Flight second stage regulator

AP4498-Bulletin 1
7/05/2010
FLIGHT Second Stage Regulator Technical Service Bulletin
FLIGHT regulator technical service 5. Locate the three kidney shaped pegs of the AT71
Bulletin Locking Ring Tool into the slots of the Inner Locking
WARNING: Compressed air can be highly Ring (3). Unscrew the Inner Locking Ring (3). Remove
explosive and is dangerous if misused. the Friction Ring (4) and the Diaphragm (5) from
inside of the Case (6).
Ensure the cylinder valve is opened slowly.
Use eye and ear personal protective
equipment when performing any tests
involving compressed air.

NOTE: Please note that the Exhaust Tee (8) has

been removed from all of the following photos for
illustrative purposes.

1. If required remove the mouthpiece. Connect the

first stage regulator to a calibrated test bench and
pressurise the system to 200 (±10) bar (2900 (±145)
psi).

2. The opening effort should indicate +1.4 in.H2O

(3.5mbar) to +1.6 in.H2O (4mbar). If the opening effort
is outside of these limits proceed to step 3. If the the
opening effort is within the above limits proceed to 6. To remove the Venturi Lever (10) from the Case (6),
step 13. position the lever vertically as shown below. Then
carefully depress the tab of the Venturi Lever (10)
inside the Case (6) and pull the Lever out.
3. Disconnect the regulator from the flow bench, and pull
back the Hose Protector, pinch the Locking Slide Ring
(19) on the opposing grips, and unscrew the hose from
the second stage.

NOTE: Alternatively Depress the Tab of the Venturi

Lever (10) using an AT77 Venturi Lever Removal Tool
and pull the Lever out.

CAUTION: DO NOT use any tools to CAUTION: Take care not to damage or
remove the Hose. The connection has been distort the Lever (15) when removing the
designed to be operated by hand only. Venturi Lever (10). DO NOT depress the
tab of the Venturi Lever too far, as this will
result in permanent deformation.
4. Remove the Purge Clamp Ring (1) squeeze at the
positions shown on the photo below and turn anti-
NOTE: The Flight second stage regulator
clockwise. Separate the Purge Clamp Ring (1) from
maintenance manual (AP4498) shows the opening
the Front Cover Assy (2) and the Case (6).
effort being set with the Front Cover Assy (2) and
the Purge Clamp Ring (1) removed. It is possible to
set the opening effort with only the Diaphragm (5),
Flight Friction Ring (4) and the Inner Locking Ring
(3) installed. However to acheive a more accurate
setting the Front Cover Assy (2) and the Purge
Clamp Ring (1) should be re-attached prior to
adjustment. This is because the opening effort may
be slightly affected by the front cover reassembly, due
to the tight tolerances of the compact second stage.

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 FLIGHT Second Stage Regulator Technical Service Bulletin
7. Refit the Diaphragm (5) into the front of the Case
(6). Using your finger carefully work the edges of the
Diaphragm into place so it sits evenly in the Case.
Insert the Flight Friction Ring (4) into the case. Use
the same technique to ensure it sits evenly onto the
Diaphragm.
CAUTION: Ensure that the Diaphragm
(5) and Flight Friction Ring (4) are seated
correctly and are not creased.
8. Using the AT71 Tool slowly screw the Inner Locking
Ring (3) into the Case. Ensure that the chamfered
inner diameter faces the Diaphragm (5). Hand tighten
only.
9. Place the Front Cover Assembly (2) into the front of
the Case (6) as shown below. Fit the Purge Clamp
Ring (1) over the top of the Front Cover Assembly
(2). Rotate the Purge Clamp Ring (1) clockwise until it
firmly clicks into place.
2
10. Insert the Flight Micro Adjuster Tool (AT76) into the
open side of the Case (6), making sure that the
hexagonal bit engages into the Micro Adjuster Screw
(20). Connect the first stage regulator to a calibrated
test bench and pressurise the system to 200 (±10) bar.
Slowly open the flowmeter control knob (start vacuum)
while watching both the magnahelic gauge and the
intermediate pressure gauge. When the intermediate
pressure begins to drop, indicating the second-stage
valve is open record the indicated opening effort.
Turn off the air supply to the regulator and purge by
depressing the Front Cover Assy (1).
CAUTION: ALWAYS ensure that the air
supply to the regulator is turned off before
turning the Micro Adjuster Screw.
NOTE: The next photo shows the Diaphragm
removed to indicate the detail of the Flight Micro
Adjuster Tool (AT76).
11. Adjust the Micro Adjuster Screw (20), turning anti-
clockwise by a 1/16th of a turn to lower the opening
effort. After each turn of the Micro Adjuster Screw
(20) disengage the hexagonal bit of the Flight Micro
Adjuster Tool from the Micro Adjuster Screw and turn
on the air suply to the regulator. Tap the Front Cover
Assy (1) once or twice to purge the regulator. This
ensures that the Flight Micro Adjuster Tool does not
affect the reading. No more than 1/4 of a turn will be
necessary. Retake the reading.
NOTE: If no magnahelic gauge is available then
unscrew the Micro Adjuster Screw (20) anti-clockwise
until the regulator slightly free flows. Then screw the
Micro Adjuster Screw clockwise 1/8” turn until the free
flow stops.
 FLIGHT Second Stage Regulator Technical Service Bulletin

12. If the opening effort requires further adjustment re-
engage the hexagonal bit of the Flight Micro Adjuster
Tool and repeat step 11.
NOTE: A 2.5mm Allen key can be used to adjust the
Micro Adjuster Screw (20) if a Flight Micro Adjuster
Tool (AT76) is not available. The open end of the case
must be blanked off to obtain a reading on the test
bench.
17. Slide the Sliding Locking Ring (19) back onto the Inlet
Fitting (18) half way, without engaging the notches
on the Case (6). Turn the Sliding Locking Ring (19)
anti-clockwise to unscrew the Inlet Fitting (18). If the
Inlet Fitting is too tight unscrew using tool AT77 Flight
Venturi Combination Tool.

18. Carefully remove the Rubber Seating (26) from the

end of the Shuttle Valve (25) using either your finger
or an ‘O’ ring pick.

13. Disconnect the regulator from the flow bench, and

connect it to a gas cylinder filled to approximately 200
(±10) bar (2900 (±145) psi). Open the cylinder valve
to repressurise the regulator, and submerge the entire
system in a test tank of clean water.

14. Observe for any bubbles arising from the 19. Carefully insert a new Rubber Seating (26) into the
submerged regulator over a one minute period. The end of the Shuttle Valve (25).
recommended time is necessary due to slower bubble
formation that occurs in smaller leaks. Bubbles
indicate a leak, which requires the system to be
disassembled at the source to check sealing surfaces,
assembly sequence and component positioning in
order to correct the problem(s).

NOTE: Extremely small leaks may be better

detected by applying a soap solution or Snoop™
to the leak area. Bubble streams will indicate the
source of the leak. Before disassembling to correct
any leaks blow out all residual moisture with filtered,
low-pressure air.
15. If there are no leaks then the regulator is set correctly,
proceed to step 23. If the regulator leaks then
proceed to step 16 to replace the Rubber Seating
(26).
16. Remove the Sliding Locking Ring (19) by pulling in an
axial direction away from the case whilst oscillating
the part.
CAUTION: Use only the end of your finger
to insert the new Rubber Seating, NOT
your finger nail. DO NOT mark the face of
the Rubber Seating, this will cause the 2nd
stage to leak when fully assembled.
20. Whilst depressing the Front Cover Assy (1) (This will
prevent the Rubber Seating from being scored by the
seat.), screw the Inlet Fitting (18) into the end of the
Spindle Body (14) and hand tighten until the grooves
line up. Use the Slide Locking Ring (19) if necessary
or the AT77 Flight Venturi Combination Tool.

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 FLIGHT Second Stage Regulator Technical Service Bulletin

WARNING: DO NOT use any tools to tighten Subjective Breathing Test

the Inlet Fitting into the Spindle Body other
than AT77 Flight Venturi Combination Tool.
Over tightening of this part will result in
damage.
21. Align the location splines of the Locking Slide Ring
(19) to the grooves on the Inlet Fitting (18) and Case
(6). Using the palm of your hand carefully push the
Slide Locking Ring (19) fully upto the Case (6) until it
clicks.
1. Depress the Front Cover Assembly (2) fully to ensure
that an adequate volume of air needed to clear the
second stage flows through the mouthpiece. Then,
inhale slowly but deeply from the mouthpiece. A
properly serviced and adjusted regulator should
deliver air upon deep inhalation without excessive
inhalation effort, freeflow, or “fluttering” of the
second-stage diaphragm. When exhaling, there
should be no fluttering or sticking of the exhalation
valve. If any of these problems occur, refer to “Table
1 - Troubleshooting” in the Flight second stage
maintenance manual.

2. With the Venturi Lever set to the + position tap the

Front Cover Assembly (2) quickly, this should cause
the regulator to freeflow. Stop the freeflow after
a couple of seconds by placing a hand over the
mouthpiece.
22. Once the Slide Locking Ring is in place repeat step 1
and check the opening effort.

23. Align the Venturi Lever (10) in a vertical position with

the Case (6) and using the palm of your hand press
the lever into place. Ensure that the Venturi Lever
rotates freely and feels secure. If the mouthpiece was
removed, refit and proceed to the next step.

NOTE: To check that the Diaphragm has sealed

correctly, place your thumb over the end of the Inlet
Fitting. Suck and hold at the mouthpiece port, a
vacuum should be held without any leakage.

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 FLIGHT Second Stage Regulator Technical Service Bulletin

FLIGHT 2nd STAGE Exploded Parts Diagram

* All marked items must be replaced when serviced.

1 AP7589 Purge Clamp Ring Pewter 10 AP7579 Flight Venturi Lever

AP7589/F Purge Clamp Ring Female 11* AP1267 ‘O’ Ring
AP7589/G Purge Clamp Ring Green 12 APF129154 Mouthpiece Clip
AP7589/Nitrox Purge Clamp Ring Nitrox 13 AP5324 Comforbite Mouthpiece
AP7589/Y/M Purge Clamp Ring Male Octo AP1434/G Mouthpiece Green
AP7589/Y/F Purge Clamp Ring Female Octo APF127826 Small Mouthpiece
2 AP0175/MALE Front Cover Assy 14 AP7581 Flight Spindle Body
AP0175/F Front Cover Assy Female 15 AP2035 Lever
AP0175/T Front Cover Assy Green 16* AP1154 ‘O’ Ring
AP0175-O Front Cover Assy Female Octo 17 AP7563 Valve Seat
3 AP7577 Inner Locking Ring 18 AP7586 Inlet Fitting
4 AP7592 Flight Friction Ring 19 AP7595 Locking Slide Ring
5 100181 Diaphragm 20 AP7570 Micro Adjuster Screw
6 AP7590 Flight Case 21 AP7582 Spindle Adjuster Sleeve
7 AP6223 Exhaust Valve 22 AP7584 Spring Carrier
8 AP7578 Flight Exhaust Tee 23 AP2021 Spring
9 AP7596/B Apeks ‘A’ Insert Logo Black 24* AP5711 ‘O’ Ring
AP7596/P Apeks ‘A’ Insert Logo Pink 25 AP5707 Shuttle Valve
AP7596/G Apeks ‘A’ Insert Logo Green 26* AP2034 Rubber Seating
AP7596/Y Apeks ‘A’ Insert Logo Yellow