13
FLIGHT First Stage Regulator Maintenance Manual
12
FLIGHT First Stage Regulator Maintenance Manual
position.
3. Attach a MP test gauge (0 - 20 bar) to a medium pressure
hose and thread the hose into a MP port. If your test gauge
does not have an over pressure relief valve, you must also
attach a properly adjusted second stage to the rst stage
to act as the relief valve in case of a HP leak. Make sure
Blanking Plugs are installed in any open ports.
Final Assembly
1. Stretch the top of the Hood (15) over the end of the
assembled rst stage. Ensure that the spigot of the Hood ts
down the hexagonal hole of the Large Spring Adjuster (1)
and that the Hood ts without leaving any distortion.
6. Close the cylinder valve and depressurise the regulator.
Remove the test gauge and reinstall the Blanking Plug.
4. Assuming there are no leaks, close the cylinder valve and
depressurise the regulator by opening the gauge relief
valve or by pressing the purge button of the second stage
regulator. Adjust the medium pressure by turning the Large
Spring Adjuster (1) with a 10mm allen key: Turning in the
Spring Adjuster increases the MP; Turning out the Spring
Adjuster decreases the MP. Turn the Spring Adjuster in
1/8th turn increments and purge the relief valve several
times after each adjustment. When the MP is between 9 and
10 bar , purge the relief valve on and o 10-15 times. After
cycling, watch the gauge needle. The rst stage MP should
“lock-up” between 9 and 10 bar. Make any adjustments
as necessary. Allow the rst stage to stay pressurised for
several minutes and check the MP again to make sure it
remains “locked-up” between 9 and 10 bar. If the MP creeps
upward more than 0.25 bar, then there is a leak. Refer to the
troubleshooting table for possible causes.
CAUTION: If the pressure gauge rapidly exceeds
11 bar, then there is a HP leak. Quickly close the
cylinder valve and purge the regulator. Refer to the
troubleshooting table for the causes of the leak.
A pressure relief valve or down stream second
stage must be tted to prevent failure or inadequate
adjustment.
1. Attach the rst stage
(with no Blanking
Plugs tted) to a fully
charged 232 or 300
bar cylinder. Slowly
open the cylinder
valve, this will remove
any particles or
contaminants from the
rst stage.
Adjusting the First Stage
2. Install new lubricated
‘O’ rings (12,14) on all
of the Blanking Plugs
(11,13). Using a 5mm
Allen key, install all of
the Blanking Plugs into
the Valve Body.
WARNING: Compressed air can be highly explosive
and is dangerous if misused. Ensure cylinder valve is
opened slowly. Use Eye and Ear Personal Protective
Equipment when performing any tests involving
Compressed air.
5. Close the cylinder valve and depressurise the regulator by
opening the gauge relief valve or by pressing the purge
button of the second stage regulator. Close the relief valve
and repressurise the system. The MP should still read
between 9 and 10 bar. If the pressure reading is dierent
than the original setting, repeat steps 3 and 4 until the MP is
stable.
IMMERSION TEST
With the Blanking Plugs and at least one properly
adjusted second stage installed, slowly open
the cylinder valve and pressurise the rst stage.
Completely Submerge the rst stage in fresh water
and check for leaks.
NOTE: Do not confuse bubbles from trapped air with
a true air leak. If there is an air leak, bubbles will come
out in a steady constant stream.
Assuming that there are no leaks, close the cylinder valve
and depressurise the regulator. Remove the rst stage from
the valve and secure the Dust Cap (33) in place with the
Hex Axle (36). If the regulator has a DIN connection replace
the Dust Cap (26).
If a leak is detected, note the source of the leak and refer to
the troubleshooting table on page 12 for possible causes and
corrective actions.
This Ends Testing
This Ends Reassembly
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