MAINTENANCE PROCEDURE FOR AIR 2 3° GEN.

AIR 2 - 1/1 -
 MAINTENANCE PROCEDURE
FOR A.I.R 2 3RD GENERATION
WARNING: This maintenance procedure is only for appointed Scubapro technicians that
followed a complete course on equipment repair and in no case can replace a technical repair
course delivered by a Scubapro / Uwatec appointed staff.

Tools needed:
1. O ring extractor P/N 43.300.107
2. Air 2 tool P/N 43.300.201
3. Multi tool P/N 43.040.000
4. 2nd stage adjustment tool P/N 41.043.000
5. Air 2 extension tool P/N 41.044.00
6. Adjustable spanner
7. Small screw driver
8. 12 mm socket wrench
9. 1/4 " socket wrench
10. Bench vice or 2nd adjustable spanner
11. MK 20 assembly tool

DISASSEMBLY

1. Remove the quick disconnect assembly from the hose with the multi tool, maintaining the quick
coupling with the adjustable spanner.

2. With the o ring extractor, remove the o ring from the swivel end of the hose.

3. Hold the front part of the quick coupling ( it has 2 flat sides ) either in the bench vice or with the
2nd adjustable spanner. With the other adjustable spanner, disassemble the coupling.

4. Remove the housing, the 2 springs, the poppet, the sleeve, the body and the balls. With the o
ring extractor remove the seal from the body.

5. Carefully insert the small screw driver in the central slot of the cover facing the safety pin ( taking
care not to puncture the diaphragm ) and push the safety pin out. Remove the safety pin.

6. Unscrew the cover with the Air 2 tool, remove the diaphragm ring and the diaphragm.

7. Rotate the retaining ring of the inlet tube with the small screw driver to free the ring and remove
it.

8. Slowly push the inlet tube to remove the demand valve assembly out of the Air 2 housing.

9. Unscrew by hand the inlet tube from the poppet housing. If hard to unscrew, use the 2 adjustable
spanners.

AIR 2 - 2/2 -
10. Carefully pull out the orifice from the inlet tube. Remove the o ring from the orifice with the o ring
extractor.

11. With the o ring extractor, remove the 2 o rings from the inlet tube.

12. Use the 1/4 " socket wrench to unscrew the nylock nut, remove the small washer and the lever.

13. On the other side, remove the poppet assembly, the small washer, the spring and the housing
insert.

14. Split apart the poppet assembly into the following parts: the seat, the stem and the poppet.

15. Unscrew the exhaust cover and the inflator plug with the Air 2 tool.

16. Remove the o ring from the groove under the inflator plug. With the small screw driver, unscrew
the inflator seat assembly. Remove the o ring from the seat assembly with the o ring extractor.
Remove the inflator button and spring. Remove the o ring from the shaft of the inflator button with
the o ring extractor.

17. With the Air 2 tool, unscrew the spider exhaust retainer. Remove the neoprene washer found
under the spider retainer. It is not compulsory to remove the exhaust valve from the spider
retainer as long as the exhaust valve is in good condition and sits perfectly without any
distortion.

18. With the 1/4 " socket wrench, unscrew the nut retaining the double action exhaust valve and
remove it. On the other side, remove the purge button, the spring the washer and the o ring.

19. Remove the mouthpiece by either cutting the strap or opening the quick removable mouthpiece
clip.

PARTS CLEANING

WARNING: Refer to the parts cleaning procedure.

ASSEMBLY

After careful inspection of all the cleaned parts and the static o rings that do not need replacement,
prepare all the parts that need to be changed at every annual service.

a. P/N 01.050.132 the interstage pressure hose o ring

1. Place the o ring P/N 01.050.132 on the interstage pressure hose using the o ring extractor tool
and grease slightly.

AIR 2 - 3/3 -
2. Grease the 3 holes of the quick coupling before inserting the 3 balls to keep them in position.

3. Place the seal in position, then slightly grease the poppet and place it inside the seal.

4. Place this assembly into the sleeve then insert the big spring between the 2 parts.

5. Place the small end of the conical spring on the poppet.

6. Slightly grease the threads of the housing before assembling the coupling. Do not over torque (
hand tight then 1/16 turn with the adjustable spanner )

7. Slightly grease the purge button shaft. Fit the spring then the washer then the o ring P/N
01.050.126. Place this assembly in the body of the Air 2.

8. Turn round the Air 2 and place the double action exhaust valve and then thread the nut. Tighten
very lightly ( 0.3 Newton / meter ) with the 1/4 " socket.

9. If the exhaust valve was removed from the spider retainer, fit a new exhaust valve P/N
11.109.122. It is important to trim the excess silicone " tail " of the exhaust valve with a
pair of scissors. Not doing so will prevent oral inflation of the jacket.

10. Place the rubber seal in position then screw snug with the Air 2 tool the spider exhaust
assembly.

11. Fit the exhaust cover and tighten lightly.

12. Place on the inflator button shaft the o ring P/N 01.050.117 and slightly lubricate. Fit the spring on
the shaft and place this assembly in the body of the Air 2.

13. Assemble the o ring P/N 01.050.117 on the seat retainer ( do not grease ).

14. Screw this assembly on the shaft of the inflator button. Tighten very slightly ( 0.3 Newton / meter )

15. Place the o ring P/N 01.050.161 in the groove then lightly screw the plug with the Air 2 tool.

16. Place the 2 o rings on the inlet tube with the help of the o ring extractor and slightly grease.

17. Place the o ring on the adjustable orifice and slightly grease the threads and the o ring before
inserting this assembly in the inlet tube.

18. Put the valve stem in the poppet and place the seat in the recess and press on a flat surface to
secure. ( No glue should be used to hold the seat on the seat retainer )

19. Insert the washer P/N 11.500.029 on the poppet stem then place the spring.
Insert this assembly into the housing. Fix the MK 20 assembly tool in a vice with the hollow side
facing up. Push the housing down on the MK 20 assembly tool to expose sufficient shaft length
to place the housing insert on the housing, then the lever, then the washer. ( note: the lever
should be placed on the left of the housing when the flat surface of the housing faces the
technician ) and finally the nylock nut.

20. Screw the nylock nut with the 1/4 " socket wrench until the shaft of the poppet sticks out of the
nut by approximately 2.0 to 2.5 mm.

21. Slowly screw the inlet tube with the orifice in position in the poppet housing assembly. Make sure
the inlet tube is completely hand screwed in order to obtain alignment of the 2 flat parts.

AIR 2 - 4/4 -
 Sometimes it is needed to back up slightly to achieve alignment. (During this operation, to
preserve the seat, it is recommended to push down the lever ).

22. Fit the complete inlet tube assembly in the body. Place the retaining ring and immediately rotate
it to secure.

23. Place the diaphragm in position then the diaphragm ring ( note: the flattest part of the diaphragm
ring should be in contact with diaphragm ).

24. Screw the cover with the Air 2 tool to align the safety pin holes then insert the safety pin.

25. Place back the mouthpiece with a new strap or with the quick removable clip.

THE A.I.R 2 IS NOW READY FOR THE ADJUSTMENT PHASE

ADJUSTMENT PHASE

1. Connect the interstage pressure hose of the Air 2 to a well maintained 1st stage mounted on a full
tank. ( It is important to have a 1st stage delivering a stable interstage pressure not
exceeding 10 bars for adjustment ).

2. Screw the Air 2 extension tool on the 2nd stage adjustment tool.

3. Connect the interstage pressure hose to the adjustment tool assembly. Insert and connect the
quick coupling and slowly open the tank valve.

4. Two situations can be found a) The regulator part leaks, b) The regulator part does not leak.

5. A) If the regulator part leaks, slowly turn clockwise the knob of the adjustment tool until the leak
stops. Cycle several times the regulator part by pushing on the purge and check for a leak. If a
small leak persists, screw slowly clockwise the adjustment knob of the tool to stop the leak and
cycle the regulator part again. If the leak has stopped, the regulator part of the Air 2 is perfectly
adjusted.

6. B) If the regulator part does not leak, slowly unscrew the adjustment knob until a leak is detected,
then proceed turning clockwise by 1/16 turn and cycling several times between each adjustment
until the leak stops. The regulator part of the Air 2 is now perfectly adjusted.

7. Close the tank valve and purge before removing the adjustment tool assembly and connect the
interstage pressure hose to the quick coupling after slight lubrication of the threads and using the
multi tool and the adjustable spanner.

8. Pressurise the system ( only when the Air 2 is connected to the hose ). Check if there is no
air leak between the female quick coupling and the hose. Check also for a leak from the seal
inside the female quick coupling. If a leak is detected, locate it and either a) change the hose o
ring or b) change the seal PN 21.009.112.

9. Cycle a few times the inflator by pushing a few times on the inflator button slowly at first then
completely. Check if the flow is progressive and high.

10. Check the exhaust valve by completely inflating a jacket and immersing the inflator in water to
detect any leak coming from the mouthpiece or from under the purge button. In case of a leak,
change the o ring P/N 01.050.126 or the double action seal P/N 21.080.004.

AIR 2 - 5/5 -