Uwatec AIR 2 Assembly instructions

2003 SCUBAPRO
Important note: The following information is not designed to be a complete training guide for servicing the listed SCUBAPRO regulators. All SCUBAPRO
technicians are required to attend an annual service training program to insure safe handling and servicing of SCUBAPRO products. All SCUBAPRO technicians
must be employed by an authorized SCUBAPRO facility.
SCUBAPRO
Repair Guide
AIR 2
Alternate Inflator
Regulator
USE THIS GUIDE AS A REFERENCE WHEN SERVICING
THE AIR 2 (3rd and 4th Generation)

SCUBAPRO AIR2 3rd & 4th Generations
2003 SCUBAPRO
Important note: The following information is not designed to be a complete training guide for servicing the listed SCUBAPRO regulators. All SCUBAPRO
technicians are required to attend an annual service training program to insure safe handling and servicing of SCUBAPRO products. All SCUBAPRO technicians
must be employed by an authorized SCUBAPRO facility.
2
TOOLS NEEDED FOR REPAIR OF AIR2
P/N43040000
TOOLS
NEEDED
Quantity Part Number Description
1 set 10.102.100
(Peter Built)
Brass o’ring picks
1 tube 41.047.000 Christo-Lube Christo-Lube
OXYGEN COMPATIBLE LUBRICANT
P/N 41-047-000
1 47.010.000 Counter Mat
1 41.496.101 Lubricant syringe Monoject
2 Adjustable wrench
1 Small screwdriver
1 20-136-100 Air 2 Spider Tool
(Peter Built)
20-125-200 Seat Slider
(Peter Built)
1 20.500.200
(Peter Built)
Pneumatic Adjusting tool
1 18.300.500 Blow Gun/Air Nozzle
1 ¼” Nut Driver
1 43.040.000 Universal Tool
1 79-400-505 Magnehelic Gauge
(Peter Built)
1 Torque Wrench - 100 in-lb range
ICON LEGEND
Inspect carefully, replace if needed
Monoject Lubricate properly
Replace annually
Dynamic o’ring, replace annually and lubricate properly
P/N43040000
TOOLS
NEEDED
No tools needed for this step

SCUBAPRO AIR2 3rd & 4th Generations
2003 SCUBAPRO
Important note: The following information is not designed to be a complete training guide for servicing the listed SCUBAPRO regulators. All SCUBAPRO
technicians are required to attend an annual service training program to insure safe handling and servicing of SCUBAPRO products. All SCUBAPRO technicians
must be employed by an authorized SCUBAPRO facility.
3
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Remove hoses from unit.
Remove the alignment pin using a pick.
Use the Seat Slider to remove the front
cover as shown.
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Remove the cover, friction ring and
diaphragm. Note the position of the
lever and air barrel.

SCUBAPRO AIR2 3rd & 4th Generations
2003 SCUBAPRO
Important note: The following information is not designed to be a complete training guide for servicing the listed SCUBAPRO regulators. All SCUBAPRO
technicians are required to attend an annual service training program to insure safe handling and servicing of SCUBAPRO products. All SCUBAPRO technicians
must be employed by an authorized SCUBAPRO facility.
4
Remove the “c” clip using a pick or
other tool.
Avoid scratching the Air 2 body with a
sharp instrument.
Push the air barrel forward, removing it
through the front cover area.
Use the seat slider tool to loosen and
remove the covers for the exhaust
valve and the inflation valve.
Use the Air 2 spider tool to loosen the
exhaust valve “spider.” Remove the
spider, exhaust valve, and washer.

SCUBAPRO AIR2 3rd & 4th Generations
2003 SCUBAPRO
Important note: The following information is not designed to be a complete training guide for servicing the listed SCUBAPRO regulators. All SCUBAPRO
technicians are required to attend an annual service training program to insure safe handling and servicing of SCUBAPRO products. All SCUBAPRO technicians
must be employed by an authorized SCUBAPRO facility.
5
Remove the nyloc nut holding the
exhaust seat assembly together.
CAUTION: Hold the exhaust button in
while performing this step to prevent
loss of spring.
Carefully remove the inflation seat.
CAUTION: Keep constant pressure on
the inflation button while loosening to
prevent loss of the spring.
Disassemble the air barrel and all of its
components.
Use the Air 2 spider tool to apply
pressure to the downstream valve
components. This will facilitate
removal of these parts.

SCUBAPRO AIR2 3rd & 4th Generations
2003 SCUBAPRO
Important note: The following information is not designed to be a complete training guide for servicing the listed SCUBAPRO regulators. All SCUBAPRO
technicians are required to attend an annual service training program to insure safe handling and servicing of SCUBAPRO products. All SCUBAPRO technicians
must be employed by an authorized SCUBAPRO facility.
6
If needed, disassemble and clean the
quick-disconnect inflator mechanism.
Use the universal tool to hold the
splined hose fitting. Remove the quick
disconnect mechanism from the hose
using an adjustable wrench.
(2)
Disassemble the quick disconnect
mechanism and check the seat for
wear. Use this opportunity to clean the
components.
CAUTION: Disassemble the
mechanism carefully to avoid losing the
three bearings.
(2)
Reassemble the quick disconnect
mechanism and tighten.

SCUBAPRO AIR2 3rd & 4th Generations
2003 SCUBAPRO
Important note: The following information is not designed to be a complete training guide for servicing the listed SCUBAPRO regulators. All SCUBAPRO
technicians are required to attend an annual service training program to insure safe handling and servicing of SCUBAPRO products. All SCUBAPRO technicians
must be employed by an authorized SCUBAPRO facility.
7
Replace all annual replacement
components (seat and nyloc nut).
Inspect and lubricate all o’rings.
Reassemble the air barrel. Use the Air
2 spider tool to assist in replacing the
nyloc nut and valve assembly.
Replace the inflator seat. Thread onto
the end of the inflator button as shown.
Hold the inflator button down to prevent
loss of spring while threading the seat
in place.
Torque to 2.7 in-lbs or 0.3 Newton
Meters.

SCUBAPRO AIR2 3rd & 4th Generations
2003 SCUBAPRO
Important note: The following information is not designed to be a complete training guide for servicing the listed SCUBAPRO regulators. All SCUBAPRO
technicians are required to attend an annual service training program to insure safe handling and servicing of SCUBAPRO products. All SCUBAPRO technicians
must be employed by an authorized SCUBAPRO facility.
8
Use the Seat Slider tool to position the
exhaust seat into the Air 2 body. Insert
the exhaust button assembly as shown.
Use the ¼” nut driver to tighten the
nyloc nut on the exhaust button stem.
Torque to 2.7 in-lbs or 0.3 Newton
Meters.
Assemble the exhaust valve and
spider.
Thread into the Air 2 body and lightly
tighten using the Air 2 spider tool as
shown.

SCUBAPRO AIR2 3rd & 4th Generations
2003 SCUBAPRO
Important note: The following information is not designed to be a complete training guide for servicing the listed SCUBAPRO regulators. All SCUBAPRO
technicians are required to attend an annual service training program to insure safe handling and servicing of SCUBAPRO products. All SCUBAPRO technicians
must be employed by an authorized SCUBAPRO facility.
9
Inspect and lubricate the inflator
mechanism cover o’ring.
Insert the covers for the exhaust and
the inflator mechanisms. Lightly
tighten using the Seat Slider tool.
Replace the poppet seat. Inspect and
lubricate o’rings as shown.
Assemble the poppet, orifice, lever and
other components of the air barrel.
Two threads should show on the seat
carrier.
CAUTION: Protect the poppet seat to
prevent engraving when assembling
the air barrel.
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Insert the air barrel assembly into the
Air 2 body.
NOTE: The flat edge of the air barrel
must rest against the flat internal edge
of the Air 2 body as shown.

SCUBAPRO AIR2 3rd & 4th Generations
2003 SCUBAPRO
Important note: The following information is not designed to be a complete training guide for servicing the listed SCUBAPRO regulators. All SCUBAPRO
technicians are required to attend an annual service training program to insure safe handling and servicing of SCUBAPRO products. All SCUBAPRO technicians
must be employed by an authorized SCUBAPRO facility.
10
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Replace the “c” clip. If needed, use a
small screwdriver or flat pick to insure
that the “c” clip is tightly in place.
Inspect the diaphragm to insure there
are no punctures or wear.
Reassemble the diaphragm, friction
washer and front cover. Tighten using
the Seat Slider tool.
Adjustments are made by inserting the
Air 2 spider tool into the quick
disconnect side of the air barrel.
Turning clockwise reduces the distance
between the orifice and the poppet seat
and increases the cracking effort.
Turning counter-clockwise increases
the distance and reduces the cracking
effort.

SCUBAPRO AIR2 3rd & 4th Generations
2003 SCUBAPRO
Important note: The following information is not designed to be a complete training guide for servicing the listed SCUBAPRO regulators. All SCUBAPRO
technicians are required to attend an annual service training program to insure safe handling and servicing of SCUBAPRO products. All SCUBAPRO technicians
must be employed by an authorized SCUBAPRO facility.
11
Alternate between the Air 2 spider tool
and the quick disconnect hose fitting to
make final air-on adjustments.
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Attach quick disconnect as shown in
preparation for testing.
Install the Magnehelic gauge as shown.
Turn the air on gently.
Use the mouthpiece extension and
inhale gently, noting the “cracking”
effort required to deliver air.
Adjust as needed using the Air 2 spider
tool.
Inhalation range: 1.4 – 2.0 inches of
water.

SCUBAPRO AIR2 3rd & 4th Generations
2003 SCUBAPRO
Important note: The following information is not designed to be a complete training guide for servicing the listed SCUBAPRO regulators. All SCUBAPRO
technicians are required to attend an annual service training program to insure safe handling and servicing of SCUBAPRO products. All SCUBAPRO technicians
must be employed by an authorized SCUBAPRO facility.
12
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Attach quick disconnect and large bore
inflator hose. If the BC uses a “pull
dump” attached to the inflator hose the
mechanism pin must be attached prior
to securing the Air 2 to the large bore
hose.
CAUTION: Be certain that the large
bore inflation hose is securely attached
to prevent disconnection while in use.