Scubapro maintenance procedure a700

MAINTENANCE PROCEDURE FOR A 700 2nd STAGE

A 700 Maintenance Procedure - 1 -

MAINTENANCE PROCEDURE FOR A 700 2ND STAGE WARNING: This maintenance procedure is only for appointed Scubapro technicians that have completed a course on equipment repair and in no case can replace a technical repair course delivered by a SCUBAPRO UWATEC appointed staff. Tools needed:

1. Universal tool P/N 43.040.000 2. Adjustment tool P/N 41.043.000 3. O ring extractor P/N 43.300.107 4. 4 mm Allen key 5. Small flat blade screwdriver 6. T 10 Torx screwdriver 7. Wooden chop stick 8. Small pliers

DISASSEMBLY

1. Pull back the hose sleeve and unscrew the interstage pressure hose with the universal tool. Remove the inlet tube o ring with the o ring extractor.

Warning: Do not attempt to remove the chrome plated nut with the 4 small

holes. This is a cosmetic nut that has been glued with Locktite during

assembly.

2. Remove the hose o-ring with the o ring extractor. Remove the mouthpiece clip with the small screwdriver, remove the mouthpiece and the mouthpiece support.

3. With the Torx screwdriver, remove the 4 Torx screw on the cover, remove also the 4 small o rings. Separate the purge cover, the ring and the diaphragm.

4. With the small screwdriver using it as a lever, remove the safety clip from the Dive Switch.

5. Pull the complete Dive Switch assembly out of the 2nd stage housing. Remove the 2 o-rings from the Dive Switch with the o ring extractor..

6. Remove the decal from the adjustment knob with the o-ring extractor.

7. With the 4 mm Allen key, unscrew and remove the screw and the o-ring P/N 01.050.126. Pull on the adjustment knob to remove it from the adjustment shaft.


8. Push on the adjustment shaft to separate the shaft assembly from the Dive Switch.

9. Screw the adjustment shaft inwards to remove it from the sleeve.

10. Remove the o-ring P/N 01.050.293 from this shaft with the o-ring extractor.

11. With the small screwdriver, screw clockwise the inner fine adjustment screw to remove it from the adjustment shaft.

12. Remove the P/N 01.050.126 o-ring from this fine adjustment screw with the o ring extractor.

13. Remove the balance chamber and the spring from the inlet tube.

14. With great care push the poppet assembly out of the barrel through the adjustable orifice, with the small screwdriver.

15. With the o-ring extractor remove the 2 o-rings P/N 01.050.363 from the poppet shaft. Remove also the seat P/N 11.250.221.

16. With the universal tool unscrew the adjustable orifice and push it carefully out with the wooden chop stick from the hose side.

17. Remove the o-ring from the orifice with the extractor tool.

18. It is not necessary to remove the lever from the inlet tube for cleaning. If necessary, spread the lever legs carefully and remove one lever tab before the other to minimise the risk of distorting the lever.

19. It is not necessary to remove the flow reducer from the inlet tube.

20. Inspect the antifriction insert on the inlet tube to detect any wear on the 2 small square holes. It is not necessary to remove this inset.

21. To remove the exhaust tee using no tools.

22. It is not necessary to remove the exhaust valve unless it needs replacing. Pull on the exhaust valve to remove it from the housing.

PARTS CLEANING WARNING: Refer to parts cleaning procedure. ASSEMBLY

1. After careful inspection of the cleaned parts and the static o rings that do not need to be changed, prepare all the parts that need to be changed at every annual service.

a. P/N 11.250.221 the seat

b. P/N 01.050.363 the 2 poppet o rings

c. P/N 01.050.132 the interstage pressure hose o ring


d. P/N 01.050.293 the adjustment screw o ring

e. P/N 01.006.719 the decal

Or P/N 11.650.045 the annual repair kit.

If the exhaust valve has been removed, it must be replaced with a new valve

P/N 11.250.103.

2. Insert the new exhaust valve and use the pliers to pull it from the inside of the case. Make sure that the valve is correctly fitted, the shoulder on the nipple should stick out of the retainer and the lip of the valve should rest properly on the regulator case. Check the valve by pulling slightly on the lip at several places and make sure the outer part of the valve rests on the regulator case. Trim the top of the nipple away leaving 1mm of nipple above the remaining shoulder.

3. Refit the exhaust tee.

4. Place the o-ring on the adjustable orifice and slightly lubricate the threads and the o-ring.

5. Using the universal tool to screw the orifice about 3 or 4 turns into the inlet tube.

6. In case the lever has been removed from the inlet tube, reassemble as follows: First of all verify the symmetry of the lever when placed on a flat surface. The four legs should touch the flat surface without any distortion. In case of doubt, replace the lever. First enter one lever tab in the square hole of the sleeve, then with the minimum possible distortion, glide the other lever tab over the tube into the other square hole. Check again that there is no distortion of the lever.

7. If the antifriction sleeve has been removed, replace it with a new one.

8. Place the 2 o-rings P/N 01.050.363 on the balanced poppet. Place a new seat on a flat and clean surface. Hold the poppet vertically to insert the seat into it. Push firmly into place. Lubricate the 2 o-rings, taking care to place some grease in between the o rings.

9. Assemble the poppet with the spring and the balance chamber. Hold the 2nd stage housing with the mouthpiece tube facing the ground. Hold the balance chamber, spring and poppet assembly. Position the assembled poppet so that the 2 tabs face the ground. Glide the poppet assembly inside the inlet tube making sure the poppet does not rotate. The poppet should engage in the lever.

10. Place the o-ring P/N 01.050.126 on the small spring fine adjustment screw.

11. Assemble the fine adjustment screw inside the adjustment shaft by unscrewing with the small screwdriver until the shoulder of the fine adjustment screw sticks out of the rim of the adjustment shaft by 1 mm.


The inner thread and o-ring of that fine adjustment screw should not be lubricated.

12. Place the new o-ring P/N 01.050.293 on the adjustment shaft and lubricate both the threads and o-ring. Assemble this into the sleeve by totally unscrewing until the stem is completely sticking out.

13. Fit the 2 o-rings P/N 01.050.160 on the Dive Switch and slightly lubricate.

14. Assemble the shaft and sleeve assembly inside the Dive Switch. Put the o ring P/N 01.050.126 on the stainless steel screw and fix the adjustment knob using the 4mm Allen key.

15. Now insert this complete assembly on the inlet tube to align the ‘’tail’’ of the Dive Switch in the grove of the flow reducer.

Warning: Make sure that the injection hole is facing the mouthpiece tube

when engaging the ‘’tail’’ of the Dive Switch in the flow reducer grove. If it is

not the case, back the complete assembly and rotate the flow reducer in the

correct position.

16. It is now important to engage the 2 tabs of the Dive Switch in the 2 recesses of the inlet tube. Place the Dive Switch lever in front of the rotation limiting grove. Pull with one finger the lever into the case and at the same time rotate anticlockwise the adjustment knob. When the 2 tabs are aligned with the 2 recesses, the Dive Switch will go in position.

17. Maintain the pull on the Dive Switch lever and insert the clip to lock the system in the case. Make sure that the clip is completely inserted in the grove.

18. Check the diaphragm, there should be neither punctures nor distortion after cleaning. Please follow the standard cleaning procedure.

19. Position the diaphragm on the case making sure that it is not distorted.

20. Assemble the retaining ring and purge cover..

21. Align the locator of the ring in the recess of the case and press.

22. Put the 4 small o rings in their groves on the inside of the front cover. Place this assembly on the purge cover and maintain a constant pressure to keep all the parts together.

23. Tighten crosswise the 4 screws with the Torx screwdriver without excessive torque.

24. Assemble the mouthpiece support and the mouthpiece and secure with the mouthpiece clip.

25. Place the inter stage pressure o ring in the groove of the inter stage pressure hose and slightly lubricate.


THE 2ND STAGE IS NOW READY FOR ADJUSTMENT

WARNING: DO NOT ATTEMPT TO ADJUST A 2ND STAGE IF THE

INTERSTAGE PRESSURE IS NOT CORRECTLT ADJUSTED.

1. Before connecting the adjustment tool to the 2nd stage, and without pushing on the purge, slowly blow through the inlet tube to detect a leak. This information will indicate if the orifice is in contact (no leak) or not (leak) with the seat. If a leak is detected, screw the 2nd stage adjustment tool to the 2nd stage and slowly screw the orifice about one or two turns to stop any leak.

2. Make sure that the in halation effort adjustment knob is completely

unscrewed.

3. Connect an appropriate and well adjusted 1st stage to a full tank, connect the 1st stage to the adjustment tool with the interstage pressure hose and slowly open the tank valve.

4. Push slowly on the tool adjustment knob to counteract the thrust of the

inter stage pressure. Turn the knob slowly to look for the groove of the adjustable orifice. As soon as the groove is found, slowly unscrew the adjustable orifice until a small leak is detected, then turn the orifice clockwise to just stop the leak without having to turn more than 1/8 of a turn on the orifice. Note: 1/16 of a clockwise turn of the adjustment tool acting on the orifice should stop the leak. If more than ¼ of a turn is required to stop the leak, it means that the spring compression is too light and the fine adjustment internal screw has to be screwed as follows: (This procedure must only be applied to stop the leak described above) With the small screwdriver, (proceed by steps of ¼ of a turn at a time) screw the internal fine spring tension adjustment in order to obtain a sharp stop of the leak (1/16 of a turn) when adjusting the orifice with the tool. Do not exceed more than 2 turns of clockwise adjustment on the fine adjustment screw. Proceed as in paragraph 4.

5. Cycle the 2nd stage about 10 to 15 times by pushing on the purge, then

finalise the adjustment as indicated in paragraph 5.

6. Close the tank valve and purge the 2nd stage. Remove the adjustment tool from the 2nd stage and assemble the hose with the universal tool with moderate tightening torque. Do not over tighten.

7. Place back the hose sleeve.


Scubapro maintenance procedure a700

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