Atlas & Yukon (Part Numbers GRXXX & ) Second Stage SERVICE & REPAIR GUIDE
Contents Introduction ............................................................................ 3 About This Manual .........................................................................3 Scheduled Service ....................................................................................... 3 EAN/ Nitrox Service .................................................................................... 3 Use of Warnings, Cautions, & Notes ........................................................
Service & Repair Manual About This Manual 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.
Atlas & Yukon Second Stage 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: 3 2 1 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.
Service & Repair Manual 1 Facility Requirements s e c t i o n 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.
Atlas & Yukon Second Stage 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. www.scubatools.com Manufacturer of custom designed specialty tools and test fixtures Galion, OH 44833 Phone: 419-468-2212 Branson Ultrasonics www.bransoncleaning.
Service & Repair Manual 2 Preliminary Inspection s e c t i o n 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 positively 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.
Atlas & Yukon Second Stage 3 Disassembly Procedures s e c t i o n 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. ▼ All o-rings are classified as being either dynamic or static.
Service & Repair Manual CAUTION: Whenever possible, use only plastic or brass 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 surface of a softer brass part, causing irreparable leakage and requiring the part to be replaced with new. Fig. 1 –␣ Serial Number Location 1. Snip the plastic tie-strap(14) that holds the mouthpiece(12), and gently pull the mouthpiece off the second stage case(11).
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 remove 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.
Service & Repair Manual CAUTION: Do not over-tighten the vise. Doing so may permanently distort or fracture the cover ring and the case, requiring their replacement. Fig. 6 – Cover Ring Removal 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.
Atlas & Yukon 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) for inspection. CAUTION: It is important to follow the correct procedure for removing the exhaust tee.
Service & Repair Manual Atlas Second Stage Only: 22. Stand the case upside down with the mouthpiece tube facing forward. Wedge 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(11c). While holding it secure, apply the 3.5mm screwdriver to the other end of the retaining ring and press it through the mouthpiece tube (see Fig. 11). Fig. 11 – Atlas Retaining Ring Removal 23.
Atlas & Yukon Second Stage 4 Cleaning Procedures s e c t i o n Acidic Cleaning Procedure (For Equipment Used With Compressed Air) Introduction This procedure provides complete instructions for cleaning reusable, non-wearing components and parts of regulators and valves used with standard Grade E compressed air.
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 help to remove salt deposits and grime from plastic parts, and remove excessive residues of lubricant grease and grime from metal parts.
Atlas & Yukon Second Stage CAUTION: Harsh acids, such as muriatic acid, may cause damage to parts and must be strictly avoided. Undiluted white vinegar, although less effective, is the only recommended substitute for LFW™. STEP 4 – Neutralizing Bath: ▼ Thoroughly mix 8 cup sodium bicarbonate (baking soda) with one quart fresh tap water in a clean container. Remove the parts from the acid bath, and immerse in this solution for 2-3 minutes.
Service & Repair Manual EAN/Nitrox Cleaning Procedure (For 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% oxygen. This upgrade must only be performed by an Authorized Genesis Dealer, and requires the installation of the first stage Nitrox overhaul/ upgrade parts kit that is provided specifically for each model first stage regulator (refer to the schematic parts list).
Atlas & Yukon 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 Water Rinse Final Inspection (direct light, ultraviolet, and wipe test) NOTE: Although second stage components are not usually exposed to high pressure oxygen enriched air, Genesis Scuba recommends that the same cleaning and assembly procedures be followed for the complete regulator.
Service & Repair Manual NOTE: All tools and fixtures, including the ultrasonic cleaner well, must be kept completely clean of any contaminants. For this reason, a separate set of clean tools should be used for the reassembly of enriched air equipment, different from those used for normal air equipment. ACIDIC PRE-CLEANING – Before performing aqueous cleaning, parts must first be cleaned with the acidic cleaning procedure outlined on page 15 to ensure the complete removal of any corrosion or scale.
Atlas & Yukon Second Stage 1. Place the parts 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 Table 1 for an approved and recommended solution, and follow the manufacturer’s instructions for dilution rates and recommended working temperatures.
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 necessary to re-clean the part. Inspection is a critical procedure that must be performed in three consecutive steps. 1.
Atlas & Yukon 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 necessary, using a small nylon brush. 3. Run aqueous cleaning solution through the hose in both directions, checking to ensure that no foreign matter or loose material exits the hose when it is drained.
Service & Repair Manual ▼ Set the O-rings aside on a perfectly clean surface that is covered with cellophane. Do not use lubricant that appears to be contaminated with any particulate matter or other foreign debris. CAUTION: The use of aerosol spray or petroleum based lubricants must be strictly avoided. The propellant gas or petroleum base may attack or weaken plastic or rubber parts, and is not compatible with enriched air.
Atlas & Yukon Second Stage 5 Reassembly Procedures s e c t i o n General 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 the Annual Service Kit.
Service & Repair Manual WARNING: DO NOT attempt to use any other manufacturer’s part as a substitute for any Genesis part, regardless of any similarity in shape, size, or appearance. Doing so may render the product unsafe, and could result in serious injury or death. Atlas Second Stage Only (Yukon proceed to Step 5) 1. Install the O-ring(11b) onto the dive/ pre-dive switch(11c). 2.
Atlas & Yukon Second Stage 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 Poppet Drive Tool (provided in the Genesis Poppet Tool Kit – PN 20-640-100) on its knob, with the drive socket facing straight up. Index the tabs of the poppet head with the driver, and stand the poppet inside the tool with the shaft facing straight up. 9.
Service & Repair Manual observe locknut Fig. 18 – Orifice Preliminary Setting 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. Continue turning the orifice very slowly while closely observing the locknut on the end of the poppet (see Fig. 18). STOP turning the orifice when the locknut begins to move slightly.
Atlas & Yukon Second Stage 6 Final Testing Procedures s e c t i o n CAUTION: If the regulator has been upgraded for use with EAN/ Nitrox, it is important to pressurize and flow test the regulator using only hydrocarbon-free gas. The regulator will otherwise become contaminated with hydrocarbons if normal compressed air is used. Industrial grade compressed Nitrogen is strongly recommended as a less expensive alternative to EAN/ Nitrox for the purposes of flow testing. 1.
Service & Repair Manual 4. Ensure that all the first stage ports are 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 regulator. Listen to verify that a leak can be heard from the second stage valve, and proceed to step 6. a. If airflow cannot be heard, it will be necessary to initiate a slight leak between the orifice and poppet.
Atlas & Yukon 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 Tool (PN 20-640-100) onto the second stage inlet, and engage the driver with the head of the poppet. e. While holding the locknut secure with the Poppet Tool Wrench, turn the knob of the Poppet Drive Tool clockwise a small fraction of a turn.
Service & Repair Manual ▼ A properly serviced 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 Table 2 - Troubleshooting. Flowbench Testing (optional) The Subjective Breathing Test, combined with the Intermediate Pressure Test, will sufficiently verify the regulator's performance in most circumstances.
Atlas & Yukon Second Stage Table 2 – Troubleshooting Guide SYMPTOM Freeflow or leakage Excessive Inhalation Resistance or Hesitation Insufficient airflow when purge button is depressed Water entering second stage POSSIBLE CAUSE TREATMENT 1. Excessive intermediate pressure. 1. Refer to first stage troubleshooting guide 2. Damaged or worn LP seat(8). 2. Replace with new. 3. Damaged orifice(5) sealing surface. 3. Replace with new. 4. Damaged orifice O-ring(4) 4. Replace with new. 5.
Service & Repair Manual Schematic & Parts List Atlas Second Stage (EAN/Nitrox & Compressed Air) 11c 12 4 5 6 7 11b 8 13 14 9 11 10 15 11a 3 17 16 2 22 21 18 20 19 1 23 Ref # PN *ARP Qty 24 Ref # PN Description ....... PK040 ....... GXXXX - Annual Service Kit Atlas Second Stage, Assembled 1 ....... G5240 2 ....... G5239-07B 3 ....... G5236 4 .......G2-010 5 .......G6621 6 ....... G4330 7 ....... G3-906 8 ....... G4340 9 ....... G4333 10 ...... G5074 11 ...... G5248 11a .....
NOTES
Service & Repair Manual Schematic & Parts List Yukon Second Stage (EAN/Nitrox & Compressed Air) 4 12 5 6 7 8 13 9 11 10 14 15 3 17 16 18 2 22 21 20 19 1 23 Ref # PN *ARP Qty 24 Ref # PN Description ....... PK040 ....... GXXXX - Annual Service Kit Atlas Second Stage, Assembled 1 ....... G5240 2 ....... G5239-07C 3 ....... G5236 4 .......G2-010 5 .......G6621 6 ....... G4330 7 ....... G3-906 8 ....... G4340 9 ....... G4333 10 ...... G5074 11 ...... G5248 12 ...... G4485-07 13 ......
