GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET MAINTENANCE MANUAL FOR AUTHORISED TECHNICIANS

Transcription

1 Home TECHNICAL SUPPORT GX300 REGULATOR FOR THE AQUA LUNG G3000SS DIVING HELMET MAINTENANCE MANUAL FOR AUTHORISED TECHNICIANS Document No. AP2548 Issue 4 19/07/2015 APEKS MARINE EQUIPMENT LTD, NEPTUNE WAY, BLACKBURN, LANCASHIRE. BB1 2BT Tel: +44 (0) Fax: +44 (0) info@apeks.co.uk Web:

2 AMENDMENTS RECORD: Amendments and approval of this document can only be carried out by the relevant people listed on the Approved list of signatures, which is listed in the Apeks Quality Manual. To instigate a change, a Task / Change request form, (Form No. DESI/10002 ), must be completed and passed to the relevant person(s) for approval which are listed on the Approved List of Signatures. When approval has been granted and recorded this table can then be completed and the document up issued. Change No. Change Request No N/A Description & Comments: AP2553 Diaphragm part number 30. Bought in diaphragm changed to Apeks. Page 13 Functional Bench Test of Helmet and Regulator. Various spelling mistakes and ammendments made to pages 3, 5, 7, 8, 11, 12, 13, 15, 17 and 18. Change Date New Issue No. Changed By: Approved By: 12/03/15 2 CT DL 20/03/15 3 CT DL 19/07/16 4 RH DL 2

3 COPYRIGHT NOTICE This manual is copyrighted, all rights reserved. It may not, in whole or in part, be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine readable form without prior consent in writing from Apeks Marine Equipment Ltd. It may not be distributed through the internet or computer bulletin board systems without prior consent in writing from Apeks Marine Equipment Ltd Apeks Marine Equipment Ltd. G3000SS DIVING HELMET (APEKS GX300 REGULATOR) Maintenance Manual(19/03/2015 Issue 3) INTRODUCTION This manual provides factory prescribed procedures for the correct installation, adjustment and maintenance of the Apeks GX300 regulator fitted to the G3000SS diving helmet. This is intended as a supplement to the Gorski G2000SS helmet technical maintenance manual. The G3000SS diving helmet is a G2000SS helmet but with the following important revisions: - Apeks GX300 2nd stage regulator - Double exhaust and double water dump. - Ergonomic free flow knob - 4-wire communications (Marsh Marine or Hi-Use version) This manual should be read in conjunction with the G2000SS manual. Instructions for upgrading a G2000SS to a G3000SS are included in this manual. All the checklists and set-up procedures described in the G2000SS technical manual need to be followed.the procedures outlined within this manual are to be performed only by personnel who have received factory authorised training. If you do not completely understand all of the procedures outlined in this manual, contact Apeks or Aqualung to speak directly with a Technical Advisor before proceeding any further. As with the G2000SS helmet the diver is recommended to carry an emergency gas supply so that in the event of an interupted umbilical supply the diver has enough reserve gas to return to a place of safety. With the G3000SS diving helmet there are various options for the emergency gas supply or bail out. These options are laid out later in this manual. WARNINGS, CAUTIONS & NOTES WARNINGS indicate a procedure or situation that may result in serious injury or death if instructions are not followed correctly. CAUTIONS indicate any situation or technique that will result in potential damage to the product, or render the product unsafe if instructions are not followed correctly. NOTES are used to emphasise important points, tips, and reminders. SCHEDULED SERVICE The same service schedule as outlined in the Gorski technical manual should be followed but using the regulator service kit and tools described in this manual. The G3000SS diving helmet is subject to annual service regardless of usage. With heavy use in contaminated water it is recommended to service the regulator more regularly. In some contaminated water it may be preferable to replace the regulator seals after every use and this should be determined via risk assessment. GENERAL GUIDELINES 1. In order to correctly perform the procedures outlined in this manual, it is important to follow each step exactly in the order given. Read over the entire manual to become familiar with all procedures and to learn which specialty tools and replacement parts will be required before commencing disassembly. Keep the manual open beside you for reference while performing each procedure. Do not rely on memory. 2. All service and repairs should be carried out in a work area specifically set up and equipped for the task. Adequate lighting, cleanliness and easy access to all required tools are essential for an efficient repair facility. 3. Before beginning any disassembly, it is important to first perform the initial inspection procedure. Refer to Table 1 : Troubleshooting Guide page 17, to determine the possible cause of any symptoms which may be present. 4. As each unit is disassembled, reusable components should be segregated and not allowed to intermix with non-reusable parts or parts from other units. Delicate parts, including valve spindles and valve seats which contain critical sealing surfaces, must be protected and isolated from other parts to prevent damage during the cleaning procedure. 5. Use only genuine Apeks parts provided in the service kit. 6. Do not attempt to reuse mandatory replacement parts under any circumstances, regardless of the amount of use the product has received since it was manufactured or last serviced. 7. When reassembling, it is important to follow every torque specification prescribed in this manual, using a calibrated Newton Meter (Nm) or Inch Pound (in-lb) torque wrench. Most parts are made of either marine brass or plastic, and can be permanently damaged by undue stress. The G3000SS helmet has been CE certified by Germanischer Lloyd SE, Brooktorkai Hamburg, Germany Notified Body number 0098 and has been found to be in accordance with the requirements of Council Directive 89/686/EEC. When examined the product satisfied the requirements of the manufacturer s technical specifications (based upon BS EN requirements), which has been previously assessed and deemed to meet the basic health and safety requirements (Annex II) ot the directive. 3

4 Disassembly Procedures for the GX300 Regulator Case 1. Unscrew valve cover (11) counter clock wise. Leave the purge button in place unless defective. 6. Remove O ring (3) using O ring removal tool AT Remove spring carrier (9), diaphragm spring (8) and valve diaphragm assembly. 7. Unscrew side valve case (2) from side valve diaphragm housing (7) counter clock wise by hand whilst gently pulling apart. 3. Using a 3/4 spanner (AT33) unscrew valve lock nut (1). 8. Remove O ring (3) from valve case (2) using O ring removal tool AT Remove spindle assembly by pushing exposed thread from valve lock nut removal. Use the lever (25) to guide out the spindle if required. 9. Remove O ring (6) from valve diaphragm housing (7) using O ring removal tool AT79 5. Unscrew the 4 mouthpiece screws (5) using the 5/64 allen key. Disassembly of the GX300 Regulator Case is Now Complete 4

5 Disassembly Procedures for the Valve Spindle Assembly 14. Using the protruding arms of the spindle locking washer (22) pull the whole side valve shuttle assembly from the side valve spindle (15). 10. Remove Nylock nut (27) using 7mm nut driver or spanner and put to one side. Caution: Take care when removing parts 25 and 26 as they may fall out easily. The lever washer (26) is not replaced during service and must be retained. 11. Remove lever washer (26) and lever (25) by sliding out of valve spindle slots. 15. Using slotted valve adjustment tool (AT51/L) unscrew the valve seat (13) until the thread disengages. 16. Guide the seat tool (109437) into the shaft of the side valve spindle (15) plastic end first and push the valve seat (13) until it protrudes from the other end. Caution: Take care when handling the valve seat (13) that no damage is caused to the actual sealing edge. 12. Unscrew the spindle adjuster (24) counter clockwise by hand. 13. Refit Nyloc nut (27) by hand, screw down until male thread of the valve shuttle (17) reaches nylon in the nut. 17. Remove the O ring (12) from the valve seat (13) using the O ring removal tool AT Remove the O ring (14) from the valve spindle (15) using O ring removal tool AT79. 5

6 19. Unscrew nyloc nut (27) and dispose of, then slide the spindle bush (23) and spindle locking washer (22) free from the side valve shuttle (17). 24. Remove O ring (18) from valve shuttle (17). 25. Remove silicone seat (16) from valve shuttle (17). 20. Remove O ring (12) from the spindle bush (23). Disassembly of the Valve Spindle Assembly is Now Complete 21. Slide the valve sleeve (21) from the side valve shuttle (17) and remove O ring (12) 22. Remove spring (20) from valve shuttle (17). 23. Remove O ring (19) from valve shuttle (17). 6

7 Disassembly Procedures for the Valve Diaphragm 1. Remove sealing disc (34) by gently lifting it by the edges and sliding it out of the diaphragm ring (32). 6. Push on the underside of the diaphragm ring (32) to reveal the diaphragm (30). Peel the diaphragm (30) at one edge to reveal the groove which it was seated in and work free all the way around until the diaphragm ring (32) is free. 2. Gently lift the exhalation diaphragm (33) at the edge and pull away from the diaphragm ring (32). 3. Remove O ring (28) from diaphragm carrier (29) groove. 7. Lift the edge of the diaphragm (30) and pull away from the diaphragm carrier (29). Ease out the diaphragm (30) from the groove which it was seated into all the way round to release. 4. Remove diaphragm pad (31) by holding the assembly firmly and pulling the pad outwards. Caution: Check the diaphragm (30) and exhalation diaphragm (33) for holes or imperfections. Disassembly of the Valve Diaphragm is Now Complete 5. Push on the underside of the diaphragm ring (32) to reveal the diaphragm (30) and retaining ring (35). Remove retaining ring (35) gently to avoid damage to the diaphragm (30) and teeth of the ring. 7

8 Assembly Procedures for the Valve Diaphragm Assembly 5. Carefully push on retaining ring (35) to diaphragm (30). Ensure the eight teeth on the retaining ring (35) are facing towards the diaphragm (30). They must also fit between the four stop lugs of the diaphragm (30) but not go past or over them. Caution: Check air escape holes are clear on the underside of the diaphragm carrier (29), hold it up to the light to check. If the holes are not clear (30) it will not seat. Use a pin to remove any debris if required. 1. Place the diaphragm carrier (29) flat on the bench with the internal diaphragm groove facing upwards. 6. Fit the exhalation diaphragm (33) to the centre pin on the diaphragm ring (32). Press well down into the valve seat so that the sealing edge is pre-loaded towards the diaphragm ring (32) with the projecting part facing outwards. 2. Press the diaphragm (30) into the carrier groove with the text on the diaphragm facing upwards. 3. Work the diaphragm (30) around pressing it firmly into the carrier groove evenly so the face with text sit s flush. Check for creases. 4. With the projecting guide pin of the diaphragm ring (32) facing upwards fit inner edge of diaphragm (30) into diaphragm ring (32) pressing into groove. Press into place all the way around evenly. 7. Push diaphragm pad (31) into the groove on diaphragm ring (32). Press firmly until the pad is seated flush or clicks into place. 8. Place the sealing disc spigot (34) into the hole on the projecting guide pin of the diaphragm ring (32) and press lightly into place. 9. Fit the lightly lubricated O-ring (28) into the diaphragm carrier (29) groove. Caution: When fitting diaphragm (30) make sure not to disengage from carrier (29). Assembly of the Valve Diaphragm is Now Complete 8

9 Assembly Procedures for the GX300 Inlet Valve GX300 Regulator Maintenance Manual NOTE: Lubricate valve shuttle (17) shaft only. Do not lubricate threads or silicone valve seat end. 6. Place the silicone valve seat (16) on a clean flat surface face down. Press the valve shuttle (17) onto the seal until its fully located into place. 1. Push O ring (14) over threads of spindle (15) into O ring groove. 2. Fit O ring (12) onto valve seat (13). Caution: Take care when handling the silicone valve seat (16), not to cause damage to the face side. 7. Fit O ring (12) into groove on side valve sleeve (21). 3. Push valve seat (13) into the valve spindle (15) then screw all the way in with the slotted valve seat adjuster (AT51/L). Caution: Do not overtighten valve seat (13) into side valve spindle (15). 8. Slide spring (20) over valve shuttle (17). 4. Fit O ring (19) into the first groove on valve shuttle (17) using seal expander (AT67). 9. Slide side valve sleeve (21) over valve shuttle (17). Pass valve shuttle (17) through large bore end of the valve sleeve (21). Locate over O rings until it meets the spring making sure it will compress the spring. 5. Fit O ring (18) into groove on valve shuttle (17) into O ring bottom groove. 10. Slide valve shuttle assembly into spindle (15) seat end first. 9

10 11. Fit spindle locking washer (22) onto exposed thread on valve shuttle. Locate into long spindle slots with flats on washer. The side valve shuttle (17) can be rotated to aid lining up. 12. Screw spindle adjuster (24) over exposed thread on valve shuttle (17) and onto spindle all the way down. Then back off (turn counter clockwise)1 full turn and 1/6 of a turn (7 holes). NOTE: The spindle adjuster sets the cracking effort. The 7 hole setting is the optimum setting for normal diving operations. For further adjustment see page Fit O ring (12) onto spindle bush (23). 16. Fit lever washer (26) over threads on spindle and rest against the lever. 17. Tighten nyloc nut (27) with 7mm nut driver or spanner onto spindle until there are two complete threads visible past the end of the nyloc nut. There should be roughly 5mm of free movement at the end of the lever. This is a preliminary setting only Assembly of the GX300 Inlet Valve is Now Complete Assembly Procedures for the GX300 Regulator Case 14. Place spindle bush over exposed thread on valve shuttle and push into the spindle as far as it will go using seal expander (AT82). 18. Fit lightly lubricated O-ring (3) onto valve case (2), locate into groove. 19. Fit lightly lubricated O ring (6) onto valve diaphragm housing (7), locate into groove. 15. Place lever (25) into spindle slots on spindle facing spindle hole. NOTE: The lever will only fit one way easily and should not be forced into the slots. It should be positioned with the spoon back facing upwards. 20. Screw valve case (2) into diaphragm housing (7) all the way in until the thread disengages. The valve case should rotate freely. Align mouthpiece slot up with diaphragm housing. Correct Incorrect 10

11 21. Fit O ring (3) into groove on mouthpiece (4). Regulator Adjustment and Leak Test 1. Connect to a regulated air source between 9.2 bar (133 psi) and 9.8 bar (142 psi). 22. Place mouthpiece (4) onto valve case and fasten with the 4 allen key screws (5) using 5/64 allen key to 0.5Nm (4 in-lb). NOTE: If air starts to vent when supply is started, turn locknut counter clockwise until it stops. NOTE: If the air continues to vent, disassemble and check parts. 2. Partially actuate the lever to check the regulator vents. Then submerge in water and check for leaks. Caution: Check O ring is still engaged whilst tightening screws. Partially take screws down, then tighten until the mouthpiece bottoms out. Any further tightening may damage the case. 23. Fit spindle assembly (A) into valve case locating into slot at bottom face of case. Position lever as shown. Press the lever on to the housing to ensure free movement. 24. Pull thread of spindle assembly to reveal fully. Screw valve lock nut (1) over spindle, flange side out using 3/4 spanner (AT33) and tighten to a torque value of 5nM (44 in-lb). Assembly of the GX300 Regulator Case is Now Complete Regulator Adjustment is Now Required NOTE: Ensure the mouthpiece is facing upwards to allow trapped air to release. 3. Remove from water.turn the locknut clockwise until air starts to vent. As soon as air starts to vent loosen (i.e. turn counter clockwise) the locknut until the leak completely stops, then continue to loosen at least a further 1/4 turn to a maximum of 1/2 turn. There should be some free play in the lever. Exhaust Assembly Required See Page Once set the full regulator is submerged in water and checked for leaks. 5. Remove from water. Depress the purge button fully to expel any water and to ensure that an adequate volume of air needed to clear the second stage flows through the mouthpiece. Regulator Adjustment is Now Complete See Page 12 for Optional Magnehelic Setting 11

12 Assembly Procedure of the Exhaust Valve NOTE: For assembly instructions of the exhaust valve internal components see page Fit valve diaphragm assembly into diaphragm housing (7). Cracking Effort Fine Adjustment Using Optional Magnehelic Gauge 1. With the cover installed place the regulator mouthpiece onto the Magnehelic test bench and read the figure on the gauge.this should read between 2.0 and 2.5 H2O. Repeat again to ensure a constant reading. NOTE: Make sure O-ring (28) on diaphragm assembly remains in place. 2. Fit diaphragm spring (8) to spring carrier (9) and fit assembly into valve cover (11). 3. Screw cover onto diaphragm housing until hand tight. NOTE: If the reading is outside the given range the cover and exhaust valve must be removed and the regulator adjusted. 2. To adjust the regulator use a small allen key to engage the spindle adjuster holes and turn. To reduce the cracking effort turn counter clockwise. To increase the cracking effort turn clockwise. Adjust one hole span at a time before reassembling the cap and retesting from point 4 from page 11. NOTE: The regulator can be adjusted whilst fitted into the helmet (i.e. field adjustment) and without using a Magnehelic gauge. It must be recognised that in order to achieve the most accurate setting the regulator should always be removed from the helmet and set on a Magnehelic gauge. Cracking Effort User Adjustment Guidelines 4. Press the purge button to ensure all parts are operational and have free movement. 1. The normal 7 hole setting of the spindle adjuster (see page 10) is the optimum setting for normal diving operations. At this setting the regulator will function correctly within a wide range of regulated supply pressures (see Table on page 14). Assembly of the Exhaust Valve is Now Complete Return to Page 11 to Complete Leak Testing Step 4 2. The spindle adjuster may be adjusted as detailed above to take account of local diving conditions. For example, when using a LP compressor supply it is acceptable to reduce the cracking effort by turning the spindle adjuster counter clockwise up to 14 holes. After adjustment the regulator must be reassembled and retested from point 4 from page

13 Final Assembly of the GX300 Regulator into the Helmet Functional Bench Test of Helmet and Regulator ( Neck Dam Pull Test ) 1. Fit complete regulator into helmet. Position mouthpiece to bottom of helmet, then rotate into place for entry. 2. Push spindle into freeflow device until it locates into place. 6. Fit the regulator into the helmet and fit the neck dam assembly. Connect the helmet to a regulated air source between 9.2 bar (133 psi) and 9.8 bar (142 psi). 7. Take hold of the open end of the neckseal and bunch tightly to ensure that the open end is sealed. 3. Place oral nasal mask over mouthpiece. 4. Screw down regulator cap (11) until it is hand tight. Ensure the grooves on the cap line up with the screw holes. 8. Slowly pull the bunched end of the neck seal out to full extension, then push back fully into the helmet. Repeat this 3 or 4 times. The regulator should be heard to open and close (i.e. inhale and exhale). This pull & push action simulates a diver breathing in the helmet. A properly serviced and adjusted regulator should deliver air upon deep inhalation without excessive inhalation effort, freeflow, or fluttering of the second-stage regulator. 5. Fit the 3 new cap head screws (10), tighten each screw using a 5/32 allen key to 5NM (44 in-lbs). Final Installation of the GX300 Regulator is Now Complete Caution:Do not overtighten as this may damage the cover or valve case! 13

14 Upgrading the G2000SS Diving Helmet with the GX300 Regulator NOTE: When retro fitting the new GX300 regulator to an existing G2000SS helmet it will then be known as the Aqualung G3000SS helmet. A double exhaust kit (water dump), PN , should be fitted to the helmet at the same time. Removing the Old Regulator Fitting the GX300 Regulator 1. Remove the 5 dome head screws using a Phillips#3 screwdriver. 6. Fit complete regulator into helmet. Position mouthpiece to bottom of helmet, then rotate into place for entry. 2. Remove cover plate. 7. Push regulator spindle onto freeflow valve until it locates firmly into place. 3. Disengage oral nasal mask. 8. Place oral nasal mask over mouthpiece. 4. Remove Poseidon regulator using a flat blade screwdriver. Use screwdriver as a lever against nose clearing device to push the regulator out. 5. Slide out regulator rotating downward to ease removal. 9. Screw down regulator cap (11) until it is hand tight. Ensure the grooves on the cap line up with the screw holes. 10. Fit the 3 new cap head screws (10), tighten each screw using a 5/32 allen key to 5NM (44 in.lbs). NOTE: Keep all screws and cover plate (needed to fit the optional free flow blanking plug system). Caution: Do not overtighten as this may damage the cover or valve case! 14

15 GX300 Regulated Supply Pressure Guidelines DEPTH RECOMMENDED SUPPLY PRESSURE RANGE (MSW) (FSW) (BAR) (PSIG) MINIMUM MAXIMUM MINIMUM MAXIMUM (not recommended when using normal air) Pressures based on providing sufficient breathing performance at a RMV of 62.5 lpm High Pressure (HP) Gas Supply Systems. The GX300 Regulated Supply Pressure Guidelines apply to conventional surface supply systems providing a regulated gas supply to the diver through an MP umbilical. If a high pressure (HP) gas supply system is used these guidelines do not apply. The HP gas supply system will automatically adjust the diver s gas supply pressure with changes in depth. Always refer to the manufacturer s instructions for the system being used. Emergency Gas Supply Options The G3000SS is designed to be used with the following configurations of Emergency Gas Supply (EGS) or bail out system: Option 1: a. AquaLung G3000SS Diving Helmet b. Main surface MP gas supply, using surface gas control panel and standard diver s umbilical, connected directly into one port of the G3000SS Helmet c. Apeks Quick Disconnect Hose -AP0205/Y, into the second port of the G3000SS Helmet d. Apeks Switch Block - AP0281/G, connected to the other end of the QD hose via the bail out port e. One of Apeks First Stage Regulators: i. DS4 First Stage Regulator - AP0528 ii. DST First Stage Regulator - AP & AP0361F-1 iii. FST First Stage Regulator - AP & AP0362F-1 iv. FSR First Stage Regulator - AP & AP0364F-1 f. Apeks Pressure Gauge - AP0633, on the first stage g. Apeks Pressure Relief Valve - AP0849, on the first stage h. AquaLung H3 Harness , to mount the Switch Block (chest strap or waist strap position) and the bail out cylinder i. IDEST certified bail out cylinder (with sufficient volume for emergency) j. Apeks 36 Regulator Hose - AP0206, connecting the Switch Block and first stage regulator k. Apeks CE certified cylinder valve with the first stage connected 15

16 Option 2: a. AquaLung G3000SS Diving Helmet GX300 Regulator Maintenance Manual b. Tatum SLS high pressure (HP) gas supply system with high pressure umbilical connected to the Tatum pressure reducer (mounted on diver) c. Apeks Quick Disconnect Hose -AP0205/Y, into one port of the G3000SS Helmet from the Tatum pressure reducer d. One of Apeks First Stage Regulators: i. DS4 First Stage Regulator - AP0528 ii. DST First Stage Regulator - AP & AP0361F-1 iii. FST First Stage Regulator - AP & AP0362F-1 iv. FSR First Stage Regulator - AP & AP0364F-1 e. Apeks Pressure Gauge - AP0633, on the first stage f. Apeks Pressure Relief Valve - AP0849, on the first stage g. AquaLung H3 Harness , to mount the pressure reducer and the bail out cylinder h. IDEST (or equivalent) certified bail out cylinder (with sufficient volume for emergency) i. Apeks 36 Regulator Hose - AP0206, connecting the Tatum pressure reducer and first stage regulator j. Apeks CE certified cylinder valve with the first stage connected Option 3: a. AquaLung G3000SS Diving Helmet b. Main surface MP gas supply, using surface gas control panel and standard diver s umbilical, connected directly into one port of the G3000SS Helmet c. Apeks Quick Disconnect Hose -AP0205/Y, from the first stage regulator to the second port of the G3000SS Helmet d. One of Apeks First Stage Regulators: i. DS4 First Stage Regulator - AP0528 ii. DST First Stage Regulator - AP & AP0361F-1 iii. FST First Stage Regulator -AP & AP0362F-1 iv. FSR First Stage Regulator - AP & AP0364F-1 e. Apeks Pressure Gauge - AP0633, on the first stage f. Apeks Pressure Relief Valve - AP0849, on the first stage g. AquaLung H3 Harness , to mount the bail out cylinder h. IDEST certified bail out cylinder (with sufficient volume for dive undertaken) i. Apeks CE certified cylinder valve with the first stage connected NOTE: In option 3, prior to diving the cylinder valve is to be opened fully and then closed: this leaves the bailout hose pressurised during the dive. WARNING: In option 3, when not using a switch block the cylinder should be mounted with the cylinder valve at the bottom. The valve should be left switched off to prevent accidental loss of the back up air. The diver should check that they can access the cylinder valve in an emergency to switch to the bail out supply. WARNING: The diver should ensure the two check valves are in position on the G3000SS helmet and that they are fully operational. In an emergency situation the lack of operational check valves could lead to loss of pressure and even a fatality. 16

17 Guide to troubleshooting. Table 1 - Troubleshooting GX300 Regulator Maintenance Manual SYMPTOM POSSIBLE CAUSE TREATMENT Leakage from regulator exhaust ports. 1. Excessively high supply pressure. 1. Ensure supply pressure is below the maximum stated within the pressure guidlines. 2. Supply pressure is above the standard setting. 3. Silicone seat (16) damaged or not seating correctly. 4. Lever (25) set too high. 4. Adjust lever. 5. Lever (25) bent. 5. Replace lever. 6. Valve spring (20) damaged or incorrect. 6. Replace spring. 7. Shuttle valve O rings (18,19) damaged. 7. Replace O rings. 8. Sleeve (21) bore damaged. 8. Replace sleeve. 9. Valve seat O ring (12) damaged. 9. Replace O ring. 10. Diaphragm spring (8) out of position or incorrect. 11. Exhalation Diaphragm (Diaphragm Assembly - item 33) damaged or snagged. 12. Sealing disc (Diaphragm Assembly - item 34) not in contact with rubber seating edge. 2. Wind in the spindle adjuster (24) until leaking stops (Note: This will affect breathing performance). 3. Replace seat and ensure metal valve is fully screwed in and undamaged (13). 10. Remove cap and check spring. 13. Dirt or ice build up around exhausts. 13. Check and clean. 14. Diaphragm O ring (Diaphragm Assembly - item 28) damaged or out of position. 15. Diaphragm (Diaphragm Assembly item 30) disengaged or out of position. 11. Check Exhalation Diaphragm around its sealing edge and replace if required. 12. Check for free movement of sealing disc and check sealing surface. 14. Check and replace O ring. 15. Inspect diaphragm, make sure it s secure in the groove and replace if torn or looking perished. 17

18 SYMPTON POSSIBLE CAUSE TREATMENT Excessive work of breathing. 1. Low supply pressure. 1. Check equipment upstream. 2. Lever (25) set too low. 2. Adjust lever. 3. Interruption in supply to the regulator. 4. Lever (25) bent and catching on valve spindle. 3. Check for leaks. Check the supply hoses are clear and not kinked. 4. Check lever slots are clear and replace lever if bent. 5. Spindle (15) orientated incorrectly. 5. Check position against diaphragm in manual. 6. Diaphragm ( Diaphragm Assembly - item 30) or sealing disc (34) failing to create a seal. 7. Oral nasal mask failing to create a good seal. 6. Inspect parts then remove regulator for vacuum test. 7. Check mask condition, correct seating of oral nasal valve, microphone and also check the mask is properly engaged on the regulator mouthpiece. 8. Regulator failing to make a good seal. 8. Check all O rings in regulator case (3,6) and check alignment with free flow device. 9. Check that the adjuster (24) is in its default setting. 9. Check first with setting tool and then with a pressure gauge. Water entering regulator 10. Seizing of the spindle parts. 10. Manually check for dirt ingress and free movement of the shuttle valve (17) inside the spindle (15). 1. Diaphragm (30) damaged or disengaged. 1. Inspect diaphragm, make sure its secure in the groove and replace if torn or looks perished. 2. Diaphragm (30) improperly seated. 2. Check diaphragm for any ripples, remove and refit keeping it level all the way around and flush with the carrier. 3. Exhalation Diaphragm (33) damaged or snagged. 3. Inspect Exhalation Diaphragm and replace. 4. Housing (7) cracked. 4. Disassemble and replace the housing. 5. Regulator cover (11) not fully screwed down. 5. Fully hand tighten cover. 6. Diaphragm O ring (28) damaged. 6. Replace O ring. 7. Housing O ring (6) damaged. 7. Replace O ring. 8. Sealing disc (34) not in contact with rubber seating edge. 9. Dirt or ice build up around exhausts. 9. Check and clean. 10. Diaphragm spring (8) out of position or incorrect. 8. Check for free movement of sealing disc and check sealing surface. 10. Remove cap and check spring. 18

19 Table 2 - Recommended Tool List PART NO. DESCRIPTION APPLICATION AT33 3/4 Spanner Side Valve Lock Nut (1) AT51/L Slotted Valve adjustment Tool Valve Seat (13) AT88 Seal Expander O Ring (18+19) AT79 O Ring Tool O Ring Removal Seat Tool Valve Seat Removal (13) N/A 7mm Nut Driver Nyloc Nut (27) N/A 5/32 Allen key Cap Head Screws (10) N/A 5/64 Allen key Mouthpiece Screws (5) N/A Phillips #3 Screwdriver Cap Head screws (exhaust valve cover) N/A Flat Head Screwdriver Regulator Removal from Helmet AT33 NUT DRIVER AT51/L PHILIPS SCREWDRIVER AT88 AT FLAT HEAD SCREWDRIVER 5/64 ALLEN KEY 5/32 ALLEN KEY 19

20 Cleaning and Lubrication Procedure Cleaning Brass and Stainless Steel Parts 1. If required, pre-clean in warm, soapy water* using a nylon bristle tooth brush. 2. Thoroughly clean parts in an ultrasonic cleaner filled with a solution of household white distilled vinegar (Acetic Acid) mixed with fresh water (max 50% vinegar). Clean ultrasonically for 5 minutes (max 10 minutes). DO NOT place plastic, rubber, silicone or anodized aluminium parts in vinegar. 3. Remove parts from the ultrasonic cleaner and rinse with fresh water. If tap water is extremely hard, place the parts in a bath of distilled water to prevent any mineral residue. Agitate lightly, and allow to soak for 5-10 minutes. Remove and blow dry with low pressure (25 PSI/1.7Bar) filtered air. Inspect closely to ensure proper cleaning and like-new condition. Cleaning Plastic & Rubber Parts Parts made of plastic or rubber may be soaked and cleaned in a solution of warm water mixed with mild dish soap. Use only a soft nylon toothbrush to scrub away any deposits. Rinse in fresh water and thoroughly blow dry, using low pressure filtered air. Caution: Do not place plastic and rubber parts in acid solutions. Doing so may alter the physical properties of the component, causing it to prematurely degrade and/or break. Lubrication and Dressing All O rings should be lubricated with Christo-Lube MCG-111 or PerFluoroLube 20/1. Dress the O rings with a very light film of grease, and remove any visible excess by running the O ring between thumb and forefinger. Avoid applying excessive amounts of lubricant as this will attract particulate matter that may cause damage to the O ring. *Soapy water is defined as household grade liquid dishwashing detergent diluted in warm water. 20

21 Table 3 - Recommended Lubricants & Cleaners LUBRICANT / CLEANER APPLICATION SOURCE Christo-Lube MCG-111 (Lubricant). All O ring seals Lubrication Technologies 310 Morton Street Jackson, OH 45640, USA (800) , or Apeks Marine Equipment Ltd PN AP1495 PerFluoroLube 20/1 (Lubricant). All O ring seals Performance Fluids Suite 101 Lomeshaye Buisness Park Turner Road Nelson Lancashire BB9 7DR CAUTION: Silicone rubber requires no lubrication or preservative treatment. DO NOT apply grease or spray to silicone rubber parts (eg. Diaphragm, Exhaust Valves.) Doing so may cause a chemical breakdown and premature deterioration of the material. Biox (Cleaning agent) White distilled vinegar (100gr.) (Cleaning agent) Biological immersion fluid for reusable stainless steel and brass parts Acid bath / ultrasonic cleaner for reusable stainless steel and brass parts Biox LTD 52 Hughenden Avenue High Wycombe Bucks HP13 5SJ Household grade CAUTION: Do not use muriatic acid for the cleaning of any parts. Even if strongly diluted, muriatic acid can harm chrome plating and may leave a residue that is harmful to o-ring seals and other parts. Liquid dish washing detergent diluted with warm water (Cleaning agent) Degreaser for stainless steel and brass parts, general cleaning solution for plastic and rubber Household grade 21

22 Table 4 - Torque Specifications GX300 Regulator Maintenance Manual PART NUMBER DESCRIPTION / KEY NUMBER TORQUE AP2502 Lock Nut 5NM (44 in.lbs) AP2512 AP2510 A2 Stainless Steel Socket Head Cap Screw UNC x NM (44 in.lbs) A2 Stainless Steel Socket Countersunk Screw UNC 6-32 x NM (4 in.lbs) Table 5 - Test Bench Specifications TEST CONDITION ACCEPTABLE RANGE Cracking Effort External Leak High Pressure >200 Bar Gauge (2900 psi) Med Pressure 9.5 ± 0.5 Bar (137 ± 7 psi) Gas Flow of 5 lpm High Pressure >200 Bar Gauge (2900 psi) Med Pressure 9.5 ± 0.5 Bar (137 ± 7 psi) +2.0 to 2.5 in H²0 No Visual Leaks Allowed 22

23 AP0300 GX300 Regulator Exploded Parts Diagram GX300 Regulator Maintenance Manual 1 AP2502 Valve Lock Nut 7 AP2501 Valve Diaphragm Housing 2 AP2500 Valve Case 8 AP2505 Diaphragm Spring 3 AP2509 BS029 O ring 9 AP2506 Spring Carrier 4 AP2503 Valve Mouthpiece 10 AP2512 A2 Stainless Steel Socket Head Cap Screw UNC x AP2510 A2 Stainless Steel Socket Countersunk Screw UNC6-32 x AP2508 BS034 O ring 11 AP2523 Valve Cover A - Valve Spindle Assembly - see page 24 B - Valve Diaphragm Assembly - see page 25 All items in bold italics to be replaced when servicing. Service kit AP0300/K. 23

24 AP0279 Valve Spindle Assembly Exploded Parts Diagram 12 AP1154 BS010 O ring 20 AP2021 Spring 13 AP2033 Valve Seat 21 AP2515 Valve Sleeve 14 AP1159 BS014 O ring 22 AP2516 Spindle Locking Washer 15 AP2513 Valve Spindle 23 AP2518 Spindle Bush Silicone Seat 24 AP2517 Spindle Adjuster 17 AP2514 Valve Shuttle 25 AP1685 Lever 18 AP2522 BS O ring 26 AP2519 Lever Washer 19 AP2041 BS606 O ring 27 AP2520 A4 Stainless Steel M4 Nyloc Nut All items in bold italics to be replaced when servicing. Service kit AP0300/K. 24

25 AP0278 Valve Diaphragm Assembly Exploded Parts Diagram 28 AP2525 BS O ring 32 AP2551 Diaphragm Ring 29 AP2526 Diaphragm Carrier 33 AP2550 Exhalation Diaphragm 30 AP2553 Diaphragm (qty 5) Sealing Disc (individual part no ) 31 AP2528 Diaphragm Pad (qty10) Securing Ring (individual part no ) All items in bold italics to be replaced when servicing. Service kit AP0300/K. 25

26 TECHNICAL SUPPORT GX300 REGULATOR MAINTENANCE MANUAL FOR AUTHORISED TECHNICIANS Apeks Marine Equipment Ltd Neptune Way, Blackburn, Lancashire, England, BB1 2BT Tel: 0044 (0)