2ND STAGE

A Manual for Repair and Maintenance Technicians

CAUTION

This manual is designed to help technicians who are already experienced

in workshop procedures and know how to handle tools.

Only experienced technicians should attempt to use this manual.

Improper use of tools could result in personal injury to the user, the
technician or at the least damage to the regulator.

To use this presentation effectively a parts exploded view must be on hand

to determine the correct assembly order plus to check if any parts are
missing prior to reassembly.
 TOOLING REQUIREMENTS
• Apollo seat carrier adjusting tool
P/No. 319-02-00-006
• 6” Flat blade screwdriver
• O ring pick
• Tweezers
• 12mm open end spanner
• 11/16” open end spanner
ex 2000 • 3/4” open end spanner
• Apollo valve cone adjusting tool
P/No. 319-02-00-014
FEATURES
VENTURI CONTROL
(Adjust Airflow)

SENSATIVITY CONTROL
(Adjust Inhalation Effort)
DISASSEMBLY

The ‘ex 2000’ has a unique

ball and socket swivel hose.

To remove the hose, first

slide back the rubber cover.
DISASSEMBLY

An 11/16” open end spanner and 3/4“

spanner are used to remove the hose
from the 2nd stage.

Disconnect the hose from the

2nd stage.
DISASSEMBLY

To remove the front cover a

small metal lock must be
disengaged. The lock is shown
inside the red circle.

Use a small screw driver or an

o ring pick and gently prise the
lock towards the hose fitting.
At the same time turn the cover
one quarter turn counter-clockwise.
DISASSEMBLY

Remover the cover and place

to one side.

The diaphragm snap ring is

removed next. A screw driver
can be used to engage the lock
ring as shown.
Turn the lock counter-clockwise.
DISASSEMBLY

Remove the snap ring, then

remove the diaphragm cover
ring.
DISASSEMBLY

Lift out the diaphragm.

Use an 11/16“ spanner and

undo the valve cone holder.

NB: If tight use two spanners,

one on the cone holder and one
to hold the valve housing.
DISASSEMBLY

The valve cone is inside the holder,

(sometimes called a hose connector)
place the cone and holder to one side.
The valve cone will be removed later
for cleaning and inspection.

The seat carrier adjusting tool

Part No. 319-02-00-006 is used
to compress the valve seat
carrier spring to enable removal
of the demand lever.
DISASSEMBLY

Carefully remove the demand

lever one leg at the time.

Remember to keep the spring

compressed until the lever is
completely removed.
DISASSEMBLY

The valve and spring can now

be removed by tilting the
housing.

Remove the two seat carrier

o rings and discard.
DISASSEMBLY

The tip of the valve will have a slight

witness mark plus a hole due to the
moulding process. This hole is not
cause for rejection. With normal
use the valve has a life expectancy
of approx. 3 years.

To take off the adjusting knob

the screw cover must be removed.
Gently prise up the cover using an
o ring pick.
DISASSEMBLY

Place the cover to one side.

Using a flat blade screw driver

remove the knob retaining screw.
DISASSEMBLY

Remove the knob and place

to one side.

Remove the exhaust cover. This is

accomplished by depressing the
metal lock below the mouthpiece
and turning the cover a quarter turn
counter clockwise.
DISASSEMBLY

Remove the cover and place

to one side.

Use a 12mm open end spanner to

undo the bonnet. If the bonnet is
very tight use an 11/16“ spanner
to hold the opposite end of the
valve housing.
DISASSEMBLY

Remove the bonnet, the adjusting

shaft and nut as a sub-assembly
and place to one side.

Next slide the valve housing

from the bottom box.

Take care not to damage the air

flow tube, it is held in position by
the valve housing.
DISASSEMBLY

Slide the air flow tube off the

air flow adjuster to remove.

The air flow adjuster is held in

position by a spring clip.
Grasp the head of the clip with
tweezers and simply pull to
remove.
DISASSEMBLY

The air flow adjuster is removed

through the top of the bottom box.
Push from underneath, it could be
tight due to o ring friction.

The disassembly is complete except for the following sub-assemblies.

DISASSEMBLY

Separate the adjusting assy. From

the bonnet. Then separate the nut
from the shaft.

DO NOT separate the plastic balance cylinder from

the adjusting nut unless either part is damaged.

Separate the valve cone from the

valve cone holder. Turn counter-
clockwise with a screw driver until
the thread is disengaged.

Push the valve cone out using a soft

probe so as not to damage the tip.
INSPECTION & CLEANING

A 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 white vinegar. The vinegar may
be diluted using water, however diluting usually only means a
longer soak period before the parts are clean.

Only leave the parts in the vinegar bath until clean, do not leave in
the bath for prolonged periods. Eg; hours or over night.

The parts must be rinsed in warm to hot fresh water after removal
from the acid bath, this helps to neutralise the acid.
Blow dry with clean filtered air.

Metal parts must now be carefully inspected prior to refitting.

INSPECTION & CLEANING

Non-metal parts eg; exhaust valve, bottom box, diaphragm etc.

are cleaned by washing in warm water and a mild liquid detergent.
Gentle scrubbing with a tooth brush will help remove stains.

Parts should be rinsed in fresh water after washing.

Parts must be carefully inspected for defects before refitting.

Ensure ALL parts are inspected prior to refitting.
Following are some areas presenting common problems.
INSPECTION

Inspect the demand lever for

distortion and misalignment
of the legs.

Gently stretch the diaphragm,

hold it towards the light and
check for perforations.
Next check for swelling due to
chemical contamination.
INSPECTION

Carefully examine the tip of the valve

cone for damage or imperfections.

Check to ensure the air flow adjuster

stop pin is not missing or damaged.
ASSEMBLY

All o rings and threads should be lubricated prior to assembly.

Dynamic o rings should be liberally lubricated, static o rings
and threads should be very lightly lubricated.

DO NOT lubricate all parts and then assemble, lubrication

should be carried out immediately prior to assembly.
(This avoids collecting dust particles.)

DO NOT use silicone spray as a lubricant.

DO NOT spray plastic components with silicone spray.

Suitable lubricants for Apollo 2nd stages are ‘Food grade’

silicone grease or ‘Christo-lube’ except where mentioned in
the text.
ASSEMBLY

Sub-assemblies will be assembled first.

Lightly lubricate and install the o ring

into it’s groove on the valve cone holder.

Lubricate and install the o ring on the

valve cone. Lightly lubricate the thread.
ASSEMBLY

Install the valve cone into the holder,

there is no need to screw the valve
home at this time. Place this sub-assy.
to one side.

Install the teflon washer onto the

adjusting shaft.
ASSEMBLY

Lubricate and install the o ring into

the groove on the adjusting shaft.

The shaft o ring and the adjusting

thread are dynamic ensure they
are well lubricated.
ASSEMBLY

The adjusting nut, together with the

balance cylinder are now installed
onto the adjusting shaft.

This is a left hand thread,screw the

shaft into the nut until it bottoms but
do not tighten.
ASSEMBLY

The bonnet o ring is now installed.

The adjusting shaft sub-assy. is

now fitted to the bonnet.
ASSEMBLY

The completed sub-assy. should

appear as the picture on the right.

Next install the o ring onto the

valve housing.
Remember to ensure the o ring
is against the shoulder as shown.
ASSEMBLY

Lubricate and install the air flow

adjuster shaft o ring.
Be sure to fit it to the correct groove.

Install the air flow adjuster into the

bottom box, aligning the stop pin.
ASSEMBLY

Secure the air flow adjuster by

installing the spring clip as shown.

The air flow tube can now be fitted.

Ensure the round hole in the tube is

facing the diaphragm. The elliptical
hole faces the mouthpiece.
ASSEMBLY

Ensuring the air flow tube does not

become dislodged install the valve
housing.

The housing outlet hole MUST be

engaged with air flow tube.
Fitting upside down will result in
poor performance.

Install the bonnet and adjusting

shaft assembly and tighten using
a 12mm open end spanner.
ASSEMBLY

Two new valve seat carrier o rings

are to be fitted to the grooves in
the seat carrier end.
NOTE: These are self lubricating.

The carrier spring is installed onto

the carrier.
NOTE: The spring is tapered, the
small diameter slides onto the carrier
and rests against the shoulder as
shown.
ASSEMBLY

The carrier and spring are placed

into the valve housing.

2nd stage Adjusting wrench Part

No.319-02-00-006 is used to
compress the carrier spring.
ASSEMBLY

When compressing the spring the

adjusting wrench must be hard
against the valve housing as shown.
Failure to observe this rule will result
in the incorrect positioning of the
demand lever.

While holding the carried spring

compressed install the demand
lever, gently fitting one leg at a time.

If any doubt exists whether the lever

legs have been bent the lever must
be removed inspected and refitted.
ASSEMBLY

Depress the lever several times to

ensure smooth operation.
Next install the valve cone holder
assembly.

Tighten the valve cone holder using

an 11/16” spanner.
ASSEMBLY

At this point the valve cone can be

roughly adjusted.
Using a screw driver turn the cone
clockwise until the demand lever
starts to drop.
This will require readjusting later.

Fit the adjusting knob to the

adjusting shaft.
ASSEMBLY

Install the adjusting knob retaining

screw and tighten using a screw
driver.

The adjusting knob cap is now

gently pressed into position.
ASSEMBLY

The adjusting knob cap should

be flush around the edges if
fitted correctly.

The 2nd stage diaphragm is installed.

NOTE: Use no lubricants or sprays on
the diaphragm or it’s seating area.
ASSEMBLY

The cover ring is placed on top

of the diaphragm.

Install the diaphragm snap ring,

the four legs face upper most.
ASSEMBLY

Tighten the snap ring using

a screw driver as shown.

The front cover can now fitted.

The cover has a quarter turn
bayonet type screw.
Engage as shown and turn
clockwise until the metal lock
engages.
ASSEMBLY

The exhaust tee is refitted, again

with a quarter turn clockwise until
the metal lock engages.

The basic assembly is now complete.

The 2nd stage must now be tuned and
tested. Ideally the first stage used for
the test and tuning should be the same
first stage the unit will be used with for
diving.
TEST & TUNING

Adjusting tool Part No. 319-02-00-014

is used for tuning the 2nd stage.

A standard hose assembly must be

used with this tool. The o ring sealing
surfaces are different on the new ball
joint hose.
TEST & TUNING

NOTE: If you have already fitted the

bonnet o ring shown, it must be
removed for using the adjusting tool.
TEST & TUNING

Install the adjusting tool to the

2nd stage.
Remember to use a standard hose.

The adjusting knob must be pre-set

prior to tuning the valve cone.
The adjusting knob is turned counter-
clockwise until it stops, then turned
clockwise one half turn.
TEST & TUNING

Couple the hose assembly to the

1st stage. (Ensure the correct
intermediate pressure 9.8 kg/cm2 )

With the air supply ‘on’ push the tool hand

wheel in against the pressure and engage
the screw driver slot. Turn the hand wheel
counter clockwise until a slight free flow is
heard, then turn back to stop the free flow.
Purge the 2nd stage several times, listen for
free flowing. If free flow is present, re-adjust.
ASSEMBLY

The adjusting tool must be removed to

carry out the flow (breathing) test.

Lightly lubricate and install the bonnet

o ring as shown.
ASSEMBLY

Install the ball joint hose assembly

and tighten using an 11/16” and 3/4”
spanners

Slide the rubber boot assembly

back into position.
ASSEMBLY

The assembly is now complete.

Final testing involves checking for
air leaks and carry out the flow test.
The flow test is simply turning the
flow adjuster and checking that
the regulator has a venturi flow.

If NO venturi flow occurs:

• Check your air source is

turned fully on.
• Check the intermediate
pressure is correct.
• Check the valve cone is
adjusted correctly.
HOSE ASSEMBLY (Appendix)

If necessary the ball joint hose

maybe dismantled, cleaned and
lubricated as follows.

Two 3/4” open spanners are used

to split apart the ball housing.
HOSE ASSEMBLY (Appendix)

Remove the coupling section of the

housing.

Check the o ring and thread for damage.

HOSE ASSEMBLY (Appendix)

To gain access to the o ring behind the

ball, slide the housing towards the hose.

The o ring shown sits against the rear

shoulder. Carefully remove with an
o ring pick. Take care NOT to scratch
the sealing area.

The coupling cannot be completely removed from the hose end.

The hose ends and metal parts may be placed in your acid bath
for cleaning etc.
HOSE ASSEMBLY (Appendix)

Lightly lubricate the o rings before fitting.

Care must be taken to ensure the o ring

behind the ball is sitting correctly on the
shoulder. If not, the o ring will be pinched
and damaged when tightening the coupling
halves together.

Lightly lubricate the thread and fit the

coupling to the hose end.
HOSE ASSEMBLY (Appendix)

Tighten the coupling using two 3/4”

open end spanners. The fitting must
be firm only, do not over tighten

The hose assembly is now ready

for service.