Apeks Flight User manual

FLIGHT FIRST STAGE
REGULATOR
TECHNICAL SUPPORT
APEKS MARINE EQUIPMENT LTD, NEPTUNE WAY, BLACKBURN, LANCASHIRE. BB1 2BT
Tel: [phone] Fax: [phone] E-mail: [email protected] Web: www.apeks.co.uk
MAINTENANCE MANUAL FOR
AUTHORISED TECHNICIANS
Document No. AP4497
Issue 6
28/10/11

2 3
FLIGHT First Stage Regulator Maintenance ManualFLIGHT First Stage Regulator Maintenance Manual
Contents
COPYRIGHT NOTICE............................................................................................................................................... 3
INTRODUCTION....................................................................................................................................................... 3
WARNINGS, CAUTIONS & NOTES ......................................................................................................................... 3
SCHEDULED SERVICE............................................................................................................................................ 3
GENERAL GUIDELINES........................................................................................................................................... 3
GENERAL CONVENTIONS...................................................................................................................................... 4
DISASSEMBLY PROCEDURES............................................................................................................................... 4
INSPECTION PROCEDURES .................................................................................................................................. 7
REASSEMBLY PROCEDURES................................................................................................................................ 7
IMMERSION TESTING ........................................................................................................................................... 11
TABLE 1 - TROUBLSHOOTING GUIDE................................................................................................................. 12
TABLE 2 - RECOMMENDED TOOL LIST............................................................................................................... 13
TABLE 3 - RECOMMENDED LUBRICANTS AND CLEANERS ............................................................................ 14
CLEANING AND LUBRICATION PROCEDURE .................................................................................................... 15
TABLE 4 -TORQUE SPECIFICATIONS.................................................................................................................. 16
TABLE 5 - TEST BENCH SPECIFICATIONS ......................................................................................................... 16
FLIGHT YOKE EXPLODED PARTS DRAWING..................................................................................................... 17
FLIGHT DIN EXPLODED PARTS DRAWING......................................................................................................... 18
FLIGHT NITROX EXPLODED PARTS DRAWING ................................................................................................. 19
Change
No.
Change
Request No.
Description & Comments: Change
Date
New Issue
No.
Changed
By:
Approved
By:
1116 0247 Add details of new O ring pick 16/02/11 04 RH ACD
1147 - notes regarding removal of rubber ring 30/06/11 05 JLH ACD
1175 NA Added Twilight Pt No to Drawing 28/10/11 06 AB ACD
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.

4 5
FLIGHT First Stage Regulator Maintenance Manual FLIGHT First Stage Regulator Maintenance Manual
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 writing from Apeks Marine
Equipment Ltd.
©2011 Apeks Marine Equipment Ltd.
Flight First Stage Maintenance Manual
(AP4497 Issue 6)
INTRODUCTION
This manual provides factory prescribed procedures for the correct
maintenance and repair of the Apeks Flight rst stage regulators. 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:
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 emphasise important points, tips,
and reminders.
SCHEDULED SERVICE
It is recommended that the Apeks Flight rst 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 rst stage, then it must be ocially 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 eect.
An Ocial 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 acceptable range.
3. Checking that all parts are tightly fastened together
and that no parts are loose.
4. A visual inspection of the composite Large Spring Adjuster
(1) and Composite Diaphragm Clamp (4), checking for any
visual cracking, marks or signs of damage or wear. (See
page 7. This can be done by peeling o the protector cap
(15) and inspecting all external faces where possible ithout
removal or adjustment.
5. A visual inspection of any lters 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 1,2,3 or 4 the entire regulator should be
serviced. If a regulator fails 5 it will be up to the technician’s
discretion whether or not a full service is required. Failure of step
6 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 specically set up and equipped for the task.
Adequate lighting, cleanliness, and easy access to
all required tools are essential for an ecient 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 1st stage
service kit (AP0250). 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 specication 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.
Pinch Method
Press upwards on
sides of ‘O’ Ring to
create a protrusion.
Grab ‘O’ Ring or
insert ‘O’ Ring tool
at protrusion.
Removal of hose
Removal of Blanking Plugs
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.
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.
1. Using the appropriate spanners, remove all of the hoses
from the rst stage. Refer to 2nd stage manual for removal
of the 2nd stage and ‘O’ ring removal. Exercise caution not
to scratch the‘O’ ring groove. Remove the ‘O’ ring from the
Hose Nut end of the Hose.
3. Using a 5mm Allen key remove all of the MP and HP
Blanking Plugs and remove all of the‘O’Rings.
Removal of DIN Connection.
4. Using the First Stage Work Handle Tool (PN AT 48), secure
the Regulator in a bench xed vice. Using a 6mm Allen Key
Unscrew the Din Handwheel / Balance Chamber Assembly
from the 1st Stage Body.
5. Separate the HP Valve (16) and Spring (17) from the end of
the Balance Chamber (19) and remove the ‘O’Ring, taking
care not to scratch the O-Ring Groove.
NOTE: The Din Handwheel / Balance Chamber Assembly
may not unscrew as one component. In some cases the DIN
Bolt (24) may unscrew from the Din Connector (21). If this
happens remove the DIN Moulded Handwheel (22) and
use a 22mm spanner or deep socket to unscrew the DIN
Connector.

6 7
FLIGHT First Stage Regulator Maintenance Manual FLIGHT First Stage Regulator Maintenance Manual
8. If necessary, insert an O-ring pick through the legs of
the balance chamber, NOT the centre, to gently push out
the lter. The lter must be kept square to the face of the
connector as it is removed otherwise it will jam inside.
Separating the Din Handwheel Assembly.
6. Using a 22mm deep socket, x the handwheel into a vice.
Using a 6mm Allen Key/Hex wrench, loosen the Din Bolt
(24) and remove both O-Rings.
7. Remove the DIN Filter (23) from the DIN Connector (21).
To do this, rst try to remove the lter by gently tapping the
connector on a at surface at the end face. The lter should
start to ease out.
Removal of YOKE Connection.
10. Remove the Plastic Clip (30). Unscrew the Yoke Knob (35)
from the Yoke Clamp (31). The Handwheel Hex Axle (36)
can then be removed, by continuing to unscrew the Yoke
knob. Slide the Yoke Knob laterally on the solid internal
side, to remove the knob.
12. With the Flight First Stage secured in a vice using the work
handle tool (PN AT48), t the Yoke connector tool (PN
AT74) and a long 6mm allen/hex socket. Unscrew the Yoke
Connector (27) and separate from the Yoke Clamp (31) .
The body can then be removed from the vice.
11. Separate the Dust Cap (33) from the Yoke Knob (35).
Remove the O-ring (34) from the inside of the Dust Cap
(33).
9. Remove the O-Ring (18), using the hooked end of the AT79
O ring pick. Push it through the center of the O ring and
gently pull out.
NOTE: When servicing ight regulators it is good practice to
follow the sequence of operations stated below:
1) Strip down both the 1st stage and 2nd stage
2) Clean and inspect all regulator parts as laid out in the
procedures in both manuals.
3) Reassemble the 2nd stage (but do not adjust or set)
4) Reassemble and set the 1st stage (following procedures as laid
out in the 1st stage manual)
5) Set the 2nd stage (following procedures as laid out in the
manual).
The reason for leaving the 2nd stage before setting is to allow
the seating area to“seat and bed in”better, therefore optimising
performance and adjustment.
Separation of the Balance Chamber / Yoke Connector
13. The HP Valve (16) and Spring (17) can be separated from
the Yoke Connector (27). Remove both ‘O’Rings. Using a
pair of internal Circlip removal pliers, remove the Circlip
(29) and take the disc lter (28).
Removal of the Composite Diaphragm Clamp.
14. Remove the Hood (15) from the 1st Stage body. Using the
work handle tool t the 1st Stage into a vice. Using the
Diaphragm clamp tool PN AT71 and a 3/8” drive socket
wrench carefully unscrew the Composite Diaphragm clamp
in a counter clock wise direction (4).
15. Remove the Large MP Spring (2) and Rubber Ring (5). Also
remove the Large Spring carrier (3).
16. Replace three of the MP blanking plugs (no O rings
required) and screw them in nger tight. Put the nozzle
of a compressed air blow gun in the remaining MP port
and blow a sharp blast of air to remove the diaphragm (6).
Remove the Splitter (7), and then the Valve Lifter (8). Note
the balance chamber on one side of the Valve Lifter shaft
and check to make sure that the shaft is not bent in any way.
Remove the blanking plugs.
CAUTION: The Diaphragm Clamp Tool (AT71)
hasthree nodepointsthat engage ontheComposite
Diaphragm Clamp (4). Ensure that these nodes are
correctly aligned into the Composite Diaphragm
Clamp (4) and that steady pressure is aplied to the
top of the tool whilst slowly unscrewing, ensure that
socket, tool and wrench are square at all times.
NOTE: Take care when removing the Diaphragm (6) so as
not to damage the seating face of the Flight Body (9).
17. Unscrew the Large Spring Adjuster (1) from the Composite
Diaphragm Clamp (4).
NOTE: The rubber Ring (5) is no longer used and can be
discarded when re-assembling.

8 9
FLIGHT First Stage Regulator Maintenance Manual FLIGHT First Stage Regulator Maintenance Manual
This Ends Disassembly
18. Finally, remove the Jacket (10) by separating it from the
Flight body by peeling away from one of the high pressure
ports, and working around to the other high pressure
port. (9).
INSPECTION PROCEDURES
NOTE: Before performing any reassembly procedures
several parts must be inspected. The following section
details the parts and areas that must be checked.
The following parts should be checked for cracks,
deep scratches, excessive wear and tear and distortion.
Sealing faces, grooves and bores should be checked
for scratches. Inspection should be performed in a well
lit area.
IF IN DOUBT REPLACE PART
Composite diaphragm clamp (4)
1. This component must be thoroughly visually inspected
for signs of cracks, deep scratches, excessive wear and
distortion. pay special attention to the area aound the thread
and were the thread stops.
Composite spring adjuster (1)
1. This component must be thoroughly visually inspected
for signs of cracks, deep scratches, excessive wear and
distortion, the face of the component and the thread must be
thoroughly inspected.
Diaphragm clamp and spring adjuster assembly
Once the two components are assembled it is important that
there is no excess movement between the two threads or any
signs of excess wear.
1.
8. Secure the Valve Body (9) back into the vice using the First
Stage Work Handle (PN AT48). Tighten the Composite
Diaphragm Clamp using a torque wrench and AT71
Diaphragm Clamp Tool to 20 N/M OR 15 FT.LBS
REASSEMBLY PROCEDURES
4. Screw the Large Spring Adjuster (1) into the Composite
Diaphragm Clamp (4) until the threads of the Adjuster are
covered and they become ush.
5. Insert the Large MP Spring (2) into the Large Spring
Adjuster (1).
2. Insert the Valve Lifter (8) into the Flight Body (9). Place the
Splitter (7) into the Flight Body (9) locating the round leg
into the hole, this prevents the Splitter from rotating.
7. Holding the Flight Body (9) with the Diaphragm (6) facing
down, thread the Composite Diaphragm Clamp (4) into the
Body (9), making sure that the Large Spring Carrier (3)
stays in place, until nger tight.
Assembling and tting of Composite Diaphragm Clamp
CAUTION: If the Composite Diaphragm Clamp
Assembly is not held vertically whilst it is screwed
into the Body, the Large Spring Carrier (3) may not
remain in the correct position.
Before starting reassembly, perform parts cleaning and
lubrication according to the procedures outlined in
‘Cleaning & Lubrication’on page 15 and 16.
6. Place the Large Spring Carrier (3) onto the end of the Large
MP Spring (2).
3. Press a new Diaphragm (6) into the Flight Body (9). Run
yourngeraroundthe edgeofthediaphragmtomakesureit
is properly seated.
1. Ret the Jacket (10) onto the Flight body (9). Start by
inserting one of the HP connection ports of the Body (9) into
the Jacket (10) and slowly ease the Jacket around onto the
Body.
CAUTION: When reassembling the diaphragm clamp
into the body ensure that no cross threading occurs.
Safety critical component!
See warning over the page.
NOTE: The rubber Ring (5) is no longer used and can be
discarded when re-assembling.

10 11
FLIGHT First Stage Regulator Maintenance Manual FLIGHT First Stage Regulator Maintenance Manual
9. Install a new ‘O’ ring (18) into the Balance Chamber (19)
and a new ‘O’ ring (20) onto the DIN Connector (21).
10. Insert the Spring (17) onto the end of the Balance Chamber
(19) . Insert a new HP Valve (16) into the Spring (17).
13. Insert a new DIN Filter (23) into the DIN Connector (21),
ensuring that the recessed side is facing down. Fit the
bottom of the Hood (15) onto the Jacket ensuring correct
alignment. (10). Slide the DIN Moulded Handwheel (22)
onto the DIN Connector (21).
Fitting of DIN Connection
WARNING: The Diaphragm Clamp Tool (AT71) has
three node points that engage on the Composite
Diaphragm Clamp (4). Ensure that these nodes are
correctly aligned into the Composite Diaphragm
Clamp (4) and that steady pressure is aplied to the
top of the tool whilst slowly torquing to 20 N/m (or
15 ft/lbs) to prevent the Tool from Slipping.
Excessive torque on this component will result in
damage and failure. Do not overtighten past 20 N/m
(or 15 ft/lbs). A calibrated torque wrench must be
used. Ensure that the torque wrench is the correct
scale, size and load
11. Carefully insert the HP Valve (16) into the Flight Body (9)
making sure that it slides onto the shaft of the Valve Lifter
(8). Hand tighten the DIN Connector (21).
12. Using a 22mm Deep Socket and a torque wrench, torque the
DIN Connector (21) to 25 N/m (or 18 ft/lbs).
CAUTION: Ensure that the DIN Filter (23) sits at
and is fully pressed down in the DIN Connector (21),
otherwise damage may be caused when tting the DIN
Bolt (24).
14. Install two new ‘O’ Rings (14 & 25) onto the DIN Bolt (24).
Using a torque wrench and a 6mm Allen key bit, carefully
torque the DIN Bolt to 25 N/m (0r 18 ft/lbs).
CAUTION: Care must be taken not to touch the face of
the H.P valve with mating part or nger nails, as this will
cause damage to the part.
16. Drop a new Disc Filter (28) into the Yoke Connector (27).
Using a pair of Circlip pliers insert the Circlip (29) into
the Yoke Connector (27) ensuring that it ts securely into
15. Install a new ‘O’ ring (18) into the Balance Chamber (19)
and a new ‘O’ ring (20) onto the Yoke Connector (27).
Fitting of Yoke Connection
17. Insert the Yoke Connector through theYoke Clamp (31) and
t the spring (17) onto the end of the Balance Chamber (19).
18. Fit the bottom of the Hood (15) onto the Jacket ensuring
correct alignment. (10). Insert a new HP Valve (16) into
the Spring (17). Carefully insert the HP Valve (16) into the
Flight Body (9) making sure that it slides onto the shaft
of the Valve Lifter (8). Hand tighten the Yoke Connector
ensuring that it is square. (27).
19. Using AT74 Yoke Connector Socket and a long 6mm Allen
key bit, carefully torque the Yoke Connector to 25N/m.
20. Fit a new‘O’ Ring (34) into the end of the Dust Cap (33).
21. Fit the loop end of the Dust Cap (33) onto the top of the
Yoke Covers (32). Ensure that the two lugs on the Dust Cap
t into the two recesses in the Yoke Covers. Slide and push
the Yoke Knob (35) onto the top of the Yoke Clamp (31).
22. Screw the Handwheel Hex Axle (36) through the Yoke
Knob (35) into the Yoke (31) until the end of the Axle is
engaged in the Knob. Turn the Yoke Knob (35) until the
Hex Axle (36) protrudes through the Yoke Clamp (31) so
that the Plastic Clip (30) can be t into the groove on the
Axle.
CAUTION: Care must be taken not to touch the face of
the H.P valve with mating part or nger nails, as this will
cause damage to the part.

13
FLIGHT First Stage Regulator Maintenance Manual
12
FLIGHT First Stage Regulator Maintenance Manual
position.
3. Attach a MP test gauge (0 - 20 bar) to a medium pressure
hose and thread the hose into a 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 rst stage
to act as the relief valve in case of a HP leak. Make sure
Blanking Plugs are installed in any open ports.
Final Assembly
1. Stretch the top of the Hood (15) over the end of the
assembled rst stage. Ensure that the spigot of the Hood ts
down the hexagonal hole of the Large Spring Adjuster (1)
and that the Hood ts without leaving any distortion.
6. Close the cylinder valve and depressurise the regulator.
Remove the test gauge and reinstall the Blanking Plug.
4. Assuming there are no leaks, close the cylinder valve and
depressurise 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 Large
Spring Adjuster (1) with a 10mm allen key: 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 o 10-15 times. After
cycling, watch the gauge needle. The rst stage MP should
“lock-up” between 9 and 10 bar. Make any adjustments
as necessary. Allow the rst stage to stay pressurised 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.
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.
A pressure relief valve or down stream second
stage must be tted to prevent failure or inadequate
adjustment.
1. Attach the rst stage
(with no Blanking
Plugs tted) to a fully
charged 232 or 300
bar cylinder. Slowly
open the cylinder
valve, this will remove
any particles or
contaminants from the
rst stage.
Adjusting the First Stage
2. Install new lubricated
‘O’rings (12,14) on all
of the Blanking Plugs
(11,13). Using a 5mm
Allen key, install all of
the Blanking Plugs into
the Valve Body.
WARNING: Compressed air can be highly explosive
and is dangerous if misused. Ensure cylinder valve is
opened slowly. Use Eye and Ear Personal Protective
Equipment when performing any tests involving
Compressed air.
5. Close the cylinder valve and depressurise the regulator by
opening the gauge relief valve or by pressing the purge
button of the second stage regulator. Close the relief valve
and repressurise the system. The MP should still read
between 9 and 10 bar. If the pressure reading is dierent
than the original setting, repeat steps 3 and 4 until the MP is
stable.
IMMERSION TEST
With the Blanking Plugs and at least one properly
adjusted second stage installed, slowly open
the cylinder valve and pressurise the rst stage.
Completely Submerge the rst 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 depressurise the regulator. Remove the rst stage from
the valve and secure the Dust Cap (33) in place with the
Hex Axle (36). If the regulator has a DIN connection replace
the Dust Cap (26).
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
This Ends Reassembly

14 15
FLIGHT First Stage Regulator Maintenance ManualFLIGHT First Stage Regulator Maintenance Manual
Table 1 - Troubleshooting Guide
SYMPTOM POSSIBLE CAUSE TREATMENT
High Pressure Creep
(also causes second stage leaks)
1. HP Valve (16) is worn or damaged. 1. Replace HP Valve.
2. ‘O’ ring inside HP Balance Chamber
(18) is damaged or worn. 5. Replace ‘O’ ring.
3. H.P balance chamber damaged 6. Replace balance chamber
4. HP Valve Seat in Valve Body (9) is worn
or damaged. 7. Replace Valve Body.
External air leakage
1. Blanking Plug ‘O’ rings (12,14) are
worn or damaged. 1. Replace ‘O’ Ring.
2. Diaphragm (6) worn or damaged. 2. Replace diaphragm.
3. Diaphragm seating surface
damaged. 3. Replace Valve Body (9).
4. Connector ‘O’ ring (20) worn or
damaged. 4. Replace ‘O’ Ring.
5. Diaphragm Clamp (4) loose. 5. Tighten Diaphragm Clamp to
specied torque.
6. ‘O’ rings on DIN Bolt (14,25) worn or
damaged. 6. Replace ‘O’ Rings.
Restricted air ow or high inhalation
resistance through entire system
1. Cylinder valve not completely open. 1. Open valve, check ll pressure.
2. Cylinder valve requires servicing 2. Switch to dierent cylinder.
3. DIN Filter (23) or Disc Filter (27) is
blocked. 3. Replace lter.
4. Very Low Medium Pressure. 4. Adjust Medium Pressure to
between 9 and 10 bar.
Table 2 - Recommended Tool List
PART NO. DESCRIPTION APPLICATION
AP0430 I.P. test gauge Intermediate pressure testing
AT79 ‘O’Ring removal pick ‘O’Ring removal
AT71 Diaphragm Clamp Tool Removal of Composite Diaphragm Clamp
AT48 First Stage Work Handle Clamping Valve Body in Vice
AT24 Circlip Pliers Removal and installation of Circlip
n/a Torque wrench, Nm or lbf/ft Installation of Composite Diaphragm Clamp, DIN
Connection and Yoke Connection
n/a 6mm Allen key bit for torque wrench Installation of DIN Bolt and Yoke Connector
AT34 11/16” spanner Hose Removal
AT37 5mm Allen key Blanking Plugs
AT38 6mm Allen key Removal of DIN Bolt
n/a 10mm Allen key Removal and Installation of Large Spring Adjuster
n/a 22mm Deep Socket Removal and installation of DIN Connector
AT74 Yoke Connector Socket Removal and installation of Yoke Connector
n/a 22mm Spanner Removal DIN Connector
n/a 232 or 300 bar Diving cylinder Testing of regulator
AP0430
AT34
AT24
AT79
Notes:
1. Photos not to scale.
2. Actual tools may dier
from photos.
AT48
AT37 AT38
AT71
6mm Allen Key Bit AT74

16 17
FLIGHT First Stage Regulator Maintenance ManualFLIGHT First Stage Regulator Maintenance Manual
Table 3 - Recommended Lubricants & Cleaners
LUBRICANT / CLEANER APPLICATION SOURCE
Christo-Lube® MCG-111
(Lubricant)
All ‘O’ Ring seals Apeks Marine Equipment Ltd
PN AP1495, or
Lubrication Technologies
310 Morton Street
Jackson, OH 45640, USA
[phone]
Biox
(Cleaning agent)
Biological immersion uid for reus-
able 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
Liquid dishwashing detergent diluted
with warm water
(Cleaning agent)
Degreaser for brass and stainless
steel parts; general cleaning solu-
tion for plastic and rubber
“Household” grade
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.
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
Cleaning & Lubrication Procedure
General Cleaning of all Parts
1. Place all metalic components in an ultrasonic cleaning bath containing an appropriate cleaning solution, such as Biox
2. All plastic and composite components such as diaphragm clamp and spring adjuster must be cleaned in soapy water.
3. The components should be cleaned for 6 minutes, depending upon their condition. Longer cleaning times may used if required.
4. Rinse the components in warm fresh water.
5. 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 lm of grease, and remove any visible
excess by running the ‘O’ Ring between thumb and forenger. Avoid applying excessive amounts of Christo-Lube grease, as this will attract
particulate matter that may cause damage to the‘O’ Ring.
Enriched Air Nitrox Use –
Outside EEC (European Economic Community) Countries Your Apeks regulator has been prepared for use with Enriched Air Nitrox (EAN) where
the percentage of oxygen in the EAN does not exceed 40%. This is possible because each regulator is built to a high standard of cleanliness using EAN
compatible components and lubricants. In addition, each regulator design has passed stringent adiabatic compression testing to ensure its safety and
compatibility with increased percentages of oxygen. If it is your intention to use your new Apeks regulator with Nitrox EAN (O2 not to exceed 40%), it is
imperative that you maintain the internal cleanliness of the regulator (see section on Care and Maintenance). If it is your intention to use the regulator
interchangeably with breathing air, the breathing air should be oxygen-compatible or “hyperltered” where the condensed hydrocarbons do not exceed 0.1
mg/m3. Your local authorised Apeks dealer can help you determine whether the breathing air that they provide meets this criterion.
Standard compressed breathing air meeting the EN 12021 standard, often referred to as Grade E in the United States, does not necessarily meet this
criterion. Grade E or EN 12021 breathing air may contain a certain level of hydrocarbons, including traces of compressor oils that while not considered
harmful to breathe, can pose a risk in the presence of elevated oxygen content. Passing hydrocarbons through a valve and regulator creates a cumulative
effect where the hydrocarbons build up over time along the internal passageways of the equipment. When these hydrocarbons come into contact with high-
pressure oxygen enriched air, they can pose a very real hazard that can lead to combustion. Therefore, if a regulator has had use with Grade E or EN 12021
breathing air, it should be returned to an authorised Apeks dealer for overhaul service including oxygen cleaning, prior to being put back into nitrox service.
Although 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.
Enriched Air Nitrox Use –
Inside EEC (European Economic Community ) countries EN 1443-3 and EN13949In CEE countries, diving with Nitrox/O2 is controlled by Standards EN
144-3 – Respiratory protective devices - Gas cylinder valves - Part 3: Outlet connections for diving gases Nitrox and oxygen - and EN 13949 – Respiratory
equipment - Open circuit self-contained diving apparatus for use with compressed Nitrox and oxygen - requirements, testing, marking.
NOTE : Apeks offers a range of regulators designed and manufactured specially for use with oxygen-enriched mixtures, over 21% and up to 100% oxygen.
This range has been certified according to the EN 144-3 and EN 13949 standards and meets the requirements of the adiabatic compression tests. They have
received CE certification for this type. For further information on this range, contact your Apeks specialist center.
WARNING : These regulators fitted with special connections should be used only with complementary equipment (tank valves, tanks, pressure gauges, etc.)
designed and prepared for use with an oxygen-enriched mixture. These items are marked Nitrox/O2.
WARNING: If the regulator that you use is fitted with a yoke or DIN connection, it is designed for use only with compressed breathing air (21% oxygen and 79%
nitrogen) which meets the EN 12021 standard. DO NOT USE this equipment with other mixtures or with gases containing more than 21% oxygen. Disregarding
this rule could result in serious injury or death caused by fire or explosion.
Every Nitrox/O2 regulator is assembled in a clean workshop, using compatible components and special lubricants. It is important to maintain the interior of the
regulatorinacleanstate.Breathingairusedinthe production ofamixtureshould beoxygencompatible anddoublefilteredwithahydrocarboncontentnotgreater
than 0.1 mg/m3. Your Apeks technical specialist should be able to help you determine if the breathing air he supplied meets these criteria.
WARNING: Please check the regulations regarding Nitrox in your particular country as this may dier
from Apeks standard policy.

18 19
FLIGHT First Stage Regulator Maintenance ManualFLIGHT First Stage Regulator Maintenance Manual
Table 5 - Test Bench Specications
TEST CONDITION ACCEPTABLE RANGE
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
Table 4 - Torque Specications
PART NUMBER DESCRIPTION / KEY NUMBER TORQUE
AP5761 DIN Connector (21) 25 Nm / 18.4 lbf/ft
AP5765 YOKE Connector (27) 25 Nm / 18.4 lbf/ft
AP5764 DIN Bolt (24) 25 Nm / 18.4 lbf/ft
AP5752 Composite Diaphragm Clamp (4) 20 Nm / 14.7 lbf/ft
1 AP5753 Large Spring Adjuster 18* AP1299 ‘O’ Ring
2 AP5754 Large MP Spring 19 AP0168 Balance Chamber
3 AP5755 Large Spring Carrier 20* AP1298 ‘O’ Ring
4 AP5752 Composite Diaphragm Clamp 21 N/A
5 AP5719 Rubber Ring (no longer used) 22 N/A
6* AP5756 Small Diaphragm 23 N/A
7 AP5757 Splitter 24 N/A
8 AP5717 Valve Lifter 25 N/A
9 AP5758 Flight Body 26 N/A
10 AP5751 Pewter Jacket 27 AP0168 Yoke Connector
AP5751/G Green Jacket 28* AP5769 Disc Filter
AP5751/P Pink Jacket 29 AP5768 Circlip
AP5751/Nitrox Nitrox Jacket 30 AP5695 Plastic Clip
11 AP1408 3/8” UNF Blanking Plug 31 AP5766 Flight Yoke Clamp
12* AP1409 ‘O’ Ring 32 AP5767 Flight Yoke Cover
13 AP1413 7/16” UNF Blanking Plug 33 AP5714 Dust Cap
14* AP1445 ‘O’ Ring 34* AP1166 ‘O’ Ring
15 AP5750 Hood 35 AP5716 Flight Yoke Knob
16* AP5759 Flight HP Valve 36 AP5713 Handwheel Hex Axle
17 AP1415 Spring 37 AP5770 Flight Decal
FLIGHT Yoke Exploded Parts Diagram
* All marked items must be replaced when serviced.
Please note: Item 19 and 27 do
not seperate, order part AP0168
Yoke Connector sub assembly.
NOTE: Item 5 is no
longer used. Discard
this part.

20 21
FLIGHT First Stage Regulator Maintenance ManualFLIGHT First Stage Regulator Maintenance Manual
FLIGHT DIN Exploded Parts Diagram
1 AP5753 Large Spring Adjuster 13 AP1413 7/16” UNF Blanking Plug
2 AP5754 Large MP Spring 14* AP1445 ‘O’ Ring
3 AP5755 Large Spring Carrier 15 AP5750 Hood
4 AP5752 Composite Diaphragm Clamp 16* AP5759 Flight HP Valve
5 AP5719 Rubber Ring (no longer used) 17 AP1415 Spring
6* AP5756 Small Diaphragm 18* AP1299 ‘O’ Ring
7 AP5757 Splitter 19 AP0163 Balance Chamber
8 AP5717 Valve Lifter 20* AP1298 ‘O’ Ring
9 AP5758 Flight Body 21 AP0163 DIN Connector
10 AP5751 Pewter Jacket 22 AP6201 DIN Moulded Handwheel
AP5751/G Green Jacket 23* AP5763 DIN Filter
AP5751/P Pink Jacket 24 AP5764 Flight DIN Bolt
AP5751/TL Twilight Jacket 25* AP1166 ‘O’ Ring
11 AP1408 3/8” UNF Blanking Plug 26 AP6202 DustCap
12* AP1409 ‘O’ Ring
* All marked items must be replaced when serviced.
Please note: Item 19 and 21 do
not separate, order part AP0163
DIN Connector sub assembly.
FLIGHT M26 Nitrox Exploded Parts Diagram
1 AP5753 Large Spring Adjuster 14* AP1445 ‘O’ Ring
2 AP5754 Large MP Spring 15 AP5750 Hood
3 AP5755 Large Spring Carrier 16* AP5759 Flight HP Valve
4 AP5752 Composite Diaphragm Clamp 17 AP1415 Spring
5 AP5719 Rubber Ring (no longer used) 18* AP1299 ‘O’ Ring
6* AP5756 Small Diaphragm 19 NP0168 Balance Chamber
7 AP5757 Splitter 20* AP1298 ‘O’ Ring
8 AP5717 Valve Lifter 21 NP0163 M26 Connector
9 AP5758 Flight Body 22 NP6201 M26 Moulded Handwheel
10 AP5751/Nitrox Nitrox Jacket 23* AP5763 DIN Filter
11 AP1408 3/8” UNF Blanking Plug 24 NP5764 Nitrox Flight DIN Bolt
12* AP1409 ‘O’ Ring 25* AP1166 ‘O’ Ring
13 AP1413 7/16” UNF Blanking Plug 26 NP6202 Nitrox DustCap
* All marked items must be replaced when serviced.
Please note: Item 19 and 21 do
not seperate, order part NP0163
M26 Connector sub assembly.
NOTE: Item 5 is no
longer used. Discard
this part.
NOTE: Item 5 is no
longer used. Discard
this part.

FLIGHT FIRST STAGE REGULATOR
AUTHORISED TECHNICIANS
Apeks Marine Equpment Ltd
Neptune Way, Blackburn, Lancs, England, BB1 2BT
MAINTENANCE MANUAL
FOR
TECHNICAL SUPPORT