Apeks TX100 Manuale utente
TX SECOND STAGE
REGULATOR
TECHNICAL SUPPORT
APEKS MARINE EQUIPMENT LTD, NEPTUNE WAY, BLACKBURN, LANCASHIRE. BB1 2BT
MAINTENANCE MANUAL FOR
AUTHORISED TECHNICIANS
Document No. AP5833
Issue 4
15/02/2011
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TX Second Stage Regulator Maintenance Manual
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TX Second Stage Regulator Maintenance Manual
Change
No.
Change Re-
quest No.
Description & Comments: Change Date New Issue No. Changed By: Approved
By:
0832 -
statement about leftover items after servicing,
photos of tools added, metric & Imp Units and
note about AP2038/SQ
02/08/06 02 JLH ACD
0951 Page 11 and 18. Torque setting changed from
5Nm to 3Nm for T20 due to Case damage
problems.
12/01/09 03 MW RJP
1116 0247 All heat exchanger torque settings have been
changed from 5Nm to 3Nm to prevent damage
to the case. Add new O ring pick to tools list.
31/01/11 04 RH
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
recoreded this table can then be completed and the document up issued.
ACD
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TX Second Stage Regulator Maintenance Manual
Contents
RANGE COVERED .................................................................................................................................................................... 4
COPYRIGHT NOTICE................................................................................................................................................................ 5
INTRODUCTION ........................................................................................................................................................................ 5
WARNINGS, CAUTIONS & NOTES ......................................................................................................................................... 5
SCHEDULED SERVICE ............................................................................................................................................................. 5
GENERAL GUIDELINES ........................................................................................................................................................... 5
GENERAL CONVENTIONS....................................................................................................................................................... 6
DISASSEMBLY PROCEDURES ................................................................................................................................................ 6
REASSEMBLY PROCEDURES.................................................................................................................................................. 9
FINAL TESTING ....................................................................................................................................................................... 12
TABLE 1 - TROUBLESHOOTING GUIDE ............................................................................................................................. 14
TABLE 2 - RECOMMENDED TOOL LIST.............................................................................................................................. 15
TABLE 3 - RECOMMENDED LUBRICANTS AND CLEANERS ........................................................................................ 16
CLEANING AND LUBRICATION PROCEDURE .................................................................................................................. 17
TABLE 4 -TORQUE SPECIFICATIONS .................................................................................................................................. 18
TABLE 5 - TEST BENCH SPECIFICATIONS ......................................................................................................................... 18
TX100 EXPLODED PARTS DRAWING .................................................................................................................................. 19
TX50 EXPLODED PARTS DRAWING .................................................................................................................................... 20
TX40 & T20 EXPLODED PARTS DRAWING......................................................................................................................... 21
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TX Second Stage Regulator Maintenance Manual
RANGE COVERED
This manual provides factory prescribed procedures
for the correct maintenance and repair of the following
Apeks TX second stage regulator range.
TX100
Flagship model, features include: -
Adjustable cracking control
Integrated venturi control
Pneumatically balanced valve design
Suitable for cold water use
Satin Chrome Finish
TX50
Features include: -
Adjustable cracking control
Integrated venturi control
Pneumatically balanced valve design
Suitable for cold water use
Bright Chrome Finish
TX40
Features include: -
Integrated venturi control
Pneumatically balanced valve design
Suitable for cold water use
Bright Chrome Finish
T20
Features include: -
Integrated venturi control
Pneumatically balanced valve design
Bright Chrome Finish
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TX Second Stage Regulator Maintenance Manual
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TX Second Stage Regulator Maintenance Manual
An Ofcial Inspection consists of:
1. A pressurised immersion test of the entire unit to check for
air leakage.
2. Checking for stable medium pressure that is within the ac-
ceptable range.
3. Checking for opening effort that is within the acceptable
range.
4. Checking for smooth operation of the control knob and
venturi switch.
5. A visual inspection of any lters for debris or dis-
colouration.
6. A visual inspection of the exhaust valve(s) to see that they
are in good condition and that it is seating against a clean
and undamaged surface.
7. A visual inspection of the mouthpiece looking for tears or
holes and checking the general condition.
8. Pulling back hose protectors and checking that the hoses are
secure in the hose crimps.
If a regulator fails steps 1,2,3 or 4 the entire regulator should be
serviced. If a regulator fails 5,6 or 7 it will be at the technician’s
discretion whether or not a full service is required. Failure of step
8 requires 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
specically set up and equipped for the task. Adequate
lighting, cleanliness, and easy access to all required tools are
essential for an efcient 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 ttings 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 2nd stage
service kit (AP0219). DO NOT attempt to substitute an
Apeks part with another manufacturer’s, regardless of any
similarity in shape or size. Please note that AP0219 is a
generic kit that covers several different types of 2nd stage
and therefore not all of the parts within the kit will be used
when servicing a TX 2nd stage.
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
specication 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.
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.
©2006 Apeks Marine Equipment Ltd.
TX Second Stage Maintenance Manual
(AP5833 Issue 2)
INTRODUCTION
This manual provides factory prescribed procedures for the correct
maintenance and repair of the Apeks TX second stage regulator
range. 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
authorised 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:
WARN I N G S 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 emphasise important points, tips,
and reminders.
SCHEDULED SERVICE
It is recommended that the Apeks TX second stage regulator should
be serviced annually regardless of usage.
However, If you are at all unsure about the correct functioning of the
Apeks TX, then it must be ofcially 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.
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TX Second Stage Regulator Maintenance Manual
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TX Second Stage Regulator Maintenance Manual
1. Using two 11/16” spanners, hold the Heat Exchanger (6)
stationary while turning the Hose Swivel anti-clockwise.
Remove the ‘O’ ring from inside the Hose Swivel. Exercise
caution not to scratch the ‘O’ ring groove. Remove the ‘O’
ring from the male end of the Hose.
Pinch Method
Press upwards on
sides of ‘O’ Ring to
create a protrusion.
Grab ‘O’ Ring or
insert ‘O’ Ring tool
at protrusion.
2. 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.
3. Using the Apeks Front Cover Tool (PN AT31), unscrew the
Case Cover (4). To remove the Purge Button and Spring (2
& 3), squeeze two opposite tabs inward.
NOTE: Ensure that the tool is rmly pressed against
the Case Cover whilst unscrewing.
Removal of hose
Removal of diaphragm
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 gure below) if possible, or use a brass,
aluminium 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 regula-
tor or how much use it has received since it was last
serviced.
CAUTION: Use only a plastic, brass or aluminium
‘O’ Ring removal tool (PN AT79) 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. DO NOT use a dental pick, or
any other steel instrument.
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TX Second Stage Regulator Maintenance Manual
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TX Second Stage Regulator Maintenance Manual
4. Lift out the Diaphragm
Cover (5) and Diaphragm
(7).
5. Using an 11/16”
spanner, remove the
Heat Exchanger (6).
6. Turn the Counterbalance Adjuster Knob (28) anti-clockwise
until it stops. For the TX40 and T20 models use an Allen
key to turn the Adjusting Screw (28). Press the Lever (19)
against the Valve Spindle (20). While keeping the Lever
depressed, grasp the Knob and pull the Valve Spindle
assembly out of the Case (9). Remove the Valve Spindle ‘O’
ring (8) that will probably be left behind in the left side of
the Case.
7. Grasp the Venturi Lever (14) and pull it out of the
Case. Remove the ‘O’ ring (13) from the Venturi Lever.
8. Turn the
Counterbalance
Adjuster Knob (28) or
Adjusting Screw (28)
clockwise (inward) one
turn. The Spring Pin
(21) should drop out. If
the Pin remains in the
Valve Spindle, use a
1/16” dowel or punch
to push it partially out,
then use needlenose
pliers to completely
remove it from the
valve spindle.
9. Unscrew the Counterbalance Adjuster Knob (28) or
Adjusting Screw (28) and completely remove it from the
Valve Spindle.
10. Remove the ‘O’ ring (27) from the Counterbalance Adjuster
Knob. Remove the ‘O’ ring (8) from the Valve Spindle
Removal of valve assembly
NOTE: The Venturi Lever may have come out with
the valve Spindle in step 6. If this is the case, depress
the Lever and slide the Venturi Lever off from right to
left.
11. Insert a small 1/8” wooden dowel into the threaded end of
the Valve Spindle and push out the Shuttle Valve assembly
(22-26). Separate the Shuttle Valve assembly by pulling on
each end.
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13. Using a Slotted Seat Adjuster (PN AT51), turn the Seat (17)
six to seven full turns anti-clockwise. Since the Seat is ‘O’
ring sealed, it will not completely unscrew from the Valve
Spindle. Insert a pair of external circlip pliers into the Valve
Spindle, and pull the Seat completely out. Remove the ‘O’
ring (18) from the Seat.
This Ends Disassembly
Before starting reassembly, perform parts cleaning
and lubrication according to the procedures
outlined in ‘Cleaning & Lubrication’ on page 15.
NOTE: If the Exhaust Valve (15) is to be removed, pinch
edge of Exhaust Valve and pull tail through hole in Case
(9).
Inspection and Removal of Exhaust Valve
Removal of mouthpiece
14. To remove the Exhaust Tee (16), squeeze the two exhaust
ports (see picture) together. Pull the Tee away from the Case
(9).
15. Fold back the edges of the Exhaust Valve (15) and inspect
underneath. The seating surface should be clean and free of
damage. Inspect the Exhaust Valve. It should be supple and
have well dened edges. If it looks good, there is no need
to remove it and it may be reused. If there is any sign of
deterioration, it should be replaced.
16. Using side cutters, snip the Mouthpiece Clip (11). Remove
the mouthpiece (12).
12. Using a ngernail, remove the Rubber Seating (22) and
small ‘O’ ring (24) from the Shuttle Valve.
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TX Second Stage Regulator Maintenance Manual
REASSEMBLY PROCEDURES
1. If the Exhaust Valve (15) was removed, replace by threading
the tail through the retaining hole on the outside of the Case
(9) until the barb engages on the inside. Align the rib so it is
horizontal. If the Valve is new, cut off the excess stem with
side cutters leaving approximately 5mm (0.196”) of the tail
behind.
2. Orientate the Exhaust Tee (16) with the Case (9). Clip one
corner of the Tee onto the Case. Stretch the other corner
over the Case and then stretch the bottom of the Tee onto
the Case.
3. Install a new, lubricated
‘O’ Ring (8) onto the
Valve Spindle. (20).
4. Press a new, lubricated ‘O’ ring (24) onto the stem of the
Shuttle Valve (23). Press a new Rubber Seating (22) into
the front of the Shuttle Valve.
5. Fit the Valve Spring (25) onto the leading edge of the
Counterbalance Cylinder (26). Carefully guide the stem
of the Shuttle Valve through the Spring and into the
Fitting Exhaust Valve and Exhaust Valve Cover
Assembling and tting valve assembly
WARNING: Flooding may occur if the tail of
the valve is not fully pulled through. Check
that barb has engaged on inside of Case.
NOTE: Ensure Rubber Seating has been tted ush
with Shuttle Valve.
CAUTION: Ensure that Lever is not twisted
and that legs are parallel. Lever should
appear as that shown on the left, not as
shown on the right. If necessary, gently
squeeze legs together to straighten.
Counterbalance Cylinder.
6. If you removed the Lever, replace it so that it points
upwards when the air outlet hole points to the left with the
threaded end facing you.
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TX Second Stage Regulator Maintenance Manual
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TX Second Stage Regulator Maintenance Manual
Spindle.
8. Install a new, lubricated ‘O’ ring (27) onto the
Counterbalance Adjuster Knob.
9. Install the Counterbalance Adjuster Knob into the Valve
Spindle. There should now be spring tension on the Lever.
Continue to screw clockwise until the holes for the Spring
Pin are clear. Install the Spring Pin (21). Be sure that it
sits evenly in the hole. Back the Adjuster Knob out anti-
clockwise to apply tension to the Pin and keep it from
falling out.
10. Install a new, lubricated ‘O’ ring (13) onto the Venturi Lever
(14). Point the Venturi Lever upward and insert it into the
Case. Press it against the Case so the ‘O’ ring is captured.
7. With the “feet” of the Shuttle Valve pointing downward
(away from the Lever) and the Lever pointing straight
up (perpendicular to the Valve Spindle), insert the Valve
assembly into the Valve Spindle. Using your nger, press
the Shuttle Valve assembly all the way into the Valve
NOTE: Ensure that the Lever has a full range of
movement and does not catch on the Valve Spindle.
11. While depressing the Lever, insert the Valve Spindle
through the Venturi Lever and into the Case. Be sure
that the two ats and the two Lever feet engage in the
tabs moulded into the Case .
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