Service Manual

Air Tech Second Stage

Copyright 2002, Cressi-sub Revised 3/2002
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Contents
BEFORE STARTING ....................................................................................... 3
DISASSEMBLY ................................................................................................ 3
PARTS CLEANING AND LUBRICATION ....................................................... 9
CLEANING METAL PARTS ............................................................................................ 9
CLEANING PLASTIC-ONLY PARTS .............................................................................. 9
LUBRICATION ................................................................................................................ 9
Types of Lubricant ..................................................................................................... 9
O-rings ..................................................................................................................... 10
Threaded parts ........................................................................................................ 10
REASSEMBLY ............................................................................................... 10
ADJUSTING THE SECOND STAGE.............................................................. 15
FINAL REASSEMBLY ................................................................................... 16
TABLE 1 - TROUBLESHOOTING ................................................................. 18
TABLE 2 - REQUIRED TOOLS ..................................................................... 18
EXPLODED PARTS DIAGRAM..................................................................... 19
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3

BEFORE STARTING
WARNING
This manual is not a training document. It is meant to be a
guide for experienced technicians who have also received
factory training at a Cressi-sanctioned repair seminar. Do not
attempt to repair this or any regulator without the proper train-
ing.

Before starting, Cressi recommends that you read through the entire manual
to familiarize yourself with all the required tools and techniques. Use this
manual as a guide during the servicing process to avoid missing any critical
steps. Make sure the work area is clean and that you work over a cushioned
work surface so critical parts do not get damaged.
Pay close attention to all warnings and cautions as they will alert you to any
potential hazard that may cause damage or injury. Also, pay attention to the
notes as they provide important tips and reminders.

DISASSEMBLY
1. Using a 9/16” wrench, unscrew the second stage hose from the first
stage. Remove the O-ring from the end of the hose.
2. While holding the retaining nut (18) with a 3/4” (19mm) wrench, unscrew
the swivel hose fitting using an 11/16” wrench (see figure 1). Using a
brass or plastic O-ring pick, remove the O-ring (15) located inside the
hose swivel.

Figure 1. Removing the hose.

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3. Using side cutters, snip the mouthpiece clamp (9). Pull the mouth-
piece (8) off the second stage body (4).
4. Using a Phillips screwdriver, remove the exhaust tee retaining screw
(7) as shown in figure 2.
5. To remove the exhaust tee (6), place your thumb on the top corner of
the exhaust tee and press downward.

Figure 2. Removing the Figure 3. Press down on top

exhaust tee screw corner of exhaust tee to
remove

6. Remove the exhaust valve (5) by grasping it with your thumb and
forefinger and pulling it straight out.
7. Remove the front cover by grasping the retaining ring (1) with your
fingers and turning it counterclockwise. Separate the front cover (2)
from the retaining ring. Lift out the diaphragm (3).

8. Turn the adjustment knob clock-

wise until it stops. Using a 3mm
hex wrench, remove the adjust-
ment knob retaining screw (35) as
shown in figure 4. Remove the
adjustment knob (34).

Figure 4. Remove retaining screw with

3mm hex wrench

9. To remove the circlip (33), you

must turn the adjustment screw so
one of the flat edges is facing the
two eyelets on the circlip. Using a
pair of circlip pliers, contract and
remove the circlip (see figure 5).
flat edge

Figure 5. Remove circlip

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5

10. Using a 3/4” wrench, unscrew the

retaining nut (18) as shown in figure 6.

Figure 6. Remove retaining nut with

3/4-inch wrench

11. While looking at the valve body through

the front of the second stage, slide the
valve body from left to right about a 1/2”
and lift out the valve body alignment key
(20) as shown in figure 7.

Figure 7. Remove alignment key

12. Press the lever (21) against the valve

body and slide the valve body out of the
second stage housing (see figure 8).

Figure 8. Depress the lever and slide the

valve body out of the second stage

13. Grasp the venturi channel (13) with

your fingers and pull it straight out of
the second stage (see figure 9).

Figure 9. Remove venturi channel

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14. Fit the adjustment knob (34) back onto the adjustment screw and
thread the retaining screw (35) back into the adjustment screw (see
figure 10). Turn the adjustment screw counterclockwise several times
to disengage the threads. Because the adjustment screw is O-ring
sealed, it will not freely exit the valve body; therefore, firmly grasp the
adjustment knob and pull the adjustment screw out of the valve body
(see figure 11).

Figure 10. Temporarily reinstall Figure 11. Unscrew adjustment knob to

adjustment knob disengage threads, then pull straight out

15. Remove the retaining nut and knob from the adjustment screw. Re-
move the two O-rings (32 & 30) from the adjustment screw.

16. Underneath the adjustment screw is a

metal disk (29). This disk should freely
fall out of the valve body. If it doesn’t,
gently tap the end of the valve body
against the work bench until the disk
falls out (see figure 12).

Figure 12. Remove metal disk

17. Insert a small dowel or 3mm hex wrench through the threaded end of
the valve body (22) and press out the poppet assembly (24-28) as
shown in figures 13 & 14.

Figure 13. Push against poppet Figure 14. Poppet assembly removed
assembly from valve body
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7

CAUTION
Take special care when removing the adjustable orifice so the
sealing edge is not damaged. Place the orifice on a cushioned
surface while disassembling the remainder of the second
stage. Keep it away from the edge of the work bench so it
doesn’t fall to the floor and become damaged.

18. Using a medium blade screwdriver, unscrew the adjustable orifice (17)
about 6 to 7 turns (see figure 15). Because the adjustable orifice is O-
ring sealed, it will not freely exit the valve body; therefore, insert a
wooden dowel in the opposite end of the valve body and push out the
adjustable orifice (see figure 16).

Figure 15. Unscrew the adjustable Figure 16. Push out adjustable orifice
orifice to disengage threads with small wooden dowel

19. Remove the two O-rings (19 & 23) from the valve body.
20. (This step is optional.) Unless the lever (21) is damaged, it is not nec-
essary to remove it. However, if the lever needs to be removed, gently
spread the two legs and remove it from the valve body.
21. Separate the poppet (25) and balance chamber (28) by pulling them in
opposite directions (see figure 17). Remove the spring (27). Using your
fingernail, pry the low pressure seat (24) from the end of the poppet (see
figure 18). Remove the small O-ring (26) from the end of the poppet.

Figure 17. Separate poppet from Figure 18. Remove LP seat from end
balance chamber of poppet
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22. Using a medium blade screwdriver,

rotate the retaining clip (10) so the
open side of the clip faces the
mouthpiece opening. Lay the sec-
ond-stage body on the workbench
with the mouthpiece opening facing
upward. Using a second flat blade
screwdriver, press the two “legs” of
the retaining clip and pop it off the
flow control knob (12) as shown in
figure 19. Figure 19. Push on both legs of the c-
clip to remove

23. Lift the flow control knob (12) out of

the second stage body (figure 20).
Remove the O-ring (11) from the
flow control knob.

Figure 20. Remove flow control knob

This ends disassembly

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9

PARTS CLEANING AND LUBRICATION

CLEANING METAL PARTS

CAUTION
Keep the adjustable orifice (17) separate from the other parts
while cleaning. If the sealing surface is damaged, the part will
have to be replaced.

1. Wash all the metal parts in a hot, soapy water solution. Use a soft bristle
toothbrush to clean the threads and remove any flaky corrosion.
2. After washing in the hot, soapy water, rinse all the parts in fresh water.
3. Place the metal parts in an ultrasonic cleaner with an appropriate clean-
ing solution. Avoid using harsh acids such as muriatic acid in ultrasonic
cleaners. Clean the parts for 5 to 15 minutes, depending on the amount
of corrosion.
4. Remove the parts from the ultrasonic cleaner and rinse them in fresh
water. Blow-dry the parts using low-pressure filtered air.

CLEANING PLASTIC-ONLY PARTS

Avoid placing plastic parts in an ultrasonic cleaner with an acidic cleaning
solution. To properly clean plastic parts, perform the same steps listed above.
1. Wash all the plastic parts in a hot, soapy water solution. Use a soft bristle
toothbrush to clean the threads and remove any flaky corrosion.
2. After washing in the hot, soapy water, rinse all the parts in fresh water.
3. Blow-dry the parts using low-pressure filtered air.

LUBRICATION
Types of Lubricant
Cressi recommends using only food-grade silicone grease or, more prefer-
ably, Christo-lube MCG 111.

CAUTION
DO NOT use spray silicones as the aerosol propellants may
chemically attack the rubber compound.

continued....
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O-rings
All O-rings should be treated with a thin film of lubrication. Do not over-
lubricate the O-rings with large amounts of grease. Simply place a small
amount of grease between your thumb and forefinger and run the O-ring
between them.
Threaded parts
You may lightly lubricate first two threads. As you tighten parts together,
the lubricant will spread to the other threads.

REASSEMBLY
1. Install a new, lubricated O-ring (11) onto the flow control knob (12).
Insert the flow control knob into the second stage body (4) and press
down so that the groove for the retaining clip is visible in the mouth-
piece opening.

2. Hold the second stage body with

the flow control knob facing down-
ward. One side of the retaining clip
(10) has a sharp edge; the other
side has a rounded edge. Set the
retaining clip into the mouthpiece
opening with rounded edge against
the second stage housing, and the
open side against the flow control
knob. Using your finger or a flat Figure 21. Install C-clip
blade screwdriver, press the retain-
ing clip against the flow control
knob until it snaps into place (figure 21). Move the flow control knob
back and forth to ensure that it operates smoothly.
3. Insert the stem of a new exhaust valve (5) through the center hole in
the exhaust port on the outside of the second stage housing (4) as
shown in figure 22. Grasp the stem with your fingers and pull it until
the barb pops through (figure 23).

Figure 22. Install exhaust valve Figure 23. Pull barb all the
way through
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11

4. Install new, lubricated O-rings (19 & 23)

onto the valve body (22) as shown in Install O-rings
figure (24).

Figure 24. Install valve body O-ring;

5. (Note: Perform this step only if

lever was removed during disas- machined flat surface
sembly.) One side of the valve
body has a machined flat surface.
With the machined flat surface facing
upward, gently spread the legs of the
lever (21) and insert the feet of the
lever into the two side holes in the
valve body (see figure 25). Figure 25. Install lever

6. Press a new, low pressure seat (24) into the end of the poppet (25) as
shown in figure 26. Install a new, lubricated O-ring (26) onto the stem of
the poppet (figure 27).

Install O-ring

Figure 26. Install LP seat into Figure 27. Install poppet O-ring
poppet

7. Press the spring (27) onto the balance

chamber (28). Pass the poppet stem
through the spring and press it into the
balance chamber (see figure 28).

Figure 28. Install spring onto balance

chamber; press poppet into balance chamber
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8. Install two, new lubricated O-rings

(30 & 32) onto the adjustment
screw (see figure 29).

Figure 29. Install adjustment screw O-rings Install O-rings

9. With the “feet” of the poppet face

down (away from the lever, see lever faces
figure 30), slowly drop the pop- upward
pet assembly, low pressure seat
side first, into the valve body.

poppet feet point down

Figure 30. Install poppet assembly into

valve body

10. Drop the metal disk (29) into the end of the valve body, making sure it
lays flat against the balance chamber (see figure 31). Slowly press
the adjustment screw into the valve body (see figure 32). As you
insert the adjustment screw, the lever will pop up. Continue to press
the adjustment screw into place until the outer O-ring is no longer
visible. You will hear a click sound, meaning that the poppet has
cleared the lever feet. Place the knob onto the end of the adjustment
screw and turn clockwise until it stops.

Figure 31. Install metal disk Figure 32. Press adjustment screw into
valve body
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13

12. Place the circlip (33) onto a pair of circlip pliers. Orient the two eyelets so
they are facing one of the flat edges on the adjustment screw. Compress
the circlip, pass it over the adjustment screw and install it into the end of
the valve body (see figure 33). Make sure the circlip is positioned in the
groove all the way around (see figure 34). Turn the adjustment knob in
and out to ensure it operates smoothly.
flat edge faces eyelets

Figure 33. Install circlip into valve body Figure 34. Inspect circlip to make sure it
is properly seated

13. Slide the venturi channel (13) back into

the slot as shown in figure 35.

Figure 35. Install venturi channel

14. Orient the second stage so the front is facing you. While depressing the
lever, insert the threaded end of the valve body into the second stage
from right to left (see figure 36). Continue pressing the valve body into
place until about half of the squared section is still visible (see figure 37).
Place the two legs of the retaining key (20) around the squared section
and press it into place until the “wings” are against the plastic (see figure
38). Press the valve body all the way into the second stage until it is
stopped by the retaining key.

Figure 36. Depress lever Figure 37. Leave half of the Figure 38. Install the
and insert valve body squared section visible retaining key over squared
section
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15. Thread the retaining nut (18) onto the

end of the valve body until finger
tight. Attach a 3/4” crows-foot or
socket to a torque wrench and
tighten the retaining nut to 50 inch-
pounds (see figure 39).

Figure 39. Install retaining nut and

torque to 50 inch-pounds

16. Install a new, lubricated O-ring (19) onto the adjustable orifice (17).
Insert the threaded end of the adjustable orifice into the end of the
valve body (see figure 40). Using a medium blade screwdriver, press
the orifice all the way into the valve body and start turning it clockwise
(see figure 41). As you turn in the orifice, watch the lever. When the
orifice starts pressing against the low pressure seat, the lever will
start to drop. As soon as it drops, stop turning the adjustable orifice.

Figure 40. Install adjustable orifice Figure 41. Tighten adjustable orifice
into valve body until lever starts to drop

17. Place the knob (34) onto the adjustment screw. Thread the retaining
screw (35) into the end of the adjustment screw and tighten with a
3mm hex wrench.

Notch
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15

ADJUSTING THE SECOND STAGE

A medium pressure air supply of 135±5 is required to properly adjust the
second stage. Make sure the first stage that you are using is properly ad-
justed before performing the second stage adjustments. Please refer to the
appropriate Cressi first stage repair manual for proper first stage adjustment
procedures. The first stage should be attached to a fully charged cylinder
(2500 to 3000 psi).
The use of an in-line adjustment tool is required to tune the regulator. The in-
line tool is available from other 3rd party suppliers.

ADJUSTING THE SECOND STAGE WITH AN IN-LINE ADJUSTMENT

TOOL.

1. Screw the threaded end of the second stage hose into the first stage.
Using an 11/16” wrench, tighten the hose until snug. Pull back the adjust-
ment wheel of the in-line tool and thread the in-line tool into the second
stage inlet fitting. Thread the swivel end of the second stage hose onto
the in-line tool until finger tight.
2. Turn the adjustment knob counterclockwise until it is all the way out, then
turn it clockwise a half turn.
3. Slowly open the cylinder valve and pressurize the regulator. When the
regulator pressurizes, the lever will drop.
4. Press the handwheel of the in-line tool inward until it stops. Rotate the
handwheel until the in-line tool engages the screwdriver slot in the ad-
justable orifice. Slowly rotate the handwheel counterclockwise until there
is an audible air leak. Once the leak is heard, turn the handwheel clock-
wise until the leak stops, then an additional eighth turn.
5. Turn the adjustment knob counterclockwise until it stops. You should be
able to hear a slight leak. Turn the adjustment knob back in a half turn; the
leak should stop.
6. Close the cylinder valve and purge the regulator by pressing the lever.
Pull back on the in-line tool handwheel and unscrew the in-line tool from
the second stage. Unscrew the hose from the in-line tool.
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FINAL REASSEMBLY
1. Note the two notches at the top Tab
and bottom of the diaphragm
(3). These notches mate with
two tabs inside the second
stage housing (see figure 42).
On the backside of the dia- Notch
phragm is a metal strike plate.
With the strike plate facing the
lever, place the diaphragm into
the second stage housing. Figure 42. Align notches in diaphragm
with tabs in housing

2. Orient the front cover so the

purge button logo is properly
Tab
aligned. Align the notches in
the front cover with the tabs in
the second stage (figure 43).
While holding the front cover
down with your thumb, screw
the retaining ring onto the
second stage housing. Notch

Figure 43. Align notches in front cover with

tabs in housing

3. Hang the exhaust tee (6) from the

top edge of the flange (see figure Hang tee from this
44). Press on the bottom of the ledge
exhaust tee until it snaps into
place.

Figure 44. Hang exhaust tee on top edge of

flange

4. Using a Phillips screwdriver, install the exhaust tee retaining screw (7).
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17

Note: Do not install the mouthpiece at this time if you will be performing
bench tests.
5. Install the mouthpiece onto the 2nd stage body. Secure the mouth-
piece with a new clamp (12). The clamp’s locking tab should be posi-
tioned on the hose side of the mouthpiece. Using side cutters, trim
the clamp so it is flush with the locking tab.
6. Thread the hose swivel onto the inlet fitting until finger tight. Attach an
11/16” crows-foot to a torque wrench. While holding the inlet fitting
with a 3/4” (19mm) wrench, tighten the hose swivel to 40 inch-
pounds.

This ends reassembly and testing

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TABLE 1 - TROUBLESHOOTING
Problem Cause Solution

Air leak at hose swivel a. O-ring (15) worn or damaged a. Replace O-ring
b. O-ring (16) worn or damaged b. Replace O-ring

Second stage leaks air a. Adjustable orifice (17) damaged a. Replace adjustable orifice
b. LP seat (24) Damaged or worn b. Replace seat

Hard to breathe a. Adjustable orifice too tight a. Back out adjustable orifice

TABLE 2 - REQUIRED TOOLS

Tool Description Used for
1. 9/16” open end wrench Removing hose (14)
2. 3/4” open end wrench Removing retaining nut (18)
3. Side cutters Removing mouthpiece clamp (9)
4. Phillips screwdriver Removing/installing exhaust tee screw (7)
5. O-ring tool Removing O-rings
6. 2 medium blade screwdrivers Removing adjustable orifice (17), Clip (10)
7. Small wooden dowel Removing adjustable orifice (17)
8. Torque Wrench Tightening retaining nut (18); Hose swivel
9. 9/16” crows-foot Used with torque wrench
10. 3/4” crows-foot Used with torque wrench
11. In-line adjustment tool Adjusting second-stage
12. 3mm hex wrench Removing adjustment knob screw (35)
13. Circlip pliers Removing/installing circlip (33)
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19

EXPLODED PARTS DIAGRAM

14
9
15
16 10
17 11
18 8
12

7
13
6

22

4 5 19
23
3 24
25
2
26
21
27
20
28
1 29
30
31
32
33
34
35

Key # Description Key # Description

1. Retaining Ring Assy 19. O-ring, Valve Body
2. Front Cover 20. Retaining Key
3. Diaphragm 21. Lever
4. Second Stage Body 22. Valve Body
5. Exhaust Valve 23. O-ring, Valve Body
6. Exhaust Tee 24. Low Pressure Seat
7. Retaining Screw, Exhaust Tee 25. Poppet
8. Mouthpiece 26. O-ring, Poppet
9. Clamp 27. Spring
10. C-Clip 28. Balance Chamber
11. O-ring 29. Metal Disk
12. Flow Control Knob 30. O-ring, Adjustment Screw
13. Venturi Channel 31. Adjustment Screw
14. Hose 32. O-ring, Adjustment Screw
15. O-ring, Hose Swivel 33. C-Clip, Adjustment Screw
16. O-ring, Adjustable Orifice 34. Adjustment Knob
17. Adjustable Orifice 35. Retaining Screw, Adjustment Knob
18. Retaining Nut
 Air Tech Second Stage
Service Manual

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