Genesis Scuba Atlas Istruzioni operative

Atlas & Yukon

(Part Numbers GRXXX & )

Second Stage

SERVICE & REPAIR

GUIDE

Contents

Introduction ............................................................................ 3

About This Manual .........................................................................3

Scheduled Service....................................................................................... 3

EAN/ Nitrox Service .................................................................................... 3

Use of Warnings, Cautions, & Notes ........................................................ 3

Function & Design ..........................................................................4

Section 1 – Facility Requirements ......................................... 5

Table 1 – Recommended Equipment and Suppliers ......................6

Section 2 – Preliminary Inspection ....................................... 7

External Inspection .......................................................................7

Immersion / Leak Test .....................................................................7

Section 3 – Disassembly Procedures .................................... 8

General Guidelines ........................................................................8

Section 4 – Cleaning Procedures .......................................14

Acidic Cleaning Procedure ......................................................... 14

EAN/Nitrox Cleaning Procedure ............................................... 17

Section 5 – Reassembly Procedures ...................................24

General Guidelines ..................................................................... 24

Section 6 – Final Testing Procedures ................................28

Table 2 – Troubleshooting Guide ........................................32

Schematic & Parts List – Atlas Second Stage...................33

Schematic & Parts List – Yukon Second Stage ..................35

Service & Repair Manual

About This Manual

Introduction

As a service technician, you are entrusted with maintaining your customer’s

equipment to the same standards with which it was manufactured. At Genesis, we

are committed to providing you with the tools you will need to accomplish this

important task, including the information provided in this manual.

Possession of this manual, however, does not constitute an offer by Genesis

Scuba to sell component parts, nor does it qualify you to perform service or repair

for Genesis Scuba products. In order to purchase spare parts or perform service

and repair, you must be directly employed by an Authorized Genesis Dealer. It is

also your responsibility to obtain factory authorized training through your Genesis Scuba distributor.

If you are ever unsure about how to perform any of the procedures outlined in this manual,

please contact Genesis Scuba for technical assistance.

Scheduled Service

Regulators should be given the same care and maintenance as life support equipment. It is

therefore important to perform scheduled overhaul service for the entire regulator (first and second

stages) at least once every year with normal or infrequent use.

A unit that receives heavy or frequent use, however, should be serviced at least twice each year -

or more often - depending on the conditions of use and the manner in which it is maintained. (Refer

to the maintenance procedures outlined in the Genesis Regulator Owner’s Manual.).

When performing service, whether it is a routine overhaul or a repair of a specific problem, it is

important to understand how the regulator is designed and how it operates. An illustrated

explanation of the Atlas/Yukon second stage design is provided on the following page.

EAN/ Nitrox Service

Genesis regulators can be upgraded for use with oxygen enriched air (EAN/ Nitrox) not to

exceed 40% oxygen content. This upgrade must be performed in conjunction with a complete

overhaul, and includes a special cleaning procedure that is outlined in this manual.

Use of Warnings, Cautions, & Notes

WARNING indicates a procedure or situation that may

result in serious injury or death if instructions are not

followed correctly.

CAUTION indicates any situation or technique that will

result in potential damage to the product, or render the

product unsafe if instructions are not followed correctly.

NOTE is used to emphasize important points, tips, and

reminders.

Atlas & Yukon Second Stage

Function & Design

Introduction

Function & Design

The Atlas/Yukon second stage features a high performance, low volume

design with a mechanically balanced valve. Here's how it works:

▼

Intermediate pressure air (140 psi) enters through the inlet

coupling and orifice (1), where it meets the poppet and LP

seat. The poppet spring (2) holds the poppet against the

orifice with a pre-set tension that counteracts the intermediate

pressure. The poppet is balanced between the two forces.

▼

Airflow is actuated upon inhalation or purging, when the

diaphragm is drawn down over the lever (3). This pulls the

poppet away from the orifice.

▼

Air and water are channeled to flow out through the exhaust

valve (4), which is designed to minimize exhalation resistance

while keeping the case internally dry in all positions.

▼

(Atlas only - not shown) A dive/pre-dive switch can be set to

minimize or boost peak venturi airflow, according to the

diver's preference.

Service & Repair Manual

Facility Requirements

s e c t i o n

Facility Requirements

s e c t i o n

The service facility is perhaps the most important asset of

any professional dive store. It should be clean and well

lighted, and stocked with a complete inventory of parts and

manufacturer's specialty tools for the products your store sells.

As a minimum requirement, your service facility should be

equipped with the following items:

❏

Ultrasonic Cleaner –

Select the right size model that can

keep up with the volume of regulators that your store services.

A built in timer and heater will help control the cleaning time

and temperature of the solution, since most solutions work best

when heated.

❏

Bench Mounted Vise –

A vise is sometimes needed to hold

the regulator secure – especially when removing the first stage

yoke retainer. Special care must be taken, however, to avoid

damage that can result from improper use of this tool. Be sure

to follow the instructions provided in this manual.

❏

Magnification Lamp –

Strong lighting and magnification are

essential requirements for performing a thorough parts inspec-

tion - especially when locating the cause of a small leak.

❏

Quality Wrenches & Sockets –

When working with chrome

plated brass parts, it is especially critical to use the correct size

wrench and to ensure that it fits properly over the part. The use

of an adjustable wrench is very likely to cause damage to your

customer's regulator, and should be strictly avoided at all times.

❏

Calibrated Inch-Pound Torque Wrench –

It is important to

follow the manufacturer's torque values whenever they are

specified, in order to avoid overtightening or under-tightening a

part. This is especially important for smaller parts and fittings,

when overtightening can easily damage the part.

❏

Calibrated Foot-Pound Torque Wrench –

Torque

wrenches that can be set for both inch-pound and foot-pound

measurements generally tend to be less accurate than wrenches

that are designed to measure torque within a specific range.

❏

Manufacturer's Specialty Tools –

Specialty tools are

critically important to performing each step of disassembly and

reassembly according to each manufacturer's procedures.

Genesis specialty tools that are required to perform service for

the Atlas and Yukon second stages are pictured on the following

page.

Atlas & Yukon Second Stage

Table 1 – Recommended Equipment and Suppliers

The specialty tools shown below can be purchased directly from Genesis Scuba. For other items needed to outfit your store's

service facility, we recommend the following suppliers:

Table 1 – Recommended Equipment and Suppliers

Genesis specialty tools are made in the USA by

Peter Built Co

. Illustrations courtesy of Peter Wolfinger.

Peter Built Co. Manufacturer of custom designed specialty tools Galion, OH 44833

www.scubatools.com and test fixtures Phone: 419-468-2212

Branson Ultrasonics Manufacturer of tabletop ultrasonic cleaners Danbury, CT 06813

www.bransoncleaning.com Phone: 203-796-2298

LubricationTechnology Manufacturer of Christo-Lube 111 Jackson, OH 45640

(Genesis approved lubricant) Phone: (740)286-2644

Lawrence Factor, Inc. Manufacturer of LFW™(Lawrence FactorWash) Miami Lakes, Florida 33014

www.lawrence-factor.com (Genesis approved acid bath cleaning solution) Phone: 305-430-0550

Modern Chemical Distributor of Blue Gold Aqueous Cleaner Batesville, Indiana 47006

Ohio Corporation (Genesis approved aqueous cleaning solution for EAN/ Nitrox Service) Phone: (812) 934-5915

www.a1.com/bluegold

Simple Green Manufacturer of Crystal Green Aqueous Cleaner Huntington Harbor, CA 92649

www.simplegreen.com (Approved alternative aqueous cleaning solution for EAN/ Nitrox Service) Phone: (800) 228-0709

Sears Roebuck Retail distributor of Craftsman®tools

www.sears.com/craftsman

Atlas/ Yukon Specialty Tools

100

200

20 180

160

120

IP RANGE

125-150 PSI

PSI

PETER BUILT

"Quality in the making"

(419) 468-2212

USE NO OIL

140

150

125

100

175

200

225

250

275

300

IP RANGE

125-150 PSI

PSI

USE NO OIL

PETER BUILT CO.

"Quality in the making"

(419) 468-2212

260

3.5 x 60

260

2.0 x 50

Select Tool Kit (5 pcs) # 11-090-500

Intermediate Pressure

Test Gauge, #20-510-100

O-ring Tool Set #10-102-

Dual Drive In-Line Adjusting Tool # 20-500-200

Genesis Rim Clamp # 20-680-200

Genesis Poppet Tool Kit #20-640-

Service & Repair Manual

s e c t i o n

External Inspection

1. Closely examine the conical filter of the first stage to check

for any signs that contaminants have entered the system,

including sea water, rust, or aluminum oxide.

NOTE: Agreendiscolorationpositively indicates that mois-

ture has entered the regulator, and internal corrosion may

have occurred. Other types of discoloration may indicate

that the regulator has been used with a corroded cylinder.

Advise the customer of this, and the possible need to obtain

service for their cylinder.

2. Slide back the hose protector(s) to inspect the condition of

the LP hose at its fittings and along its length. Check

closely for any signs of blistering or abrasion, or corrosion

of the fittings.

3. Inspect the condition of the mouthpiece to check for torn

bite tabs, holes, or deterioration.

Immersion / Leak Test

1. Check to ensure that the regulator is fully assembled and

connected to a first stage, and that there are no open ports

or hoses. Connect the first stage to a cylinder that is filled

with 3,000 psi, and open the cylinder valve to pressurize

the regulator.

2. If leakage cannot be heard, or if the source of leakage

detected audibly is not obvious, immerse the second stage

in fresh water to check further for any signs of air leakage

through the mouthpiece and at the hose fitting.

3. Note the source of any leakage found and refer to

Table 2

- Troubleshooting

to determine its possible cause.

4. Close the cylinder valve and depress the second stage

purge cover to depressurize the regulator.

▼

After completing the Preliminary Inspection, proceed to

Section 3 – Disassembly

Preliminary Inspection

Atlas & Yukon Second Stage

Disassembly Procedures

s e c t i o n

Disassembly Procedures

General Guidelines

▼

Prior to performing any disassembly, check to ensure that

the service facility is well equipped with all the tools and

parts needed to perform a complete service from start to

finish. DO NOT attempt to perform the service unless all of

the required tools and parts are available.

▼

All o-rings are classified as being either dynamic or static.

Dynamic o-rings are those which sustain friction and

movement, as they are either mounted directly onto a

moving part, or create a seal against a moving part.

Static o-rings simply create a seal between two non-

moving parts, and are therefore less subject to wear than

dynamic o-rings. After passing close inspection, static

O-rings may sometimes be reused, although this is not

necessarily recommended. Dynamic O-rings must be

automatically discarded and replaced with every service,

regardless of age or appearance.

▼

Refer to the schematic and parts lists provided on page 37

& 39 while performing these procedures. Each part is

identified by its reference number shown on the drawing

the first time it is referred to in the procedure.

▼

Do not attempt to reuse parts that are designated to be

automatically discarded and replaced with the parts

provided in the overhaul parts kit. These parts should be

shown to the customer, however, to ensure their confi-

dence and satisfaction that complete overhaul service has

been performed.

▼

Inspect all reusable parts as directed, either during or

immediately following the disassembly procedures. When

in doubt, compare the part with one that is new to best

determine its condition.

Service & Repair Manual

Fig. 1 –␣ Serial Number Location

Fig. 2 –␣ O-ring RemovaL

CAUTION: Whenever possible, use only plastic or brass O-

ring tools for removing O-rings in order to prevent damage

to the sealing surface. Steel instruments, such as dental

picks,caneasilydamage thesealingsurfaceofasofter brass

part, causing irreparable leakage and requiring the part to

be replaced with new.

1. Snip the plastic tie-strap(14) that holds the mouthpiece(12),

and gently pull the mouthpiece off the second stage

case(11). Record the serial number that is affixed directly

below the mouthpiece tube, and compare it to the

customer’s invoice or service record to determine whether

it is eligible for warranty service (see Fig. 1). Inspect the

condition of the mouthpiece to ensure that it is supple and

free of any tears or corrosion. If any damage is found that

could result in discomfort or leakage, discard the mouth-

piece and do not reuse.

2. Slide back the hose sleeve(27) to expose the connection of

the LP hose(25).

3. While holding the inlet coupling(6) secure with a w" open-

end wrench, apply an n" open-end wrench to the fitting

of the LP hose. Turn the hose fitting counter-clockwise to

loosen and remove.

4. Using the O-ring pick that is provided in the Select Kit (PN

11-090-500), carefully remove the O-ring(26) from the

post inside the hose fitting (see Fig. 2).

CAUTION: The O-ring pick is made of steel and is very

sharp, and is only recommended for the removal of O-rings

that cannot be removed with a brass O-ring tool. When per-

forming the above step, be very careful to avoid scratching

the O-ring sealing surface. Doing so may cause a perma-

nent leak that will require the replacement of the LP hose.

5. While holding the diaphragm cover(2) fully depressed in

the purge position, apply a w" open-end wrench to the

inlet coupling and turn it counter-clockwise to loosen and

remove.

6. Remove and discard the O-ring(7) from the inlet coupling.

Do not reuse.

7. While holding the inlet coupling secure, apply a medium

blade screwdriver to the slotted head of the valve ori-

fice(5). Turn the orifice counter-clockwise until its threads

have completely disengaged from the inlet coupling.

Atlas & Yukon Second Stage

Fig. 3 – Orifice Removal

Fig. 4 – Orifice Inspection

Fig. 5 – Genesis Rim Clamp

NOTE: The orifice is O-ring sealed and will remain inside

the inlet coupling after performing the above step. The fol-

lowing step must be performed correctly in order to remove

the orifice without damaging its polished sealing edge.

8. After the orifice has been unthreaded from the inlet cou-

pling, stand the inlet coupling on end with the orifice

sealing edge facing up. Carefully insert the handle of the

blunt probe (provided in the Select Kit) through the top of

the inlet coupling, directly over the sealing edge of the

orifice. Gently press the orifice out (see Fig. 3).

9. To avoid using a sharp tool that can damage the orifice,

squeeze the O-ring(4) between thumb and forefinger to

remove it from the orifice head. Discard the O-ring and

do not reuse.

10. Closely examine the orifice with the use of a magnifier,

checking for any scratches or other damage to the sealing

edge and the groove that holds the O-ring (see Fig. 4). If

any damage or wear is found, discard the orifice and do

not attempt to reuse. If it is in reusable condition, set it

aside on a soft surface to keep it isolated from metal parts.

11. While holding the bottom of the second stage secure with

one hand, firmly grasp the cover ring(1) with the other,

and turn the ring counter-clockwise to loosen and remove.

NOTE: If the cover ring cannot be removed by hand, it may

be necessary to use the Rim Clamp (PN 22-680-200), to-

gether with a bench-mounted vise. This Genesis specialty

tool has been designed to prevent damage to the cover ring

orthesecondstage duringdisassembly,butitmustbeused

correctly, following the steps outlined below.

a. Identify the side of the Rim Clamp that contains the

larger diameter shoulder, which is designed to hold the

Atlas/ Yukon cover ring. Place the Rim Clamp between

the jaws of a bench mounted vise with the larger diam-

eter side facing straight up, and the split edge parallel

with the vise jaws (see Fig. 5). Ensure that the top

surface of the clamp rests slightly above or flush with

the top surface of the vise jaws, and gently tighten the

vise only until the clamp is held securely in place. Do

not over-tighten or compress the clamp.

b. Place the second stage inside the clamp, with the cover

ring facing down. Tighten the vise to compress the

clamp, only as far as is needed to secure the clamp

around the cover ring to prevent slippage.

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