Service A-320 1st Stage.pdf - Apollo Sports

Technical ManualA-320 Balanced 1st StageA Manual for Repair and Maintenance TechniciansView: Select Full Screen mode to use page arrows.

FEATURESExtra durable satin chrome plated brass body.Fully balanced and environmentally sealed.3 year warranty on the high pressure seat.New non stick Zeomic plating on internal components.Either Yolk or DIN fittingReusable unique cylindrical stainless steel filter.4 X LP Ports2 X HP PortsDIN FittingYolk FittingA -320

Haapalainen Aarne Johannes s. 6.1.1912 Ii k.16.11.1970 Oulu. Vht Johan Feliks H ja Kaisa GretaVäisänen. Pso Annikki Keränen. – Vaatturiliikkeenharj. Oulu. [vm]Haapapuro Kari Antero s. 28.3.1956 Paavola. VhtReijo Antero H ja Tarja Elli Pasanen. – 1967. [vm]Haataja Pekka Tapani s. 23.9.1956 Oulu. Vht PauliOlavi H ja Kaisa Liisa Tellervo Alamikkelä. – 1967.[vm]Haataja Sirkka Kirsti Inkeri s. 9.11.1958. – 1974 yo.1977. [ka]Hahtonen Lasse Harri s. 28.2.1957 Oulu. Vht ErikLennart H ja Lisbet Göta Aurora Mattson. – 1968.[vm]Hakala Eija s. 22.1.1958. – 1974 yo. 1977. [ka]Hakkarainen Riitta Elisa s. 22.5.1956. – 1973 yo.1976. [ka]Hanhela Auli Eliisa s. 28.12.1960 Haukipudas. VhtOsmo Kalervo H ja Sirkka Liisa Niskanen. – 1972.[vm]Hannus Riitta Leena s. 25.4.1956. – 1973 yo. 1976.[ka]Harja Eino Matias s. 20.5.1958 Oulu. Vht Eino IisakkiH ja Vera Annikki Ukkola. – 1970. [vm]Harmanen Kari Tapio s. 23.5.1944 Pielisensuu. VhtKyösti Arvid Ilmari H ja Salme Marjatta Ikonen. –1962 yo 1962. [vm]Hartikainen Esa Juhani s. 21.4.1960 Oulu. Vht EinoH ja Aino Elina Vuotilainen. – 1971. [vm]Hartikka Pekka Tapani s. 26.7.1956 Oulu. Äiti MariaMargareta Hartikka. – 1967. [vm]Harvala Kari Sakari s. 16.7.1959 Oulu. Vht Kalle EinariH ja Irma Amanda Ylinikula. – 1970. [vm]Haukipuro Esko Antero s. 19.1.1956 Merijärvi. VhtErkki Antero H ja Elma Annikki Pohjanen. – 1973.[vm]Hauru Jukka Antero s. 28.9.1957 Suomussalmi. VhtPentti H ja Kerttu Marjatta Seppälä. – 1968. [vm]Hauru Veli Matti s. 29.5.1957 Oulu. Vht Paavo H jaAune Anni Väisänen. – 1968. [vm]Hautamäki Anna Maija s. 14.10.1955. – 1973 yo.1976. [ka]Hautamäki Harri Kalervo s. 26.2.1955 Oulu. VhtKalervo Iisakki H ja Tyyne Elisabet Ujanen. – 1967.[vm]Hautamäki Matti Tapio s. 27.8.1959 Oulu. Vht EeroJoonas Efraim H ja Maija Liisa Suorsa. – 1970. [vm]Hautamäki Tapani s. 13.9.1958 Oulu. Vht Juho KaukoH ja Helvi Olivia Yli-Nikkola. – 1970. [vm]Havas Marja Kristiina s. 30.4.1956. – 1974 yo. 1977.[ka]Heikkilä Timo Tapio s. 25.9.1957 Helsinki. Vht RaimoToivo H ja Pirkko Soilikki Linda. – 1968. [vm]Heikkinen Outi Helena s. 10.1.1957. – 1974 yo. 1977.[ka]Helanen Kari Benjam s. 11.10.1956 Oulunsalo. VhtAale H ja Aune Ervasti. – 1967. [vm]Helin Jyrki Juhani s. 22.1.1959 Nurmes. Vht RaimoPaavo H ja Ellen Katariina Jokelainen. – 1971. [vm]Helkkola Reijo Antero s. 23.11.1954 Rantsila. VhtAntero H ja Lyyli Elisabet Uhre. – 1972. [vm]Hemmoranta Seppo Juhani s. 24.6.1955 Oulu. VhtPauli Johannes H ja Anja Irene Pesonen. – 1966.[vm]Hepo-oja Irma Helena s. 17.12.1956. – 1974 yo.1977. [ka]Hietaniemi Esko Tapani s. 26.2.1953 Oulu. Vht VarmaTuomas H ja Aili Hillevi Väliaho. – 1964. [vm]Hilli Kalevi Martti s. 4.11.1955 Oulu. Vht KaleviMartti H ja Sirkka-Liisa Kyllikki Karjalainen. – 1966.[vm]Hiltula Veijo Ensio s. 23.6.1958 Kuivaniemi. VhtMauri Ensio H ja Annikki Mertala. – 1970. [vm]Hiltunen Kirsi-Marja s. 31.12.1957. – 1974 yo. 1977.[ka]Hiltunen Rauno Olavi Johannes s. 30.9.1957 Oulu.Vht Sulo Johannes H ja Iida Orvokki Sandelin. –1968. [vm]Himanka Mikko Ensio s. 2.7.1958 Oulu. Vht AlpoEnsio H ja Kaisu Helena Linna. – 1969. [vm]Hintsala Arto Johannes s. 3.5.1958 Oulu. Vht PaavoJohannes H ja Anja Elina Takalo. – 1970. [vm]Hissa Simo Pekka s. 9.11.1961 Isokyrö. Vht RaimoKullervo H ja Anna-Maija Kamppinen. – 1973. [vm]Holappa Pentti Olavi s. 19.9.1957 . Vht Samuli JuhaniH ja Helka Inkeri Rintala. – 1973. [vm]Holma Heikki Juha Tapani s. 31.3.1959 Oulu. VhtPentti Juhani H ja Aune Inkeri Kosunen. – 1970.[vm]Holma Kari Juhani s. 12.6.1955 Kempele. Vht TaunoH ja Kirsti Törttö. – 1971. [vm]Holma Pekka Olavi s. 6.8.1956 Oulu. Vht Pauli AlfredH ja Elli Marjatta Lumila. – 1967. [vm]3

TOOLING REQUIREMENTS• 12” adjustable wrench• Apollo wrench No. TL00005• 4mm & 6mm Allen key (wrench)• Snap ring (circlip) pliers TL00000• O ring pick TL00013• Fine tweezers• Nylon dowel - 10mm dia.• Small screw driver. (blunt edges)• Threaded rod (7/16” NF) handle• Engineers vice with soft jaws• Line pressure test gauge• Ultrasonic Cleaner TL00047Additional standard engineeringtools will also be required.A -320

DISASSEMBLYRemove the DIN fittingfrom the 1 st StageRemove the stainless steelfilter from the housing byremoving the base o’ringThis is a stainless steel filter itcan be cleaned using anultrasonic cleaner MS20582.A -320

DISASSEMBLYCarefully remove the filterretaining ring and then the filter.Remove the Yolk fittingfrom the 1 st Stage. Youcan use tool TL00006to do this.This is a stainless steel filter itcan be cleaned using anultrasonic cleaner MS20582.A -320

DISASSEMBLYHold the 1 st stage in a soft jawvice. Use old port plugs to avoidbody damage.Fit the Apollo adjusting wrenchTL0005 to the body cap.Use a 12” adjustable wrench,undo and lift off the body cap.Remove the piston assembly toexpose the adjusting assembly.A -320

DISASSEMBLYUnscrew and then remove theadjusting screw and spring (Turnanti-clockwise to unscrew)Using the bio adjusting spannerTL00008 unscrew the lock nut.(Turn anti-clockwise to unscrew)Remove the spring padA -320

DISASSEMBLYPlace a low pressure air nozzle against oneof the LP ports, use air pressure to lift thediaphragm off its seat.Apply pressure gently, and place a rag overthe top of the body to prevent the diaphragmfrom being blown out and possibly causingan injury.If you have no intention of using thediaphragm again it can be removed with apick. Make sure you do not scratch thesealing surface.Remove and inspect the diaphragm.Any sign of damage or creasing is cause forreplacement.A -320

DISASSEMBLYRemove the push rod and padusing tweezers or nose endedpliers.The HP module is removed next.Use the 1 st stage driver TL00002Do not use a screw driver this willdamage the grooves.NOTE: If the HP module is tight and appears to belocked in position do not force it.Check that there is no pressure behind it byreplacing the push rod and pad and depressing it.A -320

DISASSEMBLYPlace the HP module on a solid surfaceas shown. Exert a downward pressurewith your thumb or finger while engagingthe circlip pliers to the retaining ring.While compressing the retaining ringgradually reduce the downward pressure.The HP assembly should now disengagethe module…Remember this is under spring tension,Wear eye protection.A -320

DISASSEMBLYUsing a curved o ring picker, carefullypick up the o ring and remove fromthe chamber and discard.After removing the o ring check theteflon back up ring for damage.Any signs of damage (scoring etc) iscause for rejection, in this case a newbalance chamber must be fitted.Remove and inspect the o ringfrom the groove on the HP moduleA -320

INSPECTION & CLEANINGCheck the HP seat knife edgeorifice (cone) for damage priorto re assembly.The pushrod assembly must beinspected for corrosion on the pin,also any bending of the pin.If any damage is noted replace the shaft.All threads are checked for damage, look for peelingchrome and damage caused by crossed threads.A -320

INSPECTION & CLEANINGRubber parts o rings etc. which are going to be re used should bewashed in warm water and detergent.After washing all o rings are to be carefully inspected for damageor distortion.The polyurethane Hp Seat SP90031B is goodfor 3 years. If it is being re installed check itfor any defects.- Deep groove.- Holes.- Delaminating of the polyurethane face.Are all cause for rejection.If you have any doubt on a part REPLACE ITA -320

INSPECTION & CLEANINGA quick check of parts to be reused is carried out prior to cleaning.This will ensure you do not clean obviously defective parts.All metal parts are cleaned using an ultrasonic cleaner. The recommendedCleaning solution is Lawrence Factor Wash. Apollo code TL00040.Only leave the parts in the ultrasonic cleaner until clean, do not leave inthe bath for prolonged periods. Eg; over night.The parts must be rinsed in bicarbonate of soda after removalfrom the ultrasonic cleaner, this helps to neutralise the acid.Rinse with fresh water and then blow dry with clean filtered air.Metal parts must now be carefully inspected prior to refitting.A -320

ASSEMBLYThe lubrication of parts, o rings and threads, for Apollo regulatorsis carried out using either Christo-lube or Silicone grease.NOTE:The use of Christo-lube throughout the regulator DOES NOT constitutea regulator approved for use with Nitrox or O2 enriched Breathing Air.Other procedures (NOT covered by this manual) MUST be carriedout prior to use with mixed gases other than standard air.LUBRICATION.STATIC O RINGSMust be lightly lubricated.Wipe off any excess lubricantprior to assembly.DYNAMIC O RINGSCan be liberally lubricated.Do not wipe off excess lubricant.Ensure excess lubricant DOES NOTenter the breathing air passages.A -320

ASSEMBLYHp Module AssemblyApart from all parts being available individually.Apollo have a spare parts kit available for this 1 ststage code SP00011.The kit does not include theHP seat or filter.Replace the balance chamber o ringby using your fine tweezers as shown.The o ring must sit on top of the Teflon washerPlace the HP module, on the bench andfit the HP seat, polyurethane face down.A -320

ASSEMBLYNext place the HP spring onto the seat.Place the balance chamber onto the spring,the side with the o ring facing the seat andspring.A -320

ASSEMBLYSit the retaining ring on top of the assembly.Ensure all parts are centred or you willhave difficulty compressing the assemblyand installing the retaining ring.Compress the HP assembly and install theretaining ring.A -320

ASSEMBLYCheck to ensure the retaining ringis located correctly in its groove.CAUTIONWhen inspecting the retaining ringfor security, be sure to wear eyeprotection and never point theassembly directly at your face.Lubricate and install the o ring tothe HP module groove.A -320

ASSEMBLYLightly lubricate the o ring on theHP module, lubricate the threadsvery lightly (if at all) and install themodule assembly.Using the 1 st stage driver TL00002, screwthe module into position.DO NOT tighten down hard. Tighten untilthe module bottoms and then back outapproximately 1/64 of a turn.This will prevent the module locking intoposition after use.A -320

ASSEMBLYInstall the pushrod assembly.Be sure the pushrod engages the centreof the HP seat. Depress the assemblyseveral times with your thumb to test themovement of the seat assembly.Next install the diaphragm. Bendbetween thumb and forefinger tomake the installation easier. Pushthe diaphragm down to the innershoulder and release.A -320

ASSEMBLYUse your nylon drift (or your finger)to push the diaphragm flat all theway around against the inner shoulder.Lubricate the lock nut.The retainer must be tensioned using thebio adjusting TL00008 spanner.Tighten sufficiently to ensure no leakageof air from under the diaphragm, but notso tight as to crush the diaphragm.(Turn clockwise to tighten)A -320

ASSEMBLYThe spring pad is dropped throughthe retainer.Ensure the flat side is down, recessedside up.Lightly lubricate both ends of the springand then install onto the spring pad.A -320

ASSEMBLYReplace the adjusting screw. Onlyscrew it in far enough to take up alittle spring tensionDo not replace the adjustablepiston, outer diaphragm and outerdiaphragm holder at this stage.A -320

ASSEMBLYRe fit either the yolk or DIN to the1 st stage after replacing the filter.Re fit the dust covers.A -320

ASSEMBLYAttach the Apollo low pressuretest gauge to a low pressure port.Fit the 1st stage to a source ofhigh pressure air. Eg; a full tank.A -320

ASSEMBLYThe Apollo test gauge has a bleed screw,this should be slightly open when turningthe air on. Once the system is pressurisedtighten the bleed screw.NOTE: Ensure all the ports areblanked to carry out the adjustments.A -320

ASSEMBLYUse a 6mm Allen key wrench toset the intermediate (low) pressure.Turn clockwise to increase pressure,counter clockwise to decrease thepressure. When decreasing pressureremember to open and close the bleedscrew to obtain the correct pressurereading.Adjust the pressure to 9.8kg/cm+/- 0.5kg/cm. ( 140psi ) Supplypressure should be 100 - 200bar.Purge the valve several timesand check the low pressure isstable.A -320

ASSEMBLYInstall the the piston with adjusting screw.Place the piston height gauge on top ofthe lock nut and piston. Ensure that theclearance gap between the surface of thepiston and the surface of the lock nut hasa minimum 0.05mm to maximum 0.1mm. Ifthe piston height is incorrect, adjust theheight by turning the screw until theclearance gap is correctReplace the outer diaphragm and holderusing the Apollo adjusting wrenchTL00005. The intermediate line pressureshould not have moved.A -320

ASSEMBLYThe first stage DIN or Yolk are now ready for use.A final check for leakage should be carriedout after the installation of the 2nd stageand any accessories. (BC hose etc.)A -320