Uwatec S600 Configuration A 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
S600-S550
Second Stages
S600 Configuration A S600 Configuration B
USE THIS GUIDE AS A REFERENCE WHEN SERVICING THE S600 AND
S550 SECOND STAGES
S550

SCUBAPRO S600-S550 SECOND STAGES
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 S600-S550
P/N43040000
TOOLS
NEEDED
Quantity Part Number Description
1 43.300.227 Balance Chamber Adjusting Tool
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
1 43.040.000
(Scubapro)
Universal Tool
1 Jeweler’s screwdriver (3mm)
1 Philip’s Screwdriver
1 11.153.500
(Peter Built)
Ball-end Allen Wrench
1 43.300.225
(Scubapro)
VIVA Flow Vane Removal Tool
1 20.500.200
(Peter Built)
Pneumatic Adjusting tool
1 18.300.500
(Peter Built)
Blow Gun/Air Nozzle
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
Indicates the regulators affected by this
step

SCUBAPRO S600-S550 SECOND STAGES
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
Remove hose and jam nut from the
second stage.
Configuration A regulators: housing pin
can be removed by using the pointed
pick to push from the inside out. This
helps prevent case scratching.
Otherwise remove the housing pin
using the rounded pick or similar tool.
Use the universal tool as shown to
remove the two-piece second stage
cover of the S600.
Remove the housing pin using the
brass pick or similar tool.
Use the universal tool as shown to
remove the two-piece second stage
cover on the S550.

SCUBAPRO S600-S550 SECOND STAGES
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
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Remove the two-piece cover, friction
washers and diaphragm from the
second stage housing.
Remove the stop clip from the knob.
Configuration B: Turn the cracking
effort adjustment knob inward a few
turns for easier stop clip removal.
Remove the stop clip from the plug.

SCUBAPRO S600-S550 SECOND STAGES
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
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Hold down the lever and remove the air
barrel from the case.
P/N43040000
TOOLS
NEEDED
No tools needed this
step
Hold down the lever and remove the air
barrel from the case.
P/N43040000
TOOLS
NEEDED
No tools needed this
step
Hold down the lever and remove the
plug from the end of the air barrel.
Then remove the air barrel itself from
the case.
CAUTION: Remove the plug first to
avoid scratching the sealing surface on
the case.
Remove the cracking effort adjustment
knob from the air barrel.
Remove the decal from the cracking
effort adjustment knob. This will allow
access to the balance adjustment
mechanisms.
Remove the o’rings from the cracking
effort adjustment knob.

SCUBAPRO S600-S550 SECOND STAGES
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
Remove the cracking effort adjustment
knob from the air barrel.
Remove the decal from the cracking
effort adjustment knob. This will allow
access to the balance and anti-set
mechanisms.
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Remove the plug from the air barrel.
Remove the poppet, balance chamber,
and spring from the air barrel.
Remove all o’rings and poppet seat.
Using the Philips screwdriver remove
the cover screw and o’ring. Do not
remove the breathing effort adjustment
knob at this time.
Remove the poppet, spring and
balance chamber from the air barrel.

SCUBAPRO S600-S550 SECOND STAGES
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
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Turn the breathing effort adjustment
knob clockwise until it is no longer in
contact with the balance adjustment
mechanism.
Remove the breathing effort
adjustment knob.
Using 3mm jeweler’s screwdriver turn
the balance adjustment mechanism
clockwise and remove.
Turn the 3mm jeweler’s screwdriver
clockwise to disassemble the
remainder of the balance adjustment
mechanism.
Remove all o’rings.
Remove the knob plug using the
universal tool.

SCUBAPRO S600-S550 SECOND STAGES
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
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Remove the balance chamber and
disassemble. Use caution to avoid
losing o’rings, spring, and spring pad.
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Carefully remove the poppet. The
poppet o’ring and seat will be replaced.
It is usually not necessary to remove
the lever from the air barrel.
Use the universal tool to remove the
adjustable orifice from the air barrel.

SCUBAPRO S600-S550 SECOND STAGES
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
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Remove the adjustable orifice. Take
off the adjustable orifice o’ring, as it will
be replaced. Remove the air barrel
o’ring for inspection.
A wooden dowel or “chopstick” may be
helpful in removing the orifice.
This Step Is Only Performed As Needed
When it is necessary to remove the
VIVA flow vane, use the flow vane
removal tool (p/n 43.300.225).
This step is seldom needed, unless the
VIVA flow vane o’ring is worn or
damaged.
Top view
P/N43040000
TOOLS
NEEDED
No tools needed
this step
This Step Is Only Performed As Needed
If the VIVA flow vane is removed, it may be
necessary to replace the entire VIVA
assembly, including the o’ring.

SCUBAPRO S600-S550 SECOND STAGES
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
Monoject
This Step Is Only Performed As Needed
Carefully inspect and lubricate the o’ring.
The venturi vane is reversible.
Maximum VIVA:
Place the new knob and vane assembly
back into the housing with the crescent-
shaped notch facing forward toward the
back of the diaphragm for maximum VIVA.
Minimal VIVA:
Place the new knob and vane assembly
back into the housing with the crescent-
shaped notch facing forward toward the
mouthpiece opening for minimal VIVA (ie:
for rental equipment).
Push the vane inward until it is locked in
place.
This Step Is Only Performed As Needed
If removal of the exhaust valve is
necessary, use the ball-end allen wrench
to push out the exhaust tee pin. Remove
the center section of the exhaust tee.
To remove the exhaust valve, grasp with
fingers and pull firmly out.
The exhaust valve will seldom need to be
replaced. Careful inspection is usually all
that is necessary. If the valve is removed
during service, it may be damaged during
the process, requiring replacement.

SCUBAPRO S600-S550 SECOND STAGES
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
This Step Is Only Performed As Needed
If the exhaust valve is removed, carefully
inspect and replace if necessary.
Replace the exhaust tee center section
and use the ball-end allen wrench to
replace the exhaust tee pin.
Monoject
Turn the 3mm jeweler’s screwdriver
counterclockwise to assemble the
balance adjustment mechanism.
Inspect and lubricate all o’rings.
Monoject
Thread the balance adjustment
mechanism into the breathing
adjustment knob assembly. Turn
counterclockwise using the 3mm
jeweler’s screwdriver until enough of
the mechanism is extended to permit
contact with the external knob.
Slide the external knob on the stem
and turn counterclockwise to “pull” the
mechanism into the knob assembly.

SCUBAPRO S600-S550 SECOND STAGES
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
Replace the adjustable orifice o’ring and
lubricate properly. Inspect the air barrel
o’ring and replace if necessary. Lubricate
properly.
Push the adjustable orifice in, and then use
the universal tool to turn in the adjustable
orifice one turn.
Monoject
Inspect and lubricate the air barrel
o’ring.
Monoject
Prepare the poppet by replacing the
seat and replacing/lubricating the
dynamic o’rings.
NOTE: Do not install the poppet/spring
or balance chamber into the air barrel
at this time.

SCUBAPRO S600-S550 SECOND STAGES
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.
13
Monoject
Lubricate all dynamic o’rings properly and
replace. Carefully inspect and lubricate all
static o’rings and replace where needed.
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Assemble the two-piece balance chamber
as shown and insert it into the cracking
effort adjustment knob.
Do not install the “anti-set chamber” into
the end of the assembly at this time. The
balance chamber adjustment tool should
be installed in preparation for final
adjustments.
NOTE: The spring pad can be installed on
the poppet or the balance chamber.
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Insert the air barrel and breathing
adjustment assembly (without the
external knob) into the regulator body.
If necessary, use the universal tool and
jam nut to assist in pulling the air barrel
all the way through the regulator case.

SCUBAPRO S600-S550 SECOND STAGES
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.
14
Inspect and lubricate static o’rings.
Attach jam nut and o’rings as shown.
Tighten with universal tool.
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Install the poppet so that the “feet” are
engaged with the demand lever. Insert
the spring, then the balance chamber.
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Replace the seat on the poppet, and
replace and lubricate the poppet stem
o’ring.
Install the poppet so that the “feet” are
engaged with the demand lever. Insert the
spring, and then insert the cracking effort
adjustment knob assembly. Thread onto
the air barrel.
Holding the lever down, insert the air barrel
into the case and push all the way through.

SCUBAPRO S600-S550 SECOND STAGES
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.
15
Attach the jam nut on the air barrel.
Place the o’ring on the air barrel next to
the jam nut if needed.
Thread the cracking effort adjustment
knob inward until there is enough
clearance to install the stop clip.
Press the stop clip carefully into place.
Back the adjustment knob out against
the clip ensuring that it stops.
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Insert the breathing adjustment
assembly without the external knob
onto the air barrel.
Push the assembly all the way onto the
barrel, being sure to engage the notch
on the assembly with the key on the air
barrel as shown
Install the stop clip.
Side View Top View
Inspect and lubricate the plug o’ring.
Insert the plug. Thread onto the air
barrel.

SCUBAPRO S600-S550 SECOND STAGES
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.
16
Thread the plug inward until there is
enough clearance to install the stop
clip.
Press the stop clip carefully into place.
Back the plug out against the clip
ensuring that it stops.
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Inspect the diaphragm for wear, and
replace if necessary.
Install the diaphragm and friction
washer, being certain that the two
pieces lay flat inside the second stage
housing. Note that the friction washer
uses an alignment tab to prevent
movement once installed.
Put the two-piece cover together,
arranging the pieces so that they are
aligned properly. Use the additional
free-moving friction washer between
the two-piece cover and the
diaphragm/stationary friction washer.
Use the universal tool to tighten the
cover, being certain that the
SCUBAPRO “S” is properly positioned.
Install a new housing pin into the side
of the housing.

SCUBAPRO S600-S550 SECOND STAGES
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.
17
Use the pneumatic adjusting tool to
make the initial air-on adjustments to
the second stage. The 3mm
screwdriver can be used to make
course adjustments on the balance
chamber and to stop free flows.
Use the pneumatic adjusting tool to
make the initial air-on adjustments to
the second stage, and to stop all free
flowing. The balance chamber tool will
be used to fine-tune the breathing effort
(see the next step).
Use the pneumatic adjusting tool to
make the initial air-on adjustments to
the second stage. The universal tool
can be used to make course
adjustments on the plug to stop free
flows.
Adjusting the balance
chamber counter
clockwise reduces
cracking effort.
Adjusting the balance
chamber clockwise
increases cracking effort.

SCUBAPRO S600-S550 SECOND STAGES
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.
18
Adjusting the balance
chamber counter
clockwise reduces
cracking effort.
Adjusting the balance
chamber clockwise
increases cracking effort.
Inspect and lubricate the external
adjustment knob o’ring.
Re-install external breathing
adjustment knob and tighten using the
Philips screwdriver.
Make any additional adjustments using
the pneumatic adjusting tool.
Re-install the “anti-set chamber” and
tighten until it is flush with the outside
of the cracking effort adjustment knob.
Make any additional adjustments using
the pneumatic adjusting tool and
balance chamber adjusting tool.

SCUBAPRO S600-S550 SECOND STAGES
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.
19
P/N43040000
TOOLS
NEEDED
No tools needed
this step
Install a new “Dive” decal if
appropriate.
Check the cracking effort of the
regulator.
S600:
Inhalation effort range: 1.0 to 1.4
inches of water.
S550
Inhalation effort range: 1.0 to 1.4
inches of water.

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