G500

MAINTENANCE PROCEDURE

G500 1/ 1
 MAINTENANCE PROCEDURE FOR G500

TOOLS NEEDED FOR REPAIR

P/N
43
04
00
00

TOOLS

OF G500
NEEDED

Quantity Part Number Description

1 43.300.228 G500 Cover Tool

1 43.300.227 G500 Balance Chamber Adjusting

Tool

1 set 43.300.017 Brass o’ring picks

1 tube 41.047.000 Christo-Lube Christo-Lube

OXYGEN COMPATIBLE LUBRICANT

P/N 41-047-000

1 47.010.000 Counter Mat

1 41.496.101 Lubricant syringe Monoject

1 43.040.000 Universal Tool

1 43.002.101 Ball-end Allen Wrench

1 41.043.000 Pneumatic Adjusting tool 100

50
150
200
USE NO OIL

psi
400
250
300

350

MADE IN THE USA

Special Tools

1 40.978.000 Blow Gun/Air Nozzle

1 Soft-bristled toothbrush

1 43.300.225 Viva flow vane remover

ICON LEGEND

Inspect carefully, replace if needed

Monoject
Lubricate properly
Replace annually
Dynamic o’ring, replace annually and lubricate properly

P/N
43

Tools needed for this step

04
00
00

TOOLS
NEEDED

G500 2/ 2
 MAINTENANCE PROCEDURE FOR G500

P/N
43
04
0 00
0

TOOLS
NEEDED

Remove hose and jam nut from the

second stage.

P/N
43
0 40
00
0

TOOLS
NEEDED

Remove the housing pin using the

brass pick or similar tool.

Use the G500 cover tool to remove the

two-piece second stage cover.

No tools needed
P/N
43
04
0 00
0
P/N

TOOLS
43
0 40
00
0
this step
TOOLS NEEDED
NEEDED

Remove the two-piece cover, 2 friction

washers and diaphragm from the
second stage housing.

P/N
43
0 40
00
0

TOOLS
NEEDED

Remove the stop clip from the cracking

effort adjustment knob.

G500 3/ 3
 No tools needed
P/N
43
0 40
00
0
this step
P/N
TOOLS 43
04
NEEDED 0 00
0

TOOLS
NEEDED

Thread out the cracking effort

adjustment knob and remove. Use
caution so that the spring and spring
pad are not lost.

Remove the air barrel and demand

lever.

P/N
43
0 40
00
0

TOOLS
NEEDED

Remove the “Dive” decal from the

cracking effort adjustment knob. This
will allow access to the balance and
anti-set mechanisms.

P/N
43
0 40
00
0

TOOLS
NEEDED

Remove the knob plug using the

universal tool.

No tools needed
P/N
43
0 40
00
0
P/N
43
04
0 00
0
this step
TOOLS
TOOLS NEEDED
NEEDED

Remove the balance chamber and

disassemble. Use caution to avoid
losing o’rings, spring, and spring pad.

G500 4/ 4
Note that there are two possible
balance chamber configurations

No tools needed
P/N
43
04
0 00
0
P/N
43
04
0 00
0
this step
TOOLS
TOOLS NEEDED
NEEDED

Carefully remove the poppet. The

poppet o’ring and seat will be replaced.

It is usually not necessary to remove

the protective sleeve from the air
barrel.

P/N
43
04
0 00
0

TOOLS
NEEDED

Use the universal tool to remove the

adjustable orifice from the air barrel.

No tools needed
P/N
43
0 40
00
0
P/N
43
this step
04
00
TOOLS 00

NEEDED TOOLS
NEEDED

Remove the adjustable orifice. Take

off the adjustable orifice o’ring, as it will
be replaced. Remove the air barrel
o’ring for inspection.
A wooden dowel or “chopstick” may be
helpful in removing the orifice.

P/N
43
0 40
00
0

TOOLS
NEEDED

This Step Is Only Performed As Needed

When it is necessary to remove the VIVA
flow vane, use the flow vane remover
inserting it through the mouthpiece.
Apply pressure gently to avoid damaging
the housing.
This step is seldom needed, unless the
VIVA flow vane o’ring is worn or damaged.

G500 5/ 5
 No tools needed
P/N
43
0 40
00
0
P/N
43
04
0 00
0
this step
TOOLS TOOLS
NEEDED NEEDED

This Step Is Only Performed As Needed

If the VIVA flow vane is removed, the

entire VIVA assembly should be replaced,
including the o’ring.

P/N
43
0 40
00
0

TOOLS
NEEDED

This Step Is Only Performed As Needed

Carefully inspect and lubricate the o’ring.

Place the new knob and vane assembly

back into the housing with the crescent-
shaped notch facing forward toward the
back of the diaphragm. Push the vane
inward until it is locked in place.

P/N
43
04
0 00
0

TOOLS
NEEDED

This Step Is Only Performed As Needed

If removal of the exhaust valve is
necessary, use the ball-end allen wrench
to push out the exhaust tee pin. Remove
the center section of the exhaust tee.
To remove the exhaust valve, grasp with
fingers and pull firmly out.
The exhaust valve will seldom need to be
replaced. Careful inspection is usually all
that is necessary. If the valve is removed
during service, it may be damaged during
the process, requiring replacement.

P/N
43
0 40
00
0

TOOLS
NEEDED

If the exhaust valve is removed, carefully

inspect and replace if necessary.

Replace the exhaust tee center section

and use the ball-end allen wrench to
replace the exhaust tee pin.

G500 6/ 6
 P/N
43
0 40
00
0

TOOLS
NEEDED

Replace and lubricate the 2 dynamic

o’rings properly. Carefully inspect and do
not lubricate the internal static o’ring and
internal thread.

P/N
43
04
0 00
0

TOOLS
NEEDED

Replace the adjustable orifice o’ring and

lubricate properly. Inspect the air barrel
o’ring and replace if necessary. Lubricate
properly.

If the protective sleeve was removed, re-

install it at this time.

Use the universal tool to turn in the

adjustable orifice all the way in, then back
it out approximately two turns.

No tools needed
P/N
43
04
0 00
0
P/N
43
04
0 00
0
this step
TOOLS TOOLS
NEEDED NEEDED

Re-install the demand lever through the

protective sleeve.

Re-insert the air barrel with the barrel

turned so that the demand lever is facing
toward the diaphragm.

P/N
43
0 40
00
0

TOOLS
NEEDED

Re-install the jam nut and tighten.

Replace the seat on the poppet, and

replace and lubricate the poppet stem
o’ring.

Install the poppet so that the “feet” are

engaged with the demand lever.

G500 7/ 7
 No tools needed
P/N
43
0 40
00
0
P/N
43
04
00
00
this step
TOOLS TOOLS
NEEDED NEEDED

Assemble the two-piece balance chamber

and insert it into the cracking effort
adjustment knob.

Loosely install the anti-set chamber into

the knob. Do not tighten completely, as
this chamber will need to be removed for
final adjustments.

No tools needed
P/N
43
04
0 00
0
P/N
43
04
00
00
this step
TOOLS TOOLS
NEEDED NEEDED

Re-install the cracking effort adjustment

knob by inserting and then threading it on
to the air barrel.
Thread inward until there is enough
clearance to install the stop clip.

Press the stop clip carefully into place.

Immediately unscrew the adjustment
knob completely.

P/N
43
04
0 00
0

TOOLS
NEEDED

Remove the plug in preparation for final

adjustment.

Use the universal tool to remove the

chamber, if necessary.

No tools needed
P/N
43
0 40
00
0
P/N
43
04
00
00
this step
TOOLS TOOLS
NEEDED NEEDED

Inspect the diaphragm for wear, and

replace if necessary.

Install the diaphragm and 2 friction

washers, being certain that the two
pieces lay flat inside the second stage
housing.

G500 8/ 8
 P/N
43
0 40
00
0

TOOLS
NEEDED

Put the two-piece cover together,

arranging the pieces so that the holes
in each piece are aligned properly.

Use the cover tool to tighten the cover,

being certain that the SCUBAPRO “S”
is properly positioned.

Install a new housing pin into the side

of the housing.

200
150 250
USE NO OIL

100 300

psi 350
50
400

MADE IN THE USA

P/N
43
04
0 00
0
R

TOOLS Special Tools

NEEDED

Pressurize the regulator.

Screw the knurled knob of the balance
chamber tool close to the maximum
limit.
Use the pneumatic adjusting tool to
adjust the orifice to reach the free flow,
and just stop the free flow.
Unscrew slowly by 1/8 turn steps the
knurled knob of the balance chamber
adjustment tool until a leak is heard.
Screw by ½ turn to stop the leak.
Come back on the pneumatic
adjustment tool and fine tune the
orifice.

200
150 250
USE NO OIL

100 300

50 psi 350
400

MADE IN THE USA

P/N
43
04
0 00
0
R

TOOLS Special Tools

NEEDED

Re-install the plug and tighten until it is

flush with the outside of the cracking
effort adjustment knob.

Make any additional adjustments using

the pneumatic adjusting tool and
balance chamber adjusting tool.

After making final air-on adjustments,

install a new “Dive” decal.

G500 9/ 9