Apollo A-102 1ST STAGE Installation instructions

A-102 1ST STAGE
DISASSEMBLY

FEATURES
FEATURES
Balanced Diaphragm type 1st stage.
2 x HP port. - 7/16” NF
4 x LP port. - 3/8” NF
•Lightweight and compact
• Symmetrical service ports

TOOLING REQUIREMENTS
TOOLING REQUIREMENTS
• 12” adjustable wrench
• Apollo wrench No. 155610
• 3/16” & 5/8” Allen key (wrench)
• Snap ring (circle) pliers
• O ring pick
• Fine tweezers
• Nylon dowel - 10mm dia.
• Small screw driver. (blunt edges)
• Threaded rod (7/16” NF) handle
• Engineers vice with soft jaws
• Line pressure test gauge
P/No. 155310
Additional standard engineering
tools will also be required.

DISASSEMBLY
DISASSEMBLY
Remove the yoke screw.
To support the 1st stage fit the
7/16” threaded rod to a HP port
and hold the rod in a suitable vice.
Use a 12” adjustable wrench, undo
the yoke retainer. The retainer is
removed counter-clockwise.

DISASSEMBLY
DISASSEMBLY
Remove the yoke and yoke retainer.
Strip the yoke retainer ready
for cleaning and inspection.
Remove the yoke bolt o ring.

DISASSEMBLY
DISASSEMBLY
Carefully remove the filter
retaining ring.
Remove and discard the filter.

DISASSEMBLY
DISASSEMBLY
Fit the Apollo adjusting wrench to
the body cap.
Use a 12” adjustable wrench,
undo and lift off the body cap to
expose the adjusting assembly.
(Turn anti-clockwise to undo)

DISASSEMBLY
DISASSEMBLY
Lift off the teflon washer and
place to one side.
Lift out the adjusting screw and guide nut.

DISASSEMBLY
DISASSEMBLY
Separate the screw and nut.
(the screw is left hand thread)
Next lift out the LP spring
and the spring pad.

DISASSEMBLY
DISASSEMBLY
Install the Apollo adjusting wrench.
Engage the pins in the diaphragm
retainer.
Use the 12” adjustable wrench and
undo the diaphragm retainer turning
counter clock-wise.

DISASSEMBLY
DISASSEMBLY
Lift out the diaphragm retainer.
Carefully remove the diaphragm
washer.

DISASSEMBLY
DISASSEMBLY
Place a low pressure air nozzle against one
of the LP ports, use air pressure to lift the
diaphragm off its seat.
Apply pressure gently, and place a rag over
the top of the body to prevent the diaphragm
from being blown out and possibly causing
an injury.
Remove and inspect the diaphragm, any sign
of damage or creasing is cause for replacement.

DISASSEMBLY
DISASSEMBLY
Lift out the pushrod assembly
and place to one side.
The HP module is removed next.
Use a wide blade screw driver
to avoid damaging the groove.
NOTE: If the HP module is tight and
appears to be locked in position, refer to
HP Module Technical Update for the correct
removal procedure.

DISASSEMBLY
Place the HP module on a solid surface
as shown. Exert a downward pressure
with your thumb or finger while engaging
the circlip pliers to the retaining ring.
DISASSEMBLY
While compressing the retaining ring
gradually reduce the downward pressure.
The HP assembly should now disengage
the module…
Remember this is under spring tension,
Wear eye protection.

DISASSEMBLY
Using a curved o ring picker, carefully
pick up the o ring and remove from
the chamber and discard.
DISASSEMBLY
After removing the o ring check the
teflon back up ring for damage.
Any signs of damage (scoring etc) is
cause for rejection, in this case a new
balance chamber must be fitted.
Remove and inspect the o ring
from the groove on the HP module

A-102 1ST STAGE
INSPECTION & ASSEMBLY

INSPECTION & CLEANING
INSPECTION & CLEANING
A quick check of parts to be reused is carried out prior to cleaning.
This will ensure you do not clean obviously defective parts.
All metal parts are cleaned using white vinegar. The vinegar may
be diluted using water, however diluting usually only means a
longer soak period before the parts are clean.
Only leave the parts in the vinegar bath until clean, do not leave in
the bath for prolonged periods. Eg; over night.
The parts must be rinsed in warm to hot fresh water after removal
from the acid bath, this helps to neutralise the acid.
Blow dry with clean filtered air.
Metal parts must now be carefully inspected prior to refitting.

INSPECTION & CLEANING
INSPECTION & CLEANING
Check the HP seat knife edge
orifice (cone) for damage prior
to assembly.
The pushrod assembly must be
inspected for corrosion on the shaft,
also any bending of the shaft.
If any damage is noted replace the shaft.
All threads are checked for damage, look for peeling
chrome and damage caused by crossed threads.

INSPECTION & CLEANING
INSPECTION & CLEANING
Rubber parts o rings etc. which are going to be reused should be
washed in warm water and detergent.
After washing all o rings are to be carefully inspected for damage
or distortion.
If the HP seat is to be reused for a repair
(replace for a service) carefully inspect
the rubber face for ANY defects.
- Deep witness mark.
- Holes in the rubber face.
- Delaminating of the rubber face.
All cause for rejection.
Any doubt regarding serviceability and the parts must be replaced.

ASSEMBLY
ASSEMBLY
The lubrication of parts, o rings and threads, for Apollo regulators
is carried out using either Christo-lube or Silicone grease.
NOTE:
The use of Christo-lube throughout the regulator DOES NOT constitute
a regulator approved for use with Nitrox or O2 enriched Breathing Air.
Other procedures (NOT covered by this manual) MUST be carried
out prior to use with mixed gases other than standard air.
STATIC O RINGS
Must be lightly lubricated.
Wipe off any excess lubricant
prior to assembly.
DYNAMIC O RINGS
Can be liberally lubricated.
Do not wipe off excess lubricant.
Ensure excess lubricant DOES NOT
enter the breathing air passages.
LUBRICATION.