II stage R2 Ice/ Special, II stage R 1 Pro

DOWNSTREAM 2nd STAGE REGULATOR

Service and Repair Manual

Introduction Safety Precautions ……………………………………………………....4
General Procedures, Maintenance Schedules ………………………………….…..5
Initial Inspection and Pre-Test…………………………………………………………6
Infrequently Used Regulators Work Area & Required Tools O-ring Remove a
Lubrication………………………………………………………………………….…….8
Table 1 Recommended Tools…………………………………………………….……9
Table 2 Lubricant and Cleaner……………………………………………………….10
Table 3 II stage R2 Ice/Special Schematic Drawing… ……………………….….11
Table 4 II stage R1 Pro Schematic Drawing and list ……………………...….12
Disassembly Procedures……………………………………………………...………13
Cleaning & Inspection Procedures ……………………………………………….….22
Reassembly Procedures ………………………………………………………..……25
Final Adjustment and Testing Procedures …………………………………….……28

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Final Assembly ………………………………………………………………………...30
Table 5 Troubleshooting ………………………………………………….…….….…31

INTRODUCTION
Scubatech regulators are the products of many years of research and
development. Scubatech has utilized proven materials and design to maximize
reliability and performance. This manual is intended only as a guide for the
experienced repair person that has completed a Scubatech service and repair
seminar. It is not intended to educate inexperienced repair personnel or the
consumer in all aspects of Scubatech regulator repair. Scubatech repair seminars
are available periodically to Scubatech Dealers. Servicing and repair at the repair
shop level mainly involves cleaning, inspection, adjustment, and replacement of
worn parts.
If you have any questions on any of the procedures, inspections, or tests, please
contact Scubatech Sp. Z O.O.:
TEL: (+48) 91-453-00-17.
FAX: (+48) 91-453-00-17

SAFETY PRECAUTIONS
This manual provides step by step instructions for the disassembly, inspection,
cleaning, reassembly, and testing of the Scubatech II stage R2 Ice/Special, II
stage R1 Pro 2ed stage regulator. It is recommended that all steps are followed
in the order given. Read each section completely PRIOR to beginning work
described in that section. This will familiarize the repair technician with important
precautions to take during each service procedure. Pay close attention to all
WARNINGS, CAUTIONS, and NOTES that are intended to draw your attention to
items of importance.

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Definition of Warnings, Cautions, and Notes:

GENERAL PROCEDURES
MAINTENANCE SCHEDULES
Regulators are subjected to a variety of environmental elements that over
time can affect the performance of the product. As an Scubatech Dealer you are
advised to inform your staff and customer that Scubatech regulator require
complete servicing at least once a year. Under certain circumstances a complete
servicing is required every 3-6 months. Some of these circumstances are:
Frequent or improper use
Inadequate routine freshwater rinsing
Regulator use in dirty or polluted waters
Rental use
Regular use in chlorinated (pool) water

Recommended maintenance schedules are based on average use under

normal conditions and assume that recommended preventative maintenance and
storage procedures have been followed as outlined in the Scubatech owner’ s
manuals. Advise the customer that any adjustments or servicing on Scubatech
regulators must be performed by Scubatech, or by an Scubatech Dealer that has
attended a Scubatech service seminar.

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Pre Test – Before Disassembly:

First stage IP – high/low tank pressure test – sweep and drift.

2ed stage cracking effort at 9,0-10bar IP.
Primary preset: 32-
32-42 (mm of water)
Octopus preset: 35-47 (mm of water)

Disassemble – Forethought Preparation.

Preparation.

Check existing orifice depth.
Mean the full set of the LP seat and Orifice, the depth of the set be
determined by the Orifice profile (Shape end).

Check existing nylon insert nut location
The nylon insert should lock the poppet well. If the nylon insert cannot work
or loosing, should replace a new nylon insert nut.

Disassembly procedures
Step1:
Step1:
Remove the Cover ring, PU cover (some of types are the solid front cover with
spring purge button) and Diaphragm form Main housing, and set aside. Use the
P92 Inline tool adjustment install into the II stage R1 Pro hose inlet end, turn the
P92 counter-clockwise to loosen the Orifice for the Coupling.

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Step2:
Apply a 19mm Hex key socket on the coupling, turn counter-clockwise to loosen
the coupling. Remove and discard the static O-ring from the coupling. Separate
the Orifice form coupling.

Step3:
Step3-1: for II stage R1 Pro
Remove the Side Plug form Main Housing (Press the snap and push out the Side
Plug from Main Housing inside.). Remove and discard the static O-ring form Side
Plug.

Step3-
Step3-2: for II stage R2 Ice/Special
Remove and discard the decal form the Adjustment knob.
Apply a screwdriver into the knob screw and turn counter-clockwise to loosen the

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screw. Separate the adjustment knob.
Apply a 19mm hex key socket on the adjustment nut, turn it counter-clockwise
until the nut full loosen form the body.
Separate the Adjust Spring, Adjust Piston, Remove and discard the static O-ring,
keep the Teflon washer.

Step3-
Step3-2.1
Apply a O-ring pick tooling on the decal, remove and discard the decal

Step3-
Step3-2.2
A. Apply a screw driver on the Knob Nut. Disassembly the Knob Screw and
Adjust Knob and set aside.
B. Apply 19mm Hex key socket on the Knob Nut, turn counter-clockwise to
loosen the Knob Nut.
C. Separate the Adjust Cap Nut, Adjust Shift, 010 O-Ring, Adjust Screw, Adjust
Spring and Transmitter Piston, set all aside and discard the 010 O-Ring.

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Step3-2.3
A. Push the Adjust Tube into the Main Housing to disassembly.
B. Remove the Adjust Tube from Main Housing.

Step3-2.4
Remove and discard the 015 O-Ring from the Adjust Tube.

Step4:
Apply a poppet driver tool into the main housing form brass nut insert, hold it.
Apply a 1/4” hex key socket on the nylon insert nut. Hold on the hex key socket;
turn the poppet tool to loosen the nylon insert nut. Separate the lever arm, thin
poppet washer and thick poppet washer form internality. Remove and discard the
LP seat.

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Step5:
Remove the C-clip from the Venturi knob. Remove and discard the O-ring, set the
Venturi knob aside.

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Step6:
Remove the Nylon trip and mouthpiece form Main Housing.

Immerse the Main housing into the hot water. Soften and remove the exhaust tee,
Remove the exhaust valve.

Cleaning – Preventive Procedures:

Protect orifice and all threads form damage.

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Use Scubatech’ s specified cleaning & degreasing agents & procedures.
Clean procedures:
For Metal parts:
All metal parts should be cleaned first in a warm (not over 55C) 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 (2 bar) air. After an initial cleaning in warm soap and water
solution, metal parts should be cleaned in an ultrasonic cleaner using the
appropriate ultrasonic cleaning solution (see Lubricant and Cleaner Table 2,
the Crystal Simple Green cleaner usually use on the Oxygen Clean).

For Plastic parts:

All plastic parts should be cleaned first in a warm (not over 40C) 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 (2,0 bar) air. After an initial cleaning in warm soap and water
solution, metal parts should be cleaned in an ultrasonic cleaner using the
appropriate ultrasonic cleaning solution.

NOTICE
Be sure all O-
O-rings are removed before cleaning in an ultrasonic cleaner or
chemical bath. Cleaning solutions may damage these components.

Parts Inspection – Preventive Trouble Shooting:

Replace dynamic O-
O-rings
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

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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 Scubatech regulators. The petroleum base or
propellant gas may attack or weaken plastic or rubber parts. Refer to Table 2 for
a list of approved lubricants.

Replace LP seat. (set the shiny side on top)

Replace nylon insert nut (if needs)
Replace POM orifice (maybe the old Orifice still work, but must replace this for
the safety solution)
Inspect diaphragm for cuts and holes (if damaged, replace it )
Inspect exhaust valve for damage, check the round edge. Replace it for damage
Inspect the LP seat for imperfection.
Check through hole on air balanced poppet
Inspect hose outer cover at fitting junction

Assembly – Preventive Procedures:

Special tools where required to protect parts.
Use orifice preset tool when available
Use Scubatech’ s recommended lubricants
Torque assemblies where specified

Demand valve Setup Prior to Turing Air On:

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Preset orifice to approximate depth with
Preset tool
Thread depth reference – the cracking effort preset for Primary or Octopus
Preset nylon insert nut to end point:
Poppet thread must be full completely through the nylon insert
Preset recommended thread exposure beyond nylon insert nut – turn back
about 3.5 turns for preset
Preset lever to Maximum height with only a slight amount of slack

Do not install diaphragm assembly in this time

Install inline adjusting tool (P92) if required

Connect LP hose form the first stage

Pressurize 2ed stage

Watch for lever drop when air pressure is applied
Recheck IP for correct pressure range and drift

II stage R1Pro Schematic Drawing

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II stage R2 Ice/Special Pro -P Schematic Drawing

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The II stage R1Pro Downstream Demand valve reassemble and adjustments:
The laws of downstream demand valve adjustments.

The cracking effort of the valve is a direct result of the force required to depress
the lever
The force required to depress the lever, and open the valve, is a direct result of
spring load.
The spring load required to seal the valve airtight is the direct result of
overcoming IP downstream force, plus all seating force factors.
Always adjust the lever to maximum height to insure full poppet orifice separation.

Assemble inner valve components:

Poppet, spring, Lever, Washers and nylon insert nut.
Note: install poppet threads completely full through the nylon insert, turn back 3
or 3.5 turns of the nylon insert nut.

Install the orifice with static O-ring into coupling

Install the coupling with static O-ring into the Main Housing, adjust the orifice by
inline adjusting tool with the lever depressed to prevent cutting the soft seat.

Adjust nylon insert nut to allow for slight lever slack

Pressurize the valve at correct IP.

If the demand valve leak initially, one of the following conditions exist and must
be rectified before continuing:

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There is no slack in the lever (lever loosing)
The IP is too high
The spring is too weak
Poor seating result between the orifice and LP seat.

If the demand valve dose not leak:

Back the orifice outward until the valve leaks air, than turn the orifice inward until
the leak stops,
Note: the orifice may need to be readjusted after the LP seat has taken an initial
set during the break in period.
Depress lever several times to be certain that the valve will seal airtight when the
lever is released

Install and secure diaphragm, top cover and cover ring assembly.
Note: if diaphragm assembly causes the demand valve to leak air, the lever is too
high. Turn the orifice inward until the leak stops.
Install the side plug with static O-ring into the Main Housing
Install the 2ed stage onto flow bench.
Check the 2ed stage cracking effort

The II stage R2 Ice/Special adjustable downstream 2ed stage reassemble and

adjustments:
Additional step form Install into

SECOND STAGE TROUBLESHOOTING

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SYMPTOM CAUSE ACTION REQUIRED
Leaking or Freeflow from 2ed 1. High 1st stage intermediate 1. Refer to first-stage
Troubleshooting Guide
stage pressure.(Should be 9-10
2. Replace rubber seating
Bar)
3. Reset crown and perform
2. LP seat (12) damaged or Final Tuning & Testing
worn procedures.
3. Orifice (14) incorrectly 4. Replace Orifice
adjusted Lever Arm (16) set 5. Replace poppet spring.
too low.
4. Orifice(14) sealing surface
damaged
5. Main Spring (13) damaged.
Low purge or excessive work of 1. Low intermediate pressure. 1. Refer to first-stage
breathing (full cylinder pressure) (should be 9-10 bar) Troubleshooting Guide.
2. Lever Arm(16) not properly 2. Disassemble and inspect
engaged with shuttle valve condition of shuttle valve and
3. Orifice (14) incorrectly lever
adjusted, Lever Arm(16) set 3. Reset Orifice and perform
too low Final Tuning & Testing
4. Intermediate pressure hose procedures
Intermediate pressure hose 4. Clean or replace hose.
External air leakage 1. Intermediate pressure hose 1. Tighten to 40 inch-lbs at
loose. (Immersion Test) female second-stage fitting
2. Disassemble and replace O-
2. Orifice O-ring(15) damaged ring.
3. Main Housing(1) damaged 3. Disassemble and replace
case.

Water entering second-stage 1. Hole in mouthpiece (5). 1. Replace mouthpiece

2. Demand diaphragm(9) 2. Replace demand diaphragm
damaged 3. Replace exhaust valve
3. Exhaust valve diaphragm(3) diaphragm.
damaged 4. Disassemble and replace O-
4. Venture knob O-ring(11) ring.
dirty, damaged, or worn 5. Disassemble and replace
5. Main Housing (1) damaged. case
(Check exhaust valve 6. Disassemble and replace O-
sealing surface.) ring.
6. Heat Sink O-ring (6)
damaged.

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