WOLLIS 500SE Manual

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This 500SE Service Procedure conveys a list of components and service procedures that reflect the 500SE as it
was configured at the time of this writing. Doc. 12-4095-r04 (11/25/14)
500SE
SECOND STAGE
SERVICE PROCEDURE

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500SE SERVICE GUIDE
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©2002 DESIGN (2013)
CONTENTS
TROUBLESHOOTING................................................................................................................................................. 3
DISASSEMBLY PROCEDURE..................................................................................................................................... 5
REASSEMBLY PROCEDURE...................................................................................................................................... 9
FINAL TUNING AND TESTING ................................................................................................................................. 13
PARTS LIST AND EXPLODED VIEW DIAGRAM ....................................................................................................... 15
SPECIFICATIONS
TORQUES
LP HOSE 35 TO 40 IN-LBS (4-4.5 N-M)
CONTROL VALVE SCREW 18 TO 20 IN-LBS (2.0-2.2 N-M)
GENERAL PROCEDURES
REFER TO .............................................................................................................................................. DOC. 12-4025
TOOLS REQUIRED
STANDARD TOOLS
small flat blade screwdriver
¼" deep wall socket
9/16" open end wrench
13/16" open end wrench
15/16" open end wrench
wooden dowel
O-ring picks
SPECIALTY TOOLS
Hollis approved Halocarbon Based Lubricant (See General
Procedure Doc. 12-7508 for approved list)
OPENING EFFORT (IP = 140 PSI)
Recommended Setup Range:
1.1 to 1.4 inches of water
Acceptable Setup Range:
1.0 to 1.6 inches of water

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TROUBLESHOOTING
SYMPTOMS POSSIBLE CAUSE TREATMENT
Free-flow 1. Incorrectly positioned during
water entry.
2. Second stage adjusted too
sensitively.
3. Excessive intermediate pres-
sure from first stage.
4. Debris trapped in orifice
of main valve diaphragm
(10).
5. Bent control valve lever
(14).
6. Control valve lever (14)
seat damaged or worn.
7. Main valve diaphragm (10)
installed incorrectly.
1. Hold exhaust end of second
stage facing up when enter-
ing water.
2. Readjust. (Refer to tuning
section.)
3. Refer to first stage trouble-
shooting chart.
4. Replace with new.
5. Replace lever (14), pin (6),
and spring (13) with new
and readjust second stage.
6. Replace lever (14), pin (6),
and spring (13) with new
and readjust second stage.
7. Reverse to face larger open-
ing of orifice towards hose.
Air leakage detected from control
valve (5) orifice.
1. Control valve lever (14) seat
damaged or worn.
2. Control valve spring (13)
damaged or obstructed.
3. Control valve lever (14) bent.
4. Excessive intermediate pressure.
5. Damaged or corroded control
valve (5) orifice.
1. Replace lever (14) with new and
readjust second stage.
2. Clean or replace with new as
needed.
3. Replace with new.
4. Refer to first stage troubleshoot-
ing chart.
5. Clean or replace as needed.
Air leakage detected from control
valve flange (4).
1. Control valve screw (12)
loose.
2. Control valve O-ring (7, 8) worn
or damaged.
3. Control valve screw (12) dam-
aged.
1. Tighten.
2. Replace with new.
3. Replace with new.
Air leakage detected from ports of
inlet chamber (1).
1. Main valve diaphragm (10)
worn or improperly seated.
2. Main valve seat (9) damaged.
3. Main valve seat O-ring (8) dam-
aged or worn.
4. Slight obstruction of main valve
diaphragm (10) orifice.
5. Excessive intermediate pressure.
1. Reseat or replace with new as
needed.
2. Replace with new.
3. Replace with new.
4. Clean or replace with new as
needed.
5. Refer to first stage troubleshoot-
ing chart.

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SYMPTOMS POSSIBLE CAUSE TREATMENT
Excessive inhalation resistance 1. Debris or corrosion present, pro-
hibiting main valve diaphragm
(10) or control valve lever (14)
operation.
2. Second stage incorrectly ad-
justed.
3. Bent control valve lever (14).
4. Retainer (15) loose, prohibiting
contact between lever (14) and
adjustment screw (12).
5. Purge cover ring (20) loose,
prohibiting contact between lever
(14) and control valve screw
(12).
1. Disassemble and clean.
2. Readjust. (Refer to tuning sec-
tion.)
3. Replace with new and readjust
second stage.
4. Tighten until perfectly snug.
5. Tighten until perfectly snug.
Inconsistent performance (Free-
flow/ Excessive inhalation resis-
tance).
1. Indexed retainer of housing (2)
damaged or distorted.
2. Retainer (15) loose, prohibiting
contact between lever (14) and
control valve screw (12).
1. Replace with new.
2. Tighten until perfectly snug.
Servo lag (Delay in opening of main
valve when control valve is actu-
ated).
1. Main valve seat (9) damaged
or worn.
2. Debris trapped in orifice of the
main valve diaphragm (10).
1. Replace with new.
2. Replace with new.
Excessive water entering second
stage. Inconsistent performance
1. Exhaust valve (18) distorted or
damaged.
2. Tear in mouthpiece (23).
3. Debris trapped beneath exhaust
valve (18).
4. Improperly installed or damaged
diaphragm (19) assembly.
5. Cracked or damaged housing
(2).
6. Control piston O-ring (24) worn
or missing.
1. Replace with new.
2. Replace with new.
3. Clean and remove.
4. Disassemble, clean or replace
parts with new as needed.
5. Replace with new.
6. Replace with new.

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DISASSEMBLY PROCEDURE
!NOTE: Be sure to perform the steps outlined in the Initial
Inspection Procedures prior to disassembling the regula-
tor. Review the troubleshooting section to gain a better
idea of which internal parts may be worn, and to better
advise your customer of the service that is needed.
1. Snip the plastic ty-strap (25) that holds the mouthpiece (23),
and remove the mouthpiece (23). Inspect the condition of the
mouthpiece (23) to ensure that it is supple and free of any tears
or corrosion. Discard if found.
2. Using your hands, turn the retainer (15) counterclockwise to
remove it from the plastic housing (2). If the retainer (15) has
been over-tightened onto the housing (2) assembly and cannot
be loosened by hand, you may use a small strap wrench to loosen
it while holding the second stage firmly in place, flat on its side on
the repair bench.
3. Firmly grasp the low pressure hose at the fitting with one hand,
and pull the housing (2) straight away with the other. To avoid
bending the control valve lever (14), ensure that the control
valve body (5) does not exit at an angle to the housing (2) (Fig.
1).
!NOTE: Refer to the Leak Detection section of General Pro-
cedures to perform the immersion test before proceeding
any further, if you have not already done so.
!CAUTION: While the valve assembly module is outside of
the HOUSING (2), it is important to avoid depressing the
LEVER (14) completely, or placing pressure on the LEVER
(14) valve seat. Doing so will compress and weaken the
SPRING (13), requiring its replacement, or damage the seat,
requiring replacement of the LEVER ARM (14).
4. To remove the hose, apply an 13/16" open end wrench to the
hex portion of the fitting, and turn counterclockwise while holding
the inlet chamber (1) secure with a 15/16" open end wrench (Fig.
2). Remove and inspect the O-ring found inside the hose fitting for
any signs of decay. Discard if found.
5. Hold the inlet chamber (1) flange secure, and remove the
control valve flange (4) complete with the control valve hous-
ing (5), using a 9/16" open end wrench (Fig. 3). Remove and
inspect the inlet chamber O-ring (7) and control valve flange O-
ring (11) for any signs of decay. Discard if found.
Fig. 1
Fig. 2
Fig. 3

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!CAUTION: Proper disassembly of the main valve is crucial.
Failure to correctly perform the following procedure will
result in damage to either the VALVE DIAPHRAGM (10), the
MAIN VALVE SEAT (9), the seating surface of the INLET
CHAMBER (1), or all of these parts, requiring replacement.
Hollis USA strictly recommends the use of pneumatic pres-
sure for the removal of this VALVE DIAPHRAGM (10), and
the use of a sharp metal instrument is to be completely
avoided. Closely adhere to the following method, outlined
in steps 6&7.
6. Connect the inlet chamber (1) to an air source, via a standard
low pressure hose with an intermediate pressure of no more than
145 psi. Wrap a cloth around the open end of the inlet chamber to
prevent the main valve diaphragm (10) from exiting, and gradu-
ally pressurize, allowing the pressure to increase until the valve
diaphragm (10) is unseated (Fig. 4).
7. If the valve diaphragm (10) has not exited entirely beyond the
threaded portion of the inlet chamber (1) cavity, extreme care
must be taken to avoid damaging the inlet chamber (1). Using
your fingertips, remove the main valve diaphragm (10) from the
inlet chamber (1). Discard and DO NOT attempt to reuse.
8. Remove the inlet chamber (1) from the LP hose, and insert
a 5/16" wooden dowel through the small threaded opening to
dislodge the main valve seat (9), causing it to exit entirely (Fig.
5). Compare with new and closely inspect for any signs of pitting
or distortion that would prevent proper seating with the main valve
diaphragm (10). Discard if found.
9. Locate the main valve seat O-ring (8) by viewing through the
main cavity of the inlet chamber (1). Carefully remove the O-ring
(5), using a brass or plastic dental pick to avoid damaging the
brass seating surface, and discard.
10. While holding the CONTROL VALVE FLANGE (4) secure with
a 9/16" open end wrench, slightly loosen the CONTROL VALVE
SCREW (12) with just one turn, using a 1/4" deep wall socket (Fig.
6).
!CAUTION: DO NOT apply a slotted blade screwdriver to the
head of the SCREW (8). Doing so will result in damage to
the SCREW (8), requiring replacement.
11. Hold the control valve housing (5) secure between thumb
and forefinger, on either side of the control valve lever (14).
!CAUTION: DO NOT apply direct pressure onto the control
valve LEVER (14) seat.
Fig. 4
Fig. 5
Fig. 6

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12. Continue loosening the screw (12) with the use of the deep
wall socket to remove it from the control valve housing (5) and
control valve flange (4). Remove the control valve flange O-ring
(11) and inspect it for any signs of decay. Discard if found. Re-
move and discard the control valve block O-ring (8).
13. Closely inspect the control valve screw (12) with the use of
a magnifier, checking for any signs of stress damage caused by
unauthorized repair, either at the slotted head or just above the
threads. Discard if found, and DO NOT attempt to reuse.
!NOTE: If leakage from the control valve was detected dur-
ing the immersion test performed during the Initial Inspec-
tion Procedures, it is important to proceed directly to step
14. If no leakage from the control valve was detected
during the immersion test, perform the following inspec-
tion of the control valve assembly to determine whether
further disassembly may be necessary. If the assembly
passes this inspection after passing the immersion test,
Hollis advises that it be cleaned fully assembled, as one
part. Then proceed to step 16.
Inspection
A. Inspect the spring (13) to ensure that it is present and securely
in place, without any grit or debris inside it.
B. Examine the lock pin (6) to ensure that it is not damaged or
distorted in any way.
C. Closely examine the lever (14) and compare with new to
ensure it is not bent.
14. Using an O-ring pick remove the lock pin (6) (Fig. 7).
15. Remove and discard the spring (13) and lever (14). DO NOT
attempt to reuse.
16. Hold the housing (2) in one hand, and pull the exhaust cover
(3) off with the other hand (Fig. 8).
!NOTE: You may use water heated to a safe temperature
to to soften the exhaust cover (3) for ease of disassembly if
needed.
17. Turning counterclockwise, remove the purge cover ring (20)
(Fig. 9).
18. Press the purge cover (21) out of the purge cover ring (20).
Inspect both parts for damage. Discard if found.
Fig. 7
Fig. 8
Fig. 9

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19. Remove the diaphragm (19) assembly, which includes: the
control diaphragm (19), control piston (17), and adjustment
screw (22) (Fig. 10). Inspect the following to determine whether
further disassembly is necessary. If the assembly passes this
inspection, it may be cleaned while fully assembled, as one part.
A. Inspect the condition of the control diaphragm (19) to
ensure the silicone rubber is supple and free of any tears or
corrosion.
B. Inspect the condition of the control piston (17) to ensure it
is free of any stress cracks, warping, or other signs of distor-
tion.
C. Inspect the adjustment screw (22) to ensure the threads
are in good condition, without any signs of distortion.
!NOTE: If the DIAPHRAGM (19) assembly passed the in-
spection (step 19), skip step 20.
20. Disassemble the diaphragm (19) assembly as follows.
A. Pull the diaphragm (19) off of the control piston (17).
Inspect the groove on the control piston (17) for damage.
Discard if found.
B. Turning counterclockwise with a small flat blade screw-
driver, remove the adjustment screw (22).
C. Carefully, remove the O-ring (24) from the control piston
(17) using an O-ring pick. Inspect the O-ring (24) and con-
trol piston (17) for signs of deterioration or damage. Discard
if found.
21. Using a soft probe, inspect the condition of the exhaust valve
(18) to ensure that it is supple and free of any tears or corrosion,
and that it seals completely around the seating surface of the
housing (2).
!NOTE: If the EXHAUST VALVE (18) is in good condition, it
is not necessary to remove it. The HOUSING (2) may be
cleaned with it attached.
22. If the exhaust valve (18) requires replacement, it may be
removed by grasping it at the flange and pulling it straight out,
snipping the retainer stem if necessary. Discard.
!NOTE: If replacing the EXHAUST VALVE (18) ensure not to
place damaging stress on the HOUSING (2).
Fig. 10

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23. Inspect the condition of the housing (2) assembly:
A. The plastic housing (2) should be free of any stress cracks,
and the threads should be clean and free of any signs of dam-
age or distortion.
C. The indexed valve retainer inside the inlet portion of the
housing (2) should be intact, and free of any signs of damage
or distortion caused by improper removal of the LP hose (Fig.
11).
REASSEMBLY PROCEDURE
!NOTE: Prior to reassembly, it is necessary to inspect all
parts, both new and those being reused. Check to ensure
that O-rings are clean and supple, and that every part and
component has been thoroughly cleaned and dried.
!WARNING: Use only genuine Hollis parts, subassemblies,
and components whenever assembling Hollis products.
DO NOT attempt to substitute any Hollis part with another
manufacturer’s, regardless of any similarity in shape, size,
or appearance. Doing so may render the product unsafe,
and could result in serious injury or death of the user.
!NOTE: If the CONTROL VALVE (5) assembly has not been
disassembled, proceed directly to step 3.
1. Turn the control valve housing (5) towards you, so that the
grooved side is facing up. Place the control valve spring (13) into
the recessed hole inside the groove, standing on end. Examine
the control valve lever (14) to find the spring retaining tab on its
underside, and lower the lever (14) directly onto the control valve
housing (5), mating this tab into the spring (13) and positioning
the lever (14) seat over the orifice cone (Fig. 12). Press the lever
(14) into the groove, slightly compressing the spring (13), and
place your forefinger over the tab to hold it there.
!CAUTION: Avoid applying excessive pressure over either
end of the LEVER ARM (13) while holding it in place. Do-
ing so will either weaken the SPRING (13) or damage the
LEVER (14) seat which rests over the sharp orice cone of
the control valve HOUSING (5).
Fig. 12
Fig. 11

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2. While continuing to hold the lever (14) in place, slide the lock
pin (6) into place until it locks (Fig. 13).
!CAUTION: It is important not to excessively bend, or distort
the LOCK PIN (6) in the process of installing. If any distor-
tion is visible, or if the LEVER (14) movement is not correct,
remove, replace, and repeat the steps outlined above.
3. Insert the threaded end of the control valve screw (7) through
the open end of the control valve flange (4), until the control
valve screw (7) protrudes out the other end. Lubricate and install
the control valve O-ring (8) onto the threaded end of the control
valve screw (7).
6. Examine the outer side of the control valve flange (4) to find
three flat surfaces and a fourth, which is rounded. Align the
control valve flange (4) with the control valve housing (5) so
that this rounded surface faces down and opposite the lever (14),
which should face up. Mate the two parts, and hold them together
while turning the control valve screw (12) in a clockwise direc-
tion, using a 1/4" deep wall socket mounted on a hand driver.
Tighten to a torque of 18-20 in-lbs (2.0-2.2 N-m).
!CAUTION: DO NOT use a socket wrench or screwdriver to
tighten the CONTROL VALVE SCREW (12). Doing so may
result in over-tightening and breakage of the screw, requir-
ing its replacement.
7. Lubricate and install the control valve flange O-ring (11) onto
the control valve flange (4).
8. Lubricate and install the main valve seat O-ring (8) into the inlet
chamber (1), using a 5/16" wooden dowel and a smoothly pol-
ished blunt dental probe from opposite ends to guide it into place.
9. Install the main valve seat (9) into the inlet chamber (1),
pressing the valve seat (6) inlet stem through the O-ring (5) until
seated (Fig. 14).
10. Lubricate and install the inlet chamber O-ring (4) onto the
inlet chamber (1).Fig. 14
Fig. 13