200264 esohwolFrepuSlateMrepiV 401 13078164 rekcitslavomm52ceTrepiV




03 91248164 metsteppopegatsdn2 341 57101164 5212RO


23 C esacdloGrepiV 441 52078164 tropevlavtsuahxerepiV

33 15058164 tunreveldnameD 541 22078164 dirgtsuahxeyarG




24 C rotcelfedeliboM 761 81200264 3403RO

34 48975174 parts8.4x002kcalB

44 71078174 eceiphtuoM

54 63078164 rotcetorpesohegatsdn2 SEILBMESSA

74 26048164 taesteppoP

17 11201164 0502RO B 09200264 ylbmessaegatsdn2dloGrepiV

17 31401164 notiV0502RO C 98200264 esacegatsdn2.F.PDLOGREPIV

38 52201164 8602RO )59-24-23(

38 02401164 notiV8602RO *** 22278164 tikecivresegatSdn2dloGrepiV



1-14REPAIR PROCEDURE


06/02


VIPER 2nd STAGES TROUBLESHOOTING


-1-ROSUOUNITNOC

SKAELRIATNETTIMRETNIEGATSDNOCESEHTMORF

CETREPIVACIREMAREPIV

LATEMREPIVDLOGREPIV

REPIV

)1 roytridtaesteppopegatsdnoceSdegamad

)1 ecalperrotrevni,naelC

)2 rotcennoctaesfoecafrusgnilaeSdegamadroytrid

)1 ecalperronaelC

)3 hgihooterusserpetaidemretnI )1 erusserpetaidemretniehttsujdA

)4 hgihoottesreveldnameD )1 yltcerroctsujdA

)5 yltcerrocnignirpsteppoPdegamadrodenoitisop

)1 ecalperroyltcerrocnoitisoP

)6 nignir-OtaeselbatsujdAdegamadroytridrotcennoc

)1 ecalperronaelC

)7 woloottaesrotcennocelbatsujdA )1 yltcerroctsujdA

-2-ERUSSERPGNIKCARC

HGIHOOT


LATEMREPIVDLOGREPIV

REPIV

)1 woloottesreveldnameD )1 yltcerroctsujdA

)2 wolooterusserpetaidemretnI )1 yltcerroctsujdA

)3 ehtniteppopegatsdn2rofeloHdetcurtsboesacegatsdn2

)1 ylluferacnaelC

)4 denepoylluftonevlavlortnocknaT )1 yletelpmocevlavknatehtnepO

)5 demrofedgnirpsegatsdnoceSdegamadro/dna

)1 ecalpeR

)6 deggolcretlifegatstsriF )1 ecalperdnaegatstsrifluahrevOretlifeht

)7 hgihootgnidaolgnirpsteppoP )1 yrassecenfidnayltcerroctsujdAgnirpsehtecalper


LATEMREPIVDLOGREPIV

)8 ro/dnaytridenavwolfgnitoviPdegamad

)1 degamadehtecalperro/dnanaelCstnenopmoc


1-15REPAIR PROCEDURE


06/02


VIPER 2nd STAGES TROUBLESHOOTING


-3-ERUSSERPGNIKCARC

WOLOOT


LATEMREPIVDLOGREPIV

REPIV

)1 hgihooterusserpetaidemretnI )1 yltcerroctsujdA

)2 demrofedgnirpsegatsdnoceSdegamadro/dna

)1 ecalpeR

)3 wolootgnidaolgnirpsteppoP )1 yrassecenfidnayltcerroctsujdAgnirpsehtecalper

-4-LEVIWSNEEWTEBKAELRIA

DNAGNILPUOCESOHEGATSDNOCES

ROTCENNOC


LATEMREPIVDLOGREPIV

REPIV

)1 gniR-OgnilpuocesohleviwSevitcefed

)1 gniR-OehtecalpeR

)2 rotcennocesohfoecafrusgnilaeSdegamadroytridgniR-O

)1 esohehtecalperronaelCrotcennoc

-5-RETAWFOSECART

EHTEDISNIEGATSDNOCES


LATEMREPIVDLOGREPIV

REPIV

)1 yltcerrocni,ytridevlavtsuahxEdegamadrodenoitisop

)1 ecalperroyltcerrocnoitisop,naelC

)2 roytridtroppusevlavtsuahxEdegamad

)1 evlavtsuahxeehtecalperronaelCtroppus

)3 ytridgniR-OtroppusevlavtsuahxEdegamadro

)1 ecalperronaelC

)4 yltcerrocni,ytridmgarhpaiDdegamadrodenoitisop


)5 degamadroesooleceiphtuoM )1 ronethgitdnapmalcehtecalpeReceiphtuomehtecalper

)6 evitcefedgniR-OrotcennoctaeS )1 ecalpeR

)7 depmalcyltcerrocnirevoC )1 swercsehtnwodkcoL

)8 egatsdnocesfoecafrusgnilaeSroytridmgarhpaidhtiwesac

degamad

)1 ecalperronaelC

-6-EHTGNIRUDSNOITARBIV

ESAHPNOITALAHNI


LATEMREPIVDLOGREPIV

REPIV



)2 denoitisopyltcerrocnimgarhpaiD )1 yltcerrocnoitisoP

)3 detsujdayltcerrocnireveldnameD )1 yltcerroctsujdA


SECTION 2

SECOND STAGE REGULATORS

CLASSICSECOND STAGE


1-1

CLASSIC SECOND STAGE


06/02


DrawingNo. E 20

Drawing updatedon: 03/04/2000CLASSIC SECOND STAGE


1-1.1



06/02



1 45000264 nottubegrup.F.P 71 41578164 teppopegatsdn2detaoc-nofleT

2 30578164 gnirpsnottub-hsuP 81 70578164 taesteppopegatsdn2

4 58578164 dnabdetalp-emorhcrocaD 91 11578164 tungnikcoltnemtsujdataeS

5 30678164 swercsdnaB 02 42301164 09RBNgniR-O

6 55000264 revoccissalC 12 75000264 rotcennoctaesdetalp-emorhC

7 50578164 ylbmessamgarhpaiD 22 50201164 5202gniR-O

8 48975174 pmalceceiphtuoM 32 73078164 esoh5.5rocaD

9 21578164 reveldnameD 42 40258164 gulptroP"8/3

01 52578164 gnirtnemtsujdawolfirutneV 52 27578164 3402gniR-O

11 51578164 swercstnemtsujdA *** 47000264 pmupnoitcusrevoC

21 78578164 esacegatsdn2ELX

31 49000264 eceiphtuomlartuenkcalB SEILBMESSA


51 39000264 eettsuahxeELX B 92100264 ylbmessaegatsdn2cissalC

61 26578164 gnirpsteppopegatsdn2 *** 78678164 tikecivresegatSdn2cissalC

TableNo. 104

Drawing reference No.: E 20Table updated on: 03/04/2000CLASSIC SECOND STAGE


DISASSEMBLY

1. Unscrew the hose (23) from the 1st Stage using the wrench (B-18)2. Unscrew the hose (23) from the 2nd stage using an 18-mm wrench (B-32) and a 17-mm wrench (B-17).3. Remove the O-Ring (22) from the swivel coupling of the hose (23).4. Remove the exhaust tee (15).5. Remove the clamp (8) from the mouthpiece using a cutting nippers or a similar tool.

NOTEONLY REMOVE THE CLAMP FROM THE MOUTHPIECE IF A REPLACEMENT PART IS AVAILABLE.

6. Remove the mouthpiece (13).7. Using a flat-blade screwdriver (type USAG 326 - 0.8 x 4) completely back off the screw (5) and remove the ring clamp

(4).

8. Remove the 2ND stage cover assembly (6) and the diaphragm (7).

NOTETHE COMPLETE COVER ASSEMBLY (PURGE BUTTON, SPRING, COVER) ONLY NEEDS TO BE REMOVED IF THE COVER IS VERY DIRTY OR CRUSTED, OR IF THE

BUTTON TENDS TO STICK WHEN IT IS PRESSED.

9. Back off the retaining nut (19) using the 18-mm wrench (B-32).10.Using the hex wrench (B 33) unscrew the seat connector (21) and remove the O-Ring (20).

11.Back off the retaining nut (19) from the seat connector (21).12. Insert the multi-purpose tool (B-34) into the 2nd stage case and press on the poppet seat holder. (Fig. 1)

WARNING ��BE CAREFUL NOT TO DAMAGE THE SEAT CONNECTOR WHILE REMOVING THE O-RING.

WARNING ��DO NOT WIDEN THE METAL RING CLAMP BY MORE THAN 2.5 CM.


1-2



06/02


FIG. 1

13.Remove the lever (9) that has thus been loosened, releasing one side at a time from the support chamber.14.Keeping the multi-purpose tool inside the 2nd Stage case (see Fig. 1), remove the adjusting screw (11), rotating the

poppet seat holder in a clockwise direction until the adjusting screw (11), the poppet seat holder (17) and its spring(16) are released from the outer end of the poppet seat support chamber.

15.Remove the poppet seat (18) from the poppet seat holder (17).16.Remove the Venturi flow control ring (10), sliding it outward from the end of the seat connector support housing. (Fig. 2)

FIG. 2

17.Using a 4-mm hex wrench, remove the 3/8" plug (24) and its O-Ring (20), to access the hole in the second stage case.18.At this point, disassemble the exhaust valves (14).

NOTEONLY REMOVE THE EXHAUST VALVE IF A REPLACEMENT PART IS AVAILABLE


1-3



06/02


CLEANING

For routine cleaning of reusable rubber components, wash all parts in a mixture of hot water and mild detergent. Makesure all the components have been thoroughly rinsed in fresh water before reassembling them. Chrome plated brassand stainless steel parts can be cleaned with an ultrasonic cleaner in fresh water, or in a mild acid solution (for examplewhite vinegar, diluted as necessary).

INSPECTION

Certain key components of the second stage should be routinely replaced at each scheduled overhaul. In addition,considering their relatively low cost, it is recommended to replace all the O-Rings each time.



2nd stage case (12) Inspect the sealing surfaces for scratches or cracksSeat connector (21) Check that the sealing surface and the O-Ring seat are intactDiaphragm (7) Check for tears or pinholes around the metal disk, deformation of the outer rim

or signs of separation of the diaphragm from the metal diskO-Ring (20-22) Check for cuts, burrs or foreign particles. The presence of any of these defects

may result in leaks2nd stage poppet seat (18) Check for cuts, burrs or abrasion of the rubberPoppet seat holder (17) Check for cracks, cuts or deformationAdjusting screw (11) Check that the sealing surface is intactMouthpiece (13) Inspect for cuts, tears or signs of wearExhaust tee (15) Check that it is intactHose (23) Inspect for splits, blistering or any other signs of damageSpring (16) Check for any split or broken coils

ytitnauQ .N.feR noitpircseD edoC

1 52 3402gniR-O 27578164.doC

2 02 09RBNgniR-O 42301164.doC

1 22 5202gniR-O 50201164.doC

1 81 taesteppopegatsdn2 70578164.doC

2 41 sevlavtsuahxE 24678164.doC

1 8 pmalceceiphtuoM 48975174.doC

WARNING ��ACIDS OR OTHER SOLVENTS MAY DAMAGE PLASTIC AND RUBBER PARTS. BEFORE CLEANING METAL COMPONENTS, MAKE SURETHAT ALL SEALS AND OTHER PARTS SUBJECT TO DETERIORATION HAVE BEEN REMOVED.



1-4



06/02


REASSEMBLY

Before reassembling, lightly lubricate all the O-Rings with silicone grease (type General Electric Versalube G-322 orequivalent). Lubrication reduces the likelihood of damage during reassembly.1. Install two new exhaust valves (14), carefully pulling the silicone stem through the center holes of the second stage

case.

2. Insert the 2nd stage poppet seat (18) in the 2nd stage poppet seat holder.3. Fit the O-Ring (20) in the seat of the seat connector (21).4. Lock down the retaining nut (19) on the seat connector.

NOTETHE UNTHREADED PART OF THE NUT MUST BE TURNED TOWARD THE LARGER SIDE OF THE SEAT CONNECTOR (FIG. 3).

Fig. 3

5. Position the spring (16) on the poppet seat holder (17).6. Position the adjusting screw (11) on the square end of the 2nd Stage poppet seat holder and insert the entire group

inside the 2nd Stage case. (Fig. 4)

WARNING ��DURING THE OPERATION DESCRIBED IN STEP 4 TAKE CARE NOT TO DAMAGE THE AREA OF THE CONE.

WARNING ��DO NOT PULL TOO HARD ON SILICONE STEM AS THIS MAY DAMAGE THE EXHAUST VALVE.


1-5



06/02


FIG. 4

7. Using the multi-purpose tool (B-34), turn the group in a clockwise direction until it is fully locked down. Do not forceit beyond this point.

8. Keep the multi-purpose tool inserted in the 2nd Stage case as shown in (Fig. 1) and press on the poppet seat holder(17) so that about 3/8" of the stem protrudes from the adjusting screw (11).

9. Insert the ends of the demand lever (9) one at a time in the square holes on the sides of the 2nd stage poppet seatholder and release the multipurpose tool (B-34). (Fig. 5)

FIG.5

IMPORTANT ��TO MAKE A PRELIMINARY ADJUSTMENT, ROTATE THE GROUP IN AN ANTICLOCKWISE DIRECTION THROUGH 3-1/2 TURNS.

WARNING ��DO NOT OVER-TIGHTEN THE SCREW.


1-6



06/02


10.Install the Venturi flow control ring (10) on the support housing, bringing it into contact with the demand lever (9).

NOTETHE 2 ENDS OF THE RING (10) MUST BE TURNED TOWARD INSIDE OF THE 2ND STAGE CASE (12).

NOTECHECK THAT THE LEVER IS ABLE TO MOVE FREELY, BY OPERATING IT A FEW TIMES.

11.Using the hex wrench (B-33) install the seat connector (21), turning it in a clockwise direction until the lever (9) islevel with the bottom edge of the 2nd stage case (12).

12.Lock down the nut (19) fully up against the exhaust tee of the 2nd Stage case (12).13.Position the diaphragm (7).14.Position the cover assembly (6).15. Install the clamp (4) and tighten it with the screw (5), using a flat-blade screwdriver (type USAG 326- 0.8 X 4).16.Assemble the exhaust tee (15) on the support flange on the second stage case.

17.Assemble the mouthpiece (44), securing it with a new mouthpiece clamp (43).18. Insert the O-Ring (22) in the swivel coupling of the hose (23).19.Using an 18-mm wrench (B-32) and a 17-mm wrench (B-17), screw the hose (23) onto the 2nd Stage assembly.

PROCEDURE FOR ADJUSTING THE DEMAND LEVER

To obtain a correct adjustment of the regulator:

A. The repair shop should be equipped with a high and low pressure compressed air supply.B. It is necessary to have a pressure gauge for checking the intermediate pressure (the pressure gauge should have a

full scale value MAX 30 - 40 BAR, for greater accuracy of adjustment).1. Screw the intermediate pressure gauge into one of the 3/8" low pressure ports on the first stage, using the wrench

(B-17).2. Assemble the hose with the partially finished 2nd stage on the port marked D.F.C., tightening it with the wrench (B-18).3. Mount the regulator group on the control valve (of a tank or Test Bench).4. While pressing the purge button, slowly open the tank valve and, almost simultaneously, release the demand lever.5. Read the pressure gauge to check whether the 1st stage pressure is correct.

6. Unscrew the swivel hose coupling and the retaining nut (19) through approximately one turn.7. Hold the hose (23), the swivel coupling and the retaining nut (19) in place with one hand, and the 2nd stage with the

other. (Fig. 6)

WARNING ��THE FIRST STAGE INTERMEDIATE PRESSURE MUST BE MEASURED WHEN THERE IS NO AIR COMING OUT OF THE 2ND STAGE. FORANY NECESSARY ADJUSTMENTS OF THE 1ST STAGE, REFER TO THE SEPARATE MANUAL.

WARNING ��MAKE SURE THAT THE EDGE OF THE EXHAUST TEE IS CORRECTLY INSERTED IN THE FLANGE. LIGHT LUBRICATION WITH LIQUIDSOAP OR DETERGENT FACILITATES INSTALLATION. DO NOT USE SILICONE LUBRICANTS, AS THEY MAY DAMAGE CERTAINCOMPONENTS (DIAPHRAGMS) AND CAUSE THE EXHAUST TEE TO COME OUT OF ITS SEAT DURING USE.


1-7



06/02


FIG. 6

8. Rotate the 2nd stage in an counter clockwise direction until there is plentiful free-flow.9. Rotate the 2nd stage in a clockwise direction until the free-flow stops.

10.Check the travel of the purge button.

11.Back off the retaining nut (19) using the wrench (B-32).12.Lock down the swivel coupling using the wrench (B-18).13. Check the travel of the purge button again.14.Then try breathing through the newly adjusted 2nd Stage. The air should come out gently and smoothly, without free-

flow In addition, there should be plenty of air flow when the purge button is pressed.

FINAL CHECKS AND ADJUSTMENTS

Perform the checks described below to ensure that the regulator is working perfectly.

Tab. A

1. Mount the regulator group on the control valve (of a tank or Test Bench).2. Using the laboratory Test Bench or the portable Test Bench, after adjusting the 1st Stage, breathe in through the

mouthpiece and read out the "cracking" pressure value (value required to trigger air delivery) on the U-gauge, at theinstant when the gauge detects a drop in the intermediate pressure.

WARNING ��WHEN PERFORMING THIS CHECK ALWAYS MAKE SURE THAT THE ADJUSTMENT ACCESS HOLE IN THE 2ND STAGE CASE (17) ISCLOSED WITH ITS PLUG (24) AND O-RING (20).

ERUSSERP"GNIKCARC"FOSEULAV

LEDOM HFOSEHCNI 2O HFOMC 2O

EGATSDN2CISSALC 5.1-1 5.3-5.2

WARNING ��IF THE RESULT OBTAINED IS NOT AS DESCRIBED IN STEP 14, REPEAT THE ADJUSTMENT PROCEDURE.

WARNING ��ROTATE THE 2ND STAGE IN A CLOCKWISE DIRECTION UNTIL THE PURGE BUTTON HAS APPROXIMATELY 1MM OF IDLE TRAVELBEFORE AIR DELIVERY BEGINS.


1-8



06/02


FIG. 7

3. If the value of the Cracking Pressure is less than that shown in table A it is necessary to increase the loading of thespring as follows:a) Insert a flat-blade screwdriver through the access hole and into the groove on the 2nd stage poppet seat holder.b) Rotate the 2nd Stage poppet seat holder in a clockwise direction to increase the loading of the spring and hence

the breathing effort.4. If the value of the Cracking Pressure is greater than that shown in table A it is necessary to reduce the loading of

the spring as follows:c) Insert a flat-blade screwdriver through the access hole and into the groove on the 2nd stage poppet seat holder.d) Rotate the 2nd Stage poppet seat holder in an counter clockwise direction to reduce the loading of the spring and

hence the breathing effort.5. Submerge the 2nd stage in water with the mouthpiece facing up, allowing water to enter the exhaust tee and keeping

it in this position for about 30 seconds.6. Remove the 2nd stage from the water, then turn the mouthpiece downward.7. Check for any traces of water inside the second stage.

8. Press the purge button a few times and check that it operates smoothly, and does not jam.9. Completely submerge the 2nd stage in water (allowing water to enter the mouthpiece) and check for any air leaks.

WARNING ��IF MORE THAN A FEW DROPS OF WATER COME OUT OF THE SECOND STAGE, CHECK THE SEALING SURFACES OF THEMOUTHPIECE CLAMP, THE EXHAUST VALVE AND THE RIM OF THE DIAPHRAGM.

LEDOMEGATSDN2 STRATSYREVILEDRIAEREHWTNIOP

CISSALC )7.giF(ERUGIFEHTNIDETACIDNITNIOP

WARNING ��IN THE ABSENCE OF A TEST BENCH IT IS POSSIBLE TO RUN AN APPROXIMATE CHECK OF THE CRACKING PRESSURE USING ABASIN OF WATER AND CARRYING OUT THE PROCEDURE BELOW:A. SLOWLY SUBMERGE THE 2ND STAGE IN THE WATER WITH THE MOUTHPIECE FACING UP, AND WITHOUT ALLOWING WATER TO

GO INSIDE.B. WHEN THE WATER LEVEL, MEASURED FROM THE POINT INDICATED IN THE DIAGRAM (FIG. 7) FALLS BETWEEN THE CRACKING

VALUES INDICATED IN THE TABLE, THE AIR SHOULD START TO FLOW. (SEE TAB. A)


1-9



06/02


CLASSIC SECOND STAGE TROUBLESHOOTING


1-10



06/02



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EGATSDNOCES

CISSALC

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)6 roytridgniR-OtaeselbatsujdAdegamad

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)7 woloottaeselbatsujdA )1 yltcerroctsujdA

-2-ERUSSERPGNIKCARC

HGIHOOTCISSALC




)1 ylluferacnaelC

)4 denepoylluftonevlavlortnocknaT )1 evlavknatehtnepoylluF

)5 ro/dnademrofedgnirpsegatsdn2degamad

)1 ecalpeR

)6 detcurtsboretlifegatsts1 )1 ecalperdnaegatsts1ehtluahrevOretlifeht


-3-ERUSSERPGNIKCARC

WOLOOTCISSALC



)1 ecalpeR

)3 wolootgnidaolgnirpS )1 yrassecenfidnayltcerroctsujdAgnirpsehtecalper


1-11



06/02


CLASSIC SECOND STAGE TROUBLESHOOTING




ROTCENNOC

CISSALC


)1 gniR-OehtecalpeR



-5-EDISNIRETAWFOSECART

EGATSDNOCESEHT

CISSALC

)1 yltcerrocni,ytridsevlavtsuahxEdegamadrodenoitisop


)2 ro,ytridstaesevlavtsuahxEdegamad

)1 esacegatsdn2ehtecalperronaelC



)4 degamadroesooleceiphtuoM )1 ropmalcwenahtiwnethgiTeceiphtuomehtecalper

)5 degamadroesoolpmalcgnirrevoC )1 ecalperronethgiT

)6 ytridsgniR-OdnasecafrusgnilaeSevitcefedro

)1 gnilaesehtllanaelcdnatcepsnIsgniR-Oehtgnicalper,secafrus

-6-NOTTUBEGRUPREVOC

DEMMAJCISSALC

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ESAHPNOITALAHNICISSALC






SECTION 2

SECOND STAGE REGULATOR

CLASSIC PROSECOND STAGE


1-1

CLASSIC PRO SECOND STAGE


06/02


DrawingNo. E 27

Drawing updatedon: 03/04/2002CLASSIC PRO SECOND STAGE


1-1.1



06/02



91 60101164 601RO 93 42400264 revocylbmessaorPcissalC

12 40200264 gnirpsnottub-hsuP 04 60048164 evlavtsuahxE

62 73078164 esohrebburomrehtkcalB 14 39000264 eettsuahxE

62 55200264 esohwolFrepuS2/1 34 48975174 pmalceceiphtuoM

72 50201164 5202RO 44 71078164 eceiphtuoM

82 28248164 rotcennocylbmessaesaC 54 63078164 rotcetorpesohegatsdn2

92 11201164 0502RO 54 48300264 rotcetorpesohegatsdn2wolleY

03 91248164 metsevlaV 64 41078164 rotcetorpesohegatsts1

13 75058164 gnirpsteppoP 74 26048164 taesteppoP

23 54300264 esaC 29 02248164 ydobevlaV

33 15058164 tunreveldnameD

43 94058164 rehsawreveL SEILBMESSA

53 72078164 reveldnameD

63 92068164 mgarhpaiD B 32400264 ylbmessaegatsdn2orPcissalC

73 37058164 pmalcgniR *** 72400264 tikecivresegatSdn2orPcissalC

83 57058164 swercsdnaB

TableNo. 112

Drawing reference No.: E 27Table updated on: 09/05/2002CLASSIC PRO SECOND STAGE

CLASSIC PRO

DISASSEMBLY

1. Using cutting nippers (or pliers), cut the mouthpiece clamp (43) and remove the mouthpiece (44).2. Remove the exhaust tee (41) from the second stage case.3. Shift the hose protector (46) and using two wrenches (B-17) unscrew the hose (26) from the second stage.4. Remove the O-Ring (27) from the hose (26).5. Unscrew the connector (28) from the second stage using the wrench (B-17).6. Remove the O-Ring (29) and, using the hex wrench (B-4) unscrew the seat connector (21) with the O-Ring (27) from

the case assembly connector (28).7. Back off the screw (38) of the ring clamp (37).8. Open the ring clamp (37) and pull it out of the second stage case (32).9. Remove the cover (39) and the diaphragm (36).

NOTEDISASSEMBLING THE COMPLETE COVER ASSEMBLY (PURGE BUTTON, SPRING, COVER) IS NECESSARY ONLY IF THE COVER IS VERY DIRTY OR ENCRUSTED,

OR IF THE BUTTON DOES NOT RETURN TO ITS INITIAL POSITION WHEN PRESSED.

10.Using the special tool (B-12), back off the adjusting nut (33) from the poppet stem (30), removing the demand lever(35), the washer (34) and the spring (31).

11.Remove the poppet (30) and the spring (31) from the second stage.12.Remove the rubber poppet seat (47) from poppet body (30).13.Remove the exhaust valve (40).

CLEANING

For routine cleaning of reusable rubber components, wash all parts in a mixture of hot water and mild detergent. Makesure all the components have been thoroughly rinsed in fresh water before reassembling them. Chrome plated brassand stainless steel parts can be cleaned with an ultrasonic cleaner in fresh water, or in a mild acid solution (for examplewhite vinegar, diluted as necessary).



WARNING ��TO PREVENT THE SECOND STAGE POPPET AND SPRING FROM BEING EJECTED, COVER THE OPENING OF THE CASE ASSEMBLYCONNECTOR WITH A FINGER.


1-2



06/02


INSPECTION

Certain key components of the second stage should be regularly replaced at each scheduled overhaul. In addition,considering their relatively low cost, it is recommended to replace all the O-Rings.



2nd stage case (32) Inspect the sealing surfaces for scratches or cracks. Check that the exhaustvalve seat is perfectly clean and intact. Check that the by-pass is not deformed

Seat connector (21) Check that the sealing surface and the O-Ring seat are intactCase assembly connector (28) Check that the sealing surface and the O-Ring seat are intactDiaphragm (36) Check for tears or pinholes around the metal disk, deformation of the outer rim

or signs of separation of the diaphragm from the metal diskO-Ring (27 - 29) Check for cuts, burrs or foreign particles The presence of any of these defects

may result in leakage2nd stage poppet seat (47) Check for cuts, burrs or abrasion of the rubberDemand lever adjusting nut (33) Verify its self-locking capacity and inspect for rust. It is recommended to replace

it at each scheduled overhaulMouthpiece (44) Inspect for cuts, tears or signs of wearExhaust tee (41) Check that it is intactHose (26) Inspect for splits, blistering or any other signs of damageMouthpiece clamp (37) Check for breakage or distortionSpring (31) Check for any split or broken coils

REASSEMBLY

Before reassembling, lightly lubricate all the O-Rings with silicone grease (type General Electric Versalube G-322 orequivalent). Lubrication reduces the likelihood of damage during reassembly.

1. Install a new exhaust valve (40), carefully pulling its silicone stem through the center hole of the second stageexhaust valve support.

WARNING ��DO NOT PULL TOO HARD ON THE STEM TO AVOID DAMAGING THE EXHAUST VALVE.

WARNING ��IF THE SECOND STAGE IS USED FOR DIVING WITH OXYGEN-RICH MIXTURES, IT MUST BE PERFECTLY CLEANED AND FREE OF ANYRESIDUAL SILICONE OR OTHER IMPURITIES. VITON O-RINGS MUST BE LUBRICATED WITH SPECIAL OXYGEN-COMPATIBLE GREASE.DO NOT USE SILICONE GREASE.

ytitnauQ .oNfeR noitpircseD edoC

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1 )92( 0502gniR-O 31401164notiV.doc11201164.doC

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1 )33( tungnitsujdareveldnameD 15058164.doC

1 )04( evlavtsuahxE 60048164.doC

1 )34( pmalceceiphtuoM 48975174.doC


1-3



06/02


2. Using cutting nippers, cut the silicone stem by about 7 mm.3. Reassemble the poppet seat (47) on the poppet body (30).4. Place the complete 2nd stage poppet assembly and its spring (31) on the special tool (B-6).5. Exerting a slight pressure, correctly insert the 2nd stage poppet assembly and its spring into the inlet fitting of the

2nd stage case. (Fig. 1)

FIG. 1

6. Correctly position the demand lever in the groove of the second stage case (32), fit the washer (34) on the poppetstem and lock down the adjusting nut (33) by a few turns, using the special wrench (B-12 or B-20). (Fig. 2)

IMPORTANT ��ROTATE THE SECOND STAGE CASE SLIGHTLY TO THE RIGHT AND LEFT TO OBTAIN CORRECT POSITIONING OF THE 2ND STAGEPOPPET STEM.


1-4



06/02


FIG. 2

NOTECHECK THAT THE LEVER IS ABLE TO MOVE FREELY, BY OPERATING IT A FEW TIMES.

7. Fit the O-Ring (27) in its seat in the case assembly connector (28).8. Insert and lock down the seat connector (21) onto the case assembly connector (28) using the 5-mm hex wrench

(B-4), so that it projects by about 3 mm.

9. Position the O-Ring (29) in the seat on the case assembly connector (28).10.Using a 17 mm open end wrench (B-17), fully lock down the case assembly connector on the 2nd stage case.

WARNING ��THE POPPET SEAT SHOULD NOT PROTRUDE MORE THAN 3.8 MM FROM THE CASE ASSEMBLY CONNECTOR.

WARNING ��DO NOT OVER-TIGHTEN THE ADJUSTING NUT. IF THE ADJUSTING NUT IS TOO TIGHT IT MAY CAUSE FREE FLOWING OF THESECOND STAGE, INTERFERING WITH THE ADJUSTMENT OF THE INTERMEDIATE PRESSURE.


1-5



06/02


NOTEIF A TORQUE WRENCH IS USED, SET A MAXIMUM TORQUE OF 8 - 8.5 N/m.

11.Fit the O-Ring (27) in the seat on the swivel connector of the hose (26).12.Screw the hose (26) onto the case assembly connector (28) with the help of two 17-mm open end wrenches (B-17).

ADJUSTMENTS AND FINAL ASSEMBLY

To obtain a correct adjustment of the regulator:A. The repair shop should be equipped with a high and low pressure compressed air supply.B. It is necessary to have a pressure gauge for checking the intermediate pressure (the pressure gauge should have a

full scale value MAX 30 - 40 BAR, for greater accuracy of adjustment).1. Screw the intermediate pressure measuring gauge into one of the 3/8" low pressure ports on the first stage, using

the special wrench (B-18).2. Using the wrench B-18, assemble the hose with the partially finished 2nd stage on the port marked D.F.C.3. Mount the regulator group on the control valve (of a tank or Test Bench).4. Depress the second stage demand lever, slowly open the tank valve and, almost simultaneously, release the demand

lever.5. Read the pressure gauge to check whether the 1st stage pressure adjustment is correct.

6. Rest the ends of the gauge on the edge of the 2nd stage case. (Fig. 3)

FIG. 3

7. Using the special tool (B-12 or B-20) lock down or back off the adjusting nut (33) to adjust the demand lever (35).

WARNING ��THE DEMAND LEVER IS CORRECTLY ADJUSTED WHEN IT JUST TOUCHES THE GAUGE BUT THERE IS NO AIR COMING OUT.

WARNING ��THE FIRST STAGE INTERMEDIATE PRESSURE MUST BE MEASURED WHEN THERE IS NO AIR COMING OUT OF THE 2ND STAGE FORADJUSTMENT OF THE FIRST STAGE, REFER TO THE SEPARATE MANUAL.


1-6



06/02



1-7



06/02


8. Depress and trigger the demand lever a few times.9. Correctly fit the diaphragm (36) with the metal disk in contact with the demand lever.

10.Fit the cover (39) on the diaphragm, orienting it the right way round.11.Fit the ring clamp (37) so that the eye-holes are on top of the second stage fitting.12.Lock down the clamp screw (38).13.Assemble the exhaust tee (41) on the support flange on the second stage.

14.Carefully assemble the mouthpiece (44), securing it with a new mouthpiece clamp (43).


The checks described below are designed to verify the perfect operation of the regulator.

Tab. A



Fig. 4

WARNING ��IN THE ABSENCE OF A TEST BENCH IT IS POSSIBLE TO RUN AN APPROXIMATE CHECK OF THE CRACKING PRESSURE USING ABASIN OF WATER AND CARRYING OUT THE PROCEDURE BELOW:A. Slowly submerge the 2nd stage in the water with the mouthpiece facing up, and without allowing water to go inside.B. When the water level, measured from the point indicated in the diagram (Fig. 4) falls between the cracking values indicated in the table, the

air should start to flow. (see tab. A)

SEGATSDNOCESROFERUSSERP"GNIKCARC"FOSEULAV

LEDOM HFOSEHCNI 2O HFOMC 2O

EGATSDN2YRAMIRP 5.1-1 8.3-5.2

WARNING ��MAKE SURE THAT THE EDGE OF THE EXHAUST TEE IS CORRECTLY FITTED ON THE FLANGE. LIGHT LUBRICATION WITH LIQUIDSOAP OR DETERGENT FACILITATES INSTALLATION. DO NOT USE SILICONE LUBRICANTS, AS THEY MAY DAMAGE CERTAINCOMPONENTS (DIAPHRAGMS) AND CAUSE THE EXHAUST TEE TO COME OUT OF ITS SEAT DURING USE.

3. If the Cracking Pressure Value does not fall between the values specified in the table, proceed as follows:a. If the cracking pressure is greater, it is necessary to reduce the load on the spring.b. If the cracking pressure is lower, it is necessary to increase the load on the spring.

4. Submerge the 2nd stage in water with the mouthpiece facing up, allowing water to enter the exhaust tee and keepingit in this position for about 30 seconds.

5. Remove the 2nd stage from the water, then turn the mouthpiece downward.6. Check for any traces of water inside the second stage.


WARNING ��IF MORE THAN A FEW DROPS OF WATER COME OUT OF THE SECOND STAGE, CHECK THE SEALS ON THE MOUTHPIECE CLAMP,THE EXHAUST VALVE AND THE RIM OF THE DIAPHRAGM.

WARNING ��WHENEVER THE LOADING OF THE SPRING IS CHANGED (INCREASED OR REDUCED) IT IS NECESSARY TO ADJUST THE DEMANDLEVER AS INSTRUCTED IN THE MANUAL.

LEDOMEGATSDN2 TNIOPGNIKCARC

ORPCISSALC )4.giF(ERUGIFEHTNIDETACIDNITNIOP


1-8



06/02


CLASSIC PRO 2ND STAGE TROUBLESHOOTING


1-9



06/02



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ORPCISSALC

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3- -ERUSSERPGNIKCARC

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CLASSIC PRO 2ND STAGE TROUBLESHOOTING


1-10



06/02



-4-EHTNEEWTEBKAELRIAGNILPUOCESOHLEVIWS

EGATSDN2EHTDNAROTCENNOC

ORPCISSALC


)1 gniR-OehtecalpeR



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)5 evitcefedgniR-OrotcennoctaeS )1 ecalpeR

)6 degamadroesoolpmalcrevoC )1 ecalperronethgiT

-6-NOTTUBEGRUPREVOC

DEMMAJORPCISSALC




ESAHPNOITALAHNIORPCISSALC






SECTION 2

SECOND STAGE REGULATORS

EAGLE DPD -EAGLE -

OCTOPUS EAGLESECOND STAGE


1-1

EAGLE DPD - EAGLE - OCTOPUS EAGLESECOND STAGE


06/02


DrawingNo. E 29

Drawing updatedon: 21/03/2002EAGLE DIVE/PRE-DIVE SECOND STAGE


1-1.1



06/02


TableNo. 114

Drawing reference No.: E 29Table updated on: 09/05/2002EAGLE DIVE/PRE-DIVE SECOND STAGE


6 10101164 2102RO 201 57195174 gnirpS

6 10401164 notiV2102RO 301 78300264 nottub-hsuP

91 60101164 601RO 401 28200264 lebalnottuB

91 20401164 notiV601RO 461 --- rehsawnoitator-noN

12 40200264 taesteppopegatsdn2 561 22400264 gnihsubrotcennocelgaE

62 73078164 esohwolFrepuSlartuen8/3 171 01101164 7302RO

72 50201164 5202RO 171 89200264 notiV7302RO

72 11401164 notiV5202RO 271 +++ animalrevocelgaE

82 28248164 rotcennocylbmessaesaC 371 99300264 rekcitsesaC

03 91248164 metsteppopegatsdn2 471 16300264 nipgnixifgulptsuahxE

13 95058164 gnirpsteppoP 081 88300264 reveLeviDerP/eviD

23 40400264 esacelgaE 181 19300264 troppusreveleviDerP/eviD

33 15058164 tunreveldnameD 281 68300264 ydoBeviDerP/eviD

43 94058164 rehsawreveL 381 09300264 kcolbeviDerP/eviD

53 72078164 reveldnameddetaoc-nolfeT 481 98300264 bonkeviDerP/eviD

63 11300264 mgarhpaidegatsdn225.D 581 59300264 4A8867INU01x2MswercS

04 60048164 evlavtsuahxE 681 10200264 rekcitsbonkeviDerP/eviD

14 20400264 gulpnoitcepsninotorP

34 48975174 parts8.4x002kcalB SEILBMESSA

44 71078164 eceiphtuoM

64 63078164 rotcetorpesohegatsdn2 B 03400264 ylbmessaegatsdn2DPDelgaE

74 26048164 taesteppoP +++ 82400264 revocylbmessaDPDelgaE

36 98248164 nipkcolrevoC )271-401-301-201-101(

17 11201164 0502RO *** 52400264 egatsdn2DPDelgaE/elgaE.tik.vreS

17 31401164 notiV0502RO )171-17-74-34-04-33-72-91-6(

87 12300264 gnirreniatermgarhpaiD *** 62400264 egatsdn2XNDPDelgaE/elgaE.tik.vreS

29 12248164 ydobteppopegatsdn2 )171-17-74-34-04-33-72-91-6(

101 +++ revoclavorocaD


1-1.2



06/02


DrawingNo. E 28

Drawing updatedon: 21/03/2002EAGLE - EAGLE OCTOPUS SECOND STAGE


1-1.3



06/02




91 20401164 notiV601RO 101 +++ revoclavorocaD

12 40200264 taesteppopegatsdn2 201 57195174 gnirpS

62 54078164 esohwolFiH8/3 301 78300264 nottub-hsuP

62 44078164 esohwolFiH8/3wolleY 401 13078164 lebalnottuB

72 50201164 5202RO 461 rehsawnoitator-noN

72 11401164 notiV5202RO 561 22400264 gnihsubrotcennocelgaE

82 28248164 rotcennocylbmessaesaC 171 01101164 7302RO


13 95058164 gnirpsteppoP 271 +++ tnorfrevocelgaE

23 30400264 esacelgaE 271 +++ tnorfrevocsupotcoelgaE

33 15058164 tunreveldnameD 371 99300264 rekcitsesaC

43 94058164 rehsawreveL 371 00400264 rekcitsesacsupotcO

53 72078164 reveldnameddetaoc-nolfeT 471 16300264 nipgnixifgulptsuahxE

63 11300264 mgarhpaidegatsdn225.D

04 60048164 evlavtsuahxE SEILBMESSA

14 20400264 gulpnoitcepsninotorP

34 48975174 parts8.4x002kcalB B 13400264 ylbmessaegatsdn2elgaE

44 71078164 eceiphtuoM +++ 92400264 revocylbmessaelgaE

64 63078164 rotcetorpesohegatsdn2 )271-401-301-201-101(

74 26048164 taesteppoP +++ 23400264 revocylbmessasupotcoelgaE

45 38058164 paceceiphtuomsupotcO )271-401-301-201-101(

36 98248164 nipkcolrevoC *** 52400264 egatsdn2DPDelgaE/elgaE.tik.vreS

46 39300264 gulpsseccaretsujdA )171-17-74-34-04-33-72-91-6(

17 11201164 0502RO *** 62400264 egatsdn2XNDPDelgaE/elgaE.tik.vreS

17 31401164 notiV0502RO )171-17-74-34-04-33-72-91-6(

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TableNo. 113

Drawing reference No.: E 28Table updated on: 09/05/2002EAGLE - EAGLE OCTOPUS SECOND STAGE

EAGLE DPD SECOND STAGEEAGLE SECOND STAGE

EAGLE OCTOPUS SECOND STAGE

DISASSEMBLY

1. Unscrew the hose (26) from the first stage using the 14-mm open end wrench (B-18) or the 17-mm open end wrench(B-17).

2. Remove the mouthpiece clamp (43) from the mouthpiece (44).

NOTEONLY REMOVE THE CLAMP FROM THE MOUTHPIECE IF A REPLACEMENT PART IS AVAILABLE.

3. Remove the mouthpiece (44).4. Remove the fixing pin (174) from the cap (41) of the exhaust tee. (Fig. 1)

NOTEFOR THE OPERATION DESCRIBED IN STEP 4, IT IS RECOMMENDED TO USE A METAL PRICKER HAVING A MAX DIAMETER OF 2mm (Fig. 1).

FIG. 1


1-2



06/02


5. Remove the inspection cap (41).6. Shift the hose protector (46) along the hose (26).7. Using the two 17-mm open end wrenches (B-17) unscrew the hose (26) from the case assembly connector (28).8. Remove the O-Ring (27) and the O-Ring (19) from the hose (26).9. Unscrew the case assembly connector (28) using a 17-mm open end wrench (B-17).

10.Remove the O-Ring (71) from the case assembly connector (28).11.Unscrew the seat connector (21) from the case assembly connector (28) using a 5-mm hex wrench (B-4).12.Remove the O-Ring (27) from the seat connector (21).

13.Remove the safety clip (63).14.Unscrew the cover assembly.

15.Remove the diaphragm retaining ring (78) and the diaphragm (36) from the 2nd stage case (32).

DPD VERSIONS

a) Remove the sticker (186) from the Dive/Pre Dive knob (184).b) Using a Phillips screwdriver (type USAG 327) back off the screw (185) and remove the DPD knob (184), the DPD

clamp (183) and the spring (102) (Fig. 10).c) Remove the lever support (181) and the DPD lever (180) from the DPD body (Fig. 9).d) Remove the O-Ring (6) from the DPD lever support (181) (Fig. 9).e) Using the special wrench (B-37), unscrew the DPD body (182) (Fig. 10).f) Remove the O-Ring (171) from the DPD body (182).

STANDARD VERSIONS

16.Unscrew the case plug (64) using a 10-mm hex wrench (B-13).17.Remove the O-Ring (171) from the case plug (64).

ALL VERSIONS

18.Position the 2nd stage case (32) on the special tool (B-6) (Fig. 2).19.Exerting a slight pressure, back off the demand lever adjusting nut (33) using the special tool (B-12), and working

through the hole in the 2nd stage case (Fig. 2).

WARNING ��REMOVE THE DPD LEVER (180) FROM THE DPD LEVER SUPPORT (181) ONLY IF NECESSARY.

WARNING ��DISASSEMBLE THE COVER ONLY IF NECESSARY.

WARNING ��REMOVE THE CASE ASSEMBLY BUSHING (165) ONLY IF NECESSARY, AND IF SO USING PLASTIC TOOLS.


1-3



06/02


FIG. 2

20.Remove the demand lever adjusting nut (33), the washer (34), the 2nd stage poppet assembly and the spring (31)from the 2nd stage case (32) (Fig. 2).

21.Remove the poppet seat (47) from the poppet seat holder (92).22.Remove the poppet seat holder (92) from the 2nd stage poppet stem (30).23.Remove the exhaust valve (40).

CLEANING

For routine cleaning of reusable rubber components, wash all parts in a mixture of hot water and mild detergent. Makesure all the components have been thoroughly rinsed in fresh water before reassembling them. Chrome plated brass andstainless steel parts can be cleaned with an ultrasonic cleaner in fresh water, or in a mild acid solution (for example whitevinegar, diluted as necessary).



WARNING ��DON NOT UNDER ANY CIRCUMSTANCES REMOVE THE ROTATION STOP WASHER (164) FROM THE SECOND STAGE CASE (32).


1-4



06/02


INSPECTION

Certain key components of the second stage should be routinely replaced at each scheduled overhaul. In addition,considering their relatively low cost, it is recommended to replace all the O-Rings.



2nd stage case (32) Inspect the sealing surfaces for scratches or cracks Seat connector (21) Check that the sealing surface and the O-Ring seat are intactDiaphragm (36) Check for tears or pinholes around the metal disk, deformation of the outer rim

or signs of separation of the diaphragm from the metal diskO-Rings (6-19-27- 71- 171) Check for cuts, burrs or foreign particles. The presence of any of these defects

may result in leaks2nd stage poppet seat (47) Check for cuts, burrs or abrasion of the rubberPoppet seat holder (92) Check for cracks, cuts or deformationsDemand lever adjusting nut (33) Verify its self-locking capacity and inspect for rust. It is recommended to replace

it at each scheduled overhaul and/or whenever it is disassembled.Mouthpiece (44) Inspect for cuts, tears or signs of wearExhaust tee cap (41) Check that it is intactHose (26) Inspect for splits, blistering or any other signs of damageSpring (31) Check for any split, broken or misshapen coils

REASSEMBLY

Before reassembling, lightly lubricate all the O-Rings with silicone grease (type General Electric Versalube G-322 orequivalent). Lubrication reduces the likelihood of damage during reassembly.

1. Install a new exhaust valve (40), carefully pulling its silicone stem through the center hole of the second stageexhaust valve support.

WARNING ��IF THE SECOND STAGE IS USED FOR DIVING WITH OXYGEN-RICH MIXTURES, IT MUST BE PERFECTLY CLEANED AND FREE OFOIL/SILICONE GREASE RESIDUES OR OTHER IMPURITIES. VITON O-RINGS MUST BE LUBRICATED WITH SPECIAL OXYGEN-COMPATIBLE GREASE.DO NOT USE SILICONE GREASE !!!

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1-5



06/02


2. Using cutting nippers, cut the silicone stem by about 7 mm.3. Reassemble the poppet seat holder (92) on the 2nd stage poppet stem (30).4. Reassemble the poppet seat (47) in the poppet seat holder (92).

ASSEMBLING THE DEMAND LEVER

METHOD "A"A.1 Place the 2nd stage poppet assembly (30-47-92) together with its spring (31) on the special tool (B-6).A.2 Insert the 2nd stage case (32) on the poppet assembly with spring and exert a slight pressure so that the poppet

protrudes from the 2nd stage case. (Fig. 3)

FIG. 3

WARNING ��PRESS AND ROTATE THE 2ND STAGE CASE (32) SLIGHTLY TO THE RIGHT AND LEFT TO OBTAIN CORRECT POSITIONING OF THE 2NDSTAGE POPPET STEM.

WARNING ��ON EAGLE SECOND STAGES IT IS POSSIBLE TO ASSEMBLE THE DEMAND LEVER IN TWO DIFFERENT WAYS. THE TWO DIFFERENTASSEMBLY PROCEDURES ARE DESCRIBED BELOW.

WARNING ��ASSEMBLE THE BUSHING (165) IF IT WAS PREVIOUSLY DISASSEMBLED.

WARNING ��DO NOT PULL TOO HARD ON SILICONE STEM TO AVOID DAMAGING THE EXHAUST VALVE.


1-6



06/02


A.3 Fit the washer (34) on the poppet stem which protrudes inside the 2nd stage case and lock down the adjusting nut(33) through a few turns, using the special wrench (B-20) (Fig. 4).

FIG. 4

WARNING ��TO FACILITATE THE SUBSEQUENT ASSEMBLY OPERATIONS, DURING STEP -A.3- IT IS ADVISABLE TO PERFORM ONLY ANAPPROXIMATE (NOT FINAL) ADJUSTMENT OF NUT (33). THE RECOMMENDED APPROXIMATE ADJUSTMENT IS ACHIEVED WHEN THEPOPPET STEM PROTRUDES FROM THE ADJUSTING NUT BY ABOUT 1 mm.

WARNING ��TO FACILITATE THE OPERATION DESCRIBED IN STEP -A.3-, AFTER LOCKING DOWN THE NUT THROUGH A FEW TURNS WITHSPECIAL WRENCH (B-20) IT IS RECOMMENDED TO FINISH LOCKING IT DOWN USING SPECIAL WRENCH (B-12).

WARNING ��IF THERE ARE DIFFICULTIES INSERTING AND/OR POSITIONING THE SPECIAL WRENCH (B-20) ON THE POPPET STEM DURING THEOPERATION DESCRIBED IN STEP -A.3- IT IS RECOMMENDED TO REDUCE THE PRESSURE EXERTED ON THE 2ND STAGE CASESLIGHTLY UNTIL INSERTION AND/OR CORRECT ALIGNMENT IS ACHIEVED.


1-7



06/02


A.4 Keeping the special tool (B-6) positioned inside the case assembly connector of the 2nd stage (32), insert thedemand lever (35) between the washer (34) and the seat in the 2nd stage case, proceeding as shown in (Fig. 5).

FIG. 5 A FIG. 5 B

WARNING ��TO CHECK THAT THE 2ND STAGE POPPET IS POSITIONED CORRECTLY, PUSH THE DEMAND LEVER A FEW TIMES, MAKING SURE ITIS ABLE TO MOVE FREELY.

WARNING ��USING THE SPECIAL TOOL (B-6) AND THE SPECIAL WRENCH (B-12), IT IS RECOMMENDED TO CONTINUE LOCKING DOWN THE NUT(33) TO ACHIEVE AN APPROXIMATE (NOT FINAL) ADJUSTMENT IN WHICH THE VALVE STEM (30) PROTRUDES BY ABOUT 3 mm.


1-8



06/02


METHOD "B"

B.1 Position the spring (31) in the 2nd stage case assembly connector (Fig. 6).B.2 Insert the 2nd stage poppet assembly (30-47-92) in the previously inserted spring (31) (Fig. 6).

FIG. 6

WARNING ��IF THE CONNECTOR BUSHING (165) COMES OUT DURING THE PROCEDURE DESCRIBED IN STEP B. 3, REASSEMBLE IT FOLLOWINGTHE INSTRUCTIONS GIVEN FOR METHOD "A".


1-9



06/02


B.3 Insert the special tool (B-36) (Cod. 46200383) into the 2nd stage case assembly connector until it engages thebushing (165) (Fig. 7).

FIG. 7

B.4 Fit the washer (34) on the poppet stem (30).B.5 Using the special wrench (B-12) lock down the adjusting nut (33) on the poppet stem (30).

B.6 Insert the demand lever (35) between the washer (34) and the seat in the 2nd stage case, proceeding as shown in(Fig. 5).

B.7 After having positioned the demand lever (35), remove the special tool (B-36) from the connector bushing (165).

FINAL ASSEMBLY

5. Fit the O-Ring (27) in its seat in the case assembly connector (21).6. Insert and lock down seat connector (21) into the case assembly connector (28) using the 5-mm hex wrench (B-4),

so that it protrudes from the connector by about 2 mm.

WARNING ��HTM SPORT TAKING THE UTMOST CARE DURING THE REASSEMBLY OPERATIONS DESCRIBED IN STEP "6" TO AVOID DAMAGINGTHE THREADS OF THE POPPET SEAT.

WARNING ��TO CHECK THAT THE 2ND STAGE POPPET IS POSITIONED CORRECTLY, PUSH THE DEMAND LEVER A FEW TIMES, MAKING SURE ITIS ABLE TO MOVE FREELY.

WARNING ��USING THE SPECIAL WRENCH (B-12) IT IS RECOMMENDED TO FINISH LOCKING DOWN NUT (33) TO ACHIEVE AN APPROXIMATE (NOTFINAL) ADJUSTMENT IN WHICH THE VALVE STEM (30) PROTRUDES BY ABOUT 3 mm.

WARNING ��TO FACILITATE THE SUBSEQUENT ASSEMBLY OPERATIONS, DURING STEP -B.5- IT IS ADVISABLE TO PERFORM ONLY ANAPPROXIMATE (NOT FINAL) ADJUSTMENT OF NUT (33). THE RECOMMENDED APPROXIMATE ADJUSTMENT IS ACHIEVED WHEN THEPOPPET STEM PROTRUDES FROM THE ADJUSTING NUT BY ABOUT 1 mm.

WARNING ��PRESS AND ROTATE THE SPECIAL TOOL (B-36) SLIGHTLY TO THE RIGHT AND LEFT TO OBTAIN CORRECT POSITIONING OF THE 2NDSTAGE POPPET STEM.


1-10



06/02


7. Fit O-Ring (71) in the seat of the case assembly connector (28).8. Using a 17-mm open end wrench (B-17), lock down the case assembly connector into the 2nd stage case (32).

NOTEIF A TORQUE WRENCH IS USED, SELECT A TORQUE SETTING OF APPROXIMATELY 8 - 8.5 N/m

9. Fit the O-Ring (27) in the seat on the swivel connector of the hose (26).10.Screw the hose (26) into the case assembly connector (28) with the help of two 17-mm open end wrenches (B-17).

FINAL ADJUSTMENTS

To obtain a correct adjustment of the regulator:A. The repair shop should be equipped with a high and low pressure compressed air supply.B. It is necessary to have a pressure gauge for checking the intermediate pressure (the pressure gauge should have a

full scale value MAX 30 - 40 BAR, for greater accuracy of adjustment).

1. Screw the intermediate pressure measuring gauge into one of the 3/8" low pressure ports on the first stage, usingthe wrench (B-18).

2. Assemble the hose with the partially finished 2nd stage on the port marked D.F.C., locking it down with the 14-mmwrench (B-18) or the 17-mm wrench (B-17).

3. Mount the regulator group on the control valve (of a tank or Test Bench).4. Depress the second stage demand lever, slowly open the tank valve and, almost simultaneously, release the demand

lever.5. Read the pressure gauge to check whether the 1st stage pressure adjustment is correct.

6. Fit the 2nd stage diaphragm (36) in the 2nd stage case (32).7. Insert the diaphragm retaining ring (78).8. Screw on the cover.

9. Insert the safety clip (63).10.Working through the hole in the second stage case, use the wrench (B-12) to lock down or back off nut (33) in order

to adjust the demand lever (35).

11.Press the purge button a few times.

WARNING ��THE DEMAND LEVER (35) IS CORRECTLY ADJUSTED WHEN AIR DELIVERY IS TRIGGERED ABOUT 1MM FROM THE START OF THEPURGE BUTTON'S TRAVEL, AND WHEN, ON SHAKING THE SECOND STAGE UP AND DOWN, THE "TAPPING" SOUND OF THE DEMANDLEVER TOUCHING THE METAL DISK OF THE DIAPHRAGM CAN BE HEARD.

IMPORTANT ��CONTINUE LOCKING DOWN THE COVER UNTIL THE TWO SEATS (ON THE CASE AND COVER) WHICH ACCOMMODATE THE SAFETYCLIP ARE ALIGNED.TO FACILITATE THIS OPERATION, USE THE SHAPED EDGE OF THE COVER AS A REFERENCE.

WARNING ��THE FIRST STAGE INTERMEDIATE PRESSURE MUST BE MEASURED WHEN THERE IS NO AIR COMING OUT OF THE 2ND STAGE. FORANY NECESSARY ADJUSTMENTS OF THE 1ST STAGE, REFER TO THE SEPARATE MANUAL.

WARNING ��IF THE DEMAND LEVER MOVES DOWN CONSIDERABLY DURING THE PROCEDURE DESCRIBED IN STEP -8-, TO PREVENT IT FROMCOMING OUT DURING THE SUBSEQUENT ASSEMBLY OPERATIONS, LOCK DOWN THE ADJUSTING NUT THROUGH A FEW TURNSUSING THE SPECIAL WRENCH (B-12) AND WORKING THROUGH THE HOLE IN THE SECOND STAGE CASE.

WARNING ��THE POPPET SEAT SHOULD NOT PROTRUDE BY MORE THAN 3.8 MM FROM THE CASE ASSEMBLY CONNECTOR.


1-11



06/02


PDP VERSION ONLY

a) Pull out the safety clip (63).b) Back off the cover and remove the diaphragm retaining ring (78) and the diaphragm (36).c) Position the O-Ring (171) in its seat in the DPD body (182).d) Using the special wrench (B 37), lock down the DPD body on the 2nd Stage case (32).

FIG. 8

NOTEASSEMBLE THE DPD LEVER ON THE DPD LEVER SUPPORT IF IT WAS PREVIOUSLY DISASSEMBLED.

e) Position the O-Ring (6) in the seat in the DPD lever support (181) (Fig. 9).f) Insert the DPD lever support (181) complete with lever (180) inside the DPD body (182). (Fig. 9).

WARNING ��THE DPD BODY (182) MUST BE FULLY LOCKED DOWN, MAKING SURE THAT ITS GROOVE IS PERFECTLY ALIGNED WITH THEREFERENCE ON THE SECOND STAGE CASE (32) AS ILLUSTRATED IN FIG. 8.


1-12



06/02


FIG. 9 A FIG. 9 B

g) Correctly insert the concave spring (102) inside the DPD body (182).

h) Correctly fit the DPD clamp (182) on the spring (102) (Fig. 10).i) Correctly insert the DPD knob (184) on the DPD body (182) (Fig. 10).

FIG. 10

WARNING ��DURING THE OPERATIONS DESCRIBED IN STEPS "G-H-I-J" HTM SPORT RECOMMENDS HOLDING THE DPD LEVER (180) AND ITSSUPPORT (181) IN PLACE INSIDE THE DPD BODY, IF NECESSARY USING ONE FINGER.

WARNING ��THE TAPERED SPRING IS CORRECTLY POSITIONED BY INSERTING IT INTO THE DPD BODY WITH THE SMALLER DIAMETER ENDFACING DOWNWARD.

WARNING ��AFTER COMPLETING THE OPERATION DESCRIBED IN STEP "F", MAKE SURE THAT:1. THE DPD LEVER (180) IS POSITIONED WITH THE CONCAVE PART FACING UPWARD 2. THE GROOVE ON THE DPD LEVER SUPPORT (181) IS FACING UPWARD (FIG. 9 B).


1-13



06/02


j) Lock down the screw (185) on the DPD knob (184) using a Phillips screwdriver (type USAG 327).

k) Apply the knob sticker (186) on the DPD knob (184).l) Fit the 2nd stage diaphragm (36) in the 2nd stage case (32).

m) Insert the diaphragm retaining ring (78).n) Screw on the cover.

o) Insert the safety clip (63).

STANDARD VERSIONS

12.Reassemble the O-Ring (72) on the case plug (64).13.Using the hex wrench (B-8), screw the case plug (64) into the threaded bushing

ALL VERSIONS

14.Position the hose protector (46).15.Disassemble the control valve group.16.Disassemble the intermediate pressure measuring gauge and screw in the port plug with its O-Ring seal.17.Assemble the mouthpiece (44), securing it with a new mouthpiece clamp (43).18.Fit the exhaust tee cap (41) and secure it with the fixing pin (174).


The checks described below are designed to verify the perfect operation of the regulator

Tab. A



SEGATSDNOCESROFERUSSERP"GNIKCARC"FOSEULAV

LEDOM HFOSEHCNI 2O HFOmc 2O

EGATSDN2YRAMIRP 5.1-1 5.3-5.2

EGATSDN2SUPOTCO 6.1-2.1 4-0.3

WARNING ��IF A TORQUE WRENCH IS USED, SELECT A TORQUE SETTING OF APPROXIMATELY 90 N/cm.

WARNING ��CONTINUE LOCKING DOWN THE COVER UNTIL THE TWO SEATS (ON THE CASE AND COVER) WHICH ACCOMMODATE THE SAFETYCLIP ARE ALIGNED.TO FACILITATE THIS OPERATION, USE THE SHAPED EDGE OF THE COVER AS A REFERENCE.

WARNING ��AFTER COMPLETING THE OPERATION DESCRIBED IN STEP "J" MAKE SURE THAT:1. IN THE PRE-DIVE POSITION, THE DPD LEVER PREVENTS THE DEMAND LEVER (32) FROM MOVING.2. IN THE DIVE POSITION THE DEMAND LEVER (32) IS ABLE TO MOVE FREELY.


1-14



06/02


FIG. 11

3. If the Cracking Pressure Value does not fall between the values specified in the table, proceed as follows:a. If the cracking pressure is greater, it is necessary to reduce the load on the spring.

- On second stages equipped with a case assembly connector (28) with adjustable seat connector (21), it is nec-essary to reduce the amount by which it protrudes using the hex wrench (B-4)

b. If the cracking pressure is lower, it is necessary to increase the loading on the spring.- On second stages equipped with a case assembly connector (28) with adjustable seat connector (21), it is nec-

essary to increase the amount by which it protrudes (MAX 3 mm) using the hex wrench (B-4).

4. Submerge the 2nd stage in water with the mouthpiece facing up, allowing water to enter the exhaust tee and keepingit in this position for about 30 seconds.

5. Remove the 2nd stage from the water, then turn the mouthpiece downward.6. Check for any traces of water inside the second stage.


WARNING ��IF MORE THAN A FEW DROPS OF WATER COME OUT OF THE SECOND STAGE, CHECK THE SEALS ON THE MOUTHPIECE CLAMP,THE EXHAUST VALVE AND THE RIM OF THE DIAPHRAGM.

WARNING ��WHENEVER THE LOADING OF THE SPRING IS CHANGED IT IS NECESSARY TO ADJUST THE DEMAND LEVER AS INSTRUCTED INTHE MANUAL.

WARNING ��IN THE ABSENCE OF A TEST BENCH IT IS POSSIBLE TO RUN AN APPROXIMATE CHECK OF THE CRACKING PRESSURE USING ABASIN OF WATER AND CARRYING OUT THE PROCEDURE BELOW:a. Remove the clamp (43) and the mouthpiece (44) from the second stage.b. Slowly submerge the 2nd stage in the water with the mouthpiece facing up, and without allowing water to go inside.c. When the water level, measured from the point shown in the diagram (Fig. 11) falls between the cracking values indicated in the table, the

air should start to flow.


1-15



06/02


TROUBLESHOOTING EAGLE/EAGLE DPD 2ND STAGES


1-16



06/02



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1-17



06/02





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PULSE INFLATORPAGE


InflatorJackets

06/02



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TableNo. 203

Drawing reference No.: J 4Table updated on: 30/10/2001PULSE INFLATOR HOSE

INTEGRATED SYSTEM H.U.B.PAGE


H.U.B. 06/02


TableNo. 204

Drawing reference No.: J 76Table updated on: 30/10/2001DACOR H.U.B.


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72 30011154 174596INU5.9x9.2wercS *** 74100264 tiKecivreSesoh/rotubirtsidroiretni.B.U.HrocaD

82 50201164 5202gniR-O )1302RO-411RO-79-25-82-91-4(

92 13785174 )mc05(LX-L"61/9-"2/1esoH.P.L xxx 67300274 ylbmessarotalfnIlarO.B.U.H

92 03785174 )mc34(M-S"61/9-"2/1esoH.P.L )04-93-83-33-13-32-22-12(

03 52000274 )LX-SeziS(gabycnayoub.B.U.HrocaD D ---- )77J.grd312.on.bat(rotalfnicitamuenp.B.U.H

13 80785174 81.maidgnirpanS E ---- )81E.grd201elbat(supotcOREPIV

33 17201174 0013gniR-O F ---- )9E).grd81.nelbat(egatSts1.B.U.H

43 52195174 laesevlavfeilernoisnapxe-revO G ---- )91E.grd301elbat(egatSdn2CETREPIV

53 45095174 ksidesabgnirpS H ---- )87J.grd602.on.bat(evlavtsuahxecitamuenP

INTEGRATED SYSTEM H.U.B. PAGE


H.U.B. 06/02


DrawingNo. J 79

Drawing updatedon: 05/04/2002EVOLUTION H.U.B.



H.U.B. 06/02


TableNo. 214

Drawing reference No.: J 79Table updated on: 09/05/2002EVOLUTION H.U.B.


1 60785174 rotubirtsidyaw7 63 05195164 evlavpmudriakciuQ

2 42785174 FNU"61/7rotcennoC 73 65095174 pacerusserprevO

3 61011154 02x5MwercS 83 xxx gnittifwobleleviwsrofegnalF

4 24201164 300-2gniR-O 93 01201164 6502gniR-O

5 37027144 ylbmessaleviwS 04 xxx gnittifwobleleviwS

6 63785174 mc55esoh.P.H 14 59000274 rekcitS

7 53785174 mc05gnilpuockciuqCB-"8/3esoh.P.L 34 42000264 kcapkcaB

7 43785174 mc54gnilpuockciuqCB-"8/3esoh.P.L 44 63195174 bonkkcalB

8 62785174 "8/3FNU2/1rotcennoC 54 96200274 )LX-Sezis(dnabgniniater.B.U.H

9 92785174 )leviws("2/1-"2/1esoH.P.L 74 31785174 4M370rotcennoCxepaT

01 70000264 relloR 84 00000264 rotubirtsidroftroppuS

11 71011154 621-NID3956-INU3.4.DrehsaW 05 32785174 "61/9FNU"2/1rotcennoC

31 51000264 etalppirG 15 50785174 rotubirtsidyaw4

51 90000264 dapknaT 25 80101164 801gniR-O

61 80000264 eldnaH 35 50258164 FNU"61/7gulP

71 51785174 mm08x5.ddoR 45 23785174 )tfosmc07("61/9-"8/3esoh.P.L

91 60101164 601gniR-O 65 18695174 ylbmessaesohPLlartueN

02 40258164 FNU"8/3gulP 66 22896134 droC

12 xxx ebuT 69 11395174 rotcetorpknaT

22 36897154 pmalcebuT 79 51201164 3402gniR-O

32 xxx evlavAOR037streboRyeklaH

42 71000264 revocevlav4UCA637yeklaH SEILBMESSA

52 81011154 A/521NID2956INU3.5.DrehsaW

62 51011154 CCT41x4MwercS B 59295174 kcapkcabdexifBMylbmessatleB

72 30011154 174596INU5.9x9.2wercS *** 74100264 tiKecivreSesoh/rotubirtsidroiretni.B.U.HrocaD

82 50201164 5202gniR-O )1302RO-411RO-79-25-82-91-4(

92 13785174 )mc05(LX-L"61/9-"2/1esoH.P.L xxx 67300274 ylbmessarotalfnIlarO.B.U.H

92 03785174 )mc34(M-S"61/9-"2/1esoH.P.L )04-93-83-33-13-32-22-12(

03 29200274 )LX-SeziS(gabycnayoub.B.U.HnoitulovE D ---- )77J.grd312.on.bat(rotalfnicitamuenp.B.U.H

13 80785174 81.maidgnirpanS E ---- )81E.grd201elbat(supotcOREPIV

33 17201174 0013gniR-O F ---- )9E).grd81.nelbat(egatSts1.B.U.H

43 52195174 laesevlavfeilernoisnapxe-revO G ---- )12E.grd501elbat(egatSdn2LATEMREPIV

53 45095174 ksidesabgnirpS H ---- )87J.grd602.on.bat(evlavtsuahxecitamuenP

INTEGRATED SYSTEM H.U.B. PAGE


H.U.B. 06/02


DrawingNo. J 78

Drawing continuedfrom previous tablePNEUMATIC EXHAUST VALVE H.U.B.



H.U.B. 06/02


TableNo. 206

Drawing reference No.: J 78Table updated on: 30/10/2001PNEUMATIC EXHAUST VALVE H.U.B.


32 20101164 5102gniR-O 54 73785174 rehsawnoitcirF

42 27201174 1x3gniR-O 64 10785174 gnirpsevlavcitamuenP

52 === rotcennocriA 74 32000264 gnirevlaV

72 30011154 5.9x9.2swercS 84 30785174 rekcitS

82 52000264 pacnoitcetorP

23 56201164 1323gniR-O SEILBMESSA

33 12785174 tfahsevlavyaw2

43 02785174 evlavrofgulP H 82100264 ylbmessaevlavtsuahxe.B.U.H

53 61785174 gnirpukcabhsaD -14-04-93-73-53-33-82-72-32(

73 21000264 egnalfevlavcitamuenP )84-74-64-54-44

83 52785174 tuntfahsevlaV xxx 62100264 ylbmessaesohPLgnol.B.U.H

93 01000264 tunksidgnilaeS )63-62-52-42(

04 72785174 ksidgnilaeS xxx 52100264 ylbmessaesohPLtrohs.B.U.H

14 11000264 troppusksidgnilaeS )63-62-52-42(

24 01101164 7302gniR-O *** 44100264 sevlavcitamuenp.B.U.HrocaD.tik.vreS

34 62000264 tunmgarhpaiD )24-402.bat93-53-402.bat33-23-42-32(

44 82785174 mgarhpaiD



H.U.B. 06/02


TableNo. 213

Drawing reference No.: J 77Table updated on: 30/10/2001

PNEUMATIC INFLATOR ASSEMBLYA.T. DACOR


1 31000264 ydobrotalfnI 32 20101164 5102gniR-O

2 71785174 snotsiprofgnirpS 42 27201174 1x3gniR-O

3 31201164 7002gniR-O 52 === rotcennocriA

4 04785174 gnihsubnottubnoitalfeD 72 30011154 5.9x9.2swercS

5 11201164 0502gniR-O 82 52000264 pacnoitcetorP

6 54785174 taesnotsipnoitalfeD 92 22785174 tfahsevlaV

7 10101164 2102gniR-O 03 41000264 egnalfrotalfnI

8 24785174 notsipnoitalfeD 13 70785174 6.maidgnirpanslaidaR

9 81000264 nottubnoitalfeD 23 56201164 1323gniR-O

01 91000264 nottubnoitalfnI

11 22000264 gnirrotalfnI

21 02000264 gnirevocrewoL SEILBMESSA

31 12000264 gnirevocreppU

41 40011154 91x9.2swercS D 58200274 .B.U.HylbmessarotalfnicitamuenP

51 57058164 61x3MswercS +++ 14100264 rotalfnicitamuenPylbmessamsinahcemlanretnI

61 64195174 retliF )02-91-81-71-61-51-8-7-6-5-4-3-2-1(

71 60101164 601gniR-O xxx 62100264 ylbmessaesohPLgnol.B.U.H

81 81785174 gnilpuockciuqelaM )63-62-52-42(

91 14785174 notsipnoitalfnI xxx 52100264 ylbmessaesohPLtrohs.B.U.H

02 64785174 taesnotsipnoitalfnI )63-62-52-42(

12 07201174 6513gniR-O *** 64100264 rotalfnicitamuenp.B.U.HrocaD.tik.vreS

22 06983114 rotcennocegnalfrotalfnI )23-42-32-12-71-7-5-3(

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