APEK TEK3 Doubles First Stage Pair Instructions

APEK TEK3 Doubles First Stage Pair

Product Specifications

• Model: APEK637
• Total Pieces: 2248
• LED Type: 3.5*2350 LED
• Piece Count: A – 46PCS, B – 41PCS, C – 840, D – 4PCS, E – 12PCS, F – 31162, G – 2PCS, H – 3.5*1164, I – 12PCS

Product Usage Instructions

• Follow the correct placement of pieces as per the provided diagrams and instructions.
• Ensure pieces A1 and B are correctly placed in the designated boards.
• For LED components, carefully connect the LEDs following the provided instructions to ensure proper functioning.

Frequently Asked Questions

• Q: How do I know if I’ve assembled the product correctly?
• A: Make sure all pieces are placed according to the diagrams provided in the manual. Double-check the board placements of pieces A1 and B for accuracy.
• Q: Can I customize the LED settings?
• A: The LED components provided are pre-set for optimal performance and cannot be customized.
• Q: Are additional pieces available for purchase?
• A: Additional pieces may be available for purchase separately. Contact customer support for more information.

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.| Description & Comments:| Change Date| New Issue No.| Changed By:| Approved By:
---|---|---|---|---|---|---
| | | | | |

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 from Apeks Marine Equipment Ltd.
©2005 Apeks Marine Equipment Ltd.
DS, US, TEK3 & Extrair First Stage Maintenance Manual (AP5317 Issue 1)

INTRODUCTION

This manual provides factory-prescribed procedures for the correct maintenance and repair of the Apeks DS, US, TEK3 and Extrair first-stage regulators. The model shown in this manual is the DS4, although the other first stages differ in appearance, most components are identical. It is not intended to be used as an instructional manual for untrained personnel. The procedures outlined within this manual are to be performed only by personnel who have received factory-authorized training through an Apeks Service & Repair Seminar. If you do not completely understand all of the procedures outlined in this manual, contact Apeks to speak directly with a Technical Advisor before proceeding any further.

WARNINGS, CAUTIONS & NOTES
Pay special attention to information provided in warnings, cautions, and notes that are accompanied by one of these symbols:

• 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 emphasize important points, tips, and reminders.

SCHEDULED SERVICE

• It is recommended that the Apeks DS, US, TEK3 and Extrair first stage regulators should be examined annually regardless of usage. A full service should be performed every two years.
• However, If at all unsure about the correct functioning of the Apeks first stage, then it must be officially inspected immediately.
• All service and inspection details need to be documented in the Regulator Service Record in the back of the Owner’s Manual to keep the Limited Lifetime Warranty in effect.

An Official Inspection consists of:

1. A pressurized immersion test of the entire unit to check for air leakage.
2. Checking for stable medium pressure that is within the acceptable range.
3. Checking that all parts are tightly fastened together and that no parts are loose.
4. A visual inspection of the Environmental Diaphragm looking for tears or holes and checking the general condition.
5. A visual inspection of any filters for debris or dis-colouration.
6. Pulling back hose protectors and checking that the hoses are secure in the hose crimps.

If a regulator fails steps 1,2, or 3 the entire regulator should be serviced. If a regulator fails 4 or 5 it will be up to the technician’s discretion whether or not a full service is required. Failure of step 6 requires the replacement of the Hose.

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 repair 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. During disassembly, reusable components should be segregated and not allowed to intermix with non-reusable parts or parts from other units. Delicate parts, including inlet fittings and valve seats which contain critical sealing surfaces, must be protected and isolated from other parts to prevent damage during the cleaning procedure.
4. Use only genuine Apeks parts provided in the 1st stage service kit (AP0241). DO NOT attempt to substitute an Apeks part with another manufacturer’s, regardless of any similarity in shape or size.
5. 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.
6. When reassembling, it is important to follow every torque specification prescribed in this manual, using a calibrated torque wrench. Most parts are made of either marine brass or plastic and can be permanently damaged by undue stress.

GENERAL CONVENTIONS
Unless otherwise instructed, the following terminology and techniques are assumed:

1. When instructed to remove, unscrew, or loosen a threaded part, turn the part anti-clockwise.
2. When instructed to install, screw in, or tighten a threaded part, turn the part clockwise.
3. When instructed to remove an ‘O’ Ring, use the pinch method (see figure below) if possible, or use a brass, aluminum or plastic ‘O’ Ring removal tool. Avoid using hardened steel picks, as they may damage ‘O’ Ring sealing surfaces. All ‘O’ Rings that are removed are discarded and replaced with brand new ‘O’ Rings.
4. The following acronyms are used throughout the manual: MP is Medium Pressure; HP is High Pressure; PN is Part Number.
5. Numbers in parentheses reference the key numbers on the exploded parts schematics. For example, in the statement, “…remove ‘O’ ring (4) from…”, the number 4 is the key number to the Spring Carrier ‘O’ Ring.

DISASSEMBLY PROCEDURES

NOTE: Before performing any disassembly, refer to the exploded parts drawing, which references all mandatory replacement parts. These parts should be replaced with new, and must not be reused under any circumstances – regardless of the age of the regulator or how much use it has received since it was last serviced.
CAUTION: Use only a plastic, brass or aluminum ‘O’ Ring removal tool (PN AT54) when removing ‘O’ Rings to prevent damage to the sealing surface. Even a small scratch across an ‘O’ Ring sealing surface could result in leakage. Once an ‘O’ Ring sealing surface has been damaged, the part must be replaced with new one. DO NOT use a dental pick or any other steel instrument.

Removal of hose

• Using the appropriate spanners, remove all of the hoses from the first stage. Remove the ‘O’ ring from inside the Hose Swivel. Exercise caution not to scratch the ‘O’ ring groove. Remove the ‘O’ ring from the Hose Nut end of the Hose.
• Pull back the two Hose Protectors and inspect the Hose Crimps. If either Crimp is damaged or the Hose is pulling out of the crimp then the Hose must be replaced.

Removal of Blanking Plugs

• Using a 5mm Allen key remove all of the MP and HP blanking plugs.
• Remove all of the ‘O’ rings from the Blanking Plugs.
• Using the First Stage Work Handle (PN AT48) clamp the regulator in a vice.

Removal of Balance Plug Assembly

• Using a 6mm Allen key unscrew the Balance Plug (17) and withdraw the Balance Plug assembly.
• Separate the Balance Plug assembly by pulling on each end.
• Remove the three ‘O’ rings from the Balance Plug (17), taking care not to scratch the ‘O’ ring grooves.

Removal of Dry Sealed Chamber

• Using a C Spanner (PN AT30) unscrew the Environmental End Cap (1). Remove the Load Transmitter (4) from inside the Diaphragm Clamp (7).
• Using the same C Spanner (PN AT30) unscrew the Diaphragm Clamp (7). This will remove the Spring Adjuster (5) and the Spring (6). Remove the Hydrostatic Diaphragm (2) from the Environmental End Cap (1).

Removal of TEK3 & DS4 Tungsten Diaphragm Clamp

• Remove the Moulded Ring (34) and using a 34mm open-ended spanner unscrew the Diaphragm Clamp (7).

NOTE: The thickness of the spanner must not exceed 11mm or it will not fit between the thread and the flange. The correct spanner can be purchased from Apeks (PN AT47)

Removal of Un-Sealed End Cap (UST)

• Using a C Spanner (PN AT30) unscrew the Diaphragm Cap (35). This will remove the spring Adjuster (36)

• Remove the Spring Carrier (8) and using an ‘O’ ring removal tool carefully prise the Diaphragm (9) out.

NOTE: Take care when removing the Diaphragm so as not to damage the seating face of the Valve Body (11).

• Remove the Valve Lifter (10) from the Valve Body (11).

NOTE: If the First Stage has a DIN Connection, go to step 13: if it has a Yoke Connection follow step 14.

Removal of Din Connection

• Using a 6mm Allen key, unscrew the DIN Connection Assembly and separate it into four pieces. Remove the ‘O’ ring from the end of the Handwheel connector (32).

Removal of Yoke Connection

• Unscrew the Yoke Clamp Screw (28) and remove the Protective Cap (27) from the Yoke Clamp (25). Using a 3/4” A/F spanner, loosen the Yoke Clamp Connector (23). Unscrew the Yoke Connector and Yoke Clamp. Remove the ‘O’ ring from the Yoke Clamp Connector (23).

• Insert a dowel through the open end of the Yoke Clamp Connector (23) and push out the Disc Filter (24).

This Ends Disassembly

• Before starting reassembly, perform parts cleaning and lubrication according to the procedures outlined in ‘Cleaning & Lubrication

REASSEMBLY PROCEDURES

Assembling and fitting of Yoke Connection

• Insert a new Disc Filter (24) with the smooth side out, into the Yoke Clamp Connector (23). Install a new lubricated ‘O’ ring (19) into the end of the Connector.
• Insert the Yoke Clamp Connector (23) through the Yoke Clamp (25). With the Valve Body held so that the inlet connection port points down, screw the Yoke Clamp Connector into the Valve Body (11) until finger tight.

CAUTION: If the Yoke Clamp Assembly is not held vertically whilst it is screwed into the Valve Body, the ‘O’ ring in the end of the Yoke Clamp Connector may not remain in the correct position.

Secure the Valve Body (11) back into the vice using the First Stage Work Handle (PN AT48). Tighten the Yoke Clamp Connector using a 3/4” A/F spanner. Install the Protective Cap (27) with the logo facing outwards, onto the Yoke Clamp (25). Screw the Yoke Clamp Screw (28) back into the Yoke Clamp (25), until the Protective Cap (27) is retained in place.

Assembling and fitting of DIN Connection

• Install a new ‘O’ ring (26) into the face of the Handwheel Connector (32). Install a new lubricated ‘O’ ring (19) into the opposite end of the Connector. Install the Conical Filter (30) into the Connector, through the ‘O’ ring.

NOTE: Ensure that the ‘O’ ring is retained in the Connector after the Conical Filter has been fitted.

• Insert the threaded end of the Handwheel Connector through the threaded end of the Handwheel (31). With the Valve Body held so that the inlet connection port points down, screw the Handwheel Connector into the Valve Body (11) until the finger tight.

CAUTION: If the Handwheel Connector Assembly is not held vertically whilst it is screwed into the Valve Body, the ‘O’ ring in the end of the Handwheel Connector may not remain in the correct position.

• Secure the Valve Body (11) back into the vice using the First Stage Work Handle (PN AT48). Tighten the Handwheel Connector (32) using a 6mm Allen key bit in a torque wrench to 20 Nm.

Fitting of Dry Sealed Chamber

• Drop the Valve Lifter (10) through the center hole of the Valve Body (11). Press a new Diaphragm (9) into the Body. Run your finger around the edge of the diaphragm to make sure it is properly seated.

• Place the Spring Carrier (8), flat side down, in the center of the diaphragm. Place the Spring (6) on the Spring Carrier. Thread the Diaphragm Clamp (7) onto the Valve Body (11), making sure that the Spring (6) remains on the Spring Carrier (8), until hand tight. Using a C Spanner (PN AT30) tighten the Diaphragm Clamp (7) until there is metal-to-metal contact.

Fitting of TEK3 & DS4 Tungsten Diaphragm Clamp

• Thread the Diaphragm Clamp (7) onto the Valve Body (11), making sure that the Spring (6) remains on the Spring Carrier (8), until hand tight. Using a 34mm Spanner (PN AT47) tighten the Diaphragm Clamp (7) until there is metal-to-metal contact. Refit the Moulded Ring (34).

Fitting of Un-Sealed End Cap (UST)

• Thread the Diaphragm Cap (35) onto the Valve Body (11), making sure that the Spring (6) remains on the Spring Carrier (8), until hand tight. Using a C Spanner (PN AT30) tighten the Diaphragm Cap (35) until there is metal-to-metal contact.

• Fit new Lubricated ‘O’ rings (15 & 16) onto the H.P. Balance Plug. Install a new lubricated ‘O’ ring (14) into the end of the H.P Balance Plug (17).

• Press the Spring (13) onto the end of the H.P. Balance Plug. Carefully insert a new H.P. Valve (12) into the Valve Body (11) making sure that it slides onto the shaft of the Valve Lifter (10).

• Insert the H.P. Balance Plug (17) into the Valve Body (11) and tighten using a 6mm Allen key bit in a torque wrench to to 8 Nm.

WARNING: Compressed air can be highly explosive and is dangerous if misused. Ensure the cylinder valve is opened slowly. Use Eye and Ear Personal Protective Equipment when performing any tests involving Compressed air.

Adjusting the First Stage

NOTE: To Adjust the Extrair First Stage refer to AP6520 Extrair Cylinder Valve Maintenance Manual.

• Attach the first stage (with no Blanking Plugs fitted) to a fully charged 232 or 300-bar cylinder. Slowly open the cylinder valve, this will remove any particles or contaminants from the first stage.
• Install new lubricated ‘O’ rings (19,21) on all of the Blanking Plugs (18,20). Using a 5mm Allen key, install all of the Blanking Plugs into the Valve Body.
• Attach a MP test gauge (0 – 20 bar) to a medium-pressure hose and thread the hose into an MP port. If your test gauge does not have an over-pressure relief valve, you must also attach a properly adjusted second stage to the first stage to act as the relief valve in case of a HP leak. Make sure Blanking Plugs are installed in any open ports.

CAUTION: If the pressure gauge rapidly exceeds 11 bar, then there is a HP leak. Quickly close the cylinder valve and purge the regulator. Refer to the troubleshooting table for the causes of the leak.

Assuming there are no leaks, close the cylinder valve and depressurize the regulator by opening the gauge relief valve or by pressing the purge button of the second-stage regulator. Adjust the medium pressure by turning the Spring Adjuster (5,36): Turning in the Spring Adjuster increases the MP; Turning out the Spring Adjuster decreases the MP. Turn the Spring Adjuster in 1/8th turn increments and purge the relief valve several times after each adjustment. When the MP is between 9 and 10 bar , purge the relief valve on and off 10-15 times. After cycling, watch the gauge needle. The first stage MP should “lock up” between 9 and 10 bar. Make any adjustments as necessary. Allow the first stage to stay pressurized for several minutes and check the MP again to make sure it remains “locked up” between 9 and 10 bar. If the MP creeps upward more than 0.25 bar, then there is a leak. Refer to the troubleshooting table for possible causes.

• Close the cylinder valve and depressurize the regulator by opening the gauge relief valve or by pressing the purge button of the second stage regulator. Close the relief valve and repressurize the system. The MP should still read between 9 and 10 bar. If the pressure reading is different than the original setting, repeat steps 3 and 4 until the MP is stable.

Final Assembly

• With the regulator still pressurized, insert the Load Transmitter (4) into the Diaphragm Clamp (7). Press a new Hydrostatic Diaphragm (2) into the Environmental End Cap (1).

NOTE: The Hydrostatic Diaphragm (2) in the TEK3 and DS4 Tungsten does not need to be replaced with a new one.

• Thread the Environmental End Cap (1) onto the Diaphragm Clamp (7) until hand tight. Using the C Spanner (PN AT30), tighten the Environmental End Cap (1) until there is metal-to-metal contact. Re-check the medium pressure, making sure that it is still between 9 and 10 bar.

This Ends Reassembly

IMMERSION TEST

With the Blanking Plugs and at least one properly adjusted second stage installed, slowly open the cylinder valve and pressurize the first stage. Completely Submerge the first stage in fresh water and check for leaks.
NOTE: Do not confuse bubbles from trapped air with a true air leak. If there is an air leak, bubbles will come out in a steady constant stream.
Assuming that there are no leaks, close the cylinder valve and depressurize the regulator. Remove the first stage from the valve and secure the Protective Cap (27) in place with the Yoke Clamp Screw (28). If the regulator has a DIN connection replace the Protective DIN Cap (33).
If a leak is detected, note the source of the leak and refer to the troubleshooting table on page 12 for possible causes and corrective actions.

This Ends Testing

Troubleshooting

Table 1 – Troubleshooting Guide

High Pressure Creep (also causes second-stage leaks)

| 1. HP Valve (12) is worn or damaged.| 1. Replace HP Valve.
2. Spring Adjuster (5,36) too far in.| 2. Unscrew Spring Adjuster out.
3. HP Valve Seat in the Valve Body (11) is worn or damaged.| 3. Replace Valve Body.
4. HP Balance Plug (14) internal wall damaged.| 4. Replace HP Balance Plug.
5. ‘O’ ring inside HP Balance Plug (14) is damaged or worn.| 5. Replace ‘O’ ring.
6. ‘O’ ring on the HP Balance Plug (15) is damaged or worn.| 6. Replace ‘O’ ring.

External air leakage or Secondary diaphragm distended or burst

| 1. Blanking Plug ‘O’ rings (21,19) are worn or damaged.| 1. Replace ‘O’ Ring.
2. Diaphragm (9) worn or damaged.| 2. Replace diaphragm.
3. Diaphragm seating surface damaged.| 3. Replace Valve Body.
4. Connector ‘O’ ring (26) worn or damaged.| 4. Replace ‘O’ Ring.
5. Diaphragm Clamp (7) loose.| 5. Tighten Diaphragm Clamp.
6. ‘O’ ring on HP Balance Plug (16) worn or damaged.| 6. Replace ‘O’ Ring.

Restricted airflow or high inhalation resistance through the entire system

| 1. The cylinder valve is not completely open.| 1. Open the valve, and check the fill pressure.
2. Cylinder valve requires servicing| 2. Switch to a different cylinder.
3. Conical Filter (30) or Disc Filter (24) is clogged.| 3. Replace filter.
4. Very Low Medium Pressure.| 4. Adjust Medium Pressure to between 9 and 10 bar.

Recommended Tool List

Table 2 – Recommended Tool List

Connection
n/a| 6mm Allen key bit for torque wrench| Installation of Balance Plug & DIN Connection
AT34| 11/16” spanner| Hose Removal
AT37| 5mm Allen key| Blanking Plugs
AT38| 6mm Allen key| Removal of Balance Plug, DIN Connection & Spring Adjuster
AT47| 34mm open-ended spanner| Removal of TEK3 Diaphragm Clamp
AT33| 3/4” ring spanner| Removal and installation of Yoke Clamp Connector
n/a| 232 or 300 bar Diving cylinder| Testing of regulator

Recommended Lubricants & Cleaners

Table 3 – Recommended Lubricants & Cleaners

Ltd PN AP1495, or

Lubrication Technologies 310 Morton Street Jackson, OH 45640, USA 800-477-8704

| 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)| Biological immersion fluid for reusable stainless steel and brass parts.| Solent Divers Ltd

122-128 Lake Rd, Portsmouth, Hants, PO1 4HH

White distilled vinegar (100 gr.) (Cleaning agent)| Acid bath for reusable stainless steel and brass parts.| “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 dishwashing detergent diluted with warm water

(Cleaning agent)

| Degreaser for brass and stainless steel parts; general cleaning solution for plastic and rubber| “Household” grade

Cleaning & Lubrication Procedure

General Cleaning of all Parts

1. Place all components in an ultrasonic cleaning bath containing an appropriate cleaning solution, such as Biox.
2. The components should be cleaned for 6 minutes, depending upon their condition. Longer cleaning times may used if required.
3. Rinse the components in warm fresh water.
4. The components should then be blown dry or left to dry naturally.

Lubrication and Dressing
All ‘O’ Rings should be lubricated with Christo-Lube® MCG-111. 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 Christo-Lube grease, as this will attract particulate matter that may cause damage to the ‘O’ Ring.

Nitrox
When it comes to issues of nitrox safety and compatibility, the concerns lie primarily with the first stage as it is subjected to high inlet pressures. High inlet pressures lead to adiabatic compression or heating of the gas. As they leave the factory, standard Apeks regulators are suitable for use with oxygen-enriched gases (i.e. nitrox, etc.) providing the oxygen content does NOT EXCEED 40% (EAN40).
Any Apeks regulator, when properly cleaned, lubricated and assembled, is authorized for use with enriched air nitrox (EAN) up to 100% (EAN100). It is authorized because it has undergone adiabatic compression testing and the authorized service kit components and lubricants are compatible in elevated oxygen environments. During cleaning, a mild detergent is used to remove condensed hydrocarbons (compressor oils) from the inside passageways of the first stage. For the first stage to remain EAN100 compatible, only use hyperfiltered compressed gas (hydrocarbons < 0.1 mg/m3). Ordinary compressed breathing air to BS EN 12021:1999 does not meet this criteria. Once ordinary breathing air is used, the first stage is no longer EAN100 compatible until it is cleaned and serviced again.
Although regulator second-stage components are not exposed to high-pressure EAN, Apeks recommends that the same cleaning procedures be followed for the complete regulator. This prevents the possibility of cross-contamination and guarantees the cleanliness of the entire regulator.
WARNING: Please check the regulations regarding Nitrox in your particular country as this may differ from Apeks standard policy.

Specifications

Table 4 – Torque Specifications

Table 5 – Test Bench Specifications

Leak Test

|

Inlet pressure 150 – 232 bar

|

No Leaks allowed

Medium Pressure

|

Inlet pressure 150 – 232 bar

|

9 to 10 bar

Medium Pressure Creep

|

Inlet pressure 150 – 232 bar

| 0.25 bar max for 15 seconds after purging regulator

Exploded Parts Diagram

DS4 & DS1 Exploded Parts Diagram

All marked items must be replaced when serviced.

Tungsten DS4 Exploded Parts Diagram

All marked items must be replaced when serviced.

US4 & US1 Exploded Parts Diagram

All marked items must be replaced when serviced.

TEK3 Exploded Parts Diagram

All marked items must be replaced when serviced.

Extrair Exploded Parts Diagram

All marked items must be replaced when serviced.

DS, US, TEK3 & EXTRAIR FIRST STAGE REGULATOR MAINTENANCE MANUAL FOR AUTHORISED TECHNICIANS Apeks Marine Equipment Ltd Neptune Way, Blackburn, Lancs, England, BB1 2BT

CONTACT

• APEKS MARINE EQUIPMENT LTD, NEPTUNE WAY, BLACKBURN, LANCASHIRE. BB1 2BT
• Tel: 0044 (0) 1254 692200 Fax: 0044 (0) 1254 692211 E-mail: info@apeks.co.uk Web: www.apeks.co.uk

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