Genesis Advanced Technologies GRXXX User Manual
Atlas & Yukon
(Part Numbers GRXXX & )
Second Stage
SERVICE & REPAIR
GUIDE
Contents
Contents
Introduction ............................................................................ 3
About This Manual .........................................................................3
Scheduled Service....................................................................................... 3
EAN/ Nitrox Service .................................................................................... 3
Use of Warnings, Cautions, & Notes ........................................................ 3
Function & Design ..........................................................................4
Section 1 – Facility Requirements ......................................... 5
Table 1 – Recommended Equipment and Suppliers ......................6
Section 2 – Preliminary Inspection ....................................... 7
External Inspection .......................................................................7
Immersion / Leak Test .....................................................................7
Section 3 – Disassembly Procedures .................................... 8
General Guidelines ........................................................................8
Section 4 – Cleaning Procedures ....................................... 14
Acidic Cleaning Procedure ......................................................... 14
EAN/Nitrox Cleaning Procedure ............................................... 17
Section 5 – Reassembly Procedures ...................................24
General Guidelines ..................................................................... 24
Section 6 – Final Testing Procedures ................................28
Table 2 – Troubleshooting Guide ........................................32
Schematic & Parts List – Atlas Second Stage...................33
Schematic & Parts List – Yukon Second Stage ..................35
Service & Repair Manual
About This Manual
About This Manual
Introduction
Introduction
As a service technician, you are entrusted with maintaining your customer’s
equipment to the same standards with which it was manufactured. At Genesis, we
are committed to providing you with the tools you will need to accomplish this
important task, including the information provided in this manual.
Possession of this manual, however, does not constitute an offer by Genesis
Scuba to sell component parts, nor does it qualify you to perform service or repair
for Genesis Scuba products. In order to purchase spare parts or perform service
and repair, you must be directly employed by an Authorized Genesis Dealer. It is
also your responsibility to obtain factory authorized training through your Genesis Scuba distributor.
If you are ever unsure about how to perform any of the procedures outlined in this manual,
please contact Genesis Scuba for technical assistance.
Scheduled Service
Regulators should be given the same care and maintenance as life support equipment. It is
therefore important to perform scheduled overhaul service for the entire regulator (first and second
stages) at least once every year with normal or infrequent use.
A unit that receives heavy or frequent use, however, should be serviced at least twice each year or more often - depending on the conditions of use and the manner in which it is maintained. (Refer
to the maintenance procedures outlined in the Genesis Regulator Owner’s Manual.).
When performing service, whether it is a routine overhaul or a repair of a specific problem, it is
important to understand how the regulator is designed and how it operates. An illustrated
explanation of the Atlas/Yukon second stage design is provided on the following page.
EAN/ Nitrox Service
Genesis regulators can be upgraded for use with oxygen enriched air (EAN/ Nitrox) not to
exceed 40% oxygen content. This upgrade must be performed in conjunction with a complete
overhaul, and includes a special cleaning procedure that is outlined in this manual.
Use of Warnings, Cautions, & Notes
WARNING indicates a procedure or situation that may
result in serious injury or death if instructions are not
followed correctly.
CAUTION indicates any situation or technique that will
result in potential damage to the product, or render the
product unsafe if instructions are not followed correctly.
NOTE is used to emphasize important points, tips, and
reminders.
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Copyright ©2001 Liberty Group
Atlas & Yukon Second Stage
Function & Design
Function & Design
Introduction
The Atlas/Yukon second stage features a high performance, low volume
design with a mechanically balanced valve. Here's how it works:
Introduction
3
4
▼
Intermediate pressure air (140 psi) enters through the inlet
coupling and orifice (1), where it meets the poppet and LP
seat. The poppet spring (2) holds the poppet against the
orifice with a pre-set tension that counteracts the intermediate
pressure. The poppet is balanced between the two forces.
▼
Airflow is actuated upon inhalation or purging, when the
diaphragm is drawn down over the lever (3). This pulls the
poppet away from the orifice.
▼
Air and water are channeled to flow out through the exhaust
valve (4), which is designed to minimize exhalation resistance
while keeping the case internally dry in all positions.
▼
(Atlas only - not shown) A dive/pre-dive switch can be set to
minimize or boost peak venturi airflow, according to the
diver's preference.
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Copyright ©2001 Liberty Group
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Service & Repair Manual
Facility Requirements
Facility Requirements
The service facility is perhaps the most important asset of
any professional dive store. It should be clean and well
lighted, and stocked with a complete inventory of parts and
manufacturer's specialty tools for the products your store sells.
As a minimum requirement, your service facility should be
equipped with the following items:
❏
Ultrasonic Cleaner –
keep up with the volume of regulators that your store services.
A built in timer and heater will help control the cleaning time
and temperature of the solution, since most solutions work best
when heated.
Select the right size model that can
❏
Bench Mounted Vise –
the regulator secure – especially when removing the first stage
yoke retainer. Special care must be taken, however, to avoid
damage that can result from improper use of this tool. Be sure
to follow the instructions provided in this manual.
❏
Magnification Lamp –
essential requirements for performing a thorough parts inspection - especially when locating the cause of a small leak.
❏
Quality Wrenches & Sockets –
plated brass parts, it is especially critical to use the correct size
wrench and to ensure that it fits properly over the part. The use
of an adjustable wrench is very likely to cause damage to your
customer's regulator, and should be strictly avoided at all times.
❏
Calibrated Inch-Pound Torque Wrench –
follow the manufacturer's torque values whenever they are
specified, in order to avoid overtightening or under-tightening a
part. This is especially important for smaller parts and fittings,
when overtightening can easily damage the part.
❏
Calibrated Foot-Pound Torque Wrench –
wrenches that can be set for both inch-pound and foot-pound
measurements generally tend to be less accurate than wrenches
that are designed to measure torque within a specific range.
A vise is sometimes needed to hold
Strong lighting and magnification are
When working with chrome
It is important to
Torque
❏
Manufacturer's Specialty Tools –
critically important to performing each step of disassembly and
reassembly according to each manufacturer's procedures.
Genesis specialty tools that are required to perform service for
the Atlas and Yukon second stages are pictured on the following
page.
5
Specialty tools are
Copyright ©2001 Liberty Group
Atlas & Yukon Second Stage
Table 1 – Recommended Equipment and Suppliers
Table 1 – Recommended Equipment and Suppliers
The specialty tools shown below can be purchased directly from Genesis Scuba. For other items needed to outfit your store's
service facility, we recommend the following suppliers:
Peter Built Co. Manufacturer of custom designed specialty tools Galion, OH 44833
www.scubatools.com and test fixtures Phone: 419-468-2212
Branson Ultrasonics Manufacturer of tabletop ultrasonic cleaners Danbury, CT 06813
www.bransoncleaning.com Phone: 203-796-2298
Lubrication Technology Manufacturer of Christo-Lube 111 Jackson, OH 45640
(Genesis approved lubricant) Phone: (740)286-2644
Lawrence Factor, Inc. Manufacturer of LFW
www.lawrence-factor.com (Genesis approved acid bath cleaning solution) Phone: 305-430-0550
Modern Chemical Distributor of Blue Gold Aqueous Cleaner Batesville, Indiana 47006
Ohio Corporation (Genesis approved aqueous cleaning solution for EAN/ Nitrox Service) Phone: (812) 934-5915
www.a1.com/bluegold
Simple Green Manufacturer of Crystal Green Aqueous Cleaner Huntington Harbor, CA 92649
www.simplegreen.com (Approved alternative aqueous cleaning solution for EAN/ Nitrox Service) Phone: (800) 228-0709
Sears Roebuck Retail distributor of Craftsman
www.sears.com/craftsman
™
(Lawrence Factor Wash) Miami Lakes, Florida 33014
®
tools
Atlas/ Yukon Specialty Tools
150
100
175
125
120
80
IP RANGE
100
60
75
IP RANGE
125-150 PSI
40
50
25
20
0
PETER BUILT CO.
"Quality in the making"
"Quality in the making"
Intermediate Pressure
Test Gauge, #20-510-100
125-150 PSI
PSI
PSI
USE NO OIL
USE NO OIL
PETER BUILT
(419) 468-2212
(419) 468-2212
200
300
200
140
225
180
275
160
250
Dual Drive In-Line Adjusting Tool # 20-500-200
O-ring Tool Set #10-102-
Select Tool Kit (5 pcs) # 11-090-500
260
2.0 x 50
260
3.5 x 60
Genesis Rim Clamp # 20-680-200
Genesis Poppet Tool Kit #20-640-
Genesis specialty tools are made in the USA by
Copyright ©2001 Liberty Group
Peter Built Co
. Illustrations courtesy of Peter Wolfinger.
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Service & Repair Manual
Preliminary Inspection
Preliminary Inspection
External Inspection
1. Closely examine the conical filter of the first stage to check
for any signs that contaminants have entered the system,
including sea water, rust, or aluminum oxide.
NOTE: A green discoloration positiv ely indicates that moisture has entered the regulator, and internal corrosion may
have occurred. Other types of discoloration may indicate
that the regulator has been used with a corroded cylinder.
Advise the customer of this, and the possible need to obtain
service for their cylinder.
2. Slide back the hose protector(s) to inspect the condition of
the LP hose at its fittings and along its length. Check
closely for any signs of blistering or abrasion, or corrosion
of the fittings.
3. Inspect the condition of the mouthpiece to check for torn
bite tabs, holes, or deterioration.
Immersion / Leak Test
1. Check to ensure that the regulator is fully assembled and
connected to a first stage, and that there are no open ports
or hoses. Connect the first stage to a cylinder that is filled
with 3,000 psi, and open the cylinder valve to pressurize
the regulator.
2. If leakage cannot be heard, or if the source of leakage
detected audibly is not obvious, immerse the second stage
in fresh water to check further for any signs of air leakage
through the mouthpiece and at the hose fitting.
3. Note the source of any leakage found and refer to
- Troubleshooting
to determine its possible cause.
Table 2
4. Close the cylinder valve and depress the second stage
purge cover to depressurize the regulator.
▼
After completing the Preliminary Inspection, proceed to
Section 3 – Disassembly
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Copyright ©2001 Liberty Group
Atlas & Yukon Second Stage
Disassembly Procedures
Disassembly Procedures
General Guidelines
▼
Prior to performing any disassembly, check to ensure that
the service facility is well equipped with all the tools and
parts needed to perform a complete service from start to
finish. DO NOT attempt to perform the service unless all of
the required tools and parts are available.
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▼
All o-rings are classified as being either dynamic or static.
Dynamic o-rings are those which sustain friction and
movement, as they are either mounted directly onto a
moving part, or create a seal against a moving part.
Static o-rings simply create a seal between two nonmoving parts, and are therefore less subject to wear than
dynamic o-rings. After passing close inspection, static
O-rings may sometimes be reused, although this is not
necessarily recommended. Dynamic O-rings must be
automatically discarded and replaced with every service,
regardless of age or appearance.
▼
Refer to the schematic and parts lists provided on page 37
& 39 while performing these procedures. Each part is
identified by its reference number shown on the drawing
the first time it is referred to in the procedure.
▼
Do not attempt to reuse parts that are designated to be
automatically discarded and replaced with the parts
provided in the overhaul parts kit. These parts should be
shown to the customer, however, to ensure their confidence and satisfaction that complete overhaul service has
been performed.
▼
Inspect all reusable parts as directed, either during or
immediately following the disassembly procedures. When
in doubt, compare the part with one that is new to best
determine its condition.
Copyright ©2001 Liberty Group
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Fig. 1 –␣ Serial Number Location
Service & Repair Manual
CAUTION: Whenev er possible, use only plastic or br ass Oring tools for removing O-rings in order to prevent damage
to the sealing surface. Steel instruments, such as dental
picks, can easily damage the sealing surf ace of a softer brass
part, causing irreparable leakage and requiring the part to
be replaced with new.
1. Snip the plastic tie-strap(14) that holds the mouthpiece(12),
and gently pull the mouthpiece off the second stage
case(11). Record the serial number that is affixed directly
below the mouthpiece tube, and compare it to the
customer’s invoice or service record to determine whether
it is eligible for warranty service (see Fig. 1). Inspect the
condition of the mouthpiece to ensure that it is supple and
free of any tears or corrosion. If any damage is found that
could result in discomfort or leakage, discard the mouthpiece and do not reuse.
2. Slide back the hose sleeve(27) to expose the connection of
the LP hose(25).
Fig. 2 –␣ O-ring RemovaL
3. While holding the inlet coupling(6) secure with a w" open-
end wrench, apply an n" open-end wrench to the fitting
of the LP hose. Turn the hose fitting counter-clockwise to
loosen and remove.
4. Using the O-ring pick that is provided in the Select Kit (PN
11-090-500), carefully remove the O-ring(26) from the
post inside the hose fitting (see Fig. 2).
CAUTION: The O-ring pick is made of steel and is very
sharp, and is only recommended for the remov al of O-rings
that cannot be removed with a brass O-ring tool. When performing the above step, be very careful to avoid scratching
the O-ring sealing surface. Doing so may cause a permanent leak that will require the replacement of the LP hose.
5. While holding the diaphragm cover(2) fully depressed in
the purge position, apply a w" open-end wrench to the
inlet coupling and turn it counter-clockwise to loosen and
remove.
6. Remove and discard the O-ring(7) from the inlet coupling.
Do not reuse.
7. While holding the inlet coupling secure, apply a medium
blade screwdriver to the slotted head of the valve orifice(5). Turn the orifice counter-clockwise until its threads
have completely disengaged from the inlet coupling.
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Copyright ©2001 Liberty Group
Atlas & Yukon Second Stage
NOTE: The orifice is O-ring sealed and will remain inside
the inlet coupling after performing the above step. The following step must be performed correctly in order to remov e
the orifice without damaging its polished sealing edge.
8. After the orifice has been unthreaded from the inlet coupling, stand the inlet coupling on end with the orifice
sealing edge facing up. Carefully insert the handle of the
blunt probe (provided in the Select Kit) through the top of
the inlet coupling, directly over the sealing edge of the
orifice. Gently press the orifice out (see Fig. 3).
9. To avoid using a sharp tool that can damage the orifice,
squeeze the O-ring(4) between thumb and forefinger to
remove it from the orifice head. Discard the O-ring and
do not reuse.
10. Closely examine the orifice with the use of a magnifier,
checking for any scratches or other damage to the sealing
edge and the groove that holds the O-ring (see Fig. 4). If
any damage or wear is found, discard the orifice and do
not attempt to reuse. If it is in reusable condition, set it
aside on a soft surface to keep it isolated from metal parts.
Fig. 3 – Orifice Removal
11. While holding the bottom of the second stage secure with
one hand, firmly grasp the cover ring(1) with the other,
and turn the ring counter-clockwise to loosen and remove.
NOTE: If the cov er ring cannot be remov ed by hand, it may
be necessary to use the Rim Clamp (PN 22-680-200), together with a bench-mounted vise. This Genesis specialty
tool has been designed to prev ent damage to the cover ring
or the second stage during disassembly , but it m ust be used
correctly, following the steps outlined below.
a. Identify the side of the Rim Clamp that contains the
larger diameter shoulder, which is designed to hold the
Atlas/ Yukon cover ring. Place the Rim Clamp between
the jaws of a bench mounted vise with the larger diameter side facing straight up, and the split edge parallel
with the vise jaws (see Fig. 5). Ensure that the top
surface of the clamp rests slightly above or flush with
the top surface of the vise jaws, and gently tighten the
vise only until the clamp is held securely in place. Do
not over-tighten or compress the clamp.
Fig. 4 – Orifice Inspection
b. Place the second stage inside the clamp, with the cover
ring facing down. Tighten the vise to compress the
clamp, only as far as is needed to secure the clamp
around the cover ring to prevent slippage.
Copyright ©2001 Liberty Group
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Fig. 5 – Genesis Rim Clamp
Fig. 6 – Cover Ring Removal
Service & Repair Manual
CAUTION: Do not over-tighten the vise. Doing so may
permanently distort or fracture the co v er ring and the case,
requiring their replacement.
c. When the cover ring is held secure, firmly grasp the
second stage with both hands and rotate the second
stage counter-clockwise in a level direction above the
clamp (see Fig. 6).
d. After loosening the cover ring, open the vise to loosen it
further by hand to remove it.
12. Lift the diaphragm cover directly out of the case to expose
the diaphragm(3), and closely inspect the cover to ensure it
is perfectly round and free of any distortion or other damage. If any damage is found, discard the cover and
replace with new.
13. Grasp the diaphragm by the raised edges of the center
plate, and lift it out of the case with a slight twist. Inspect
the diaphragm to ensure it is supple and free of any pinholes, tears, corrosion, or other damage. If any damage is
found, discard it and replace with new.
Fig. 7 – Genesis Pop p et Drive Tool
14. Mate the Poppet Drive Tool (provided in the Genesis Poppet Tool Kit, PN 20-640-100) into the inlet tube of the
second stage, and turn the knob slightly in either direction
to engage the driver with the poppet(9). (See Fig. 7.)
Then, turn the hex nut clockwise by hand until lightly snug
to fasten the tool onto the second stage.
15. Press the knob of the tool inward to compress the poppet
spring until the arms of the lever(21) are visible, and pull
the lever out of the second stage. Relax the tool. Examine
the lever arm and compare with new to ensure that it is not
bent or distorted in any way. Discard if damage is found.
16. Apply the Poppet Nut Wrench (provided in the Poppet Tool
Kit) to hold the locknut(19) secure. Engage the Poppet
Drive Tool to turn the poppet counter-clockwise until the
locknut falls off the end of the poppet shaft. (See Fig. 8.)
17. Turn the case over to drop out the spacer(20) and
washer(22). Discard the washer and locknut, and do not
reuse. Inspect the spacer to check for any signs of wear.
If found, discard and replace the spacer with new, or set it
aside to be reused if it is in satisfactory condition.
Fig. 8 – Disassembly of Pop p et
18. Unscrew the nut of the Poppet Drive Tool from the second
stage inlet, and remove the tool to allow the poppet and
poppet spring(10) to fall out. Inspect the spring with a
magnifier to check for any signs of corrosion. Discard it if
corrosion is found, and do not reuse.
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Copyright ©2001 Liberty Group
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