Apeks

Second Stage Regulator

Service & Repair Manual

for Authorized Sea Quest Service Centers

©2000 Sea Quest, Inc.

Contents
Introduction .................................................................................................................................................... 3
Safety Precautions .......................................................................................................................................... 3
General Procedures ........................................................................................................................................ 3
Maintenance Schedules ............................................................................................................................ 3
Initial Inspection and Pre-Test ................................................................................................................. 3
Infrequently Used Regulators .................................................................................................................. 4
Work Area & Required Tools ................................................................................................................... 4
O-ring Removal ........................................................................................................................................ 4
Lubrication ............................................................................................................................................... 4
Table 1 – Recommended Tools....................................................................................................................... 5
Table 2 – Lubricant and Cleaner .................................................................................................................. 6
Disassembly Procedures ................................................................................................................................. 7
Cleaning & Inspection Procedures.............................................................................................................. 10
Reassembly Procedures ................................................................................................................................ 12
Final Adjustment and Testing Procedures ................................................................................................. 15
External Leak Test .................................................................................................................................. 16
Subjective Breathing Test ....................................................................................................................... 16
Table 3 – Troubleshooting ............................................................................................................................ 17
Repair & Replacement Parts ....................................................................................................................... 18
Schematic Drawing ....................................................................................................................................... 19
Apeks Regulator Service and Repair Manual 3

INTRODUCTION GENERAL PROCEDURES

Apeks regulators are the product of many years of research
MAINTENANCE SCHEDULES
and development. Apeks has utilized proven materials
and design to maximize reliability and performance. Regulators are subjected to a variety of environmental el-
This manual is intended only as a guide for the experi- ements that over time can affect the performance of the
enced repair person that has completed a Sea Quest/ Apeks product. As an Authorized Sea Quest/Apeks Dealer you
service and repair seminar. It is not intended to educate are advised to inform your staff and customer that Sea
inexperienced repair personnel or the consumer in all as- Quest/Apeks regulator require complete servicing at least
pects of Apeks regulator repair. Sea Quest/Apeks repair once a year. Under certain circumstances a complete ser-
vicing is required every 3-6 months. Some of these cir-
seminars are available periodically to Authorized Sea Quest
cumstances are:
Dealers. Servicing and repair at the repair shop level
mainly involves cleaning, inspection, adjustment, and re- ● Frequent or improper use
placement of worn parts. ● Inadequate routine freshwater rinsing

If you have any questions on any of the procedures, in- ● Regulator use in dirty or polluted waters
spections, or tests, please contact Sea Quest at:
● Rental use
(877) 253-3483. ● Regular use in chlorinated (pool) water

Recommended maintenance schedules are based on aver-

SAFETY PRECAUTIONS age use under normal conditions and assume that recom-
mended preventative maintenance and storage procedures
This manual provides step by step instructions for the dis- have been followed as outlined in the Sea Quest/Apeks
assembly, inspection, cleaning, reassembly, and testing of owner’s manuals.
the Apeks second stage regulator. It is recommended that
Advise the customer that any adjustments or servicing on
all steps are followed in the order given. Read each sec- Sea Quest/Apeks regulators must be performed by Sea
tion completely PRIOR to beginning work described in
Quest, or by an Authorized Sea Quest/Apeks Dealer that
that section. This will familiarize the repair technician
has attended a Sea Quest authorized service seminar.
with important precautions to take during each service pro-
cedure. INITIAL INSPECTION AND PRE-TEST
Pay close attention to all WARNINGS, CAUTIONS, and Prior to beginning the servicing of the regulator, a pre-
NOTES that are intended to draw your attention to items liminary inspection and pre-test of the entire breathing sys-
of importance. tem is recommended. This will help the repair technician
Definition of Warnings, Cautions, and Notes: identify any problems that may affect the second stage.
Preliminary inspection should include:
● First stage inlet filter - If the first stage inlet filter is

discolored, the entire regulator should be completely ser-

Indicates a procedure or situation that may result in viced. Deposits of rust (red powder) or aluminum oxide
serious injury or death for either the technician or (gray powder) on the filter may indicate that water has
the user if instructions are not followed correctly. entered the SCUBA cylinder and caused internal cylinder
corrosion. The customer should be notified that their
SCUBA cylinder(s) may be in need of visual inspection,
cleaning and testing. Advise your customers to regularly
Indicates any situation or technique that may result inspect the inlet filter for any discoloration or corrosion.
in potential damage to the product, or render the
● High pressure (HP) and low pressure (LP) hoses -
product unsafe if instructions are not followed cor-
rectly. Inspect the hoses carefully for any evidence of cracking,
tearing, or excessive abrasion of the outer rubber cover-
ing. Remove all of the hose protectors and examine the
Is used to emphasize important points and area around the metal fittings for any damage to the hose.
NOTE
tips. Inspect the fittings for signs of excessive corrosion.
4 Apeks Regulator Service and Repair Manual

● All chrome plated parts - Inspect for any excessive cor-

rosion indicating weak or absent chrome plating. Also look
for any signs of peeling or flaking of the chrome plating.
Do not use any petroleum based lubricants or products,
● Regulator pre-test - A regulator pre-test should include or any aerosol sprays to lubricate or clean any part or
all tests outlined in the test section for each regulator. A component of Apeks regulators. The petroleum base
pre-test will assist the technician in determining if there are or propellant gas may attack or weaken the plastic or
any specific performance deficiencies not mentioned by the rubber parts. Refer to Table 2 for approved lubricants.
customer.

INFREQUENTLY USED REGULATORS

Do not assume that the regulator is in good condition be- Apeks regulators are intended for use in water tempera-
cause of infrequent use or because it has been in storage. tures warmer than 45ºF (7ºC). Colder water may cause
Deterioration of the O-rings and corrosion can still occur regulators to be more sensitive to a freeflow condition
under these circumstances. and can lead to a situation that requires an appropriate
response to prevent serious injury or death. Users of
WORK AREA & REQUIRED TOOLS Sea Quest regulators are advised to ensure that they are
Servicing and repair of the regulator should be carried out adequately trained to deal with a regulator in a freeflow
in a clean well lighted work area. As each regulator is dis- condition or an out-of-air emergency before attempting
assembled all parts should be kept separate from parts of to dive in a cold water environment.
other regulators. Some special tools are required for proper
disassembly and reassembly. Please see Table 1 (page 5)
for a list of these tools.

O-RING REMOVAL
When removing O-rings, care must be taken to not damage
the regulator surfaces in contact with the O-rings. Tools
used to remove O-rings must not have any sharp edges or
points that could scratch metal sealing surfaces. Sea Quest
strongly recommends that all O-ring removal tools should
be made of either brass or plastic.

LUBRICATION
O-rings should be lubricated with an approved compound
(please refer to Table 2 for proper lubricants). O-rings should
be lubricated only with a very light film of grease. Do not
use spray (aerosol) lubricants under any circumstances. The
aerosol propellant may damage the plastic and rubber com-
ponents of the regulator, and the lubricant will quickly
evaporate, providing little or no lasting benefit.
Apeks Regulator Service and Repair Manual 5

TABLE 1
RECOMMENDED TOOLS - APEKS SECOND STAGES
Sea Quest Part No. Description Application

5116236 Seal/seat extractor Removal/ installation of seat crown

AT31 Case Cover Tool (TX50/40/T20) Removal/installation of case cover

AT42 Case Cover Tool (TX100) Removal/installation of case cover

N/A 5mm hex key & hex key socket Removal/installation of blanking plugs

N/A 11/16" open end wrench/ hex socket Removal/ installation of LP hose, retaining nut

N/A 0-120 inch-lbs torque wrench Small fittings

1116-10 I.P. test gauge Intermediate pressure testing

9440-22 O-ring tools O-ring removal & installation

41532 LP air nozzle Parts drying

N/A Magnifier w/ illumination Sealing surface inspection

N/A Ultrasonic cleaner - 60HZ, 1.3 amp Brass & stainless steel parts cleaning
6 Apeks Regulator Service and Repair Manual

TABLE 2
LUBRICANT AND CLEANER
Lubricant / Cleaner Recommended Type Application Source

Christo-Lube MCG-111 All O-rings, Lubrication Technologies

threaded metal parts 310 Morton Street
as indicated Jackson, OH 45640
800-477-8704

Chemical Bath Solution Chromesafe Chrome-plated brass, Sea Quest/ Aqua Lung America
brass, and stainless P/N 0201-05
steel parts

50/50 mix distilled Chrome-plated brass, Local grocery stores

white vinegar and water brass, and stainless
steel parts

Liquid dishwashing detergent Joy® General cleaning solution, Local grocery stores
(diluted with warm water) degreaser for plastic
and rubber parts,
leak detection

DO NOT use muriatic acid for the cleaning of any parts. Muriatic acid, even when strongly diluted, can
harm chrome plating, and may leave a residue that is harmful to O-ring seals and other parts.

Aerosol spray silicone should be avoided because (1) common aerosol propellants may attack plastic
and rubber parts, and (2) because only a slight amount of silicone remains after the solvent evapo-
rates, and provides no lasting benefit.

Silicone rubber requires no lubrication or preservative treatment. DO NOT apply silicone grease or
spray to silicone rubber parts. Doing so will cause a chemical breakdown and premature deteriora-
tion of the material.
Apeks Regulator Service and Repair Manual 7

DISASSEMBLY PROCEDURES

Before performing any disassembly, refer to Table 4, which

NOTE references all mandatory replacement parts. These parts must
be replaced with new, and must not be reused under any cir-
cumstances - regardless of the age of the regulator or how
much use it has received since it was last serviced.

To prevent damage to critical sealing surfaces, use only a plastic or

brass O-ring removal tool (P/N 9440-22) when removing O-rings. Once
an O-ring sealing surface has been damaged, the part must be replaced
with new in order to prevent the possibility of leakage. DO NOT use a
dental pick, or any other type of steel instrument.

1. While holding the retaining nut(2) secure at the second stage inlet
fitting with an n" open end wrench, apply a second n" open-end
wrench to the female fitting of the LP hose(16). Turn the fitting
counter-clockwise to loosen and remove the hose from the second
stage. Remove the O-rings from the hose and discard. Set the hose
aside.
2. While holding the case(11) secure, remove the exhaust tee(16) by
firmly pulling one side off and then the other.

Do not use a tool to remove the exhaust tee. Doing so may cause
serious damage to the seating flange, requiring replacement of the case.

3. Remove the exhaust valve diaphragm(12) from the case. Discard,

and do not reuse.
4. Carefully snip the mouthpiece clip(15) and remove the mouth-
piece(14) from the case(11). Inspect the mouthpiece to ensure it is
Figure 1 free of any tears or cuts that may cause leakage of water into the
second stage or other discomfort. Discard the mouthpiece or set it
Case Cover Tool Alignment aside to be reused, depending on its condition.
5. To remove the case cover, mate the two pins of the case cover tool
(P/N AT31) into the case cover with the opening aligned over the
APEKS logo at one o’clock (see Fig. 1). While holding the tool
pressed inward and securely engaged, turn the case cover counter-
clockwise to loosen and remove.
NOTE: The TX100 requires a different case cover tool (P/N
NOTE AT42) which can be mated into any two opposing slots.

6. The purge button can be removed, if cleaning or replacement is nec-

essary, by flexing two opposing arms inward while holding the case
cover between thumb and forefinger with its underside facing up
Figure 2 (see Fig. 2). Separate the spring from the button, and replace the
Removing Purge Button decal with new if needed.
8 Apeks Regulator Service and Repair Manual

7. Lift out the diaphragm cover(9) and diaphragm(10) from the case,
and closely inspect the diaphragm to ensure that it is perfectly round
and free of any tears, deterioration, or other damage. If deterioration
or damage is found, discard the diaphragm and do not reuse.
8. Turn the adjusting screw(25) completely out counter-clockwise until
it stops, either by hand for models TX100 and TX50, or with the use
of a 5mm hex key for models TX40 and T20 (see Fig. 3). This will
hold the retaining pin(18) in place when the valve module is removed
from the case.
9. Apply an 11/16” open end or box wrench to the retaining nut(2), and
turn the nut counter-clockwise to loosen and remove from the threaded Figure 3
inlet portion of the spindle. Remove either the heat exchanger or Removing Adjusting Screw (TX40/ T20)
spacer (item #3), which will slide off freely after the retaining nut has
been removed.
More recent models may contain a threaded heat exchanger or
NOTE spacer which do not require a separate retaining nut.

10. While holding the case secure and the lever(22) completely depressed,
press against the threaded inlet as needed until the valve spindle can
be grasped from the opposite side. Firmly grasp the end of the spindle
or the external adjusting screw, and pull the entire valve assembly
straight out of the case (see Fig. 4). Remove and discard the O-ring(23)
from inside the case if it did not fall off the end of the spindle.
Figure 4
Removing Valve Module

Do not attempt to remove the valve module assembly from the case
without first holding the lever depressed. Doing so may cause serious
damage to the case, lever, or shuttle valve, which will require their re-
placement.

11. Remove the venturi lever(17) from the case, if it remained inside when
the valve assembly was removed, or hold the lever depressed to re-
move it from the spindle (see Fig. 5). Remove and discard the O-
ring(13).
12. While holding the valve spindle secure and horizontal with the lever
Figure 5
facing down, turn the adjusting screw slightly clockwise to allow the
retaining pin(18) to fall out. Set the pin aside. Removing Venturi Lever

If the retaining pin does not easily fall out of the valve spindle
NOTE after the adjusting screw has been turned slightly clockwise, it
may be necessary to press it out, using the pin of the Seat
Extraction Tool (P/N 1094-36).

13. Continue to hold the valve spindle secure, and turn the adjusting screw
counter-clockwise until it has disengaged from the threads of the
spindle. Remove and discard the O-ring(25).
14. While holding the valve spindle vertical with the inlet end facing up,
lift the lever up to allow the shuttle valve(30) and counter balance
cylinder(27) to fall out of the valve spindle (see Fig. 6). Separate
these items from the spring(28) between them. Figure 6
Removing Yoke Connector
Apeks Regulator Service and Repair Manual 9

15. Closely examine the spring with a magnifier to ensure it is not dam-
aged (bent) or corroded. If any signs of damage or corrosion are
found, discard the spring and do not reuse.
16. Using a fingernail, remove the rubber seat(31) and the small O-ring(29)
from the shuttle valve. Discard both the seat and O-ring and do not
reuse.

Do not use a metallic instrument or any other tool to remove the seat or
the O-ring. Doing so may damage the shuttle valve, which could result
in a leak if the damage is undetected and the shuttle valve is not re-
placed.

17. Closely inspect the condition of the shuttle valve to check for any
signs of damage, especially at the “ears,” which engage with the le-
ver. Set the shuttle valve aside if it is found to be in reusable condi-
tion, or discard and replace it with new if damage is present.
18. While holding the spindle secure, apply a 5mm hex key to the head
of the seat crown(19) inside the threaded inlet. Turn the crown coun-
terclockwise to disengage its threads.
Because the seat crown is O-ring sealed, it will not freely exit
NOTE the valve spindle after it has been unthreaded. The following
step must be performed correctly in order to remove the crown
without damaging its delicate sealing surface.

19. When the seat crown has been unthreaded from the valve spindle,
Figure 7 carefully insert the pin of the Seat Extraction Tool through the oppo-
Removing Seat Crown site end of the valve spindle and through the opening in the center of
the crown. Gently pull the crown out, and remove and discard the O-
ring(20). (See Fig. 7.)
20. Closely examine the seat crown with the use of magnifier, checking
for any scoring, nicks, or other damage to the polished sealing sur-
face. If damage is found, discard the crown, and do not attempt to
reuse. If it is in reusable condition, set it aside on a soft surface to
prevent damage to the sealing surface.
21. Remove and discard the O-ring(23) from the valve spindle.
Do not attempt to remove the lever from the valve spindle un-
NOTE less it is suspected to be damaged. If removal is necessary,
the lever should automatically be discarded and replaced with
new, due to the damage that may result in the process of re-
moving it.

22. To remove the lever, hold one arm pressed against the side of the
valve spindle while pulling the other arm out of the opposite side.
When it has disengaged from the valve spindle, pull the other arm
out. Discard the lever and do not reuse.

This concludes the disassembly procedures.

10 Apeks Regulator Service and Repair Manual

CLEANING & INSPECTION PROCEDURES

1. All parts should be cleaned first in a warm (not over 120°F) mild soap
and water solution. Use a soft nylon bristle brush to help remove any
excess or loose contamination. After an initial warm water and soap
cleaning all parts should be thoroughly rinsed in clean fresh water
and dried with filtered low pressure (30 psig) air. After an initial
cleaning in warm soap and water solution, metal parts should be
cleaned in an ultrasonic cleaner using the appropriate ultrasonic clean-
ing solution (see Lubricant and Cleaner Table 2).
Be sure all O-rings and other rubber or plastic parts are re-
NOTE moved before cleaning in an ultrasonic cleaner or chemical bath.
Cleaning solutions may damage these components.

2. If an ultrasonic cleaner is not available, metal parts can be cleaned by

soaking the metal parts in a chemical bath solution of Chromesafe
(see Lubricant and Cleaner Table 2) and agitating gently for 3-4 min-
utes. Cleaning of metal parts can also be done by soaking in a mild
acetic solution (distilled white household vinegar) for 10-15 minutes.
Cleaning times in excess of those recommended may damage
NOTE plated parts. Never clean parts for longer than specified by the
manufacturer of the solution used. After completion of clean-
ing in any solution, thoroughly rinse parts with clean fresh water
and blow dry with low pressure (30 psig) air. Only brass, plated
brass, and stainless steel parts should be immersed in chemi-
cal cleaning solutions.

Use hand and eye protection when handling chemical cleaning solu-
tions.

3. After cleaning, all parts should be thoroughly rinsed in fresh water

and dried with filtered low pressure (30 psig) air.
Before performing any reassembly, it is important to inspect all
NOTE parts, both new and those that are being reused, to ensure that
each part is clean and free of any contamination, corrosion, or
blemish.

4. All O-rings should be replaced at every servicing. New O-rings should

be inspected for contamination and/or imperfections, and lightly
dressed with a thin film of approved lubricant prior to installation.
(See Lubricant and Cleaner Table 2.)

Do not use any petroleum based lubricants or products, or any aerosol

silicone sprays on any part of Sea Quest/ Apeks regulators. The petro-
leum base or propellant gas may attack or weaken plastic or rubber
parts. Refer to Table 2 for a list of approved lubricants.
Apeks Regulator Service and Repair Manual 11

5. In addition to the O-rings, the following parts should be routinely

replaced at the time of servicing:
● Exhaust Valve Diaphragm (12)

● Rubber Seating (31)

● Mouthpiece Clip (15)

All O-rings and the above mentioned routine replacement parts are
included in the Overhaul Service Kit (P/N APO219).
6. The following parts should be closely inspected for the damage listed
below. Close inspection is best accomplished by using strong magni-
fication under bright lighting.
● Lever (22) Compare with new to inspect for bending or distortion.
● Valve Spring (28) Inspect for signs of permanent corrosion, includ-
ing pitting or cracks in the surface of the metal.
● Seat Crown (19) Inspect the cone area for nicks, scratches, pitting,
or any defects in the plating. Pay particular attention to the sealing
edge of the cone.
● Shuttle Valve (30) Inspect for scratches or other damage, particu-
larly at the groove which holds the small O-ring, and around the "ears."
● Demand diaphragm (10) Inspect for tears or pinholes. To detect
pinholes, hold diaphragm up to a light source as you gently stretch
the diaphragm. Inspect the round plastic diaphragm plate for any
evidence of damage.
● Mouthpiece (14) Inspect for cracking or tears or any excessive wear
especially around the bite tabs.
● Case (11) Inspect for any indication of cracks or thread damage.
Closely examine the seating ledge which indexes with the poppet
housing, to ensure it is free of any distortion or other damage.
7. If any of the listed parts show any damage, they must be replaced
with new.
8. Check all metal parts for excessive wear or corrosion. Check all metal
sealing surfaces which make contact with O-rings for any signs of
contamination and/or imperfections that may cause leakage past the
O-ring seal. Examine all chrome plated surfaces for any evidence of
peeling or flaking of the chrome plating. Inspect all threads for gall-
ing, cross threading, or damage to the chrome plating. If any parts
show damage or excessive wear, they must be replaced with new.
12 Apeks Regulator Service and Repair Manual

REASSEMBLY PROCEDURES

Before performing any reassembly, it is important to inspect all

NOTE parts, both new and those that are being reused, to ensure that
every part and component is perfectly clean and free of any
dust, corrosion, or blemishes. Before dressing each O-ring
with Christo-Lube®, check to ensure it is clean, supple, and
free of any blemish.
Figure 8
Installing Lever Arm

Use only genuine Apeks parts, subassemblies, and components when-

ever assembling any Apeks product. DO NOT attempt to substitute an
Apeks 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.

1. Install the O-ring(26) into the groove on the small end of the adjust-
ing screw(25), and set the adjusting screw aside.
2. Install a new rubber seat(31) into the shuttle valve(30) by pressing
the stem inward until the lip of the seat is seated evenly on all sides.
Next, install the small O-ring(29) onto the opposite end of the shuttle
valve.
3. Fit one end of the spring(28) over the open end of the counterbalance
cylinder(27), and then insert the stem of the shuttle valve into the
opposite end. While holding these items together, press the counter-
balance cylinder and shuttle valve together, compressing the spring
slightly, so that the counterbalance cylinder seals over the small O-
Figure 9
ring on the stem of the shuttle valve.
Installing Shuttle Valve - Step 1
4. Install the O-ring(23) onto the grooved flange of the valve spindle(21).
5. If the lever(22) was removed, lay the valve spindle lengthwise with
the threaded inlet facing to the right (3 o’clock) and the outlet port
facing toward 6 o’clock (see Fig. 8). While holding the lever stand-
ing up, perpendicular to the spindle, insert one arm into one of the
square holes that are located near the flange, and then hold it securely
in place while rotating the lever slightly over the spindle until the
other arm fits into the opposite square hole. Closely examine the
shape and position of the lever to ensure that the arms have not be-
come stretched or bent during installation.
6. While holding the lever in place, stand the valve spindle vertically
with the male threaded inlet end facing down, and positioned so that
the lever faces to the right. While holding the shuttle valve and spring
by the counterbalance cylinder, align the shuttle valve above the spindle
so that the two retaining ears which engage the arms of the lever are
facing directly to the left; opposite of the lever (see Fig. 9).
7. Lift the lever completely up and hold it against the valve spindle.
Then, drop the shuttle valve and counterbalance cylinder straight down
Figure 10
inside the barrel of the spindle while being careful to avoid disturbing
the alignment of the shuttle valve (see Fig. 10). Slowly lower the Installing Shuttle Valve - Step 2
Apeks Regulator Service and Repair Manual 13

lever until the shuttle valve drops slightly, while viewing its position
through the outlet port of the spindle (see Fig. 11). Then, raise the
lever halfway up until it is perpendicular to the valve spindle.
8. Being careful to avoid disturbing the engagement of the lever with
the shuttle valve, lay the valve spindle horizontal with the lever fac-
ing up. While holding the spindle secure, mate the adjusting screw
into the open end of the spindle, and hold it pressed inward while
turning it clockwise until the threads are engaged.
Watch to ensure that the lever rises initially as the adjusting
NOTE screw is installed into the valve spindle. If the lever does not
rise, the arms are not properly engaged with the shuttle valve.
Disassemble and repeat steps 6-8 before proceeding.
Figure 11
Installing Shuttle Valve - Step 3 9. Insert the retaining pin(18) into the valve spindle, near the grooved
flange. Hold it centered in place, and then turn the adjusting screw
completely out counter-clockwise until it stops. This will hold the
pin securely in place to prevent it from falling out while installing the
valve module into the case.
10. Install the O-ring(13) onto the venturi lever(17).
11. While holding the valve lever depressed against the spindle, fit the
venturi lever over the threaded inlet with the plastic lever facing to-
ward the adjusting screw. Gently pass it over the spindle until it is
seated against the opposite end, and then slowly release the valve
lever to prevent it from springing up.

Figure 12
Installing Seat Crown
Be careful not to turn the external adjusting screw while installing the
venturi lever onto the valve spindle. It is very important to keep the
screw turned completely out counter-clockwise, in order to hold the
retaining pin in place.

12. Install the O-ring(20) onto the seat crown(19), and carefully insert
the threaded end of the crown into the inlet end of the valve spindle.
Gently press it in further with the blunt end of the seat extraction tool
(P/N 1094-36) until it stops (see Fig. 12).
13. Apply a 5mm hex key to the head of the seat crown, and turn the
crown clockwise to engage the threads. Continue turning the crown
Figure 13 clockwise only until the lever begins to drop slightly.
Installing Valve Module 14. Orient the case with the exhaust valve facing down, at 6 o’clock. While
holding the lever depressed, guide the inlet end of the valve spindle
through the opening in the right side of the case and into the opening
on the opposite side, until the lever can stand up (see Fig. 13). Check
to ensure that the venturi lever is correctly aligned to fit in its groove
outside the case, and the valve lever is facing straight up. Carefully
guide the valve spindle completely to the left until the flange is seated
flush against the inside of the case, and the arms of the lever are posi-
tioned inside the retaining tabs on either side (see Fig. 14).
15. While holding the valve module securely seated inside the case, fit
Figure 14 the O-ring(4) down over the threaded inlet of the valve spindle.
Correct Index of Valve Spindle w/ Case
14 Apeks Regulator Service and Repair Manual

16. Fit either the spacer or the large diameter end of the heat exchanger
(item #3) over the threaded inlet of the spindle, and then thread the
retaining nut(2) clockwise by hand onto the spindle until it is finger
snug. Check again to ensure that the valve module is held secure
inside the case with the flange and lever arms fitted inside the retain-
ing tabs. Then, apply a torque wrench with n" socket to tighten the
retaining nut (or the hex fitting of a newer revision spacer/ heat ex-
changer) to a torque measurement of 50 inch-lbs.
17. Check the height of the lever to ensure that it stands perfectly level
with the rim of the case, with a slight freeplay that does not exceed
1.0 mm. If necessary, apply a 5mm hex key to adjust the seat crown
as needed to raise or lower the lever until it is level with the case rim.
18. Install the exhaust valve diaphragm(12) into the box bottom by gen-
tly pulling the stem through the hole in the center of the support spokes,
until the barb has passed through and is securely seated against the
opposite side. Gently turn the diaphragm outside the case to position
the rib perfectly horizontal. Then, carefully snip off the excess mate-
rial of the stem inside the case with a small pair of scissors.
19. Install the exhaust tee(16) onto the case by fitting it over one upper
corner of the seating flange and then stretching it over the other. Firmly
press the lower portion of the tee onto the flange until it is completely
seated.
20. Install the diaphragm(10) into the case with its raised center facing
up, and check to ensure it is evenly seated onto the shoulder at the
base of the threads.
21. Place the diaphragm cover(9) over the diaphragm with the support
cone facing up, and press it down to ensure that it seated evenly on all
sides.
22. If the purge button(6) was disassembled from the case cover(8), fit
the spring(7) over the four tabs of the purge button with the smaller
diameter end facing down. Then, position the purge button inside the
front of the case cover so that the logos on the decal and the cover are
correctly aligned with each other. Press the purge button into place
so that all four mating tabs are seated inside of the case cover.
23. Mate the case cover onto the case, and turn it clockwise by hand until
snug. Apply the case cover tool (P/N AT31 or AT42) to tighten it
further until the purge button logo is properly aligned.
24. Install the mouthpiece(14) onto the box bottom, and lightly fasten a
clamp(15) onto the groove of the mouthpiece. Turn the clamp so that
the locking tab is facing toward the inlet side of the box bottom, and
pull the clamp sufficiently snug. Snip the extra length with a small
pair of scissors or wire cutters.

This concludes the reassembly of the second stage. Refer directly

to the following section, titled Final Adjustment & Testing.
Apeks Regulator Service and Repair Manual 15

FINAL ADJUSTMENT AND TESTING PROCEDURES

Prior to adjusting and testing the Apeks second stage regulator, the
accompanying first stage must be correctly serviced, adjusted to a stable
intermediate pressure of 140 psi , and fully tested. Refer to the corre-
sponding first stage service procedures before attempting to perform
the adjustment and testing of the second stage.

Figure 15 1. Thread the male fitting of the IP hose into the preferred low pressure
port of the first stage, and apply a torque wrench with n" crow-foot
Venturi Lever "MIN" Setting to tighten to 40 inch-pounds (±2).
2. Turn the second stage adjustment screw completely out counter-clock-
wise, and set the venturi lever to the "MIN" position (see Fig. X).
3. Connect the first stage to a filtered air source of 3,000 psi.
4. Turn the second stage adjustment screw exactly one full turn (360º)
clockwise.
5. Slowly open the air supply valve to fully pressurize the regulator.
a. If airflow can immediately be heard when the regulator is pres-
surized, depressurize and purge the system. Disconnect the IP
hose and remove the case cover, diaphragm cover, and diaphragm
to re-check the height of the lever. The lever should be set at a
height level with the rim of the case, with approximately 1.0 mm
Minimum free movement freeplay (see Fig. 16). If the lever is set too low or too high,
Lever set correctly apply a 5mm hex key through the inlet to adjust the crown seat –
either counter-clockwise to raise or clockwise to lower the lever.
case rim
When the lever is set correctly, re-install the diaphragm, diaphragm
0–1.0 mm

cover, and case cover, and connect the IP hose to the second stage.
6. When no airflow can be heard after the regulator has been pressur-
ized, slowly depress the purge button to verify whether a strong air-
flow can be initiated when the button has traveled no more than 2mm.
Excessive free movement

If a strong purge cannot be initiated by depressing the purge

Lever set too low
NOTE button a maximum distance of 2mm, it will be necessary to
adjust the seat crown slightly counter-clockwise. Excessive
case rim
travel of the purge button indicates that the lever is set too low.

7. Depress the purge button sharply several times to ensure that leakage
or freeflow does not occur.
Zero free movement

Lever set too high If a slight leak occurs after sharply purging the second stage, it
NOTE will be necessary to adjust the seat crown slightly clockwise,
being careful to adust only as far as needed to create a seal
case rim
between the seat crown and rubber seating, without raising the
lever too high.

8. Move the venturi lever to the "MAX" position and depress the purge
button sharply. This should initiate a strong, continuous freeflow that
Figure 16 can be eliminated by turning the venturi lever back to the "MIN"
Relationship between seat crown and position.
lever height adjustment
16 Apeks Regulator Service and Repair Manual

9. To test the setting of the seat crown, turn the second stage adjustment
screw completely out counter-clockwise to initiate a slight flow of
air, and then slowly turn it back in clockwise to verify that the airflow
has stopped completely before it has been turned 1 full turn. If more
than 1 turn is required to shut off the airflow, it will be necessary to
readjust the crown as described in step 5.
10. When all adjustments have been satisfactorily performed, apply a
torque wrench with n" crow-foot to tighten the IP hose fitting to a
torque measurement of 40 inch-lbs (±3).
EXTERNAL LEAK TEST
1. After disconnecting the regulator from the flow bench, connect to a
scuba cylinder filled to approximately 3,000 psi. Open the cylinder
valve to repressurize the regulator, and submerge the entire system in
a test tank of clean water.
2. Observe any bubbles arising from the submerged regulator over a one
minute period. The recommended time is necessary due to slower
bubble formation that occurs in smaller leaks. Bubbles indicate a
leak, which requires that the system must be disassembled at the source
to check sealing surfaces, assembly sequence and component posi-
tioning in order to correct the problem(s).
Bubble streams will indicate the source of the leak. Before dis-
NOTE assembling to correct any leaks, rinse the entire regulator thor-
oughly with fresh water and blow out all residual moisture with
filtered, low-pressure (50 psi) air. Disassemble and remedy
the problem, referring to Table 1 - Troubleshooting.

SUBJECTIVE BREATHING TEST

1. While the regulator is connected to a cylinder containing 3,000 psi
and pressurized, turn the second stage adjustment knob completely
out counterclockwise to the full positive position, and verify that a
slight leak of airflow is present.
2. Slowly turn the adjustment knob in clockwise to verify that the air-
flow stops between 2-1 turn.
3. Turn the adjustment knob completely in clockwise, and depress the
second stage purge to ensure that an adequate volume of air needed to
clear the second stage flows through the mouthpiece..
4. Turn the adjustment knob back to 2-1 turn negative, and breathe from
the second stage. A properly serviced and adjusted regulator should
deliver air upon deep inhalation without excessive inhalation effort,
freeflow, or “fluttering” of the second-stage diaphragm. When ex-
haling, there should be no fluttering or sticking of the exhalation valve.
If any of these problems occur, refer to Table 3 - Troubleshooting.

This concludes the annual service procedures for

Apeks Second Stage Regulators.
Apeks Regulator Service and Repair Manual 17

TABLE 3 – APEKS SECOND STAGE TROUBLESHOOTING

SYMPTOM CAUSE ACTION REQUIRED
Leakage or freeflow from 1. High first-stage intermediate pressure. 1. Refer to first-stage Troubleshoot-
second stage (should be 140 ±5 psi) ing Guide.
2. Rubber seating(31) damaged or worn. 2. Replace rubber seating
3. Seat crown(19) incorrectly adjusted, 3. Reset crown and perform Final
lever(22) set too high. Tuning & Testing procedures.
4. Seat crown(19) sealing surface damaged. 4. Replace seat crown.
5. Valve spring(28) damaged. 5. Replace poppet spring.

Low purge or excessive work 1. Low intermediate pressure. 1. Refer to first-stage Troubleshoot-
of breathing (full cylinder) (should be 140 ±5 psi) ing Guide.
2. Lever(22) not properly engaged with 2. Disassemble and inspect condi-
shuttle valve(30). tion of shuttle valve and lever.
3. Seat crown(19) incorrectly adjusted, 3. Reset crown and perform Final
lever(22) set too low. Tuning & Testing procedures.
4. Intermediate pressure hose 4. Clean or replace hose.
clogged or obstructed.

External air leakage 1. Intermediate pressure hose loose. 1. Tighten to 40 inch-lbs at female
(Immersion Test) second-stage fitting.
2. Seat crown O-ring(20) damaged. 2. Disassemble and replace O-ring.
3. Case(11) damaged. 3. Disassemble and replace case.

Water entering second-stage 1. Hole in mouthpiece(14). 1. Replace mouthpiece.

2. Demand diaphragm(10) damaged. 2. Replace demand diaphragm.
3. Exhaust valve diaphragm(12) damaged. 3. Replace exhaust valve diaphragm.
4. Venture lever O-ring(13) 4. Disassemble and replace O-ring.
dirty, damaged, or worn.
5. Case(11) damaged. 5. Disassemble and replace case.
(Check exhaust valve sealing surface.)
6. Valve spindle O-ring(4) damaged. 6. Disassemble and replace O-ring.

Recommended treatments which require disassembly of the regulator must be performed during
a complete overhaul, according to the prescribed procedures for scheduled, annual service. Do
not attempt to perform partial service. For assistance with a problem not described here, contact
a Sea Quest Technical Advisor.
18 Apeks Regulator Service and Repair Manual

REGULATOR REPAIR AND REPLACEMENT PARTS

APEKS SECOND STAGES

Item Description Part # Item Description Part #

1 Deflector AP2037 14 Comfo-Bite Mouthpiece 109438

2 Nut - TX100 AP2031/S 15 Mouthpiece Clip 104913
Nut - TX50/40, T20 AP2031 16 Exhaust Tee AP2040
3 Heat Exchanger - TX100 AP5013/S 17 Venturi Lever - TX100 AP5339
Heat Exchanger - TX50/40 AP5013 Venturi Lever - TX50/40, T20 AP2039
Spacer - T20 AP5003 18 Spring Pin AP1151
Heat Exch., Threaded - TX50/40 *AP5002 19 Seat Crown AP2033
Heat Exch., Threaded - TX100 *AP5013 20 O-ring AP1154
Spacer, Threaded - T20 *AP5003 21 Valve Spindle - TX100 AP2028/S
4 O-ring AP1267 Valve Spindle - TX50/40, T20 AP2028
5 Decal - TX100 AP5015 22 Lever AP2035
Decal - TX50 AP5004/1 23 O-ring AP1267
Decal - TX40 AP5004/2 24 Plug - TX100/50/40 AP2030
Decal - T20 AP5004/3 25 Adjusting Screw - TX100 AP2029/2S
6 Purge Button AP2053 Adjusting Screw - TX50 AP2029
7 Spring AP2020 Adjusting Screw - TX40/T20 AP2029/1
8 Case Cover - TX100 AP5326 26 O-ring AP1409
Case Cover - TX50/40, T20 AP2026 27 Counter Balance Cylinder AP2038
9 Diaphragm Cover AP2025 28 Valve Spring AP2021
10 Diaphragm AP2023 29 O-ring AP2041
11 Case AP5001 30 Shuttle Valve AP2036
12 Exhaust Valve Diaphragm AP1429 31 Rubber Seating AP2034
13 O-ring AP1438
n/s Overhaul Service Kit APO219

Items in bold are included in the Overhaul Service Kit

Apeks Regulator Service and Repair Manual 19

Apeks Second Stages

Schematic
* NOTE: Apeks has recently introduced a new
heat exchanger and spacer which feature a
threaded fitting, and do not require a hex nut (item #2).
15
1
14

2
3a *4 16

17
3b *

8
11
12 13

10

9
18

19
8 20
7 21
31 22
6 23
5 30
29
28
27
26
25a

24
25b