Genesis Advanced Technologies GRXXX & manual

Atlas & Y ukon (Part Numbers GRXXX & ) Second Stage S ER VICE & R EP AIR G UIDE[...]

Contents Contents Introduction ............................................................................ 3 About This Manu al ......................................................................... 3 Scheduled Ser vice ....................................................................................... 3 EAN/ Nitrox Ser vice ...............[...]

3 Copyright ©2001 Liberty Group Service & Repair Manual About This Manu al About This Manu al Introduction Introduction As a ser vice 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 acc[...]

4 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage F unction & Design Introduction Introduction F unction & Design The Atlas/Y ukon second stage features a high p e r f o r m a n c e , low volume design with a mechanically balanced valve. Here's how it works: ▼ Intermediate pressure air (140 psi) enters through the inle[...]

5 Copyright ©2001 Liberty Group Service & Repair Manual F acility R equirements s e c t i o n F acility R equirements s e c t i o n The ser vice facility is perhaps the most important asset of any professional dive store. It should be clean and well lighted, and stocked with a complete inventor y of parts and manufacturer's specialty tool[...]

6 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage T able 1 – R ecommended Equipment and Suppliers The specialty tools shown below can be purchased directly from Genesis Scuba. For other items needed to outfit your store's ser vice facility , we recommend the following suppliers: T able 1 – R ecommended Equipment and Supplier[...]

7 Copyright ©2001 Liberty Group Service & Repair Manual s e c t i o n 2 s e c t i o n Ex ternal 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. NO TE : A green discoloration positiv ely indicates that mois- ture [...]

8 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage Dis as sembl y Procedures s e c t i o n 3 s e c t i o n Dis as sembl y Procedures Gener al 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 fi[...]

9 Copyright ©2001 Liberty Group Service & Repair Manual Fig. 1 –␣ Serial Number Location Fig. 2 –␣ O-ring RemovaL CA UTION : Whene ver possib le, use only plastic or br ass O- ring tools for remo ving O-rings in order to prev ent damage to the sealing surf ace. Steel instruments, such as dental picks , can easily damage the sealing sur[...]

10 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage Fig. 3 – Orifice Removal Fig. 4 – Orifice Inspection Fig. 5 – Genesis Rim Clamp NO TE : The orifice is O-r ing sealed and will remain inside the inlet coupling after perf or ming the abo ve step . The fol- lowing step m ust be performed correctly in order to remov e the orifice[...]

11 Copyright ©2001 Liberty Group Service & Repair Manual Fig. 6 – Cover Ring Removal Fig. 7 – Genesis Pop p et Drive T ool Fig. 8 – Disassembly of Pop p et CA UTION: Do not ov er-tighten the vise. Doing so ma y permanently distor t or fracture the co v er ring and the case, requiring their replacement. c. When the cover ring is held secu[...]

12 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage 19. Using the O-ring pick that is provided in the Select Kit, lightly pierce the center of the LP seat(8) and pull it out of the head of the poppet. Discard the seat and do not attempt to reuse. 20. Remove the exhaust tee(13) from the second stage case to expose the exhaust valve(15)[...]

13 Copyright ©2001 Liberty Group Service & Repair Manual Atlas Second Stage Only: 22. Stand the case upside down with the mouthpiece tube facing for ward. W edge the tip of a 2mm screwdriver (provided in the Genesis Select Kit) against one end of the retaining ring(11a) to prevent it from rotating around the groove of the dive/pre-dive switch([...]

14 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage Cleaning Procedures s e c t i o n 4 s e c t i o n Cleaning Procedures A cidic Cleaning Procedure (F or Equipment Used With Compres sed Air) Introduction This procedure provides complete instructions for cleaning reusable, non-wearing components and parts of regulators and valves used[...]

15 Copyright ©2001 Liberty Group Service & Repair Manual STEP 1 – Degrease & Pre-Scrub: ▼ All reusable non-wearing parts, both plastic and metal, should first be soaked and washed in a solution of 1 quart warm (100º F) water mixed with 3-4 tablespoons of household dish soap (Dawn ® or Joy ® are recommended). This will loosen and hel[...]

16 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage CA UTION : Harsh acids, such as muriatic acid, ma y cause damage to par ts and must be strictly av oided. Undiluted white vinegar , although less eff ective , is the only recommended substitute f or LFW ™ . STEP 4 – Neutralizing Bath: ▼ Thoroughly mix 8 cup sodium bicarbonate ([...]

17 Copyright ©2001 Liberty Group Service & Repair Manual EAN/Nitrox Cleaning Procedure (F or Equipment Used With Oxygen Enriched Air) Introduction Genesis Scuba regulators may be upgraded for dedicated use with mixtures of oxygen enriched air (EAN/Nitrox), not exceeding 40% oxy- gen. This upgrade must only be perfor med by an Authorized Genesi[...]

18 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage EAN/Nitrox Cleaning is a four step procedure that includes: ▼ Pre-Cleaning with Ultrasonic Acid Bath ▼ Ultrasonic Aqueous Cleaning Bath ▼ Distilled or Demineralized W ater Rinse ▼ Final Inspection (direct light, ultraviolet, and wipe test) NO TE: Although second stage compone[...]

19 Copyright ©2001 Liberty Group Service & Repair Manual NO TE: All tools and fixtures , including the ultrasonic cleaner well, m ust be kept completely clean of an y contaminants. F or this reason, a sepa- rate set of clean tools should be used f or the reassemb ly of enriched air equipment, diff erent from those used f or nor mal air equipme[...]

20 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage 1. Place the par ts inside a clean dip basket and lower the basket into the tank of a separate ultrasonic cleaner which contains an approved aqueous cleaning solution. (Refer to T able 1 for an approved and recommended solution, and follow the manufacturer’ s instructions for dilut[...]

21 Copyright ©2001 Liberty Group Service & Repair Manual Final Inspection: When each part has been completely cleaned and dried, it must be closely inspected to ensure the total absence of contamination or cleaner residue. In the event that contamination is still found during inspection, it may be necessar y to re-clean the par t. Inspection i[...]

22 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage LOW PRESSURE HOSE ASSEMBLIES 1. Ultrasonically clean both hose fittings by dipping only the hose ends in the LFW ™ acid bath, and rinse thoroughly in distilled water . 2. Inspect each fitting to ensure that all scale and corrosion is removed, and re-clean if necessar y , using a sm[...]

23 Copyright ©2001 Liberty Group Service & Repair Manual ▼ Set the O-rings aside on a perfectly clean sur face that is covered with cellophane. Do not use lubricant that appears to be contaminated with any particulate matter or other foreign debris. CA UTION : The use of aerosol spra y or petroleum based lubricants must be strictly av oided.[...]

24 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage R eas sembl y Procedures R eas sembl y Procedures s e c t i o n 5 s e c t i o n Gener al Guidelines ▼ Refer to the schematic parts list, that highlights automatic replacement parts (ARP) which should be discarded and replaced with new during reassembly . ARP parts are provided in t[...]

25 Copyright ©2001 Liberty Group Service & Repair Manual Fig. 13 – Atlas Retaining Ring Installation W ARNING : DO NO T attempt to use any other manuf acturer’ s par t as a substitute for an y Genesis par t, regardless of any similarity in shape, siz e, or appear ance. Doing so ma y render the product unsaf e, and could result in serious i[...]

26 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage Fig. 15 – Pop p et Installation Fig. 16 – Locknut Installation Fig. 17 – Orifice Installation 7. Fit the LP seat(8) into the head of the poppet(9) with the smooth side facing out. Ensure that it is seated flush with the inner rim of the poppet. DO NOT use adhesive. 8. Stand the[...]

27 Copyright ©2001 Liberty Group Service & Repair Manual 16. Apply a medium blade screwdriver to engage the slotted head of the orifice, and turn it clockwise approximately 5 full revolutions. Then, grasp the screwdriver by the shaft, rather than the handle, for best sensitivity of touch. Con- tinue turning the orifice ver y slowly while close[...]

28 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage Final T esting Procedures s e c t i o n 6 s e c t i o n Final T esting Procedures Fig. 20 - Inline Adjustment T ool w/ IP Gauge CA UTION: If the regulator has been upgraded f or use with EAN/ Nitro x, it is impor tant to pressurize and flow test the regulator using only h ydrocarbon-[...]

29 Copyright ©2001 Liberty Group Service & Repair Manual 4. Ensure that all the first stage ports ar e sealed, and connect the first stage with a filtered gas supply of 2,500-3,000 psi. Slowly open the supply valve to pressurize the regula- tor . Listen to verify that a leak can be heard from the second stage valve, and proceed to step 6. a. I[...]

30 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage end wrench to remove the inlet fitting with orifice from the second stage. Be careful to protect the exposed sealing edge of the orifice. d. Fasten the Poppet Drive T ool (PN 20-640-100) onto the second stage inlet, and engage the driver with the head of the poppet. e. While holding [...]

31 Copyright ©2001 Liberty Group Service & Repair Manual ▼ A properly ser viced and adjusted regulator should deliver air upon deep inhalation without excessive inhalation effort, freeflow , or vibration. When exhaling, there should be no resistance or sticking of the exhalation valve. If any of these problems occur , refer to T able 2 - T r[...]

32 Copyright ©2001 Liberty Group Atlas & Y ukon Second Stage T able 2 – T roubleshooting Guide CA UTION: All repairs must be perf or med with a complete ov erhaul ser vice , unless the prob lem is detected immediately after a complete ov erhaul ser vice has already been perf ormed. Do not attempt to perf orm par tial ser vice if the regulato[...]

33 Copyright ©2001 Liberty Group Service & Repair Manual Schema tic & P ar ts List A tlas Second St age (EAN/Nitrox & Compres sed Air) Schema tic & P ar ts List A tlas Second St age (EAN/Nitrox & Compres sed Air) ....... PK040 - Annual Service Kit ....... GXXXX - Atlas Second Stage, Assembled 1 ....... G5240 1 Cover Ring 2 ....[...]

NOTES[...]

35 Copyright ©2001 Liberty Group Service & Repair Manual Schema tic & P ar ts List Y ukon Second St age (EAN/Nitrox & Compres sed Air) Schema tic & P ar ts List Y ukon Second St age (EAN/Nitrox & Compres sed Air) * ARP indicates Automatic Replacement Part - Provided in Annual Service Kit 1 2 3 4 5 10 9 8 7 6 11 12 13 14 15 20 1[...]