original copywriter 1987 INDEX A

revised 1998 - printed 1999

INDEX

MARES SERVICE MANUAL

CONTENTS
Last Last
revision revision
INTRODUCTION MR 12 II FIRST STAGE SERVICE
GENERAL INTRODUCTION I 1998
DISASSEMBLY F 5-1 1998
MARES SERVICE MANUAL I 1998
CLEANING / INSPECTION F 5-2 1998
REGULATOR SERVICE REASSEMBLY F 5-3 1998
GENERAL III 1998 MR 12 II SCHEMATIC AND PARTS LIST F 5-5 1997
SERIALIZATION III 1998
WARRANTY III 1998 R1 - R2 FIRST STAGE SERVICE
ROUTINE CARE III 1998 DISASSEMBLY F 6-1 1998
SERVICE REQUIREMENTS IV 1998 DISASSEMBLY (replacing stage 6) F 6-1 1998
SET OF TOOLS for regulators maintenace V 1998 CLEANING F 6-1 1998
SPECIAL TOOL KIT VI 1998 INSPECTION F 6-2 1998
REASSEMBLY F 6-3 1998
NITROX STATEMENT R1 - R2 DIN version REASSEMBLY F 6-4 1998
CONVERSION PROCEDURES N 1-1 1998 R1 - R2 SCHEMATIC AND PARTS LIST F 6-5 1998
DISASSEMBLY/CLEANING/DRYING/INSPECTING N 1-2 1998
LUBRIFICATION/REASSEMBLY N 1-3 1998 FIRST STAGE ADJUSTMENT
ADJUSTMENT N 1-4 1998 INTERMEDIATE PRESSURE F 7-1 1998
ADJUSTMENT IN DIAPHRAGM F 7-1 1998
CWD Kit FIRST STAGE ADJUSTMENT IN PISTON F 7-2 1998
Cold Water Diving Kit (CWD) K 1-1 1998
RUBY-MR22-MR16-V16 K 1-2 1998 FIRST STAGE TROUBLE SHOOTING F 8-1 1998
MR12-V12 K 1-5 1998
RUBY-ABYSS-VOLTREX- SECOND STAGE SERVICE
MR 22 - RUBY (Titanium) FIRST STAGE SERVICE DISASSEMBLY S 1-1 1998
DISASSEMBLY F 1-1 1998 CLEANING / INSPECTION S 1-2 1998
RUBY DIN version DISASSEMBLY F 1-3 1998 REASSEMBLY S 1-3 1998
CLEANING F 1-3 1998 ABYSS/VOLTREX SECOND STAGE ADJUSTMENT S 1-4 1998
INSPECTION F 1-4 1998 FINAL ASSEMBLY S 1-5 1998
REASSEMBLY F 1-5 1998 R.A.V. SCHEMATIC AND PARTS LIST S 1-6 1998
RUBY DIN version REASSEMBLY F 1-7 1998
MR22- RUBY SCHEMATIC AND PARTS LIST F 1-8 1998 XTR-XL-AKROS SECOND STAGE SERVICE
DISASSEMBLY S 2-1 1998
MR 16 - V 16 - FIRST STAGE SERVICE CLEANING S 2-2 1998
DISASSEMBLY F 2-1 1998 INSPECTION S 2-3 1998
MR 16-V16 DIN version DISASSEMBLY F 2-2 1998 REASSEMBLY S 2-4 1998
CLEANING / INSPECTION F 2-3 1998 ADJUSTMENT AND FINAL ASSEMBLY S 2-6 1998
REASSEMBLY F 2-4 1998 PROCEDURE A S 2-7 1998
MR 16-V16 DIN version REASSEMBLY F 2-5 1998 PROCEDURE B S 2-8 1998
MR 16 - V16 SCHEMATIC AND PARTS LIST F 2-7 1998 AKROS SCHEMATIC AND PARTS LIST S 2-10 1998

MR 12 - V 12 FIRST STAGE SERVICE NIKOS SECOND STAGE SERVICE

DISASSEMBLY F 3-1 1998 DISASSEMBLY S 3-1 1998
MR 12-V12 DIN version DISASSEMBLY F 3-1 1998 CLEANING S 3-2 1998
CLEANING F 3-2 1998 INSPECTION S 3-3 1998
INSPECTION F 3-3 1998 REASSEMBLY S 3-4 1998
REASSEMBLY F 3-4 1998 ADJUSTMENT FINAL ASSEMBLY S 3-6 1998
MR 12-V12 DIN version REASSEMBLY F 3-5 1998 PROCEDURE A S 3-7 1998
MR12-V12 SCHEMATIC AND PARTS LIST F 3-6 1997 PROCEDURE B S 3-8 1998
NIKOS SCHEMATIC AND PARTS LIST S 3-9 1998
MR 10 FIRST STAGE SERVICE
DISASSEMBLY F 4-1 1998 III - II SECOND STAGE SERVICE
MR 10 DIN version DISASSEMBLY F 4-1 1998 DISASSEMBLY S 4-1 1998
CLEANING F 4-2 1998 CLEANING S 4-2 1998
INSPECTION F 4-3 1998 INSPECTION S 4-2 1998
REASSEMBLY F 4-3 1998 REASSEMBLY S 4-3 1998
MR 10 DIN version REASSEMBLY F 4-6 1998 ADJUSTMENT FINAL ASSEMBLY S 4-4 1998
MR10 SCHEMATIC AND PARTS LIST F 4-7 1991 III SCHEMATIC AND PARTS LIST S 4-6 1998
B INDEX original copywriter 1987
revised 1998 - printed 1999

INDEX

MARES SERVICE MANUAL

CONTENTS
Last Last
revision revision
NAVY SECOND STAGE SERVICE REASSEMBLY B 2-4 1998
DISASSEMBLY S 5-1 1998 LP INFLATOR INSTALLATION B 2-6 1998
CLEANING S 5-2 1998 FINAL INSPECTION B 2-7 1998
INSPECTION S 5-2 1998 ERGO LP SCHEMATIC AND PARTS LIST B 2-8 1998
REASSEMBLY S 5-3 1998
NAVY SECOND STAGE ADJUSTMENT S 5-4 1998 MULTI AIR - INTERNATIONAL INFLATOR
NAVY SCHEMATIC AND PARTS LIST S 5-6 1998 TROUBLE SHOOTING B 3-1 1998

BETA - MR10 SECOND STAGE SERVICE ERGO INFLATOR TROUBLE SHOOTING B 4-1 1998
DISASSEMBLY S 6-1 1998 GENERAL INFORMATION GUN SERVICE
CLEANING S 6-2 1998 GENERAL IX 1998
INSPECTION S 6-3 1998 SERIALIZATION IX 1998
REASSEMBLY S 6-4 1998 WARRANTY IX 1998
BETA SECOND STAGE ADJUSTMENT S 6-6 1998 ROUTINE CARE IX 1998
CHANGING THE HOSE CONNECTION SERVICE REQUIREMENTS X 1998
FROM RIGHT TO LEFT S 6-7 1998 SPECIAL TOOL KIT XI 1998
DISASSEMBLY S 6-7 1998
REASSEMBLY S 6-8 1998 CYRANO/SPARK PNEUMATIC SPEARGUN
BETA SCHEMATIC AND PARTS LIST S 6-10 1998 DISASSEMBLY G 1-1 1998
MR10 SCHEMATIC AND PARTS LIST S 6-11 1998 CLEANING G 1-4 1998
INSPECTION G 1-4 1998
SECOND STAGE FINAL CHECKS AND ADJUSTMENT S 7-1 1998 REASSEMBLY G 1-5 1998
SECOND STAGE TROUBLE SHOOTING S 8-1 1998 TAHITIAN SHAFT SERVICE G 1-10 1998
DISASSEMBLY G 1-10 1998
LP INFLATOR SERVICE REASSEMBLY G 1-10 1998
GENERAL VII 1998 PRESSURIZING G 1-11 1998
SERIALIZATION VII 1998 PRESSURIZING USING MARES
WARRANTY VII 1998 GUN CHARGING YOKE G 1-11 1998
ROUTINE CARE VII 1998 PRESSURIZING USING MARES
SERVICE REQUIREMENTS VII 1998 HAND PUMP G 1-12 1998
SPECIAL TOOL ERGO VIII 1998 INSPECTION AND ADJUSTMENT G 1-13 1998
O-RING INSPECTION G 1-13 1998
MULTI AIR - INTERNATIONAL INFLATOR
TRIGGER STROKE INSPECTION G 1-13 1998
DISASSEMBLING THE SECOND STAGE B 1-1 1998
TRIGGER SENSITIVITY ADJUSTMENT G 1-14 1998
DISASSEMBLING THE INFLATOR UNIT B 1-1 1998
SAFETY BAR INSPECTION G 1-14 1998
DISASSEMBLING THE QUICK COUPLING B 1-1 1998
POWER REGULATOR INSPECTION G 1-14 1998
DISASSEMBLING THE DEFLATION GROUP B 1-2 1998
CYRANO SCHEMATIC AND PARTS LIST G 1-15 1998
DISASSEMBLING THE LP INFLATOR C.G. B 1-2 1998
SPARK (Pipin line) SCHEMATIC AND PARTS LIST G 1-16 1998
DISASSEMBLING THE R.E. VALVE B 1-2 1998
DISASSEMBLING THE CORRUGATED HOSE B 1-2 1998 COMPETITION PNEUMATIC SPEARGUN
CLEANING B 1-3 1998 DISASSEMBLY G 2-1 1998
INSPECTION B 1-3 1998 CLEANING G 2-4 1998
REASSEMBLY B 1-5 1998 INSPECTION G 2-4 1998
ASSEMBLING THE LP INFLATOR C.G. B 1-5 1998 REASSEMBLY G 2-5 1998
ASSEMBLING THE DEFLATION GROUP B 1-6 1998 PRESSURIZING G 2-9 1998
ASSEMBLING THE COUPLING B 1-6 1998 PRESSURIZING USING MARES
ASSEMBLING THE R.E. VALVE GROUP B 1-7 1998 GUN CHARGING YOKE G 2-10 1998
ASSEMBLING THE CORRUGATED HOSE B 1-8 1998 PRESSURIZING USING MARES
ASSEMBLING THE SECOND STAGE HAND PUMP G 2-10 1998
(Multi Air version only) B 1-8 1998 INSPECTION AND ADJUSTMENT G 2-11 1998
ASSEMBLING THE CORR. HOSE ON THE BC B 1-8 1998 O-RING INSPECTION G 2-12 1998
FINAL CHECKS B 1-9 1998 TRIGGER STROKE INSPECTION G 2-12 1998
MULTI AIR - INT. INFLATOR SCHEMATIC B 1-10 1993 TRIGGER SENSITIVITY ADJUSTMENT G 2-12 1998
SAFETY INSPECTION G 2-13 1998
ERGO LP INFLATOR
POWER REGULATOR INSPECTION G 2-13 1998
LP INFLATOR REMOVAL B 2-1 1998
SPEARGUN STEN (Pipin line) SCHEMATIC
DISASSEMBLY B 2-1 1998
AND PARTS LIST G 2-14 1998
CLEANING B 2-3 1998
INSPECTION B 2-3 1998 SPEARGUN TROUBLE SHOOTING G 3-1 1998
I INTRODUCTION original copywriter 1987
revised 1998 - printed 1999

INTRODUCTION

GENERAL INTRODUCTION
HTM SPORT, based in Via Cerisola, Rapallo, Italy, manufactures
and markets a complete line of diving equipment under the
MARES brand.
The MARES brand represents an assurance of exceptional quali-
ty, which diving enthusiasts have come to associate with this
name.

MARES SERVICE MANUAL

MARES offers all its authorized dealers the opportunity of attend-
ing technical training courses at its factory. Dealers are strongly
advised to obtain specific practical training in the servicing of
MARES diving equipment before attempting to service and repair
professional diving equipment.
This manual is intended as a guide for experienced repair per-
sonnel, and not as a substitute for a MARES Technical Training
Course or as a comprehensive instruction book on all aspects of
diving equipment for inexperienced repair personnel.

IMPORTANT !
Possession of this manual does not constitute an implicit con-
cession or authorization on the part of MARES for servicing its
products. With the exception of MARES Authorized Service
Centers, any person attempting to service the equipment auto-
matically takes on full responsibility for any damages or haz-
ards which may result from maintenance operations that are
performed incorrectly.

Should any warnings or information contained in this manual

be unclear or not fully understood, please contact Mares befo-
re performing any repairs.

IMPORTANT !
Carefully read all parts of this manual before attempting to per-
form any repairs on diving equipment.
 original copywriter 1987 INTRODUCTION II
revised 1998 - printed 1999

Any information, notices and precautions concerning operations

which may compromise the efficiency of the product, prove dan-
gerous or even fatal for the technician, the owner of the product
or other persons, are highlighted by the following symbols:

DANGER
INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH,
IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

WARNING
INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF
NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.

CAUTION
INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF
NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY.
IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES.

NOTE Indicates suggestions and recommendations on how

to correctly perform certain operations described in
the manual.

MARES reserves the right to modify any products, processes and

manufacturing techniques at any time. It is the technician’s
responsibility to acquire the latest information and parts from
MARES for service and repairs to be performed.
 original copywriter 1987 REGULATORS SERVICE III
revised 1998 - printed 1999

REGULATORS SERVICE

GENERAL
Servicing at the repair shop level mainly involves cleaning,
inspection, replacement of necessary parts and adjustment of the
regulator.
Numerous 0-rings are used throughout the regulator. Cleanliness
is of the utmost importance in obtaining effective 0-ring seals.
Tools required for maintenance and repair are shown in the spe-
cial tools section of this manual.
Reusable rubber parts can be cleaned by scrubbing with a soft
brush in a mild detergent and water solution. Do not use solvents
or acids on rubber or plastic parts. Ideally, metal parts should be
cleaned in an ultrasonic cleaner with fresh water. However, if an
ultrasonic cleaner is not available, these parts may be cleaned
with a mild acid (diluted white vinegar is recommended).

SERIALIZATION
All Mares regulators are identified by individuaI serial numbers.
The serial number for the complete regulator is located on the
regulator second stage case near the mouthpiece. The first stage
also carries the same serial number.

WARRANTY
The warranty card is packaged with the regulator and is to be
given to the buyer at the time of sale. The dealer, at the time of
sale, should complete and sign the warranty in its three parts. The
«MARES» copy should be mailed to MARES. The «STORE» copy
should be retained by retailer for their records. The «CUSTO-
MER» copy should be given to the purchaser. The warranty policy
as stated in the warranty shipped with the regulator is the final
authority.
The warranty includes also the condition for the regulator to be
serviced at least once a year in a MARES Service Center.

ROUTINE CARE
The following instructions will help increase the life and proper
functioning of the first stage.
1. The first stage should be rinsed with fresh water after every
use while it is still pressurized on the tank. This allows the
second stage to be rinsed internally without introducing con-
taminants into critical sealing areas.
2. Thoroughly rinse the first stage and also run water into the
mouthpiece of the second stage and out of the exhaust tee to
remove any foreign matter. lf the regulator is not pressurized,
IV REGULATORS SERVICE original copywriter 1987
revised 1998 - printed 1999

do not depress the purge button while rinsing. Depressing the

purge button while rinsing may allow particles to contaminate
the valve seat and cause leakage.
3. In order to avoid filter and first stage contamination, prevent
water from entering the high pressure inlet of the first stage.
Place the dust cap over the high pressure filter and secure it
with the yoke screw.
4. Allow the regulator to dry completely before storage.
5. Prolonged storage in direct sunlight or in oily and dusty areas
can be damaging to some of the regulator components.
Lubricants are not necessary and should not be used in routi-
ne care and maintenance.

SERVICE REQUIREMENTS
As stated in the owners manual, regulators should be inspected
and serviced yearly or every 100 hours of use whichever comes
first. Inspection involves disassembling, cleaning, replacement of
parts as needed, re-assembly and adjustment.
Users should not undertake inspections. Only qualified techni-
cians in a MARES Service center should do so.

WARNING
PROTECT EYES AND SKIN ADEQUATELY WHEN WORKING WITH
ANY KIND OF ACID. BEFORE CLEANING METAL PARTS, MAKE
SURE THAT ALL RUBBER AND PLASTIC PARTS HAVE BEEN
REMOVED. ACIDS OR OTHER SOLVENTS MAY DAMAGE
RUBBER AND PLASTIC PARTS.
 original copywriter 1987 REGULATORS REGULATOR MAINTENANCE KIT V
revised 1998 - printed 1999

Regulator maintenance kit Code 775009

Wrench for retaining nut 1st stage Wrench for 1st stage diaphragm retaining nut

(B-1) (B-2)
Code 106201 Code 106202

1st stage disassembling tool Wrench for 1st stage diaphragm retaining nut

(B-5) (B-16)
Code 106205 Code 106216

MR 02-1st stage seat connector disassembly Wrench for 1st stage hose connector

(B-11) (B-18)
Code 106211 Code 106218

Voltrex 2nd stage adjustament tool Wrench for 2nd stage connector and Demand lever adjustment tool
hose (n°2)

(B-4) (B-17) (B-12)

Code 106204 Code 106217 Code 106212

Wrench first stage plug MR 22 Wrench 2nd stage hose connector Nikos Demand lever adjustment tool

(B-8) (B-9) (B-20)

Code 106208 Code 106209 Code 106220

1st stage adjustment tool Beta Wrench 2nd stage hose connector 2nd stage demand lever assembling tool
2nd stage plug BETA (n°2) inserter OR

(B-13) (B-19) (B-6)

Code 106213 Code 106219 Code 106206

HP seat-disassembling tool MR 22 Cover disassembly tool Snap ring plier 1st stage
Akros-Nikos

(B-21) (B-7) (B-14)

Code 106221 Code 106207 Code 106214

R 2 piston seat-disassemblig tool Wrench for R 2 first stage cap

(B-22) (B-23)
Code 106222 Code 106223
VI SPECIAL TOOLS REGULATORS original copywriter 1987
revised 1998 - printed 1999

Special Tool Kit Code 775008

Purge button-tool (Ergo) Demand lever adjustment tool

(B-20)
Code 106190 Code 106220

1st stage disassembling tool HP seat-disassembling tool MR 22

(B-5) (B-21)
Code 106205 Code 106221

2nd stage demand-lever assembling tool R 2 piston seat disassembling tool

Insert O-ring

(B-6) (B-22)
Code 106206 Code 106222

MR 02-1st stage seat connector disassembling tool Cover disassembling tool

Akros-Nikos

(B-7)
Code 106207
(B-11)
Gauge for demand lever Akros-Nikos
Code 106211

Demand lever adjustment tool

Code 106230

Gauge for demand lever Voltrex-Beta

(B-12)
Code 106212 Code 106231
 STATEMENT
NITROX
NITROX STATEMENT
 original copywriter 1987 REGULATORS NITROX N 1-1
revised 1998 - printed 1999

MARES NITROX REGULATORS

All of the regulators in the Mares Nitrox line are specifically
designed for breathing mixes containing up to 40% oxygen. The
engineering problems arising from the use of such mixtures,
particularly with regard to compatibility with plastic polymers and
rubber, have been completely resolved through the use of specif-
ic materials such as Viton seals and special lubricating greases.

DANGER
DO NOT USE ANY MARES REGULATOR WITH AN OXYGEN-RICH
MIXTURE (NITROX - MAX 40% OXYGEN) WITHOUT FIRST RECEI-
VING ADEQUATE TRAINING IN ITS USE. FAILURE TO OBSERVE
THIS WARNING MAY RESULT IN A SERIOUS ACCIDENT.

CONVERSION PROCEDURES

WARNING !
DO NOT ATTEMPT TO CONVERT MARES REGULATORS - OR ANY
OTHER TYPE OF EQUIPMENT - FOR USE WITH OXYGEN-RICH MIX-
TURES WITHOUT HAVING THE NECESSARY TRAINING AND A THOR-
OUGH UNDERSTANDING OF ALL THE PREPARATION AND ASSEM-
BLY PROCEDURES FOR HIGH-PRESSURE OXYGEN SYSTEMS.

(for US version) Details of these procedures can be obtained from

the Compressed Gas Association of Arlington, Virginia, USA, or
the American Society of Testing and Materials of Philadelphia,
Pennsylvania, USA.

WARNING !
THE CONVERSION PROCEDURES MUST BE CARRIED OUT
EXCLUSIVELY BY QUALIFIED AND AUTHORIZED MARES TECH-
NICIANS WHO ARE ALREADY FULLY TRAINED IN THE SERVIC-
ING OF REGULATORS AND OTHER HIGH PRESSURE SYSTEMS
INTENDED FOR USE WITH OXYGEN-RICH MIXTURES.

WARNING !
AFTER COMPLETING THE CONVERSION AND AFFIXING THE
LABEL SUPPLIED IN THE KIT ONTO THE SECOND STAGE HOSE,
INFORM THE OWNER OR USER THAT THE REGULATOR MUST
NOW ONLY BE USED WITH OXYGEN-RICH MIXTURES. IF, AFTER
THE CONVERSION, THE REGULATOR IS USED WITH ORDINARY
COMPRESSED AIR, IT WILL BE NECESSARY TO REPEAT THE
ENTIRE CONVERSION PROCEDURE BEFORE USING THE REGU-
LATOR WITH OXYGEN-RICH MIXTURES AGAIN. THIS IS
BECAUSE THE REGULATOR MAY BE CONTAMINATED WITH
TRACES OF HYDROCARBONS OR OTHER IMPURITIES WHICH
COULD SPARK COMBUSTION.
N 1-2 NITROX REGULATORS original copywriter 1987
revised 1998 - printed 1999

DISASSEMBLY
In order to avoid contamination of the disassembled components,
always work in a clean area that is sufficiently well-ventilated.
To convert a regulator for use with oxygen-rich mixtures (MAX
40% oxygen) it is necessary to thoroughly clean all the compo-
nents, removing all traces of silicone and other impurities, and
replacing all O-rings with special ones suitable for this type of use
(Viton O-rings). It is therefore necessary to fully disassemble the
regulator, following the instructions provided in the separate
instruction manuals for the various regulator models.

CLEANING THE COMPONENTS

Before starting the cleaning operations, wear appropriate protec-
tive gear for the eyes and hands, and choose a work area that is
clean and well ventilated.

Before cleaning the components with the specified solutions,

remove any excess lubricant using paper towels and a nylon
toothbrush.

Metal components and hoses:

Brass and stainless steel parts can be cleaned by ultrasonic clean-
ing. If ultrasonic cleaning equipment is not available, these com-
ponents can also be cleaned using white wine vinegar. Always
check that every component submerged in the solution is per-
fectly clean, using a magnifying glass if necessary.
Next, rinse all components in hot water (distilled water is recom-
mended to avoid mineral residue).

Plastic components
Plastic parts can be cleaned by immersion in a solution of hot
water and a gentle detergent. A nylon brush (such as a tooth-
brush) can be used to remove any traces of contaminants. Always
check that every component submerged in the solution is per-
fectly clean, using a magnifying glass if necessary.
Rinse all components using warm water (distilled water is rec-
ommended to avoid mineral residue).

DRYING THE COMPONENTS

Dry all components using a perfectly clean cloth. Be careful to use
oxygen-compatible equipment and low-pressure air, to avoid
exposing components to possible contamination due to oil vapors
from the tank or compressor.

INSPECTING THE COMPONENTS

Inspect all components, using a magnifying glass if necessary,
and make sure that they are all perfectly clean and free of lubri-
 original copywriter 1987 REGULATORS NITROX N 1-3
revised 1998 - printed 1999

cants, oils, silicone grease residue, cuts or shavings. Repeat the

cleaning operations and/or replace the damaged components if
necessary.
It is recommended to reassemble the regulator immediately after
completing the cleaning and inspection procedures, to minimize
exposure of the components to possible contamination.

Make sure that the Viton O-rings used in the conversion are those
specified on the spare parts list for the regulator model in ques-
tion.

MARES supplies an O-ring kit (cod:185350) which contains all

necessary O-rings for converting all MARES compressed-air reg-
ulators currently available on the market, into regulators suitable
for use with breathing mixes containing from 22% to 40% oxy-
gen. The kit also contains a label and a hose protector which
must be applied on the second stage hose after completing the
conversion.

LUBRICATION

WARNING !
DO NOT USE SILICONE LUBRICANTS

Before reassembling the regulator, it is necessary to lubricate all

O-rings and certain other components as described in the service
manuals. Lubrication prior to installation minimizes the risk of
damage during reassembly, and helps ensure perfect operation
of the regulator.

It is essential to use only oxygen-compatible lubricant grease

(e.g. “Christo-Lube MCG 111).

Lubricate the O-rings using only a small amount of oxygen-com-

patible grease, because excess grease may attract contaminant
particles, causing the regulator to malfunction.

REASSEMBLY
Before starting the reassembly procedure, all tools and equip-
ment used for assembly must be perfectly clean. Clean the tools
using trichloroethylene or white wine vinegar, then rinse in
distilled water and dry using oxygen-compatible low-pressure air.

WARNING !
MARES RECOMMENDS DEDICATING A SET OF EQUIPMENT
EXCLUSIVELY TO THE SERVICING AND CONVERSION OF REG-
ULATORS FOR USE WITH OXYGEN-RICH MIXTURES (MAX 40%
OXYGEN).
N 1-4 NITROX REGULATORS original copywriter 1987
revised 1998 - printed 1999

In order to avoid contaminating the components with silicone

grease or oil residue on the hands, always work with perfectly
clean hands and wear perfectly clean latex gloves.

The reassembly procedures are described in the separate service

manuals for the various regulator models.

ADJUSTMENTS
The adjustment procedures are described in the separate service
manuals for the various regulator models.

WARNING !
MARES STRONGLY RECOMMENDS USING ONLY OXYGEN-COM-
PATIBLE GASES DURING THE ADJUSTMENT AND CALIBRATION
PROCEDURES OF REGULATORS FOR USE WITH OXYGEN-RICH
MIXTURES (MAX 40% OXYGEN).
 FIRST STAGE
CWD kit
CWD KIT FIRST STAGE
 original copywriter 1987 CWD KIT FIRST STAGE K 1-1
revised 1998 - printed 1999

COLD WATER DIVING KIT (CWD)

For use in cold water diving (below 47 F) we recommend that a

Cold Water Diving Kit (CWD) be installed. The assembly of this kit
must be performed by a Mares authorized service center.

WARNING !
DIVING IN COLD WATER (BELOW 47 F) WITHOUT PROPER
TRAINING CAN CAUSE SERIOUS INJURY. BEFORE DIVING IN
COLD WATER, SPECIAL TRAINING FROM A CERTIFIED
INSTRUCTOR SHOULD BE OBTAINED.
ANY SCUBA DIVING REGULATOR, EVEN THOSE EOUIPPED
WITH A CWD KIT CAN UNDERGO “FREEZE-UP” PHENOMENA.
“FREEZE-UP” OF A REGULATOR IS DETRIMENTAL TO THE EFFI-
CIENCY OF A REGULATOR AND CAN CAUSE THEM TO FAIL,
THUS INTERRUPTING AIR DELIVERY TO THE DIVER. THIS MAY
CAUSE SERIOUS INJURY OR DEATH. TO MINIMIZE SUCH
RISKS, DIVERS SHOULD BE PROPERLY TRAINED TO PREVENT
OR BE ABLE TO COPE WITH A REGULATOR AFFECTED BY
“FREEZE-UP” PHENOMENA.

CWD
MR REGULATOR PROTECTION KIT FOR COLD WATER DIVING

Fig. 1
K 1-2 CWD KIT FIRST STAGE RUBY-MR22-MR16-V16 original copywriter 1987
revised 1998 - printed 1999

RUBY-MR22-MR16-V16 CWD INSTALLATION

1. Insert the disassembling tool for the first stage (B5) into a LP
port.
2. Remove regulating nut (18) with hex wrench (B13) and
remove diaphragm spring (16) (Fig. 1).
3. Remove retaining nut (17) and shock ring (69) with wrench
(B16) then remove spring base plate (15) (Fig. 1).
4. If the CWD kit is not being installed on a newly serviced first
stage, clean the first stage diaphragm with a damp cloth and
wipe dry. Clean the diaphragm spring and spring base plate
as described in the cleaning section of this manual.
5. Lubricate both sides of the spring base plate with the silicone
oil provided in the CWD kit then place spring base plate (15)
on diaphragm.
6. Lightly lubricate the sealing edge of retaining nut (17) with
the silicone oil provided in the CWD kit and tighten into the
first stage body until snug (Approx. 25 Ft/lb. 34 N/m.).
7. Lubricate the diaphragm spring (16) with the silicone oil
provided in the CWD kit, then place it on the base plate.
8. Place the regulating nut (18) over the diaphragm spring.
Using tool (B13) tighten regulating nut until it is just below
the inside shoulder of the retaining nut.
9. Remove the disassembling tool for the first stage (B5) from
the LP port and install port plug.
10. Remove the second stage purge cover.
a. Slide the second stage hose protector towards the hose
until the clamp ring screw is exposed.
b. Remove clamp ring screw.
c. Expand the clamp ring until it will slide over the flange
of the second stage body.
d. Remove the second stage purge cover, diaphragm and
clamp ring.
11. Connect an intermediate pressure gauge to a LP port on the
first stage.

DANGER ! EXPLOSION HAZARD

DO NOT CONNECT THE INTERMEDIATE PRESSURE GAUGE TO
THE HIGH PRESSURE PORT OF THE FIRST STAGE.
CONNECTING THE INTERMEDIATE PRESSURE GAUGE TO THE B12
HIGH PRESSURE PORT OF THE FIRST STAGE WILL CAUSE THE
HOSE AND/OR INTERMEDIATE PRESSURE GAUGE TO EXPLODE
AND COULD RESULT IN SERIOUS PERSONAL INJURY OR
Low pressure
DEATH. outlet (LP) INTERMEDIATE PRESSURE
TUNING GAUGE
12. Attach the first stage to a full tank (2600-3000 psi). Fig. 2
(See Fig. 2).
 original copywriter 1987 CWD KIT FIRST STAGE RUBY-MR22-MR16-V16 K 1-3
revised 1998 - printed 1999

13. Depress the second stage demand lever while slowly

opening the tank valve. When air begins to flow from the C-SHAPED GAUGE FOR DEMAND
second stage slowly release the demand lever and fully open LEVER HEIGHT INSPECTION
the tank valve. For the correct adjustment stand the gauge on the Second Stage
case and adjust lever height until it makes contact with the gauge.
14. Read the intermediate pressure indicated by the gauge.
Intermediate pressure for the MR 22 Abyss is 128-132 psi.
NAVY E BETA
a. If the intermediate pressure is greater than specified,
slightly loosen the regulating nut, using tool (B13), RUBY / ABYSS
until the desired value is obtained. VOLTREX

NOTE Whenever intermediate pressure is decreased, excess

air must be exhausted by depressing the second stage Fig. 3
demand lever to obtain the correct reading.

b. If the intermediate pressure is lower than specified,

slightly tighten the regulating nut until the desired value
is obtained.
15. Depress the second stage demand lever a few times to make
sure that the intermediate pressure remains constant.
16. Adjust demand lever height using the demand lever height
gauge. The demand lever height gauge sides are marked
with the second stage model. Place the side of the demand
lever height gauge marked with the corresponding model
across the second stage case (Fig 3).
a. If the demand lever height is too low, tighten the demand
lever lock nut until the demand lever contacts the lower
edge of the gauge.
b. If the demand lever height is too high, loosen the
demand lever lock nut until the demand lever contacts
the lower edge of the gauge.
17. Install the second stage purge cover.
a. Expand the clamp ring until it will slide over the flange of
the second stage body.
b. Place the second stage diaphragm on to the second
stage body making sure the metal disk is against the
demand lever.
c. Place the purge cover on the diaphragm.
d. Position the clamp ring over the flange of the second
stage and the flange of the purge cover. Rotate the clamp
ring so the split end is facing the second stage hose.
e. Install clamp ring screw and tighten.
f. Slide the second stage hose protector into position over
the clamp ring.
18. After second stage adjustment, depressurize the regulator
and remove the intermediate pressure gauge.

NOTE Do not submerge the intermediate pressure gauge.

Submerging the intermediate pressure gauge can
affect accuracy and/or damage the gauge.
K 1-4 CWD KIT FIRST STAGE RUBY-MR22-MR16-V16 original copywriter 1987
revised 1998 - printed 1999

19. Position the first stage five to ten degrees from vertical with
the open end of the retaining nut facing up.
20. Fill the regulating nut with the silicone oil provided in the
CWD kit until it is full.
21. Gently tap the sides of the regulating nut with a soft object
such as a wood or plastic screwdriver handle to eliminate
bubbles from the silicone oil.
22. Install diaphragm (58) with the lip facing up (See inset Fig 1).
a. keep the first stage positioned five to ten degrees from
vertical.
b. With a thin tipped tool lift the higher edge of the
diaphragm while gently depressing the center of the
diaphragm with a blunt tool allowing air to escape.
When all the air has been removed from under the
diaphragm remove the thin tipped tool.
c. The diaphragm should be completely submerged in the
oil and seated against the shoulder of the retaining nut.
d. With a thin tipped tool gently lift the edge of the.
diaphragm to release the vacuum which may exist
under the diaphragm. Take care not to allow any air
under the diaphragm. If air is allowed under the
diaphragm repeat steps a. thru d.
23. Install CWD bezel (59) and tighten with tool provided in CWD
kit. The bottom edge of the bezel should contact the
retaining nut.
24. Pour excess oil into a suitable container. Rinse residual oil
off first stage with fresh water. Make sure the first stage dust
cap is tightened in place before rinsing.
25. Install the CWD protection cover (108).
(only version MR16-V16).

CAUTION !
DO NOT PROD CWD KIT DIAPHRAGM WITH TOOLS, FINGERS
OR DIRECT A VIOLENT STREAM OF WATER (E.G. FROM A
HOSE) AGAINST IT. PERFORATION OR DISPLACEMENT OF THE
DIAPHRAGM COULD RESULT, CAUSING OIL LEAKAGE OR
WATER SEEPAGE.
 original copywriter 1987 CWD KIT FIRST STAGE MR12-V12 K 1-5
revised 1998 - printed 1999

MR12-V12 CWD INSTALLATION

1. Insert the disassembling tool for the first stage (B5) into a LP
port.
2. Remove regulating nut cover (70).
3. Remove regulating nut (18) with hex wrench (B13) and
remove diaphragm spring (16) (Fig. 1).
4. Remove retaining nut (17) with wrench (B2) and remove
spring base plate (15) (Fig. 1).
5. If the CWD kit is not being installed on a newly serviced first
stage, clean the first stage diaphragm with a damp cloth and
wipe dry. Clean the diaphragm spring and spring base plate
as described in the cleaning section of this manual.
6. Lubricate both sides of the spring base plate with the silicone
oil provided in the CWD kit then place spring base plate (15)
on diaphragm.
7. Lightly lubricate the sealing edge of retaining nut (17) with
the silicone oil provided in the CWD kit and tighten into the
first stage body until snug (Approx. 25 Ft/lb. 34 N/m.).
8. Lubricate the diaphragm spring (16) with the silicone oil
provided in the CWD kit then place it on the base plate.
9. On MR 12 Beta and MR 12 III non DFC first stages place the
regulating nut (18) over the diaphragm spring. Using tool
(B13) tighten regulating nut until it is just below the inside
shoulder of the retaining nut. On MR 12 NAVY and ALL
MR 12 DFC first stages replace regulating nut (18) with the
regulating nut provided in the CWD kit. Place the regulating
nut (18) over the diaphragm spring. Using tool (B13) tighten
regulating nut until it is just below the inside shoulder of the
retaining nut.
10. Remove the disassembling tool for the first stage (B5) from
the LP port and install port plug.
11. Remove the second stage purge cover.
a. Voltrex second stage.
1. Slide the second stage hose protector towards the
hose until the clamp ring screw is exposed.
2. Remove clamp ring screw.
b. NAVY and BETA second stages
1. Depress the second stage safety catch towards the
exhaust tee while unscrewing the purge cover bezel.
2. Remove the bezel, purge cover, friction disk and
diaphragm.
c. Ill second stage.
1. Remove clamp ring screw.
2. Expand the clamp ring until it will slide over the flange
of the second stage body.
3. Remove the second stage purge cover, diaphragm
and clamp ring.
K 1-6 CWD KIT FIRST STAGE MR12-V12 original copywriter 1987
revised 1998 - printed 1999

12. Remove demand lever lock nut. BETA and NAVY use tool
B20. Ill and VOLTREX use tool B12.
13. Remove demand lever washer.
14. Remove demand lever.
15. Place the Teflon coated demand lever provided in the CWD
kit into the second stage.
16. Place the demand lever washer over the second stage
poppet stem and on top of the demand lever.
17. Place the new demand lever lock nut provided in the CWD
kit on the second stage poppet stem and tighten the lock nut
until the demand lever is held in place by spring tension.

NOTE Do not over-tighten demand lever lock nut 33. If the

demand lever lock nut is over-tightened, it will cause
the second stage to free-flow during intermediate
pressure adjustment. To correct this condition loosen
lock nut until free-flow stops.

18. Connect an intermediate pressure gauge to a LP port on the

first stage.

DANGER ! EXPLOSION HAZARD

DO NOT CONNECT THE INTERMEDIATE PRESSURE GAUGE TO
THE HIGH PRESSURE PORT OF THE FIRST STAGE.
CONNECTING THE INTERMEDIATE PRESSURE GAUGE TO THE
HIGH PRESSURE PORT OF THE FIRST STAGE WILL CAUSE THE
HOSE AND/OR INTERMEDIATE PRESSURE GAUGE TO EXPLODE
AND COULD RESULT IN SERIOUS PERSONAL INJURY OR
DEATH.

19. Attach the first stage to a full tank (2600-3000 psi Fig. 2).
20. Depress the second stage demand lever while slowly
opening the tank valve. When air begins to flow from the
second stage slowly release the demand lever and fully open
the tank valve.
21. Read the intermediate pressure indicated by the gauge.
Intermediate pressure for specific models are given bellow.
MR 12 Voltrex 128-132 psi
MR 12 Navy 128-132 psi
MR 12 III 128-132 psi
MR 12 Beta 128-132 psi
a. If the intermediate pressure is greater than specified,
slightly loosen the regulating nut, using tool (B13), until
the desired value is obtained.
 original copywriter 1987 CWD KIT FIRST STAGE MR12-V12 K 1-7
revised 1998 - printed 1999

NOTE Whenever intermediate pressure is decreased, excess

air must be exhausted by depressing the second stage
demand lever to obtain the correct reading.

b. If the intermediate pressure is lower than specified,

slightly tighten the regulating nut until the desired value
is obtained.
22. Depress the second stage demand lever a few times to make
sure that the intermediate pressure remains constant.
23. Adjust demand lever height using the demand lever height
gauge. The demand lever height gauge sides are marked
with the second stage model. Place the side of the demand
lever height gauge marked with the corresponding model
across the second stage case (Fig 3).
a. If the demand lever height is too low, tighten the demand
lever lock nut until the demand lever contacts the lower
edge of the gauge.
b. If the demand lever height is too high, loosen the
demand lever lock nut until the demand lever contacts
the lower edge of the gauge.
24. Install the second stage purge cover.
a. Voltrex second stage.
1. Expand the clamp ring until it will slide over the
flange of the second stage body.
2. Place the second stage diaphragm on to the second
stage body making sure the metal disk is against the
demand lever.
3. Place the purge cover on the diaphragm.
4. Position the clamp ring over the flange of the second
stage and the flange of the purge cover.
Rotate the clamp ring so the split end is facing the
second stage hose.
5. Install clamp ring screw and tighten.
6. Slide the second stage hose protector into position
over the clamp ring.
b. NAVY and BETA second stages.
1. Place the second stage diaphragm into the second
stage body making sure the metal disk is against the
demand lever.
2. Place the friction disk on the diaphragm with the
rounded side against the diaphragm.
3. Place the purge cover on the friction disk.
4. Depress the second stage safety catch towards the
exhaust tee and tighten the purge cover.
c. Ill second stage.
1. Expand the clamp ring until it will slide over the
flange of the second stage body.
2. Place the second stage diaphragm onto the second
stage body making sure the metal disk is against the
demand lever.
K 1-8 CWD KIT FIRST STAGE MR12-V12 original copywriter 1987
revised 1998 - printed 1999

3. Place the purge cover on the diaphragm.

4. Position the clamp ring over the flange of the second
stage and the flange of the purge cover. Rotate the
clamp ring so the split end is facing the second stage
hose.
5. Install clamp ring screw and tighten.
25. After second stage adjustment, depressurize the regulator
and remove the intermediate pressure gauge.

NOTE Do not submerge the intermediate pressure gauge.

Submerging the intermediate pressure gauge may
affect gauge accuracy and/or damage the gauge.

26. Position the first stage five to ten degrees from vertical with
the open end of the retaining nut facing up.
27. Fill the regulating nut with the silicone oil provided in the
CWD kit until it is full.
28. Gently tap the sides of the regulating nut with a soft object
such as a wood or plastic screwdriver handle to eliminate
bubbles from the silicone oil.
29. Install diaphragm (58) with the lip facing up
(See inset Fig 1).
a. Keep the first stage positioned five to ten degrees from
vertical.
b. With a thin tipped tool lift the higher edge of the
diaphragm while gently depressing the center of the
diaphragm with a blunt tool allowing air to escape. When
all the air has been remove from under the diaphragm
remove the thin tipped tool.
c. The diaphragm should be completely submerged in the
oil and seated against the shoulder of the retaining nut.
d. With a thin tipped tool gently lift the edge of the
diaphragm to release the vacuum which may exist under
the diaphragm. Take care not to allow any air under the
diaphragm. If air is allowed under the diaphragm repeat
steps a. thru d.
30. Install CWD bezel (59) and tighten with tool provided in CWD
kit. The bottom edge of the bezel should contact the
retaining nut.
31. Pour excess oil into a suitable container Rinse residual oil off
first stage with fresh water. Make sure the first stage dust
cap is tightened in place before rinsing.

CAUTION !
DO NOT PROD CWD KIT DIAPHRAGM WITH TOOLS, FINGERS
OR DIRECT A VIOLENT STREAM OF WATER (E.G. FROM A
HOSE) AGAINST IT. PERFORATION OR DISPLACEMENT OF THE
DIAPHRAGM COULD RESULT, CAUSING OIL LEAKAGE OR
WATER SEEPAGE.
MR22-RUBY tit.
FIRST STAGE
RUBY-MR22 FIRST STAGE
 original copywriter 1987 REGULATORS FIRST STAGE RUBY-MR22 F 1-1
revised 1998 - printed 1999

D I S A S S E M B LY :

To ease the disassembly we suggest to removing hoses

connected to the First Stage, except the one that is connected to
the D.F.C. port (the one with the 1/2 port) and replace them with
appropriate plugs.

1. Remove hose protector (46) and unscrew the Second Stage

hose flow (26), using two wrenches (B17) (Fig.1).

2. Using hex tool (B8), unscrew First Stage cover (81-71-76-

80).
Fig. 1
3. Remove O-ring (71), HP housing button (80) and spring
(76) from the cover.

4. Extract the complete HP housing (4-5-6), spring (8), the

Ruby poppet of the First Stage (9) and pin (12) from the First
Stage body (1). (Fig. 2)

5. Remove O-ring (6) from the HP housing.

WARNING !
REMOVE THE BACK-UP RING FROM THE HP HOUSING ONLY IN
CASE OF REPLACEMENT.

6. Put on the First Stage seat (75) the special tool (B21),
pressing it. Introduce compressed air (less than 7 bar -
101.5 psi) in a low pressure inlet. (Fig.3)
Fig. 2
NOTE When the shifting of the poppet seat is noticed,
because of the air inserted, lower the pressure on the
instrument (B21).

WARNING !
DO NOT ATTEMPT TO REMOVE THE POPPET SEAT BY USING
SHARP OR POINTED TOOLS. #x2 SCRATCHES ON THE SEAT -1#
SURFACE MAY CAUSE WORKING FAILURE.

7. Extract from the First Stage the poppet seat (75) and
remove O-ring (74).

8. Screw lever (B5) for the dismantling of the First Stage (3/8”
low pressure inlet).

Fig. 3
F 1-2 FIRST STAGE RUBY-MR22 REGULATORS original copywriter 1987
revised 1998 - printed 1999

9. By the special provided wrench (B13), unscrew the

regulating nut (18) and take off the spring (16). (Fig. 4)

10. Remove retaining nut (17) using tool (B16) and take off
spring base plate (15). (Fig. 5)

NOTE To dislodge ring (69) from the retaining nut (17), just
lightly press.

11. Introduce low pressure air (less than 7 bar - 101.5 psi),
remove diaphragm (14) and poppet button (13) (Fig.6).

Fig. 4

WARNING !
DO NOT ATTEMPT TO TAKE OFF DIAPHRAGM BY USING SHARP
OR POINTED TOOLS. SCRATCHES ON THE DIAPHRAGM
SURFACE OR ON THE FIRST STAGE BODY MAY CAUSE AIR
LEAKAGE.

12. Unscrew hose (26) using wrench (B17) and remove the
O-ring (19).

13. Unscrew yoke retainer nut (7) using the special wrench (B1)
and remove yoke with knob (25) (Fig.7).

14. Using a snap ring plier (B14), extract retaining ring (2)
sintered filter (22) and filter spring (61) from the yoke Fig. 5
retainer nut (Fig.8).

15. Remove the O-ring (71) from the yoke retainer nut.

Fig. 6

Fig. 8 Fig. 7
 original copywriter 1987 REGULATORS FIRST STAGE RUBY-MR22 F 1-3
revised 1998 - printed 1999

RUBY - DIN version

D I S A S S E M B LY :
(from phase 13 to phase 15)
A. Using the 6 mm specially provided wrench (B8), unscrew
DIN connector (48) from the First Stage body (1).
B. Remove O-ring (71).
C. Remove spacer ring (79) and retaining DIN connector
wheel (49).
D. Remove O-ring (23)
E. Using a small screw-driver, remove the DIN connector
spring (68) and extract sintered filter (56).

16. Unscrew lever (B5), high (53) and low (20) pressure plugs
from the body of the First Stage. Remove relevant O-rings
(52) and (19).

CLEANING

WARNING !
PROTECT EYES AND SKIN ADEQUATELY WHEN WORKING
WITH ANY KIND OF ACID.

Cleaning requires all reusable rubber and plastic parts to be care-

fully cleaned by scrubbing with a soft brush in a mild detergent
and water solution. Do not use solvents or acids on rubber or
plastic parts. Metal parts should be cleaned in an ultrasonic clean-
er with fresh water or a mild acid solution. (White vinegar diluted
with warm water is recommended).
Before re-assembly make sure all parts have been carefully rinsed
and dried.

WARNING !
ACIDS OR OTHER SOLVENTS MAY DAMAGE RUBBER AND
PLASTIC PARTS. BEFORE CLEANING METAL PARTS, MAKE
SURE THAT ALL RUBBER AND PLASTIC PARTS HAVE BEEN
REMOVED.

WARNING !
DO NOT SOAK FIRST STAGE POPPET AND SINTERED FILTER IN
ACID.
F 1-4 FIRST STAGE RUBY-MR22 REGULATORS original copywriter 1987
revised 1998 - printed 1999

INSPECTION
Some important “key instruments” of the First Stage should be regularly replaced at each revision. Moreover, all O-rings
should be replaced. They are:

- Retaining ring (2) - code. 185015

- Conical sintered filter (22) - code. 186202
- Plane sintered filter (22) - code. 185014
- O-ring Bp (19) - code. 110106 code. Viton 110402
- O-ring Hp (52) - code. 110108 code. Viton 110404
- O-ring HP housing (6) - code. 110101 code. Viton 110401
- O-ring First Stage cover (71) - code. 110211 code. Viton 110413
- O-ring poppet seat (74) - code. 110107 code. Viton 110403
- O-ring yoke retainer nut (71) - code. 110211 code. Viton 110413
- O-ring DIN connector (only DIN version) (23) - code. 110117 code. Viton 110406

If the above-mentioned parts are not replaced, they should be inspected with a jeweler’s loop for the flaws listed below.

R E P L A C E A N Y PA RT W I T H T H E S E F L AW S :
Retaining ring: Inspect for distortions, cracking or damaged edges.
It’s advisable to replace them with new ones.
First stage valve (RUBY): Make sure that the hole through the poppet stem is not obstructed by foreign matter.
First stage valve (MR 22): Inspect for cuts, nicks, abrasion or separation of the rubber from the valve.
Make sure that the hole through the poppet stem is not obstructed by foreign matter.
Conical sintered filter: Inspect for sedimentation and rust.
Rust deposits may indicate a deteriorated diving cylinder.
Check possible cracking.
Hp chamber: Inspect for foreign matter or particles.
Back-up ring: Make sure that it is properly positioned within the Hp chamber.
Inspect its surface for cuts or contamination.

WARNING !
AFTER REMOVAL, THE BACK-UP RING SHOULD ALWAYS BE REPLACED.

O-rings: Inspect for cuts, tears or contamination.

The presence of any of these flaws may cause leakage.
First Stage diaphragm: Inspect for cracking, brittleness and tears.
First Stage body: Inspect for scratches on the diaphragm surface, in the cap and poppet seats.
Poppet seat: Inspect for chipping and/or scratches on the surface and in the O-ring seat.
O-rings seat: Inspect all metal surfaces in contact with O-rings and other seals for
chipping, scratches, deteriorated plating or contamination.
Springs: Inspect for cracking or broken coils.
 original copywriter 1987 REGULATORS FIRST STAGE RUBY-MR22 F 1-5
revised 1998 - printed 1999

R E A S S E M B LY
Before reassembly, lightly lubricate all O-rings with silicone
grease (General Electric Versalube G 322 or equivalent).
Lubricating the O-rings before reassembly will minimize the risk
of damage during reassembly.

WARNING !
IF THE FIRST STAGE IS USED FOR ENRICHED AIR DIVING, IT
MUST BE PERFECTLY CLEANED AND FREE FROM RESIDUAL
SILICONE OR FROM ANY FOREIGN MATTER. VITON O-RINGS
CAN BE LUBRICATED WITH SPECIFIC GREASE OXYGENE COM- Fig. 9
PATIBLE. DO NOT USE SILICONE GREASE!

1. Place the poppet button (13) into the First Stage body.
2. Install the First Stage diaphragm (14), placing it properly
into seat.
3. Screw the lever (B5).
4. Place spring base plate (15) on the diaphragm.
5. Re-mount ring (69) on the retaining nut (17).
6. Lightly lubricate the sealing edge of the retaining nut and
tighten into the First Stage body until snug, using wrench
(B16).

NOTE If a dynamometric key is used, set on 3-3,5 Kg/m (30-

35N/m - 267.6-312.2 lb.in.).

7. After lubricating the spring bases (16), place it on the base

plate.
8. Using the hex. tool (B13), tighten regulating nut (18) 2-3 Fig. 10
turns in the retaining nut.

NOTE Do not overtighten the regulating nut. This will cause

intermediate pressure to increase and interfere with
later adjustment.
9. Re-mount O-ring (74) on the poppet seat (75).
10. Place properly poppet seat into special tool (B21).
11. Lightly pressing, push poppet seat in position into First
Stage body (Fig. 9).
12. Insert poppet pin (12) into poppet seat (75) using the
special tool (B6) (Fig.10).
13. Place properly the ruby poppet on the pin, using the
Fig. 11
special tool (B6) (Fig.11).

WARNING !
BE VERY CAREFUL INSERTING POPPET. CHECK ITS CORRECT
POSITION OVER THE SEAT.
14. Place the spring over the poppet.
F 1-6 FIRST STAGE RUBY-MR22 REGULATORS original copywriter 1987
revised 1998 - printed 1999

15. Insert O-ring (6) into HP housing.

16. Place the complete HP housing (4-5-6) in position over
spring.
17. Re-assembly O-ring (71) in the First Stage cover (81).
18. Insert the HP housing button (80) in the spring (76).
19. Pressing HP housing button, insert components (76+80)
into cover, checking appropriate position.

WARNING !
A SMALL PLASTIC ROD CAN BE USED FOR REASSEMBLING
Fig. 12
COMPONENTS (76+80) IN ORDER TO AVOID ANY DAMAGE.
(FIG.11)

20. Using the hex. tool (B8), tighten cover into the First Stage
body.
21. Place the O-ring (71) on the yoke retaining nut (7).
22. Place the filter spring (61) and the conical filter (22) on the
yoke retainer nut body.
23. Using tool (B14), tighten retaining ring (2) and place it
properly over the filter.

NOTE Turn the retaining ring to check the right position.

24. Place the yoke (3) with knob (25) on the First Stage body.
25. Using tool (B1), tighten the complete yoke retainer nut
(7-71-61-22-2).

WARNING !
TO PREVENT THE YOKE RETAINER NUT (7) FROM BECOMING
LOOSE, PLACE TWO DROPS OF THREAD COMPOUND (LOCTITE
242E) IN THE BOTTOM OF THE THREADS OF THE FIRST STAGE
BODY.
DON’T STICK THE THREAD COMPOUND (LOCTITE 242E) ON
THE O-RING !
 original copywriter 1987 REGULATORS FIRST STAGE RUBY-MR22 F 1-7
revised 1998 - printed 1999

RUBY - DIN version

R E A S S E M B LY :
(from phase 21 to phase 25)
F. Place sintered filter (56) into the proper body seat DIN
connector (48) and fix it with spring (68).
G. Place O-ring (23) in the specially provided body seat DIN
connector (48).
H. Properly insert DIN connector wheel (49) and spacer ring
(79) into the DIN connector body (48).
I. Place the O-ring (71) in the seat on the DIN connector body.
J. Using tool (B8), tighten DIN connector body (48) into First
Stage body (1).

WARNING !
TO PREVENT THE DIN CONNECTOR (48) FROM BECOMING
LOOSE, PLACE TWO DROP OF THREAD COMPOUND (LOCTITE
242 E) IN THE BOTTOM OF THE THREADS OF THE FIRST STAGE
BODY.
DON’T STICK THE THREAD COMPOUND (LOCTITE 242E) ON
THE O-RING !

26. Unscrew lever (B5).

27. Place high and low pressure O-rings (19) and (52) onto
plugs (20) and (53) or onto Mares hoses.
28. Thread hoses into appropriate ports and tighten.
F 1-8 FIRST STAGE RUBY-MR22 REGULATORS original copywriter 1987
revised 1998 - printed 1999

FIRST STAGE RUBY - DFC Table 3

FIRST STAGE MR 22 - DFC Updated to 01-04-98

Ref. N. Code Description

ASSEMBLIES
A 185999 First stage RUBY assy
A 185971 First stage RUBY J. assy
A 185959 First stage RUBY Titanium
A 185979 First stage RUBY Titanium J. assy
A 185983 First stage MR 22 assy
A 185982 First stage MR 22 assy Titanium
Ref. N. Code Description Ref. N. Code Description A 185986 First stage MR 22 Japan assy Titan.
1 186203 Body 48 183056 DIN connector - 200 BAR Titanium A 185989 First stage RUBY DIN assy
1 185551 Body Titanium 48 183049 DIN connector - 300 BAR A 185988 First stage MR 22 DIN assy
2 185015 Retaining ring Ø 13 48 183055 DIN connector - 300 BAR Titanium A 185987 First stage MR 22 DIN assy Titanium
3 185208 Yoke 49 183006 DIN connector wheel - 200 BAR. A 185993 First stage MR 22 CWD assy
3 185552 Yoke titanium 49 183057 DIN connector wheel - 200 BAR Tit. A 185992 First stage MR 22 CWD assy Titanium
4 185209 H.P. housing 49 183001 DIN connector wheel - 300 BAR A 185998 First stage MR 22 DIN/CWD assy
5 185038 Back up ring 49 183058 DIN connector wheel - 300 BAR Tit. A 185997 First stage MR 22 DIN/CWD assy Tit.
6 110101 O-Ring 2012 52 110108 O-Ring 108 D 185210 H.P. housing assy (4-5-6)
6 110401 O-Ring 2012 Viton 006-9754 52 110404 O-Ring 108 Viton 611-9754 D 186259 H.P. housing assy (4-5-6) x RUBY Viton
7 186205 Nut, yoke retainer 53 185205 Plug, HP 7/16” F 183025 DIN connector 200 BAR assy
7 185553 Nut, yoke retainer Titanium 53 185555 Plug, HP 7/16” Titanium (23-48-49-56-62-68-71-79)
8 185011 Spring, poppet MR22 56 183053 Filter for DIN connector ø 9 F 183016 DIN connector 200 BAR assy x RUBY Viton
8 186306 Spring, poppet RUBY 57 185300 Body (CWD) (23-48-49-56-62-68-71-79)
9 185002 Poppet MR22 57 185570 Body (CWD) Titanium F 183026 DIN connector 200 BAR assy Titanium
9 186250 Poppet RUBY 58 185301 Diaphragm (CWD) (23-48-49-56-62-68-71-79)
12 186214 Pin 59 185302 Bezel, (CWD) F 183030 DIN connector 300 BAR assy
13 186213 Button, poppet 59 185571 Bezel, (CWD) Titanium (23-48-49-56-62-68-71-79)
14 185022 Diaphragm 61 185013 Spring, filter F 183017 DIN connector 300 BAR assy x RUBY Viton
15 185034 Plate, spring base 62 183013 Cap, DIN connector (23-48-49-56-62-68-71-79)
16 185023 Spring, diaphragm 68 183052 Spring, DIN connector ø 9 F 183031 DIN connector 300 BAR assy Titanium
17 186219 Retaining nut 69 186218 Ring (23-48-49-56-62-68-71-79)
17 185558 Retaining nut Titanium 71 110211 O-Ring 2050 I 185332 CWD KIT MR 22
18 185028 Regulating nut 71 110413 O-Ring 2050 Viton 014-9754 I 185333 CWD KIT MR 22 Titanium
18 185559 Regulating nut Titanium 74 110107 O-Ring 2031 *** 185322 INT maintenance Kit MR22
19 110106 O-Ring 106 74 110403 O-Ring 2031 Viton 01-9754 (2-5-6-19-22-52-71-74)
19 110402 O-Ring 106 Viton 610-9754 75 186216 Poppet seat *** 185167 INT maintenance RUBY Kit Viton.
20 185204 Plug 3/8” UNF 75 186249 Poppet seat RUBY (2-5-6-19-22-52-71-74)
20 185556 Plug 3/8” UNF Titanium 76 186210 Spring, HP housing *** 186151 DIN maintenance Kit MR22 - MR V16
22 185014 Filter 79 183051 Spacer ring, DIN connector (5-6-19-23-52-56-68-71-74)
22 186202 Conical sintered Filter 79 183059 Spacer ring, DIN connector Titanium *** 185168 DIN maintenance Kit 1st stage RUBY Viton
23 110117 O-Ring 115 80 186206 HP housing button (5-6-19-23-52-56-68-71-74)
23 110406 O-Ring 115 Viton 614-9754 81 186208 Plug ACCESSORIES
24 185009 Dust cap 81 185554 Plug Titanium 97 110215 O-Ring 2043
25 184076 Knob assembly 82 184313 Knob assembly label 97 110415 O-Ring 2043 Viton 013-9754
25 185560 Knob assembly, Titanium 89 184311 Label MR 22 98 186207 Plug, 1/2” UNF
48 183036 DIN connector - 200 BAR 89 184309 Label RUBY 98 185557 Plug 1/2” UNF Titanium
 MR16 - V16
FIRST STAGE
MR16 - V16 FIRST STAGE
 original copywriter 1987 REGULATORS FIRST STAGE MR16 - V16 F 2-1
revised 1998 - printed 1999

D I S A S S E M B LY :

To make disassembly easier, disconnect the hoses connected to

the First Stage and replace them with the appropriate plugs.
1. With setscrew wrench (B-8), unscrew first stage cover
(81-71-76-80).

2. Remove O-ring (71), anti-trail head (80) and spring (76)

from cover.

3. Remove poppet assembly (4-5-6), spring (8), first stage

poppet (9) and poppet pin (12) from first stage body (1).
(Fig. 1)

4. Remove O-ring (6) from poppet retainer.

WARNING ! Fig. 1
REMOVE BACK-UP RING (5) FROM POPPET RETAINER ONLY IF
REPLACEMENT IS NEEDED.

5. Position special tool B-21 on the first stage seat connector

(75) while exerting a slight pressure. Inject compressed air
(less than 7 bar - 101.5 psi) through a low pressure port.
(Fig. 2)

NOTE When the seat connector is displaced due to the com-

pressed air being pumped in, decrease pressure on
special tool (B-21).

WARNING !
DO NOT ATTEMPT TO REMOVE THE SEAT CONNECTOR USING
SHARP OR POINTED TOOLS; SCRATCHING THE SEAT CONNEC-
TOR MAY CAUSE OPERATING FLAWS.
Fig. 2

6. Remove seat connector (75) and O-ring (74) from the First
Stage.

7. Tighten lever B-5 to disassemble the First Stage (3/8” low

pressure port).

8. Remove protection cap (110).

9. With the setscrew wrench (B-13), unscrew regulating nut

(18) and spring (16). (Fig. 3).

Fig. 3
F 2-2 FIRST STAGE MR16 - V16 REGULATORS original copywriter 1987
revised 1998 - printed 1999

10. Use wrench B-16 to unscrew retaining nut (17) and remove
spring base plate (15). (Fig. 4)

11. While injecting compressed air (less than 7 bar - 101.5 psi)
remove diaphragm (14) and poppet button (13). (Fig. 5)

WARNING !
DO NOT ATTEMPT TO REMOVE THE DIAPHRAGM WITH SHARP
OR POINTED TOOLS; SCRATCHING THE DIAPHRAGM SURFACE
OR THE FIRST STAGE BODY SEAT MAY CAUSE AIR LEAKAGE.
Fig. 4

12. Unscrew yoke retainer nut (7) with wrench B-1, then
remove yoke (3) with knob assembly (25). (Fig. 6)

13. With snap ring pliers (B-14), remove yoke retaining nut,
retaining ring (2), tapered filter (22) and filter spring (61).
(Fig. 7)

14. Remove O-ring (71) from yoke retainer nut.

Fig. 5
DIN model

D I S A S S E M B LY :
(instead of steps 12-13-14)

A. Using the 6 mm specially provided wrench (B8), unscrew

DIN connector (48) from the First Stage body (1).
B. Remove O-ring (71).
C. Remove spacer (79) and DIN locking nut (49).
D. Remove O-ring (23).
E. Using a small screwdriver, remove pentagonal spring (68) Fig. 6
and filter (56).

15. Unscrew lever B-5 and HP (53) and LP (20) plugs from the
first stage body. Remove O-rings (52) and (19).

16. Remove body protection (109).

Fig. 7
 original copywriter 1987 REGULATORS FIRST STAGE MR16 - V16 F 2-3
revised 1998 - printed 1999

CLEANING

WARNING !
USE APPROPRIATE EYE AND SKIN PROTECTION WHEN HAN-
DLING ANY TYPE OF ACIDS.

Ordinary cleaning of any rubber parts to be reused should be per-

formed by washing all parts with a mixture of lukewarm water and
mild detergent and possibly fretting them with a soft brush. Do
not use any solvents or acids on rubber parts. Chromed brass and
stainless steel parts may be cleaned by ultrasound with fresh
water or, if this equipment is not available, with a mild acid solu-
tion (e.g. white vinegar, possibly diluted with lukewarm water).
Make sure that all parts are rinsed and dried before reassembly.

WARNING !
ACIDS OR OTHER SOLVENTS MAY DAMAGE PLASTIC AND
RUBBER PARTS. BEFORE CLEANING METAL PARTS, MAKE
SURE THAT ALL SEALS AND WEAR PARTS ARE REMOVED.

WARNING !
DO NOT IMMERSE THE FILTER IN AN ACID SOLUTION.

INSPECTION
Some key parts of the First Stage should be replaced routinely
whenever inspection is performed. In addition, considering their
low price, all O-rings should be replaced.
It is recommended to replace the following parts:
- Retaining ring (2) - code 185015
- Tapered filter (22) - code 186202
- LP O-rings (19) - code 110106 Viton code 110402
- HP O-rings (52) - code 110108 Viton code 110404
- Poppet retainer O-ring (6) - code 110101 Viton code 110401
- First stage plug O-ring (71) - code 110211 Viton code 110413
- Seat connector O-ring (74) - code 110107 Viton code 110403
- Yoke retainer nut O-ring (71) - code 110211 Viton code 110413
- Cap O-ring (DIN model only) (23) - code 110117 Viton code 110406

If these parts are not replaced, they should at least be inspected

with a jeweler’s loop to identify any of the flaws listed below.
F 2-4 FIRST STAGE MR16 - V16 REGULATORS original copywriter 1987
revised 1998 - printed 1999

D O N O T U S E PA RT S W I T H A N Y O F T H E F O L L O W I N G D E F E C T S :
Retaining rings: Check for any distortion, cracks or damaged edges.
It is recommended to always replace them.
First stage poppet: (MR16) Inspect for cuts, nicks, abrasion of rubber and separation of rubber from metal.
Make sure that the hole through the poppet stem is not clogged with foreign matter.
Tapered filter: Inspect for sediment or rust.
Rust deposits may be indicative of a deteriorated air cylinder. Check for any cracks.
HP poppet retainer: Inspect for any foreign matter or particles inside it.
Back-up ring: Make sure that it is properly positioned inside the HP poppet retainer and that its
surface is not distorted, nor contaminated with foreign matter.

WARNING !
REPLACE THE BACK-UP RING WHENEVER IT HAS BEEN REMOVED FROM THE HP POPPET RETAINER.

O-rings: Inspect for cuts, tears, flat spots or contamination.

The presence of any of these flaws may cause leakage.
First stage diaphragm: Inspect for cracking, brittleness, tears or gross surface distortion.
First stage body: Inspect for chipping and/or scratching of the plug seats, diaphragm sealing surface
and seat connector sealing surface.
Seat connector: Inspect for chipping, scratching and/or contamination on the sealing surface and on
the O-ring sealing surface.
Metal sealing surfaces: With all metal surfaces which make contact with O-rings or other seals, inspect for
nicks, scratches, loose plating or contamination.

R E A S S E M B LY
Before reassembly, lightly lubricate all O-rings with silicone
grease (General Electric Versalube G 322 or equivalent type).
Lubrication will minimize the risk of damage during reassembly.

WARNING !
IF THE FIRST STAGE IS USED FOR ENRICHED AIR DIVES, IT
MUST BE PERFECTLY CLEAN AND FREE OF SILICONE
RESIDUES OR CONTAMINATION. VITON O-RINGS MAY BE
LUBRICATED WITH A SPECIAL OXYGEN-COMPATIBLE GREASE.
DO NOT USE SILICONE GREASE!

1. Properly position body protection (109) on the first stage

body.
2. Screw lever B-5 into a low pressure port (3/8”) of the first
stage.
3. Reinstall O-ring (71) on yoke retainer nut (7).
4. Put filter spring (61) and tapered filter (22) in the yoke
retainer nut body.
5. With snap ring pliers (B-14), tighten retaining ring (2) and
position it correctly on the filter.
 original copywriter 1987 REGULATORS FIRST STAGE MR16 - V16 F 2-5
revised 1998 - printed 1999

NOTE Turn the retaining ring to make sure that it is properly

positioned.

6. Position yoke (3) and knob assembly (25) on the first

stage body
7. With wrench B-1, tighten yoke retainer nut assembly
(7-71-61-22-2).

WARNING !
TO PREVENT ACCIDENTAL LOOSENING OF THE YOKE RETAIN-
ER NUT, POUR ONE OR TWO DROPS OF SEALING COMPOUND
(LOCTITE 242 E TYPE) ON ITS THREADS.

DIN model

R E A S S E M B LY :
(instead of steps 3-4-5-6-7)
F. Place filter (56) in its seat in DIN connector (48), then lock
it in position with pentagonal spring (68).
G. Place O-ring (23) in its seat in DIN connector (48).
H. Position DIN locking nut (49) and spacer (79) on DIN
connector (48).
I. Position O-ring (71) in its seat on DIN connector.
J. With the 6 mm Allen wrench (B-8), tighten DIN connector
(48) into first stage body (1).

WARNING !
TO PREVENT ACCIDENTAL LOOSENING OF DIN CONNECTOR (48), POUR ONE OR TWO DROPS OF SEALING COM-
POUND (LOCTITE 242 E TYPE) ON ITS THREADS.

8. Insert poppet button (13) in the first stage body.

9. Install first stage diaphragm (14) in its correct position.
10. Install spring base plate (15) on the diaphragm.

11. Slightly lubricate the sealing edge of retaining nut (17) and
screw it into the first stage body, tightening with wrench
B-16.

NOTE If a torque wrench is used, set a torque value of

approximately 3-3.5 kg/m (approx. 30-35 N/m, 22-26
lbs.ft.).
12. Lightly lubricate diaphragm spring (16), then install it on
spring base plate.
13. With the setscrew wrench (B-13), tighten regulating nut
(18) by 2-3 turns into the retaining nut.
F 2-6 FIRST STAGE MR16 - V16 REGULATORS original copywriter 1987
revised 1998 - printed 1999

NOTE Do not overtighten the regulating nut. This will cause

intermediate pressure to increase and interfere with
later adjustment.

14. Install protection cap (110).

15. Install O-ring (74) on seat connector (75).
16. Properly position seat connector on special tool B-21.
17. With a slight pressure, push seat connector into position in
the first stage body. (Fig. 8)
18. Unscrew lever B-5.
Fig. 8
19. Insert poppet pin (12) in seat connector (75) using special
tool B-6. (Fig. 9)
20. Properly and carefully position first stage poppet (9) on
poppet pin (12) using special tool B-6. (Fig. 10)

WARNING !
EXTREME CARE IS NEEDED DURING POPPET INSTALLATION.
MAKE SURE THAT IT IS PROPERLY POSITIONED OVER ITS
SEAT CONNECTOR.

21. Place spring (8) on the poppet.

22. Install back-up ring (5) (if it had been disassembled) and
O-ring (6) in the poppet retainer.
Fig. 9
23. Position poppet retainer assembly (4-5-6) on the spring.
24. Reinstall O-ring (71) on first stage plug (81).
25. Properly install anti-trail head (80) into spring (76).
26. Press on the anti-trail head to snug the components
(76+80) into the plug.

WARNING !
COMPONENTS (76-80) SHOULD BE REASSEMBLED USING A
PLASTIC ROD TO PREVENT DAMAGE. MAKE SURE THAT THEY Fig. 10
ARE PROPERLY POSITIONED. (Fig. 11)

27. With a setscrew wrench (B-8), tighten the plug in the first
stage body.
28. Place LP (19) and HP (52) O-rings on their plugs (20) and
(53) or hoses.
29. Screw the plugs and/or hoses into the appropriate first
stage ports.
Fig. 11
 original copywriter 1987 REGULATORS FIRST STAGE MR16 - V16 F 2-7
revised 1998 - printed 1999

FIRST STAGE, MR 16 DFC Table 4

FIRST STAGE, MR 16 DFC NITROX
FIRST STAGE, V16 SCS DFC Updated to 01-04-98

Ref. Code Description

61 185013 Spring, filter
62 183013 Dust cap, DIN connector
68 183052 Pentagonal spring, DIN connector D.9
71 110211 O-Ring 2050
71 110211 O-Ring 2050 Viton 014-9707
74 110107 O-Ring 2031
74 110107 O-Ring 2031 Viton 011-9707
75 186216 Seat connector, MR16
75 186249 Seat connector, SCS V16
76 186210 Spring, poppet retainer
79 183034 Spacer, DIN connector
Ref. Code Description 80 186206 Anti-trail head
1 186240 Body, MR16 DFC 81 186208 Plug
2 185015 Retaining ring 13 107 184313 Label, knob assembly
3 185208 Yoke 107 184366 Label, knob assembly, Nitrox
4 185209 Poppet retainer 108 185266 Protection cap, C.W.D.
5 185038 Back-up ring 109 186243 Body protection, MR 16 tamp.
6 110101 O-Ring 2012 109 186265 Body protection, V16, XTR tamp.
6 110401 O-Ring 2012 Viton 006-9707 110 186245 Protection cap, tamp
7 186241 Nut, yoke retainer ASSEMBLIES
8 185011 Spring, poppet MR16 A 185973 First stage assembly, MR16
8 186306 Spring, poppet V16 A 185972 First stage assembly, MR 16 J.
9 185002 Poppet assembly, MR16 A 185974 First stage assembly, MR16 DIN
9 186304 Poppet assembly, Titanium V16 A 185960 First stage assembly, MR16 Nitrox
12 186214 Pin, poppet A 185961 First stage assembly, V16
13 185032 Button, poppet A 185962 First stage assembly, V16 DIN
14 185022 Diaphragm A 185967 First stage assembly, MR16 Nitrox J.
15 185034 Plate, spring base A 185968 First stage assembly, V16 J.
16 185023 Spring, diaphragm D 185210 Poppet assembly (4-5-6)
17 186219 Retaining nut D 186259 Poppet assembly (4-5-6), Nitrox
18 185028 Regulating nut F 183038 DIN connector assembly 200 BAR
19 110106 O-Ring 106 (23-48-49-56-62-68-71-79)
19 110402 O-Ring 106 Viton 610-9707 F 183037 DIN connector assembly 300 BAR
20 185204 Plug, LP - 3/8” (23-48-49-56-62-68-71-79)
22 186202 Tapered filter F 183040 DIN connector assembly 200 BAR, Nitrox
23 110117 O-Ring 115 (23-48-49-56-62-68-71-79)
23 110406 O-Ring 115 Viton 614-9707 F 183039 DIN connector assembly 300 BAR, Nitrox
24 185009 Dust cap (23-48-49-56-62-68-71-79)
25 184076 Knob assembly I 185336 C.W.D. kit, MR16-V16
48 183036 DIN connector body, 200 BAR *** 186152 First stage maintenance kit MR16-V16 INT.
48 183035 DIN connector body, 300 BAR (2-5-6-19-22-52-71-74)
49 183006 DIN connector wheel, 200 BAR *** 186151 First stage maintenance kit MR16-V16 DIN
49 183006 DIN connector wheel, 300 BAR (5-6-19-23-52-56-68-71-74)
52 110108 O-Ring 108 *** 186167 First stage maintenance kit RUBY / MR16-V16 INT. VITON
52 110404 O-Ring 108 Viton 611-9707 (2-5-6-19-22-52-71-74)
53 185205 Plug, H.P. 7/16” *** 186168 First stage maintenance kit RUBY / MR16-V16 DIN VITON
56 183056 Filter, DIN connector D.9 (5-6-19-23-52-56-68-71-74)
57 185300 Body, C.W.D. NOTES
58 185301 Diaphragm, C.W.D. In maintenance kits (codes 186150 and 186152), O-ring (74) of the V16 seat
59 185302 Bezel, C.W.D. connectoris also in Viton
 MR12 - V12
FIRST STAGE
MR12 - V12 FIRST STAGE
 original copywriter 1987 REGULATORS FIRST STAGE MR12 - V12 F 3-1
revised 1998 - printed 1999

D I S A S S E M B LY :

MR12 and V12 regulators:

To make disassembly easier, disconnect the hoses connected to
the First Stage and replace them with the appropriate plugs.

1. Screw lever B-5 into a low pressure port (3/8”) to

disassemble the First Stage.

2. Unscrew yoke retainer nut (7) with the special wrench

(B-1), remove yoke (3) and knob assembly (25) (Fig. 1).

DIN version

D I S A S S E M B LY : Fig. 1

(instead of step 2)

A. With the 6 mm Allen wrench (B-8), unscrew DIN

connector valve (51) and remove O-rings (23) and (50).
B. Remove locking nut (49).
C. With wrench B-16, unscrew DIN connector (48) and
remove O-ring (23).
3. Use snap ring pliers (B-14) to remove retaining ring (2),
filter (22), HP poppet retainer assembly (4+5+6), spring
(8), poppet (9) and poppet pin (12) from first stage body
(1). (Fig. 2)

4. Remove O-ring (6) from the HP poppet retainer.

WARNING !
Fig. 2
REMOVE BACK-UP RING (5) FROM HP POPPET RETAINER ONLY
IF REPLACEMENT IS NEEDED.

For V12 regulators only:

5. Locate special tool (B-21) on First Stage seat connector
(75) and exert a slight pressure. Inject compressed air (less
than 7 bar - 101.5 psi) through a low pressure port (3/8”).
(Fig. 3)

NOTE When the seat connector is displaced due to the com-

pressed air being pumped in, decrease pressure on
special tool (B-21).

WARNING !
DO NOT ATTEMPT TO REMOVE THE SEAT CONNECTOR USING
SHARP OR POINTED TOOLS; SCRATCHING THE SEAT CONNEC-
TOR MAY CAUSE OPERATING FLAWS. Fig. 3

6. Remove seat connector (75) and O-ring (74) from the First
Stage.
F 3-2 FIRST STAGE MR12 - V12 REGULATORS original copywriter 1987
revised 1998 - printed 1999

MR12 and V12 regulators:

7. Remove regulating nut cover (70).

8. With the setscrew wrench (B-13), unscrew regulating nut

(18) and remove spring (16). (Fig. 4)

9. Unscrew retaining nut (17) with wrench B-16 and remove

spring base plate (15). (Fig. 5)

10. Introduce compressed air (less than 7 bar - 101.5 psi)

through a low pressure port (3/8”), then remove diaphragm
(14) and poppet button (13).

NOTE To facilitate diaphragm removal, plug (e.g. with a

finger) the inlet to the HP poppet retainer. (Fig. 6)
Fig. 4

WARNING !
DO NOT ATTEMPT TO REMOVE THE DIAPHRAGM WITH SHARP
OR POINTED TOOLS; SCRATCHING THE DIAPHRAGM SURFACE
OR THE FIRST STAGE BODY SEAT MAY CAUSE AIR LEAKAGE.

11. Unscrew HP plug (53) and LP plug (29) from first stage
body. Remove O-rings (52) and (19).

12. Unscrew lever B-5 from the first stage body.

CLEANING

WARNING ! Fig. 5
USE APPROPRIATE EYE AND SKIN PROTECTION WHEN HAN-
DLING ANY TYPE OF ACIDS.

Ordinary cleaning of any rubber parts to be reused should be per-

formed by washing all parts with a mixture of lukewarm water and
mild detergent and possibly fretting them with a soft brush. Do
not use any solvents or acids on rubber parts. Chromed brass and
stainless steel parts may be cleaned by ultrasound with fresh
water or, if this equipment is not available, with a mild acid solu-
tion (e.g. white vinegar, possibly diluted with lukewarm water).
Make sure that all parts are rinsed and dried before reassembly.

Fig. 6
WARNING !
ACIDS OR OTHER SOLVENTS MAY DAMAGE PLASTIC AND
RUBBER PARTS. BEFORE CLEANING METAL PARTS, MAKE
SURE THAT ALL SEALS AND WEAR PARTS ARE REMOVED.

WARNING !
DO NOT IMMERSE THE FILTER IN AN ACID SOLUTION.
 original copywriter 1987 REGULATORS FIRST STAGE MR12 - V12 F 3-3
revised 1998 - printed 1999

INSPECTION
Some key parts of the First Stage should be replaced routinely whenever inspection is performed. In addition, consider-
ing their low price, all O-rings should be replaced.
It is recommended to replace the following parts:
- Retaining ring (2) - code 185015
- Filter (22) - code 185014
- LP O-rings (19) - code 110106 Viton code 110402
- HP O-rings (52) - code 110108 Viton code 110404
- Poppet retainer O-ring (6) - code 110101 Viton code 110401
- Seat connector O-ring (V12) (74) - code 110107 Viton code 110403
- DIN connector O-ring (DIN model) (50) - code 110203 Viton code 110409
- Cap O-ring (DIN model only) (23) - code 110117 Viton code 110406
If these parts are not replaced, they should at least be inspected with a jeweler’s loupe to identify any of the flaws listed
below.

D O N O T U S E PA RT S W I T H A N Y O F T H E F O L L O W I N G D E F E C T S :
Retaining rings: Check for any distortion, cracks or damaged edges.
It is recommended to always replace them.
First stage poppet: (MR12) Inspect for cuts, nicks, abrasion of rubber and separation of rubber from metal.
Make sure that the hole through the poppet stem is not clogged with foreign matter.
First stage poppet: (V12) Inspect for chipping and/or scratching on the seating surface.
Make sure that the hole through the poppet stem is not clogged with foreign matter.
Filter: Inspect for sediment or rust. Rust deposits may be indicative of a deteriorated air
cylinder. Check for any cracks.
HP poppet retainer: Inspect for any foreign matter or particles inside it.
Back-up ring: Make sure that it is properly positioned inside the HP poppet retainer and that its
surface is not distorted, nor contaminated with foreign matter.

WARNING !
REPLACE THE BACK-UP RING WHENEVER IT HAS BEEN REMOVED FROM THE HP POPPET RETAINER.
O-rings: Inspect for cuts, tears, flat spots or contamination.
The presence of any of these flaws may cause leakage.
First stage diaphragm: Inspect for cracking, brittleness, tears or gross surface distortion.
First stage body: (MR12) Inspect for chipping and/or scratching of the plug seats, diaphragm sealing
surface and seat connector sealing surface.

NOTE For accurate cleaning of the First Stage Seat Connector,

a slightly abrasive rubber can be used.

First stage body: (V12) Inspect for chipping and/or scratching of the plug seats, diaphragm sealing
surface and seat connector sealing surface.
Seat connector: (V12 only) Inspect for chipping, scratching and/or contamination on the sealing surface
and on the O-ring sealing surface.
Metal sealing surfaces: With all metal surfaces which make contact with O-rings or other seals, inspect for
nicks, scratches, loose plating or contamination.
F 3-4 FIRST STAGE MR12 - V12 REGULATORS original copywriter 1987
revised 1998 - printed 1999

R E A S S E M B LY
MR12 and V12 regulators:
Before reassembly, lightly lubricate all O-rings with silicone
grease (General Electric Versalube G 322 or equivalent type).
Lubrication will minimize the risk of damage during reassembly.

WARNING !
IF THE FIRST STAGE IS USED FOR ENRICHED AIR DIVES, IT
MUST BE PERFECTLY CLEAN AND FREE OF SILICONE
RESIDUES OR CONTAMINATION. VITON O-RINGS MAY BE
Fig. 7
LUBRICATED WITH A SPECIAL OXYGEN-COMPATIBLE GREASE.
DO NOT USE SILICONE GREASE!
1. Screw lever B-5 into a low pressure port (3/8”).
2. Put poppet button (13) in the first stage body.
3. Install first stage diaphragm (14) into position.
4. Place spring base plate (15) on the diaphragm.
5. Lightly lubricate the sealing edge of retaining nut (17) and
tighten it up into the first stage body using wrench B-16.
NOTE If a torque wrench is used, set a torque value of
approximately 3-3.5 kg/m (approx. 30-35 N/m 267.6-
312.2 lb.in.).
6. After lightly lubricating diaphragm spring (16), install it on
the spring base plate.
7. With the setscrew wrench (B-13), tighten regulating nut
(18) by 2-3 turns into the retaining nut.

NOTE Do not overtighten the regulating nut. This will cause

intermediate pressure to increase and interfere with
later adjustment.
8. Install regulating nut cover (70).
V12 regulators only:
9. Install O-ring (74) on seat connector (75).
10. Properly position seat connector using special tool B-21. Fig. 8

11. With a slight pressure, push seat connector into position

in the first stage body. (Fig. 7)

MR12 and V12 regulators:

12. Insert poppet pin (12) in seat connector (75) using special
tool B-6. (Fig. 8)
13. Properly and carefully position poppet (9) on poppet pin
(12), using special tool B-6. (Fig. 9)

WARNING !
EXTREME CARE IS NEEDED DURING POPPET INSTALLATION.
MAKE SURE THAT IT IS PROPERLY POSITIONED OVER ITS
SEAT CONNECTOR. Fig. 9
 original copywriter 1987 REGULATORS FIRST STAGE MR12 - V12 F 3-5
revised 1998 - printed 1999

14. Place spring (8) over the poppet.

15. Position back-up ring (5) (if it had been removed) and
O-ring (6) in HP poppet retainer.
16. Locate HP poppet retainer assembly (4-5-6) over the
spring.
17. Place filter (22) on HP poppet retainer.
18. Use the snap ring pliers (B-14) to tighten retaining ring (2)
and locate the latter on the filter. Press on the filter until the
retaining ring is perfectly positioned in the first stage
groove.

NOTE Turn the retaining ring to make sure that it is

properly positioned.

19. Position yoke (3) and knob assembly (25) on first stage
body.
20. With wrench B-1, tighten yoke retainer nut (7).

WARNING !
TO PREVENT ACCIDENTAL LOOSENING OF THE YOKE RETAIN-
ER NUT, POUR ONE OR TWO DROPS OF SEALING COMPOUND
(LOCTITE 242 E TYPE) ON ITS THREADS.

DIN version

R E A S S E M B LY :
(instead of steps 19 and 20)
D. Position O-ring (23) in the DIN connector (48).
E. Tighten DIN connector (48) on the first stage body using
wrench B-16.
F. Properly position DIN locking nut (29) on the first stage.
G. Install O-rings (23) and (50) on valve DIN connector (51).
H. With the 6 mm Allen wrench, tighten the valve DIN
connector into the first stage body.

WARNING !
TO PREVENT ACCIDENTAL LOOSENING OF DIN CONNECTOR
(48) AND VALVE DIN CONNECTOR (51), POUR ONE OR TWO
DROPS OF SEALING COMPOUND (LOCTITE 242 E TYPE) ON
THEIR THREADS.

21. Unscrew lever B-5.

22. Place LP (19) and HP (52) O-rings on their plugs (20) and
(53) or hoses.
23. Screw the plugs and/or hoses into the appropriate first
stage ports.
F 3-6 FIRST STAGE MR12 - V12 REGULATORS original copywriter 1987
revised 1998 - printed 1999

FIRST STAGE, MR12 DFC

FIRST STAGE, MR12 DFC NITROX Table 5
FIRST STAGE, V12 SCS DFC Updated to 30-05-97

Ref. Code Description

1 186021 Body, MR12 DFC
1 186305 Body, V12 DFC
2 185015 Retaining ring
3 185208 Yoke
4 185209 Poppet retainer
5 185038 Back-up ring
6 110101 O-Ring 2012
6 110401 O-Ring 2012 Viton 006-9707
7 186241 Nut, yoke retainer
8 185011 Spring, poppet MR12
8 186306 Spring, poppet V12
9 185002 Poppet assembly, MR12
9 185304 Poppet assembly, Titanium V12
12 185206 Pin, poppet
12 186303 Pin, poppet
13 185032 Button, poppet
14 185022 Diaphragm
15 185034 Plate, spring base
16 185023 Spring, diaphragm
17 184510 Retaining nut
18 184511 Regulating nut
18 185028 Regulating nut (C.W.D.)
19 110106 O-Ring 106
19 110402 O-Ring 106 Viton 610-9707
20 185204 Plug, LP - 3/8”
22 185014 Tapered filter
23 110117 O-Ring 115
23 110406 O-Ring 115 Viton 614-9707
24 185009 Dust cap
25 184076 Knob assembly
48 183008 DIN connector body, 200 BAR
48 183004 DIN connector body, 300 BAR
49 183006 DIN connector wheel, 200 BAR
49 183001 DIN connector wheel, 300 BAR
50 110203 O-Ring 2018
50 110409 O-Ring 2018 Viton 008-9707
51 179261 DIN connector 200 BAR
51 183003 DIN connector 300 BAR
52 110108 O-Ring 108
52 110404 O-Ring 108 Viton 611-9707
53 185205 Plug, H.P. 7/16”
57 185300 Body, C.W.D.
58 185301 Diaphragm, C.W.D.
59 185302 Bezel, C.W.D.
62 183013 Dust cap, DIN connector
70 184454 Plug, V12
70 184452 Plug, MR12
74 110107 O-Ring 2031
74 110403 O-Ring 2031 Viton 011-9707
75 186249 Seat connector, SCS V12
107 184313 Label, knob assembly
107 184366 Label, knob assembly, Nitrox

Ref. Code Description

ASSEMBLIES
A 185980 First stage assembly, MR12
A 185981 First stage assembly, MR 12 J.
A 185985 First stage assembly, MR12 DIN
A 185990 First stage assembly, MR12 CWD
A 185995 First stage assembly, MR12 DIN/CWD
A 185963 First stage assembly, MR12 Nitrox
A 185969 First stage assembly, MR12 Nitrox J.
A 185964 First stage assembly, V12 INT.
A 185965 First stage assembly, V12 DIN
D 185210 Poppet assembly (4-5-6)
D 185259 Poppet assembly (4-5-6), Nitrox
F 183020 DIN connector assembly 200 BAR
(23-48-49-50-51-62)
F 183015 DIN connector assembly 300 BAR
(23-48-49-50-51-62)
F 183042 DIN connector assembly 200 BAR, Nitrox
(23-48-49-50-51-62)
F 183041 DIN connector assembly 300 BAR, Nitrox
(23-48-49-50-51-62)
I 185335 C.W.D. kit, MR12
*** 186150 First stage maintenance kit MR12-V12 INT./DIN
(2-5-6-19-22-23-50-52-74)
*** 186154 First stage maintenance kit MR12-V12 INT./DIN Nitrox
(2-5-6-19-22-23-50-52-74)
NOTES
In maintenance kits (codes 186150 and 186152),
O-ring (74) of the V12 seat connector is in Viton
ACCESSORIES
*** 179257 Yoke adaptor assembly, INT./DIN
*** 179258 Nut adaptor assembly, INT./DIN
*** 179260 DIN nylon cap, external threading
 FIRST STAGE
MR10 FIRST STAGE
MR 10
 original copywriter 1987 REGULATORS M R 1 0 F I R S T S TA G E F 4-1
revised 1998 - printed 1999

To facilitate disassembly, remove all the hoses connected to the

first stage and replace with port plugs.

1. Insert the first stage disassembly tool (B-5) in one 3/8” low
pressure port.
2. Remove yoke retainer nut (69) using the special wrench
(B-1), then remove the yoke (3) and yoke knob (25). (Fig. 1)
3. Using the snap ring pliers (B-14), remove the snap ring (2),
sintered filter (22) and O-ring (71) from the yoke retainer nut
(69). (Fig. 2)
4. Remove the spring (8), poppet (9) and poppet pin (12) from
Fig. 1
the first stage body (1).

DIN version

D I S A S S E M B LY :
(instead of steps 2 - 3 - 4)
A. Using the 6-mm Allen wrench (B-8), unscrew the DIN
connector coupling (51) and remove O-rings (23) and (50).
B. Remove threaded locking ring (49) and wheel (79).
Fig. 2
C. Using a 20-mm wrench, unscrew the DIN connector body
(48) and remove O-ring (71).
D. Remove the sintered filter (DIN) (22), spring (8), poppet (9)
and poppet pin (12).

5. Remove the poppet seat (68) and its O-ring (52) from the
first stage body (1).

WARNING !
DO NOT ATTEMPT TO REMOVE THE POPPET SEAT WITH SHARP
OR POINTED TOOLS. ANY SCRATCHES ON THE SURFACE OF
THE POPPET SEAT MAY IMPAIR OPERATION. IT IS RECOM-
MENDED TO OPERATE ON THE OUTER DIAMETER OF THE SEAT, Fig. 3
AND NOT IN THE CENTER HOLE.

6. Remove the protection cap (70). (Fig. 3)

7. Using Allen wrench (B-8), unscrew adjusting nut (18) and
remove spring (16). (Fig. 3)
8. Unscrew retaining nut (17) using wrench (B-2) and remove
the spring base plate (15). (Fig. 4)
9. Pressurize with compressed air (below 7 bar - 101.5 psi)
through a low pressure port (3/8”) and remove diaphragm
(14) and poppet button (13). (Fig. 5)
Fig. 4
F 4-2 MR 10 FIRST STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

NOTE To facilitate removal of the diaphragm it is recom-

mended to close (using a finger, for example) the
entrance to the high pressure chamber (Fig. 5).

WARNING !
DO NOT ATTEMPT TO REMOVE THE DIAPHRAGM WITH SHARP
OR POINTED TOOLS. SCRATCHING OF THE DIAPHRAGM OR
FIRST STAGE SEATING SURFACE COULD CAUSE AIR LEAKAGE.
Fig. 5

10. Unscrew the high (53) and low pressure (20) port plugs
from the first stage body, and remove O-rings (52) and (19).
11. Unscrew the disassembly tool (B-5) from the first stage
body.

CLEANING

WARNING !
PROTECT EYES AND SKIN ADEQUATELY WHEN WORKING WITH
ANY KIND OF ACID.

For routine cleaning of reusable rubber components, wash all

parts in a mixture of hot water and mild detergent, scrubbing if
necessary with a soft brush. Do not use solvents or acids on rub-
ber components. Chrome plated brass and stainless steel parts
can be cleaned with an ultrasonic cleaner in fresh water or, if the
necessary equipment is not available, in a mild acid solution (for
example white vinegar, diluted with hot water as necessary).
Make sure that all components have been rinsed and dried before
proceeding with reassembly.

WARNING !
ACIDS OR OTHER SOLVENTS MAY DAMAGE PLASTIC AND
RUBBER PARTS. BEFORE CLEANING METAL COMPONENTS,
MAKE SURE THAT ALL SEALS AND OTHER PARTS SUBJECT TO
DETERIORATION HAVE BEEN REMOVED.

WARNING !
DO NOT SUBMERGE THE SINTERED FILTER IN AN ACID SOLU-
TION.
 original copywriter 1987 REGULATORS M R 1 0 F I R S T S TA G E F 4-3
revised 1998 - printed 1999

INSPECTION
Certain first stage components should be regularly replaced dur-
ing routine service. Moreover, in view of their relatively low cost,
all the O-rings should also be replaced.
The components to replace are:

Description Reference Part Number

Snap ring (2) - cod. 185015
Sintered filter (22) - cod. 185014
Sintered filter (DIN version only) (22) - cod. 184074
Poppet seat (68) - cod. 184067
O-ring, LP (19) - cod. 110106 cod. Viton 110402
O-ring, HP (52) - cod. 110108 cod. Viton 110404
O-ring, DIN connector body (DIN vers.) (71) - cod. 110211 cod. Viton 110413
O-ring, Poppet seat (52) - cod. 110108 cod. Viton 110404
O-ring, DIN connector coupling (DIN version) (50) - cod. 110203 cod. Viton 110409
O-ring, DIN connector (DIN version) (23) - cod. 110117 cod. Viton 110406

If these components are not replaced, they should at least be

inspected with a jeweler’s magnifying glass for the following
defects:

D O N O T U S E PA RT S W I T H T H E F O L L O W I N G D E F E C T S :
Snap rings: Inspect for distortion, cracks or damaged edges. It is advisable to always replace them with
new ones.
First stage poppet: Inspect for chipping and/or scratches on the sealing surface.
Sintered filter: Inspect for sedimentation and rust. Rust deposits may indicate corrosion of the air tanks.
Check for any cracks.
O-rings: Inspect for cuts, deformation or foreign particles. The presence of any of these defects may
result in leakage.
First stage diaphragm: Inspect for splitting, cuts, tears or large surface deformations.
First stage body: Inspect for chipping and/or scratches in the port plug seats, the diaphragm sealing surface
and housing of the poppet seat.
O-ring seats: Inspect all the metal surfaces in contact with O-rings or other seals for scratches, chipping,
deteriorated chrome-plating or foreign particles.
Springs: Inspect for any deformed, flawed or broken coils.

R E A S S E M B LY
Before reassembling, lightly lubricate all the O-rings with silicone
grease (type General Electric Versalube G 322 or equivalent).
Lubrication reduces the likelihood of damage during reassembly.

WARNING !
IF THE FIRST STAGE IS USED FOR DIVING WITH OXYGEN-RICH
MIXTURES, IT MUST BE PERFECTLY CLEANED AND FREE OF
ANY RESIDUAL SILICONE OR OTHER IMPURITIES. VITON O-
RINGS MUST BE LUBRICATED WITH SPECIAL OXYGEN-COM-
PATIBLE GREASE. DO NOT USE SILICONE GREASE!
F 4-4 MR 10 F IRST STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

1. Screw the first stage disassembly tool (B-5) into a low

pressure port (3/8”).
2. Place the poppet button (13) in the first stage body.
3. Install the first stage diaphragm (14), positioning it
correctly in its seat.
4. Position the spring base plate (15) on the diaphragm.
5. Lightly lubricate the sealing rim of the retaining nut (17) and
screw it into the first stage body, locking it down fully with
wrench (B-2).

NOTE If using a torque wrench, set the torque for 3-3.5 kg/m
(approx. 30-35 N/m - 267.6-312.2 lb.in.).

6. After lightly lubricating the bases of spring (16), center it on

the base plate.
7. Using the Allen wrench (B-8), screw adjusting nut (18)
through 2-3 turns into the retaining nut.

NOTE Do not overtighten the adjusting nut; this causes an

increase in the intermediate pressure and interferes
with subsequent adjustments.

8. Assemble the protection cap (70).

9. Reassemble the O-ring (52) on the poppet seat (68).
10. Using the special tool (B-6), apply a slight pressure to
correctly position the complete poppet seat inside the first
stage body.
11. Insert the poppet pin (12) into the poppet (9).
12. Without applying excessive force, correctly center poppet (9)
and pin (12) inside the hole of the poppet seat (68).

WARNING !
TAKE PARTICULAR CARE DURING INSERTION OF THE POPPET.
CHECK THAT THE POPPET IS CORRECTLY POSITIONED ON ITS
SEAT.

13. Place spring (8) on top of poppet (9).

14. Position the sintered filter (22) (Diameter 13 mm -

COD. 185014) in the housing of the yoke retainer nut (69).
15. Using the snap ring pliers (B-14), tighten the snap ring (2)
and correctly position it on the filter.

NOTE Rotate the snap ring to check that it has been

correctly positioned.
 original copywriter 1987 REGULATORS M R 1 0 F I R S T S TA G E F 4-5
revised 1998 - printed 1999

CAUTION !
IF THE SMALLER SINTERED FILTER (22) (DIAMETER 8 mm -
COD. 184074) IS ASSEMBLED IN THE FIRST STAGE, POSITION
THE CENTER RELIEF INSIDE THE SPRING (8).

16. Fit the O-ring (71) inside the seat of the yoke retainer nut
(69).
17. Assemble the yoke (3) and knob (25) on the first stage body.
18. Using wrench (B-1), fully lock down the complete yoke
retainer nut assembly (2-22-69-71).

WARNING !
TAKE GREAT CARE WHEN CARRYING OUT THE OPERATION
DESCRIBED IN STEP 19, TO AVOID DAMAGING THE INTERNAL
COMPONENTS.

WARNING !
TO PREVENT THE YOKE RETAINER NUT (69) FROM ACCIDEN-
TALLY WORKING LOOSE, APPLY TWO DROPS OF THREAD
COMPOUND (TYPE LOCTITE 242 E) ON THE THREAD OF THE
YOKE RETAINER NUT AND ON THE PART FURTHEST FROM THE
O-RING.
DO NOT APPLY THREAD COMPOUND ON THE O-RINGS AND HP
HOLE OF THE YOKE RETAINER NUT!
F 4-6 MR 10 F IRST STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

DIN version

R E A S S E M B LY :
(instead of steps 15-16-17-18)
E. Correctly position the sintered filter (DIN - cod. 184074) with
the relief inside spring (8).
F. Position the O-ring (71) in the seat of the DIN connector body
(48).
G. Screw the DIN connector body (48) onto the first stage body,
locking it down fully with a 20-mm wrench.
H. Correctly position the DIN connector wheel (79) and
threaded locking ring (49) on the first stage.
I. Fit O-rings (23) and (50) on the DIN connector coupling (51).
J. Using a 6-mm Allen wrench (B-8), lock down the DIN
connector coupling (51) on the first stage body.

WARNING !
TO PREVENT THE DIN CONNECTOR BODY (48) AND THE DIN
CONNECTOR COUPLING (51) FROM WORKING LOOSE, APPLY
TWO DROPS OF THREAD COMPOUND (TYPE LOCTITE 242 E)
ON THEIR THREADS AT THE POINT FURTHEST FROM THE O-
RING.
DO NOT APPLY THREAD COMPOUND ON THE O-RINGS OR ON
THE HP HOLE OF THE DIN CONNECTOR BODY!

19. Unscrew disassembly tool (B-5)

20. Fit the low (19) and high-pressure (52) O-rings on the
corresponding plugs (20) and (53) or hoses.
21. Screw the port plugs and/or hoses onto their respective first
stage ports.
 original copywriter 1987 REGULATORS M R 1 0 F I R S T S TA G E F 4-7
revised 1998 - printed 1999

Table 25
FIRST STAGE, MR 10 Updated to 31-01-91

Ref. Code Description Ref. Code Description

1 184065 Body 19 110106 OR 106
2 185015 Snap ring - int. f 13 26 185098 Complete hose f 4.5
3 185208 Yoke 27 110205 OR 2025
8 184071 Poppet spring 28 184051 Poppet seat
9 184070 Poppet 30 184156 Poppet body
12 184072 Poppet pin 31 184078 Spring
13 185032 Poppet button 32 Second stage case (see H)
14 185022 Diaphragm 33 185051 Demand lever lock nut
15 185034 Spring base plate 34 185049 Washer
16 185023 Diaphragm spring 35 185050 Demand lever
17 184069 Diaphragm retaining nut 36 185056 Diaphragm
18 184073 Spring adjusting nut 39 184085 Cover assembly, black (line)
19 110106 OR 106 39 184086 Cover assembly, lime
20 185204 UNF 3/8” port plug 39 184087 Cover assembly, pink
22* 185014 Sintered filter 39 184130 Cover assembly, white
22 184074 Sintered filter (DIN) 39 184131 Cover assembly, orange
23 110117 OR 115 39 184132 Cover assembly, blue
24 185009 Protection cap 40 184006 Exhaust valve
25 184076 Yoke retainer knob 41 184438 Exhaust tee
48 183005 DIN connector body (DIN) 43 157984 Mouthpiece clamp
49 183006 Threaded locking ring (DIN) 44 185089 Clear mouthpiece
50 110203 OR 2018 45 179902 Black hose protector
51 179261 DIN connector coupling (DIN) 47 184062 Poppet seat, rubber
52 110108 OR 108 55 184009 Hose connector
53 185205 7/16” HP port plug 56 110247 OR 3043
57 185300 Body (EPK) 63 184050 Safety clip
58 185301 Diaphragm (EPK) 64 184154 Case plug
59 185302 Ring ((EPK) 65 184155 Case assembly snap ring
68 184067 Poppet seat 66 110220 OR 2062
69* 184063 Yoke retainer nut 67 184157 Case assembly connector
70 184066 Cap 72 184077 Antifriction disk
71 110211 OR 2050 77 184042 Case assembly connector lock
79 183007 DIN connector wheel
COMPLETE ASSEMBLIES COMPLETE ASSEMBLIES
A 184081 complete 1st stage G 184058 complete 2nd stage RH
A 184064 complete DIN 1st stage G 184059 complete 2nd stage LH
I 185306 complete EPK kit H 184158 case with vane
*** 185261 Cpl. seal kit L 184079 connector assembly
*** 185262 Cpl. repair kit (28-30-31-33-34-35-47-55-66-67)
MR12 II FIRST STAGE
FIRST STAGE
MR 12 II
 original copywriter 1987 REGULATORS FIRST STAGE MR12 II F 5-1
revised 1998 - printed 1999

D I S A S S E M B LY :

To facilitate disassembly, remove all the hoses connected to the

first stage and replace with port plugs.

1. Screw the first stage disassembly tool (B-5) into one low
pressure port (3/8”).
2. Using Allen wrench (B-13), unscrew the adjusting nut (18)
and remove the spring (16).
3. Unscrew the retaining nut (17) using wrench (B-2) and
remove the spring base plate (15).
4. Pressurize with compressed air (below 7 bar - 101.5 psi)
through a low pressure port (3/8”) and remove the
diaphragm (14), poppet button (13) and poppet pin (12).

WARNING !
DO NOT ATTEMPT TO REMOVE THE DIAPHRAGM WITH SHARP
OR POINTED TOOLS. SCRATCHING OF THE DIAPHRAGM OR
FIRST STAGE SEATING SURFACE COULD CAUSE AIR LEAKAGE.

5. Using the special wrench (B-11), unscrew the poppet seat

chamber assembly (11). (Fig.1)
6. Remove the O-ring (10) from the poppet seat chamber (11).
7. Using the snap ring pliers (B-14), remove the snap ring (2),
the balancing chamber assembly (4) and the first stage
poppet (9) from the poppet seat chamber (11). Fig. 1

8. Remove the O-ring (6) from the HP chamber.

WARNING !
REMOVE THE BACKUP RING (5) FROM THE HP CHAMBER (4)
ONLY IN CASE OF REPLACEMENT.

9. Unscrew the yoke retainer knob (25).

10. Using the snap ring pliers (B-14), remove the snap ring (2)
from the seat in the first stage body (1), extracting the
sintered filter (22) and the filter spring (61).

NOTE On older first stage models it is possible to find o-ring

(2037), with code 110110, instead of the filter spring
(61).
11. Unscrew the high (53) and low-pressure (20) port plugs
from the first stage and remove O-rings (52) and (19).
12. Unscrew the disassembly tool (B-5) from the first stage.
F 5-2 FIRST STAGE MR12 II REGULATORS original copywriter 1987
revised 1998 - printed 1999

CLEANING

WARNING !
PROTECT EYES AND SKIN ADEQUATELY WHEN WORKING
WITH ANY KIND OF ACID.

For routine cleaning of reusable rubber components, wash all

parts in a mixture of hot water and mild detergent, scrubbing if
necessary with a soft brush. Do not use solvents or acids on rub-
ber components. Chrome plated brass and stainless steel parts
can be cleaned with an ultrasonic cleaner in fresh water or, if the
necessary equipment is not available, in a mild acid solution (for
example white vinegar, diluted with hot water as necessary).
Make sure that all components have been rinsed and dried before
proceeding with reassembly.

WARNING !
ACIDS OR OTHER SOLVENTS MAY DAMAGE PLASTIC AND
RUBBER PARTS. BEFORE CLEANING METAL COMPONENTS,
MAKE SURE THAT THE SEALS AND OTHER PARTS SUBJECT TO
DETERIORATION HAVE BEEN REMOVED.

WARNING !
DO NOT SUBMERGE THE SINTERED FILTER IN AN ACID SOLU-
TION.

INSPECTION
Certain components of the first stage should be replaced at each routine service. Moreover, in view of their relatively
low cost, all the O-rings should also be replaced.
The components to replace are:

- Snap ring (2) - code 185015

- Sintered filter (22) - code 185014
- First stage poppet (9) - code 185002
- O-ring, LP (19) - code 110106
- O-ring, HP (52) - code 110108
- O-ring, HP chamber (6) - code 110101
- O-ring, poppet seat chamber (10) - code 110190

If these components are not replaced, they should at least be inspected with a jeweler’s magnifying glass for the
following defects.
 original copywriter 1987 REGULATORS FIRST STAGE MR12 II F 5-3
revised 1998 - printed 1999

D O N O T U S E PA RT S W I T H T H E F O L L O W I N G D E F E C T S :

Snap rings: Inspect for distortion, cracks or damaged edges. It is recommended to always replace
them with new ones.
First stage poppet: Inspect for cuts, nicks, rubber abrasions or separation of the rubber from the poppet seat.
Make sure that the hole through the poppet stem is not obstructed by foreign matter.
Sintered filter: Inspect for sedimentation and rust. Rust deposits may indicate corrosion of the air tanks.
Check for any cracks.
HP chamber: Inspect the interior for any foreign matter or particles.
Backup ring: Make sure that it is correctly positioned inside the HP chamber, and inspect its surface
for deformations or foreign particles.

WARNING !
THE BACKUP RING SHOULD BE REPLACED EVERY TIME IT IS REMOVED FROM THE HP CHAMBER.

O-rings: Inspect for cuts, deformation or foreign particles. The presence of any of these defects
may result in leakage.
First stage diaphragm: Inspect for splitting, cuts, tears or major surface deformations.
Poppet seat chamber: Inspect for chipping and/or scratches on the O-ring seat and the poppet sealing surface.

NOTE A slightly abrasive rubber may be used for thorough

cleaning of the poppet seat chamber.

First stage body: Inspect for chipping and/or scratches on the port plug seats, the sealing surface of the
diaphragm and the poppet seat housing.
O-ring seats: Inspect all the metal surfaces in contact with the O-rings or other seals for any scratches,
chipping, deteriorated plating or foreign particles.
Springs: Inspect for any deformed, flawed or broken coils.

R E A S S E M B LY
Before reassembling, lightly lubricate all the O-rings with silicone
grease (type General Electric Versalube G 322 or equivalent).
Lubrication reduces the likelihood of damage during reassembly.

1. Correctly position the first stage poppet (9) on the seat in

the poppet chamber (11).
2. Place the spring (8) on top of the poppet (9).
3. Fit the backup ring (5) (if disassembled) and the O-ring (6)
in the HP chamber (4).
4. Position the HP chamber assembly (4-5-6) on top of the
spring.
5. Using the snap ring pliers (B-14), tighten the snap ring (2)
and position it on top of the filter; press on the filter and
snap ring until the snap ring is perfectly positioned inside
the groove of the first stage body.

NOTE Rotate the snap ring to check that it has been

correctly positioned.
F 5-4 FIRST STAGE MR12 II REGULATORS original copywriter 1987
revised 1998 - printed 1999

6. Reassemble the O-ring (10) in the poppet seat chamber (11).

WARNING !
BE CAREFUL NOT TO DAMAGE THE O-RING ON THE THREADS
OF THE POPPET SEAT CHAMBER.

7. Position the poppet seat chamber assembly (11) in its

housing in the first stage body and lock down fully using the
special wrench (B-11).
8. Insert the poppet pin (12) in the center hole of the poppet
seat chamber (11) in the first stage.

9. Place the poppet button (13) on top of the poppet pin and
press it a few times to check its correct movement and the
exact position of the poppet (9) inside the poppet seat
chamber.
10. Install the first stage diaphragm (14), positioning it
correctly in the housing in the first stage.
11. Position the spring base plate (15) on the diaphragm (14).
12. Screw on the disassembly tool (B-5).
13. Lightly lubricate the sealing rim of the retaining nut (17) and
screw it into the first stage body, locking it down fully with
wrench (B-2).

NOTE If using a torque wrench, set the torque for approxi-

mately 3-3.5 kg/m - 0.915-1.067 ft. lbs. (30-35 N/m -
267,6-312,2 lb.in.).
14. After having lightly lubricated the bases of spring (16),
center it on the base plate (15).
15. Using the Allen wrench (B-13), screw the adjusting nut (18)
through 2-3 turns into the retaining nut.

NOTE Do not overtighten the adjusting nut; this causes an

increase in the intermediate pressure and interferes
with subsequent adjustments.

16. Unscrew the disassembly tool (B-5).

17. Place the low (19) and high-pressure (52) O-rings on port
plugs (20) and (53) or on the hoses.
18. Screw the port plugs and/or hoses onto their corresponding
first stage ports.
 original copywriter 1987 REGULATORS FIRST STAGE MR12 II F 5-5
revised 1998 - printed 1999

Table 30
FIRST STAGE, MR12 II Updated to 30-01-91

Ref. Code Description Ref. Code Description

1 185001 Body 19 110106 O-Ring 106
2 185015 Retaining ring 26 185098 Hose ø 4,5
4 185016 H.P. housing 27 110205 O-Ring 2025
5 185038 Back-up ring 28 185082 Seat connector
6 110101 O-Ring 2012 29 110191 O-Ring 3-906
8 185011 Poppet spring 30 185058 Poppet body
9 185002 Poppet assembly 31 185059 Poppet spring
10 110190 O-Ring 1A104 K6 32 *** Case (see H)
11 185012 Poppet housing 33 185051 Locknut, demand lever
12 185020 Pin, poppet 34 185049 Washer, demand lever
13 185032 Button, poppet 35 185050 Demand lever
14 185022 Diaphragm 36 185056 Diaphragm
15 185034 Plate, spring base 37 185073 Clamp, ring
16 185023 Spring, diaphragm 38 185075 Screw 3x16, clamp ring
17 185024 Retaining nut 39 184092 Cover assembly black
18 185028 Regulating nut 40 185052 Exhaust valve
19 110106 O-Ring 106 42 *** Vane (see ref. H)
20 185204 Plug, LP - 3/8” 43 157984 Mouthpiece clamp
22 185014 Tapered filter 44 185089 Mouthpiece
24 185009 Dust cap 45 179902 Hose protector, first stage, black
25 184076 Knob assembly 47 185060 Poppet seat, rubber
52 110108 O-Ring 108
53 185205 Plug, H.P. 7/16” ASSEMBLIES
61 185016 Spring, filter H 185252 Case assembly w/vane

ASSEMBLIES
A 185004 First stage assembly
D 185018 H.P. housing assy (4-5-6)
*** 185261
*** 185262 Maintenance kit assy
R1 - R2 FIRST STAGE
FIRST STAGE
R1 - R2
 original copywriter 1987 REGULATORS F I RS T S TA GE R 1 - R 2 F 6-1
revised 1998 - printed 1999

D I S A S S E M B LY :
1. Remove all hoses from the first stage
2. Insert the disassembling tool for the first stage (B5) into a
LP port.
3. With a pin wrench, unscrew cover (85), remove spring (8)
and spring washers (82), if present.

NOTE Up to two spring washers may be found.

4. Remove the compiete piston (84-88-86-50) from the cover

(Fig.1).
5. Remove 0-rings (86) and (50) from piston. Fig. 1
6. Remove the piston seat (86) with tool (B22) (Fig. 2).
7. Remove yoke retaining nut (7) with wrench (B-1) then
remove yoke (3) with knob (25) (Fig. 3).

DIN version

D I S A S S E M B LY :
(instead of step 6)
A. Using a 6 mm wrench (B-8), unscrew the DIN coupling
attachment (51) and extract the O-rings (23) and (50).
Fig. 2
B. Extract the ring nut (49).
C. Unscrew the DIN union attachment and remove O-ring (23).

8. Remove disassembly tool (BS) from LP port.

9. Remove filter retaining ring (2) with snap ring pliers (Fig.4)
10. Lift out sintered filter (22) and filter spring (61).
11. Remove low (20) and high pressure (53) port plugs.
Remove O-rings (19) and (52).

CLEANING
Cleaning requires all reusable rubber and plastic parts to be care- Fig. 3
fully cleaned by scrubbing with a soft brush in a mild detergent
and water solution. Do not use solvents or acids on rubber or
plastic parts. Metal parts should be cleaned in an ultrasonic
cleaner with fresh water or a mild acid solution. (White vinegar
diluted with warm water is recommended). Before reassembly
make sure all parts have been carefully rinsed and dried.

WARNING !
THE FIRST STAGE PISTON SEAT AND SINTERED FILTER MAY BE
DAMAGED BY ACID OR ULTRASONIC CLEANING. DO NOT SOAK
FIRST STAGE POPPET AND SINTERED FILTER IN ACID OR AN
ULTRASONIC CLEANER. THIS MAY LEAD TO REGULATOR
FAILURE RESULTING IN SERIOUS INJURY OR DEATH. Fig. 4
F 6-2 FIRST S TAGE R1-R2 REGULATORS original copywriter 1987
revised 1998 - printed 1999

WARNING !
PROTECT EYES AND SKIN ADEQUATELY WHEN WORKING WITH
ANY KIND OF ACID. BEFORE CLEANING METAL PARTS, MAKE
SURE THAT ALL RUBBER AND PLASTIC PARTS HAVE BEEN
REMOVED. ACIDS OR OTHER SOLVENTS MAY DAMAGE RUB-
BER AND PLASTIC PARIS.

INSPECTION
The following first stage components should be replaced
during routine service.

Description Part Number

Retaining ring 185015
Filter 185014
Piston seat 186223
O-ring piston (stem) 110203
O-ring piston (head) 110224
O-ring LP ports 110106
O-ring HP ports 110108
O-ring DIN coupling attachment (DIN version) 110203
O-ring DIN coupling (DIN version) 110117

If the following parts are not replaced, they should be inspected with
a jewelers loop for the defects listed below. Replace any part with these flaws.

Piston: Inspect for any signs of corrosion or wear.

Make sure the hole through the piston stem is open and not clogged with foreign matter.
Piston seat. Inspect for any deformation or trapped foreign matter. If a new piston seat is not available, the piston
housing can be reversed if the surface is not damaged or previously used.
Cover: Inspect the surface in contact with the piston 0-ring for chipping, scratches, or deteriorated plating.
Filter: Inspect for sedimentation and rust. Rust deposits may indicate a deteriorated diving cylinder.
Retaining ring: Inspect for any distortion, cracks or damaged edges.

NOTE The filter retaining ring should be replaced every time

it is removed from the first stage.

Springs: Inspect for cracking or broken coils.

Spring washers: Inspect for distortion, brittleness and cracking.
0-rings: Inspect for cuts, tears, flat spots or contamination. The presence of any of these defects may cause
leakage.
0-ring seats: Inspect all surtaces in contact with 0-rings and other seals for chipping, scratches, deteriorated
plating or contamination.
First stage body: Inspect the tapered surface of the housing for any chipping and/or deep scratches. If the housing is
damaged replace the first stage body.

NOTE A slightly abrasive rubber (such as a clean pencil

eraser) may be used to clean the housing.
 original copywriter 1987 REGULATORS F I RS T S TA G E R 1 - R 2 F 6-3
revised 1998 - printed 1999

R E A S S E M B LY
Before reassembly, slightly lubricate all 0-rings with silicone
grease (General Electric, Versalube G-322 or equivalent).
Lubricating the O-rings before reassembly will minimize the risk
of damage during reassembly.

WARNING !
IF THE FIRST STAGE IS USED FOR ENRICHED AIR DIVING, IT
MUST BE PERFECTLY CLEANED AND FREE FROM RESIDUAL
SILICONE OR FROM ANY FOREIGN MATTER. VITON O-RINGS
CAN BE LUBRICATED WITH SPECIFIC OXYGEN COMPATIBLE
GREASE. DO NOT USE SILICONE GREASE.

1. Place the filter spring (61) and sintered filter (22) into first
stage body (Fig. 4).
2. Compress the retaining ring (2) with snap ring pliers and
position the ring over the sintered filter. Compress the
sintered filter until the retaining ring fits into the groove in
the first stage body.

NOTE When the filter retaining ring is properly positioned in

the groove of the first stage body it can be rotated
freely using the snap ring pliers.

3. Insert tool (BS) in a LP port of the first stage body.

4. Place yoke (3) with knob (25) on first stage body
5. Install yoke retaining nut (7) and tighten into place with
wrench (B1) (Fig. 3).

NOTE To prevent the yoke retainer nut from becoming loose,

place two drops of thread compound (Loctite 242 E) in
the bottom of the threads of the first stage body.
Don’t stick the thread compound (Loctite 242 E) onto
the O-rings !
F 6-4 FIRST S TAGE R1-R2 REGULATORS original copywriter 1987
revised 1998 - printed 1999

DIN version
1 WASHER 2 WASHERS

R E A S S E M B LY :
(replacing stage 4 and 5)
D. Place o-ring (23) into the housing of DIN union attachment
(48).
E. Screw the DIN union attachment (48) onto the first stage
body, tightening as far as possible with the spanner.
F. Place the ring nut (49) onto the first stage correctly.
G. Connect up the o-rings (23) and (50) to the DIN coupling
attachment. Fig. 5

H. Using the 6 mm. wrench, (B-8) tighten the DIN coupling

attachment in the body of the first stage.

WARNING !
TO PREVENT THE DIN UNION ATTACHMENT (48) AND THE DIN
COUPLING ATTACHMENT (51) BECOMING ACCIDENTALLY
LOOSE, POUR ONE OR TWO DROPS OF THREAD COMPOUND
(LOCTITE 242 E TYPE) ONTO THE THREADING.
DO NOT POUR THREAD COMPOUND ONTO THE O-RINGS !

6. Insert the piston seat (88) into the piston (84).

7. Place 0-rings (50) and (86) onto piston
8. Place the complete piston (84-88-86-50) into the cover
(85) (Fig. 1).
9. Spring washers:
a. If one washer is present place it against the piston.
b. If two washers are present place one against the
piston and place the second washer into the first
stage body (Fig. 5).
10. Slightly lubricate the base of the spring (8) then place it
into the first stage body.
11. Thread cover (85) onto first stage body and tighten into
place with a pin wrench.
12. Remove tool (B5).
13. Install 0-rings (19) and (52) onto hoses or port plugs (20)
and (53). Thread hoses and port plugs into appropriate
ports and tighten.
 original copywriter 1987 REGULATORS F I RS T S TA GE R 1 - R 2 F 6-5
revised 1998 - printed 1999

FIRST STAGE, R2 DFC Table 7

FIRST STAGE, R2 DFC NITROX Updated to 01-04-98

Ref. Code Description

1 186230 Body
2 185015 Retaining ring
3 185208 Yoke
7 185212 Retaining nut, yoke
8 186220 Spring, piston
19 110106 O-Ring 106
19 110402 O-Ring 106 Viton 610-9754
20 185204 Plug 3/8 UNF
22 185014 Sintered filter
23 110117 O-Ring 115
23 110406 O-Ring 115 Viton 614-9754
24 185009 Dust cap 0,90
25 184076 Knob assembi
48 183008 DIN connector body , 200 BAR
49 183006 DIN connector wheel, 200 BAR
50 110203 O-Ring 2018
50 110409 O-Ring 2018 Viton 008-9754
51 179261 DIN connector, 200 BAR
52 110108 O-Ring 108
52 110404 O-Ring 108 Viton 611-9754
53 185205 Plug HP 7/16 UNF
61 185013 Spring ,filter
62 183013 Cap, DIN connector
82 186221 Washer
84 186228 Piston
85 186225 Cover
86 110224 O-Ring 2100
86 110419 O-Ring 2100 Viton 022-9754
88 186223 Plastic seat, piston
89 184354 Label
107 184313 Knob assembly label
107 184366 Nitrox knob assembly label
ASSEMBLIES
A 185975 First stage e assy. - complete
A 185976 First stage e assy. - R1 J - complete
A 185978 First stage e assy. - R1 DIN - complete
A 185966 First stage e assy. - R2. Nitrox - complete
A 185970 First stage e assy. - R2. Nitrox J.- complete
F 183020 DIN connector assy. 200 BAR
(23-48-49-50-51-62)
F 183015 DIN connector assy. 300 BAR
(23-48-49-50-51-62)
F 183042 DIN connector assy. 200 BAR Nitrox
(23-48-49-50-51-62)
F 183041 DIN connector assy. 300 BAR Nitrox
(23-48-49-50-51-62)
*** 185323 INT/DIN maintenance Kit
(2-19-22-23-50-52-86-88)
*** 186155 INT/DIN Nitrox maintenance Kit
(2-19-22-23-50-52-86-88)
 TROUBLESHOOTING
ADJUSTMENT
ADJUSTMENT / TROUBLESHOOTING
 original copywriter 1987 REGULATORS FIRST STAGES ADJUSTMENT F 7-1
revised 1988 - printed 1999

ADJUSTMENT AND CHECKING THE INTERMEDIATE PRESSURE (Fig. 1)

WARNING !
DO NOT SUBMERGE THE PRESSURE GAUGE FOR MEASURING THE INTERMEDIATE PRESSURE.

TA B L E O F F I R S T S TAG E I N T E R M E D I AT E P R E S S U R E S
MODEL P.S.I. BAR
RUBY 142 - 148 9,8 - 10,2
MR 22 142 - 148 9,8 - 10,2
MR 16 142 - 148 9,8 - 10,2
V 16 142 - 148 9,8 - 10,2
MR 12 142 - 148 9,8 - 10,2
V 12 142 - 148 9,8 - 10,2
MR12 II 137 - 142 9,5 - 9,8
R 2 (2900 p.s.i. / bar tank) 142 - 152 9,8 - 10,5
MR 10 (2900 p.s.i. / bar tank) 123 - 130 8,5 - 9,0
TA B L E F I R S T S TAG E I N T E R M E D I AT E P R E S S U R E S W I T H C . W. D . K I T
MODEL P.S.I. BAR
RUBY 130 - 136 9 - 9,4
MR 22 130 - 136 9 - 9,4
MR 16 130 - 136 9 - 9,4
V 16 130 - 136 9 - 9,4
MR 12 130 - 136 9 - 9,4
V 12 130 - 136 9 - 9,4
MR12 II 130 - 136 9 - 9,4

PROCEDURE FOR INTERMEDIATE PRESSURE ADJUSTMENT IN DIAPHRAGM FIRST STAGES

1. Screw the intermediate pressure calibration gauge
(cod. 106252) into one of the 3/8” low pressure ports using
the special tool (B-18).
2. Using the tool (B-18 or B-19), assemble the hose with the
partially finished second stage on the DFC port.
3. Mount the regulator group on the air valve (of a test bench
or tank).
4. Keeping the second stage demand lever pressed, slowly
open the tank valve, releasing the demand lever almost
simultaneously. Fig. 1

5. Read the first stage intermediate pressure on the gauge, and

as a function of this value proceed as follows (Fig. 1):
a) If the calibration value is greater than the specified
intermediate pressure (see table), use key (B-13) to slightly
back off adjusting nut (16) until the required value is
obtained.
NOTE Whenever the intermediate pressure is reduced, the
excess air must be discharged in order to obtain a
correct reading of the calibration value.
b) If the calibration value is lower than the specified
intermediate pressure (see table), use key (B-13) to slightly
screw down adjusting nut (16) until the required value is
obtained.
6. Press the second stage demand lever a few times to check
that the new calibration value remains constant.
7. After completing the second stage adjustments, remove the
calibration pressure gauge and screw in the port plug.
F 7-2 FIRST STAGES ADJUSTMENT REGULATORS original copywriter 1987
revised 1988 - printed 1999

PROCEDURE FOR INTERMEDIATE PRESSURE ADJUSTMENT IN PISTON FIRST STAGES (R1 - R2)
1. Screw the intermediate pressure calibration gauge
(cod. 106252) into one of the 3/8” low pressure ports using
the special tool (B-18).
2. Using the tool (B-18 or B-19), assemble the hose with the
partially finished second stage on the DFC port.
3. Mount the regulator group on the air valve (of a test bench
or tank).
4. Keeping the second stage demand lever pressed, slowly
open the tank valve, releasing the demand lever almost
simultaneously.
5. Read the first stage calibration value on the pressure gauge,
and as a function of this value proceed as follows (Fig. 1):
A) If the calibration value is higher than the specified
value (see table):
A.1) Disassemble the regulator group from the tank and
perform the operations described in steps 1 and 2 of
the disassembly instructions.
A.2) Remove one distance washer.
A.3) Reassemble the components as described in steps
8.1 - 9 - 10 - 11 - 12 of the assembly instructions.
A.4) Perform the operations described in steps 3 and 4 of
the procedure for checking the intermediate pressure,
reading the value of the intermediate pressure on the
pressure gauge.
NOTE If there are no distance washers in the first stage, then
it is necessary to replace the spring.

B) If the calibration value is lower than the specified

value (see table):
B.1) Disassemble the regulator group from the tank and
perform the operations described in steps 1 and 2 of
the disassembly instructions.
B.2) Add one distance washer (up to a maximum of two),
positioning it/them as described in step 8 of the
assembly instructions.
B.3) Reassemble the components as described in steps
9 - 10 - 11 - 12 of the assembly instructions.
B.4) Perform the operations described in steps 3 and 4 of
the procedure for checking the intermediate pressure,
reading the value of the intermediate pressure on the
pressure gauge.

NOTE If there are no distance washers in the first stage, then

it is necessary to replace the spring.

6. Press the second stage demand lever a couple of times to

check that the new calibration value remains constant.
7. After completing the second stage adjustments, remove the
calibration pressure gauge and screw in the port plug.
 original copywriter 1987 TROUBLESHOOTING FIRST STAGE F 8-1
revised 1998 - printed 1999

F I R S T S TA G E T R O U B L E S H O O T I N G
PROBLEM MODEL PROBABLE CAUSE SOLUTION

-1-
RUBY-MR22 1) Stop nut loose 1) Tighten the nut
AIR LEAK FROM
MR 16 - V 16
FIRST STAGE
MR 12 - V 12 2) First stage diaphragm damaged 1) Replace the diaphragm
DIAPHRAGM
MR 12 II
STOP NUT
MR 10 3) Diaphragm seat surface in first stage damaged 1) Replace first stage body

-2- RUBY-MR22
AIR LEAK FROM MR 16 - V 16
MR 12 - V 12 1) O-ring dirty or damaged 1) Clean the seat and replace the O-ring
FIRST STAGE
HOSE PORTS MR 12 II
MR 10 2) Plug and/or hose loose 1) Tighten
AND/OR PLUGS
R2
INT - DIN
-3- version of 1) O-ring seal dirty or damaged 1) Clean the seat and replace the O-ring
AIR LEAK RUBY-MR22
BETWEEN MR 16 - V 16 2) INT yoke clamp or DIN fitting not sufficiently 1) Tighten
FIRST STAGE MR 10 tight
BODY AND INT
OR DIN DIN
3) O-ring seal on DIN fitting dirty or damaged 1) Clean the seat and replace the O-ring
FITTING version of
MR 12 - V 12
4) Body of DIN fitting not sufficiently tight 1) Tighten
R2
RUBY-MR22
MR 16 - V 16
MR 12 II 1) O-ring seal on tank valve dirty or damaged 1) Clean the seat in the tank valve and
-4- MR 10 replace the O-ring
AIR LEAK R2
BETWEEN
FIRST STAGE RUBY-MR22 1) (INT version) Replace yoke nut
MR 16 - V 16 2) Seat of O-ring seal on first stage damaged
CONNECTION 1) (DIN version) Replace connector body
AND VALVE MR 10
SYSTEM 1) (INT version) Replace 1st stage body
MR 12 - V 12 3) Seat of O-ring seal on first stage damaged
R2 1) (DIN version) Replace connector coupling

MR 12 II 4) Seat of O-ring seal on first stage damaged 1) Replace first stage body
-5-
AIR LEAK FROM RUBY-MR22 1) Defective O-ring 1) Replace
HP CHAMBER MR 16 - V 16
PLUG
1) Piston O-rings defective 1) Replace O-rings
-6-
AIR LEAK FROM 2) Surface of piston O-ring seats dirty or 1) Clean or replace
HOLES IN R2 damaged
FIRST STAGE 3) Inner surface of cap dirty or damaged 1) Clean or replace the cap
CAP 4) Inner surface of first stage dirty or damaged 1) Clean or replace first stage body

-7- RUBY-MR22
MR 16 - V 16 1) CWD diaphragm damaged 1) Replace CWD diaphragm
(C.W.D. VERSION)
OIL LEAK FROM MR 12 - V 12
DIAPHRAGM MR 12 II 2) CWD diaphragm clamping ring loose 1) Tighten correctly
MR 10
RUBY-MR22
MR 16 - V 16
MR 12 II 1) Intermediate pressure too high 1) Adjust intermediate pressure
MR 10
R2
F 8-2 FIRST STAGE TROUBLESHOOTING original copywriter 1987
revised 1998 - printed 1999

F I R S T S TA G E T R O U B L E S H O O T I N G
PROBLEM MODEL PROBABLE CAUSE SOLUTION

RUBY-MR22
MR 16 - V 16
MR 12 II 2) First stage valve damaged 1) Replace
MR 10
R2

-8-
R2 3) Piston pad damaged 1) Replace pad
CONTINUOUS
AIR FLOW FROM
SECOND STAGE MR 12 - V 12 4) Valve seat in first stage defective 1) Clean or replace first stage body
CHARACTERIZED
BY INCREASED RUBY-MR22 1) Clean or replace seat
INTERMEDIATE MR 16 - V 16 5) Valve seat defective
PRESSURE MR 12-MR 10
2) Replace the O-ring
MR 12 II

RUBY-MR22 1) Replace O-ring

MR 16 - V 16 6) HP chamber defective 2) Replace the antiextrusion ring
MR 12-MR 10
MR 12 II 3) Clean or replace HP chamber
RUBY - ABYSS
VOLTREX
SECOND STAGE
RUBY-ABYSS-VOLTREX
SECOND STAGE
 original copywriter 1987 REGULATORS RUBY-ABYSS-VOLTREX SECOND STAGE S 1-1
revised 1998 - printed 1999

D I S A S S E M B LY :
1. Remove mouthpiece clamp (43) by cutting it with an
appropriate tool.
2 Remove mouthpiece (44).
3. Remove exhaust tee (41) from second stage case.
4. Slide hose protector (46) away from second stage.
5. Using two wrenches (B17) remove hose (26) from second
stage.
6. Remove hose connector assembly (28-29-21-27) from
second stage using wrench (B17).
7. Remove o-ring (29) from hose connector (28).
8. Using a 5 mm. allen wrench (B4) remove the seat connector
(21) and o-ring (27) from hose connector.
9. Remove o-ring (27) from seat connector.
10. Remove clamp ring screw (38).
11. Expand the clamp ring (37) until it will slide over the flange
of the second stage body.
12. Remove the second stage purge cover (39), diaphragm (36)
and clamp ring (37).

WARNING !
DO NOT UNSCREW THE 8 SCREWS WHICH FIX THE MESH TO
THE COVER AND THE CLAMP SCREW. THE MESH MAY BE
CLEANED WITH A SOFT BRUSH.
DISASSEMBLY OF THE PURGE COVER (PURGE BUTTON,
SPRING AND COVER) IS NOT NECESSARY UNLESS THE COVER
IS SEVERELY ENCRUSTED, DIRTY, OR WHENEVER THE PURGE
BUTTON DOES NOT RETURN TO ITS NORMAL POSITION.
UNLESS EXTREME CARE IS TAKEN, REMOVAL OF THE PURGE
BUTTON MAY CAUSE DAMAGE TO THE COVER COMPONENTS.

13. Remove lock nut (33), washer (34) and demand lever (35)
using tool (B12).

NOTE The poppet body (30) is under spring tension. Cover

the second stage inlet fitting with your hand to prevent
the poppet body (30) and spring (31) from being eject-
ed when the lock nut is removed.

14. Remove poppet body (30) and spring (31) from second
stage inlet.
15. Remove poppet seat (47) from poppet body.
16. Remove exhaust valve (40).
S 1-2 RUBY-ABYSS-VOLTREX SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

CLEANING
Cleaning requires all reusable rubber and plastic parts to be care-
fully cleaned by scrubbing with a soft brush in a mild detergent
and water solution. Do not use solvents or acids on rubber or
plastic parts. Metal parts should be cleaned in an ultrasonic
cleaner with fresh water and a mild acid solution (white vinegar
diluited with warm water is recommended). Before reassembly
make sure all parts have been carefully rinsed and dried.

WARNING !
PROTECT EYES AND SKIN ADEQUATELY WHEN WORKING WITH
ANY KIND OF ACID. BEFORE CLEANING METAL PARTS, MAKE
SURE THAT ALL RUBBER AND PLASTIC PARTS HAVE BEEN
REMOVED. ACIDS OR OTHER SOLVENTS MAY DAMAGE RUB-
BER AND PLASTIC PARTS.

INSPECTION
The following second stage components should be replaced
during routine service:

Quantity Description Reference ABYSS-VOLTREX Code RUBY Code

2 O-rings 2025 27 110205 110411 (Viton)
1 O-rings 3-906 29 110191 110408 (Viton)
1 2nd stage poppet seat 47 184062 184062
1 Lock nut 33 185051 185051
1 Exhaust valve 40 184006 184006
1 Mouthpiece clamp 43 157984 157984

If these components are not replaced, they should be carefully

inspected with a lens or a jeweler’s loop.

Description Inspections
Seat connector (21): Inspect the tapered seating surface for nicks, flat spots and deep scratches.
Poppet seat: Inspect for cuts, cracking and any deformation. If a new poppet seat is not available the
poppet seat can be reversed if the surface is not damaged, or previously used.
Demand lever: Inspect the pivot points for wear and straightness.
Spring: Inspect for cracking or broken coils.
Second stage case: Inspect the exhaust valve seat for any signs of oxidation.
Exhaust valve: Inspect for any cracks, tears or deterioration.
O-rings: Inspect for cuts, tears, flat spots or contamination.
The presence of any of these flaws may cause leakage.
Diaphragm: Inspect for any tears or pin holes around the metal disk, for any distortion of the outer bead
or for any signs of the disk detaching from the diaphragm.
Clamp: Inspect for cracks and signs of corrosion.
Mouthpiece: Inspect for deterioration or cuts.
Exhaust tee: Inspect for cracks or tears.
Second stage hose: Inspect for any cracks, blisters, cuts and other signs of damage. Inspect the hose o-rings
for cuts or foreign matter.
 original copywriter 1987 REGULATORS RUBY-ABYSS-VOLTREX SECOND STAGE S 1-3
revised 1998 - printed 1999

R E A S S E M B LY

WARNING !
WHENEVER THE SECOND STAGE IS USED FOR DIVES WITH
ENRICHED AIR, IT SHALL BE PERFECTLY CLEANED FROM SILI-
CONE RESIDUE OR OTHER IMPURITIES. THE VITON O-RINGS
MAY BE LUBRICATED WITH SPECIAL OXYGEN COMPATIBLE
GREASES. DO NOT USE SILICONE GREASE!

Before reassembly, lightly lubricate all 0-rings with silicone

grease (General Electric, Versalube G-322 or equivalent).
Lubricating the 0-rings before reassembly will minimize the risk
of damage during reassembly.

1. Carefully install a new exhaust valve (40) by pulling the stem

through the center hole of the exhaust valve seat until it
locks in place. The valve stem should not be pulled
excessively as damage to the valve may occur.
Using scissors, cut approximately 7 mm (1/4 in.) off of the
end of the valve stem.
2. Press poppet seat (47) into poppet body (30).
3. Place poppet body (30) onto tool (B6).
4. Place spring (31) over poppet body.
5. Insert poppet body and spring into the second stage inlet.
Align the square of the poppet stem with the square hole of
the case and press inward to compress the spring (Fig. 1).

WARNING !
TO ENSURE CORRECT POSITIONING OF THE SECOND STAGE
POPPET, IT IS RECOMMENDED TO TURN THE SECOND STAGE
CASE FROM LEFT TO RIGHT (FIG. 1).

6. Place the demand lever (35) into the second stage case
groove.
7. Place the demand lever washer (34) over the second stage
poppet stem and on top of the demand lever. Fig. 1

8. Place a new demand lever lock nut (33) on the second stage
poppet stem and tighten the lock nut, with tool (B12), until
approximately 1/16” of the poppet stem is protruding from
the nut (Fig. 2).

NOTE Do not over-tighten demand lever lock nut. If the

demand lever lock nut is over-tightened, it will cause
the second stage to free-flow during intermediate
pressure adjustment.
9. Place o-ring (29) on hose connector (28).
10. Place o-ring (27) on seat connector (21). Fig. 2
S 1-4 RUBY-ABYSS-VOLTREX SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

11. Insert the seat connector into the hose connector. Turn the
seat connector clockwise using a 5 mm. Allen wrench (B4),
until seat connector protrudes about 3 mm. from hose
connector.

WARNING !
SEAT CONNECTOR (21) MUST NOT PROTRUDE MORE THAN 3.8
mm FROM THE HOSE CONNECTOR (28); CHECK WITH GAUGE
(Cod. 106230).
GAUGE (Cod. 106230)

SEAT CONNECTOR ADJ

12. Remove allen wrench (B4) from seat connector.

13. Depress the demand lever and install hose connector (28)
into second stage case using wrench (B17).
14. Connect hose (26) to hose connector using 2 wrenches
(B17).

RUBY-ABYSS-VOLTREX SECOND STAGE ADJUSTMENT

NOTE Correct intermediate pressure adjustments are needed

for second stage opening pressures to fall within
factory-set rating. Second stage sensitivity may be
changed by adjusting intermediate pressure. All
second stage adjustments should be made while the
second stage is supplied with the appropriate inter-
B12
mediate pressure.
1. Connect an intermediate pressure gauge to a 3/8” LP port on
the first stage.
LOW PRESSURE INTERMEDIATE PRESSURE
(LP) PORT CALIBRATION GAUGE
Fig. 3
DANGER ! EXPLOSION HAZARD
DO NOT CONNECT THE INTERMEDIATE PRESSURE GAUGE TO
THE HIGH PRESSURE PORT OF THE FIRST STAGE.
CONNECTING THE INTERMEDIATE PRESSURE GAUGE TO THE
HIGH PRESSURE PORT OF THE FIRST STAGE WILL CAUSE THE
HOSE AND/ OR INTERMEDIATE PRESSURE GAUGE TO
EXPLODE AND COULD RESULT IN SERIOUS PERSONAL INJURY
OR DEATH.

2. Attach the first stage to a full tank (2000-3000 psi).

(See Fig. 3).
3. Depress the second stage demand lever while slowly
opening the tank valve. When air begins to flow from the
second stage slowly release the demand lever and fully open
the tank valve.
 original copywriter 1987 REGULATORS RUBY-ABYSS-VOLTREX SECOND STAGE S 1-5
revised 1998 - printed 1999

4. Read the intermediate pressure indicated by the gauge.

C-SHAPED GAUGE FOR DEMAND
5. Adjust demand lever height using the demand lever height LEVER HEIGHT INSPECTION
gauge. The demand lever height gauge sides are marked with For the correct adjustment stand the gauge on the Second Stage case
and adjust lever height until it makes contact with the gauge.
the second stage model. Place the side of the demand lever
height gauge marked with the corresponding model across
the second stage case (Fig. 4).
NAVY E BETA
a. If the demand lever height is too low, tighten the demand
lever lock nut, using tool (B12), until the demand lever RUBY / ABYSS
VOLTREX
contacts the lower edge of the gauge.
b. If the demand lever height is too high, loosen the
demand lever lock nut, using tool (B12), until the demand Fig. 4
lever contacts the lower edge of the gauge.
6. Depress and release the demand lever several times to
ensure freedom of movement.
7. After second stage adjustment, depressurize the regulator
and remove the intermediate pressure gauge.

FINAL ASSEMBLY

1. Expand the clamp ring (37) until it will slide over the flange
of the second stage body.
2. Place the second stage diaphragm (36) onto the second
stage body making sure the metal disk is against the demand
lever.
3. Place the purge cover (39) on the diaphragm. Make sure the
diaphragm bead is engaged in the case and cover groove.
Position the purge cover so the logos are properly
positioned.
4. Position the clamp ring over the flange of the second stage
and the flange of the purge cover. Rotate the clamp ring so
the split end is facing the second stage hose.
5. Install clamp ring screw (38) and tighten.
6. Slide the second stage hose protector (46) into position over
the clamp ring.
7. Install the exhaust tee (41) over the second stage case
mounting flange. Make sure the lip of the exhaust tee fits
fully over the mounting flange.

NOTE Liquid soap can be used to lubricate the exaust tee to

make assembly easier. Do not use silicone grease to
lubricate the exaust tee. The use of silicone grease
may cause the exhaust tee to come off during
operation.
8. Install mouthpiece (44) and secure in place with a new
clamp (43). The locking tab of the clamp should be
positioned to line up with the V.A.D. tube.
S 1-6 RUBY-ABYSS-VOLTREX SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

RUBY - ABYSS - VOLTREX Table 16

OCTOPUS VOLTREX SECOND STAGE Updated to 01-04-98

Ref.N. Code Description Ref.N. Code Description

19 110106 O-Ring 106 (Voltrex) 39 186047 Cover assembly, black (Abyss) Titanium
19 110402 O-Ring 106 Viton 610-9754 (Voltrex) 39 186050 Cover assembly, black (Voltrex)
19 110215 O-Ring 2043 (Abyss) 39 186051 Octopus cover assembly, yellow (Voltrex)
19 110415 O-Ring 2043 Viton 013-9754 (Abyss) 40 184006 Exhaustvalve
21 186023 Poppet seat 41 186028 Exhaust tee
26 184450 Hose S/Flow (Voltres) 43 157984 Mouthpiece clamp
26 184449 Hose S/Flow (Abyss) 44 185089 Mouthpiece
26 186093 Hose Octopus S/Flow Yellow 45 179904 Hose protector, first stage, black
27 110205 O-Ring 2025 46 186094 Hose protector, second stage, black
27 110411 O-Ring 2025 Viton 010-9754 47 184062 Poppet seat, rubber
28 184282 Seat connector 54 186090 Octopus plug
28 185565 Seat connector Titanium
29 110191 O-Ring 3 906
29 110408 O-Ring 3 906 Viton 906-9754 ASSEMBLIES
30 186024 Poppet body G 186030 Second stage assy, complete (Voltrex)
31 185057 Poppet spring G 186039 Second stage assy, complete (Voltres) J.
32 186025 Case G 186035 Second stage assy, complete (Abyss)
32 185564 Case Titanium G 186038 Second stage assy, complete (Abyss) J.
33 185051 Locknut, demand lever C 186036 Second stage assy, complete (Abyss) Titanium
34 185049 Washer, demand lever G 185600 Second stage assy, complete (Abyss) Titanium J.
35 185104 Demand lever, CWD G 186145 Second stage assy Ruby
36 186029 Diaphragm G 186146 Second stage assy Rubv J.
37 185073 Clamp, ring G 186147 Second stage assy Rubs Titanium J.
37 185566 Clamp, ring Titanium G 186148 Second stage assy Rubs Titanium
38 185075 Screw 3s16, clamp ring *** 186160 Maintenance Kit II° stage Voltrex - Abyss
39 186256 Cover assembly Ruby (19-27-29-33-40-43-47)
39 186263 Cover assembly Ruby Titanium *** 185166 Maintenance Kit II° stage Ruby - Viton
39 186045 Cover assembly, black (Abyss) (19-27-29-33-40-43-47)
 XTR-XL-AKROS
SECOND STAGE
XTR-XL-AKROS SECOND STAGE
 original copywriter 1987 REGULATORS XTR-XL-AKROS SECOND STAGE S 2-1
revised 1998 - printed 1999

D I S A S S E M B LY :
1. Using a 14 mm wrench (B-18), remove the hose 26 from
the first stage (see numbered Akros schematic).
2. Remove mouthpiece clamp 43 by cutting it with an
appropriate tool, then remove the mouthpiece 44.
3. Remove exhaust tee 41.
4. Slide the hose protector 46 down the hose away from the
second stage.
5. With two wrenches (B-17), remove the hose 26 from hose
connector 28.
6. Remove O-ring 27 from its seat in the swivel connection of
the hose 26.
7. With wrench (B-17), remove the hose connector 28 and
remove the by-pass tube retaining ring 96.
8. Remove O-ring 71 from hose connector 28.
9. With a 5 mm Allen wrench (B-4), unscrew seat connector 21
from the hose connector 28.
10. Remove O-ring 27 from seat connector 21.
11. With a narrow slotted screwdriver, gently pry the purge
cover safety catch 63 out and remove from the second stage
case 32.
12. Remove the purge cover 39 with a counter-clockwise
rotation, using Mares special tool B-7 (P/N 106207).
If Mares 12. tool B-7 is not available, snap ring pliers may
be used to remove the purge cover.

NOTE Disassembly of the purge cover (purge button, spring

and cover) is not necessary, unless the cover is
severely scaled, dirty or whenever the purge button
does not return to its normal position. Unless great
care is taken, removal of the purge button may cause
damage to the cover components.

13. If removal of the purge button becomes necessary, gently

compress the four purge button retaining tabs and remove
the purge button and spring. If any damage or wear exists
replace the entire purge cover.
14. Remove the diaphragm ring 78, diaphragm 36 and spacer
ring 90 from the second stage case 32.
15. With a 6 mm Allen wrench (B-8), remove the case plug 64.
16. Remove O-ring 72 from the case plug.
17. Remove the plug seat 87 by gently pressing it into the case.
18. Remove O-ring 83 from its seat in the case.
19. With a 5.5 mm nut driver (B-12), unscrew the demand lever
lock nut 33 from the poppet body 30, then remove the Fig. 1
demand lever 35, and washer 34. (See Fig.1).
S 2-2 XTR-XL-AKROS SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

NOTE The poppet assembly is under spring tension. Cover

the opening of the inlet fitting (94) with one finger to
prevent the poppet assembly and spring (31) from
being ejected when the lock nut (33) is removed.
20. Remove the poppet assembly and spring 31 from inlet
fitting 91.
21. Remove the spring 31 from the poppet assembly.
22. Remove the rubber poppet seat 47 from the plastic poppet
body 92 by grasping the plastic poppet body and the
threaded end of the metal poppet body 30. Then slide the
plastic poppet body towards the threaded end of the metal
poppet body.
23. Remove the plastic poppet body 92 from the metal poppet
body 30.
24. Remove the by-pass tube 74 by grasping it at its base and
pulling it away from the case 32.
25. Remove O-ring 75 and O-ring 83 from the by-pass tube 74.
26. Remove O-ring 66 from its seat in the poppet housing 91.
27. Gently press the poppet housing 91 into the case 32, then
remove the O-ring 83 from its seat in the case.
28. Remove the exhaust valve 40.

NOTE Removal of the vane 42 is not necessary, unless the

vane does not move freely or does not return to its
neutral position.

29. If it becomes necessary to remove the vane 42, grasp the

pin-95 from inside the case-32, with needle nose pliers near
the top of the mouthpiece tube. Slide the pin straight
towards the top of the mouthpiece tube until it protrudes
enough that the head of the pin can be grasped with pliers
and removed from the case.

CAUTION !
DO NOT APPLY LATERAL FORCE TO THE PIN-95 OR VANE-42.
THE APPLICATION OF LATERAL FORCE TO THE PIN OR VANE
MAY RESULT IN DAMAGE TO THE PIN, VANE OR CASE-32.

30. Remove the vane 42 from the mouthpiece tube.

CLEANING
Cleaning requires all reusable rubber and plastic parts to be care-
fully cleaned by scrubbing with a soft brush in a mild detergent
and water solution. Do not use solvents or acids on rubber or
plastic parts. Metal parts should be cleaned in an ultrasonic clean-
er with fresh water and a mild acid solution. (White vinegar diluit-
ed with warm water is recommended). Before reassembly make
sure all parts have been carefully rinsed and dried.
 original copywriter 1987 REGULATORS XTR-XL-AKROS SECOND STAGE S 2-3
revised 1998 - printed 1999

WARNING !
ACIDS MAY CAUSE BURNS OR SKIN, EYE OR RESPIRATORY IRRITATION. WHEN WORKING WITH ANY KIND OF ACID,
PROTECT EYES AND SKIN ADEQUATELY AND WORK IN A WELL VENTILATED AREA. ACIDS MAY DAMAGE RUBBER
AND PLASTIC PARTS. BEFORE CLEANING METAL PARTS, MAKE SURE THAT ALL RUBBER AND PLASTIC PARTS HAVE
BEEN REMOVED.

INSPECTION
The following components should be replaced during routine
service:

Description Reference Part Number Quantity

O-Ring 2025 -27- 110205 2
O-Ring 2062 -66- 110220 1
O-Ring 2050 -71- 110211 1
O-Ring 2043 -72- 110215 1
O-Ring 2031 -75- 110107 1
O-Ring 2068 -83- 110225 3
Rubber stage poppet seat -47- 184062 1
Demand lever lock nut -33- 185051 1
Exhaust valve -40- 184006 1
Clamp -43- 157984 1
If the following parts are not replaced, they should be inspected
with a jeweler's loop or similar magnifying device for the flaws
listed below. Replace any part with these flaws.

Description Reference Inspections

Second stage case -32- Inspect the sealing surfaces for cracks, scratches or distortion.
Make sure that the pivoting vane moves freely and returns to its neutral
position.
By-pass tube -74- Inspect 0-ring sealing surfaces for scratches or cracks.
Diaphragm -36- Inspect for any tears or pin holes, distortion of the outer bead and any signs
of the disk detaching from the diaphragm.
Mouthpiece -44- Inspect for deterioration or cuts.
Demand lever -35- Inspect the pivot points for wear and straightness.
Plastic poppet body -92- Inspect the plastic for cracks and wear.
Metal poppet body -30- Inspect the metal for corrosion, loose plating or wear.
Poppet seat -47- Inspect for cuts, cracks or any deformation. If a new poppet seat is not
available, the poppet seat can be reversed, if the surface is not damaged, or
used previously.
Spring -31- Inspect for cracked or broken coils.
Seat connector -21- Inspect the tapered seating surface for nicks, flat spots and deep scratches.
Exhaust valve -40- Inspect for any cracks, tears or deterioration.
Exhaust tee -41- Inspect for cracks or tears.
Second stage hose -26- Inspect for any cracks, blisters, cuts and other signs of damage.
Inspect the hose 0-rings for cuts or foreign matter.
O-rings Inspect for cuts, tears, flat spots or contamination. The presence of any of
these flaws may cause leakage.
S 2-4 XTR-XL-AKROS SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

R E A S S E M B LY
Before reassembly, lightly lubricate all 0-rings with silicone
grease (General Electric Versalube G-322 or equivalent).
Lubricating the 0-rings before reassembly will minimize he risk of
damage during reassembly.

WARNING !
IF THE SECOND STAGE IS USED FOR ENRICHED AIR DIVING, IT
MUST BE PERFECTLY CLEANED AND FREE FROM RESIDUAL
SILICONE OR FROM ANY FOREIGN MATTER. VITON 0-RINGS
CAN BE LUBRICATED WITH SPECIFIC OXYGEN COMPATIBLE
GREASE. DO NOT USE SILICONE GREASE.

1. If the vane 42 was removed, insert the tapered end of the

pin 95 into its seat in the top of the mouthpiece tube. Press
the pin into the case 32 until it just protrudes into the
mouthpiece tube.
2. Insert the vane 42 into the mouthpiece tube opening with
the smooth surface of the vane facing by-pass tube 74.
3. From the mouthpiece end of the mouthpiece tube, position
the vane 42 so that the vane stop on the lower surface of the
mouthpiece end of the mouthpiece tube is left of the vane.
4. Align the pivot holes in the vane 42 with the pin 95 and
press the pin into its seat until the head of the pin is flush
with the top of the case 32.

CAUTION !
DO NOT APPLY LATERAL FORCE TO THE PIN-95 OR VANE 42.
THE APPLICATION OF LATERAL FORCE TO THE PIN OR VANE
MAY RESULT IN DAMAGE TO THE PIN, VANE OR CASE 32.

5. Carefully install a new exhaust valve 40 by pulling the stem

through the center hole of the exhaust valve seat until it
locks in place. The valve stem should not be pulled
excessively as damage to the valve may occur.
With scissors, cut approximately 7 mm. (1/4 in.) off of the
end of the valve stem.
6. Insert the threaded stem of the metal poppet body 30 into
the larger diameter of the plastic poppet body 92. Pull the
metal poppet body through the plastic poppet body until it
is fully seated in the plastic poppet body.
7. Press the poppet seat 47 into the plastic poppet body 92.
8. Place the spring 31 over the poppet assembly.
9. Place the poppet assembly and spring onto Mares special
tool (B-6).
 original copywriter 1987 REGULATORS XTR-XL-AKROS SECOND STAGE S 2-5
revised 1998 - printed 1999

10. Insert poppet assembly and spring into the poppet

housing 91. Align the square stem of the metal poppet
body with the square hole of the poppet housing and press
inward to compress the spring. (See Fig 2).
11. Position the demand lever-35 in the groove of the poppet
housing 91 so that when the poppet is inserted into the
second stage case, the demand lever is facing the
diaphragm and the hole in the side of the poppet housing is
facing the by-pass tube 74.
12. Place the demand lever washer 34 over the stem of the
poppet assembly and on top of the demand lever 35.
13. Place a new demand lever lock nut 33 on the threaded stem Fig. 2
of the poppet assembly and tighten the lock nut, with tool
(B-12) or (B-20), until approximately 1.5 mm. (18/16 in.) of
the poppet stem is protruding from the nut. Depress the
demand lever several times to ensure freedom of
movement. (See Fig. 3).

NOTE Do not over tighten demand lever lock nut 33. If the
demand lever lock nut is over-tightened, it will cause
the second stage to free flow during intermediate pres-
sure adjustment.

14. From the inside of the case 32, insert the poppet housing
91 through the hole in the side of the case that has the by-
pass tube attachment. Align the flat edge of the poppet
housing with the flat molding of the case and pull the
poppet housing into place. (See Fig. 4). Fig. 3
15. Maintain outward pressure against the poppet housing 91 to
prevent it from being displaced. Place O-ring 83 in its seat
using Mares special tool (B-6). (See Fig. 5).
16. Place O-Ring 66 in the groove of the poppet housing 91.
17. Place O-Ring 75 on the by-bass tube 74.
18. Maintain outward pressure against the poppet housing 19 to
prevent it from being displaced. Slide the by-pass tube 74
over the poppet housing. Align the upper end of the by-pass
tube and O-Ring 75 with its seat in the case. Then press the
by-pass tube into position. Fig. 4

19. Maintain outward pressure against the poppet housing 91 to

prevent it from being displaced. Place O-Ring 83 over the
poppet housing and position it in its seat using Mares
special tool (B-6).
20. Position the O-Ring 71 on the hose connector 28.
21. Install the O-ring 27 in the groove of the seat connector 21.
22. With a 5 mm Allen wrench (B-4), thread the seat connector
21 into the hose connector 28 until the tapered end of the
seat connector protrudes from the hose connector between
3 mm minimum to 3.5 mm, maximum (.118 in. minimum
Fig. 5
to .138 in. maximum).
S 2-6 XTR-XL-AKROS SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

23. Position the by-pass tube retaining ring 96 on the hose

connector 28 so that the smaller diameter of the by-pass
tube retaining ring is against the 17 mm hex of the hose
connector.
24. Depress the demand lever 35 and thread the hose
connector 28 into the poppet housing 91 and tighten with
wrench (B-17). When using a torque, tighten to 8-8.5 N/m
(35-40 lb. in.) maximum.
25. Position the spacer ring 9O into the case 32 so that the
smooth surface of the spacer ring will be against the
diaphragm 36.
26. From the inside of the case 32 insert the plug seat 87
through the hole in the side of the case. Align the flat edge
of the plug seat with the flat molding of the case and press
the plug seat into place.
27. Maintain outward pressure against the plug seat 87 to
prevent it from being displaced. Place O-Ring-83 in its seat
using Mares special tool (B-16).
28. If the purge cover-39 was disassembled, place the larger
diameter of the purge button spring into the purge cover.
Align the purge button logo and the four retaining tabs with
the hole in the purge cover and press into position.
29. Place the o-ring-27 into the swivel connector of the second
stage hose.
30. With the two wrenches (B-17), tighten the hose 26 onto the
hose connector 28.
31. Connect the second stage hose to the first stage port
marked with D.F.C. and tighten with wrench (B-18).

ADJUSTMENT AND FINAL ASSEMBLY

NOTE Correct intermediate pressure adjustments are need-

ed for second stage opening pressure to fall within
factory specifications (2.5-3.8 cm/H20 or 1-1.5 in./
H20). Second stage sensitivity may be changed by
adjusting intermediate pressure. All second stage
adjustments should be made while the second stage is
supplied with the appropriate intermediate pressure.
1. Connect an intermediate pressure gauge to a 3/8 in. LP port
on the first stage.

WARNING !
DO NOT CONNECT THE INTERMEDIATE PRESSURE GAUGE TO
THE HIGH PRESSURE PORT OF THE FIRST STAGE.
CONNECTING THE INTERMEDIATE PRESSURE GAUGE TO THE
HIGH PRESSURE PORT OF THE FIRST STAGE WILL CAUSE THE
HOSE AND/ OR INTERMEDIATE PRESSURE GAUGE TO
EXPLODE AND COULD RESULT IN SERIOUS PERSONAL
INJURY OR DEATH.
 original copywriter 1987 REGULATORS XTR-XL-AKROS SECOND STAGE S 2-7
revised 1998 - printed 1999

2. Attach the first stage to a full tank (2000-3000 psi).

(See Fig. 6).
3. Depress the second stage demand lever while slowly
opening the tank valve. When air begins to flow from the
second stage, slowly release the demand lever. If air leakage
is detected after releasing the demand lever, refer to the
troubleshooting section of this manual. if air leakage is not
detected after releasing the demand lever, fully open the
tank valve.
4. Read the intermediate pressure indicated by the gauge. Fig. 6
Intermediate pressure specification for the MR 12 Akros is
9.8-10.2 bar (142-148 psi). If the intermediate pressure is
incorrect, refer to the MR 12 first stage service manual for
adjustment procedure.

WARNING !
IF THE REGULATOR IS TO BE USED FOR COLD WATER DIVING
(BELOW 40Þ F) OR IS EQUIPPED WITH A CWD KIT, REFER TO
THE COLD WATER DIVING KIT SECTION OF THE MR 12 FIRST
STAGE SERVICE MANUAL FOR INSTALLATION/SERVICING OF
THE CWD KIT AND INTERMEDIATE PRESSURE ADJUSTMENT.
FOR COLD WATER DIVING THE INTERMEDIATE PRESSURE
SPECIFICATION IS 8.8-9.2 BAR (128-132 PSI). FAILURE TO
FOLLOW THESE INSTRUCTIONS COULD LEAD TO A REGULA-
TOR ICING SITUATION WHICH COULD LEAD TO SERIOUS PER-
SONAL INJURY OR DEATH.

Due to the second stage case design, the Akros second stage may
be adjusted by using either of the following procedures.

PROCEDURE A
1. Measure the demand lever height with the Mares demand
lever height gauge (P/N 106230). Position lever height
gauge so that its two ends rest on the edge of the second
stage case. (See Fig. 7)
a. If the demand lever height is too low, tighten the demand
lever lock nut 33, using tool (B-12) or (B-20), until the
demand lever contacts the lower edge of the gauge.
b. if the demand lever height is too high, loosen the demand
lever lock nut 33, using tool (B-12) or (B-20), until the
demand lever just contacts the lower edge of the gauge.
2. Depress and release the demand lever several times to
ensure freedom of movement and that the pivoting vane is
moving freely.
3. Place the diaphragm 36 on the diaphragm ring 78 with
the metal disk of the diaphragm facing away from the
diaphragm ring and the flat surface of the diaphragm ring
facing away from the diaphragm.
4. Place the diaphragm and its ring in the case 32 with the
metal disk of the diaphragm facing the demand lever 35.
S 2-8 XTR-XL-AKROS SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

5. Install the purge cover 39 with a clockwise rotation using

Mares special tool (B-7) (P/N 106207). If Mares tool (B-7)
is not available, snap ring pliers may be used to install the
purge cover. Position the purge cover logo in the correct
direction and align the two holes for the safety catch (one in
the second stage case and one in the cover).
6. Insert the safety catch 63 into the hole in the case and
press into place.
7. Place the O-ring 72 on the case plug 64. Thread the case
plug into the plug seat 78 and gently tighten with a 6 mm
Allen wrench (B-3). When using a torque wrench, tighten to
Fig. 7
90 N/cm (8 lb. in.) maximum.
8. Slide the hose protector 46 into position on the second
stage.
9. After second stage adjustment, depressurize the regulator
and remove the intermediate pressure gauge.
10. Install the exhaust tee 41. Make sure the lip of the exhaust
tee fits fully over the mounting flange.

WARNING !
USE ONLY LIQUID SOAP TO LUBRICATE THE EXHAUST TEE TO
MAKE ASSEMBLY EASIER. DO NOT USE SILICONE GREASE TO
LUBRICATE THE EXHAUST TEE. THE USE OF SILICONE GREASE
MAY CAUSE THE EXHAUST TEE TO COME OFF DURING OPERA-
TION, WHICH COULD LEAD TO SERIOUS PERSONAL INJURY
OR DEATH.

11. Install the mouthpiece 44 and secure in place with a new

clamp 43. The locking tab of the clamp should be positioned
to line up with the by-pass tube.

PROCEDURE B
1. Place the diaphragm 36 on the diaphragm ring 78 with the
metal disk of the diaphragm facing away from the
diaphragm ring and the fiat surface of the diaphragm ring
facing away from the diaphragm.
2. Place the diaphragm and its ring in the case 32 with the
metal disk of the diaphragm facing the demand lever 35.
3. Install the purge cover 39 with a clockwise rotation using
Mares special tool (B-7) (P/N 106207). If Mares tool (B-7)
is not available, snap ring pliers may be used to install the
purge cover. Position the purge cover logo in the correct
direction and align the two holes for the safety catch (one in
the second stage case and one in the cover).
4. Insert the safety catch 63 into the hole in the case and press
into place.
 original copywriter 1987 REGULATORS XTR-XL-AKROS SECOND STAGE S 2-9
revised 1998 - printed 1999

5. Insert 5.5 mm nut driver (B-12) through the plug seat 87.
Tighten or loosen the lock nut 33 in order to adjust the
demand lever 35.
a. If the demand lever height is too low, tighten the demand
lever lock nut, using tool (B-12), until depressing the
purge button yelds approximately 18 mm. of travel
before air begins to flow from the second stage.
b. If the demand lever height is too high, loosen the demand
lever lock nut, using tool (B-12), until depressing the
purge button yelds approximately 18 mm. of travel
before air begins to flow from the second stage.
6. Depress the purge button several times to ensure freedom
of movement and to verify correct demand lever height
adjustment.
7. Place the O-ring 72 on the case plug 64. Thread the case
plug into the plug seat 78 and gently tighten with 6 mm
Allen wrench (B-3). When using a torque wrench, tighten to
90 N/cm (8 lb in.) maximum.
8. Slide the hose protector 46 into position on the second
stage.
9. After second stage adjustment, depressurize the regulator
and remove the intermediate pressure gauge.
10. Install the exhaust tee 41. Make sure the lip of the exhaust
tee fits fully over the mounting flange.

WARNING !
USE ONLY LIQUID SOAP TO LUBRICATE THE EXHAUST TEE TO
MAKE ASSEMBLY EASIER. DO NOT USE SILICONE GREASE TO
LUBRICATE THE EXHAUST TEE. THE USE OF SILICONE GREASE
MAY CAUSE THE EXHAUST TEE TO COME OFF DURING OPER-
ATION, WHICH COULD LEAD TO SERIOUS PERSONAL INJURY
OR DEATH.

11. Install the mouth piece 44 and secure it in place with a

new clamp 43. The locking tab of the clamp should be
positioned to line up with the by-pass tube.
S 2-10 XTR-XL-AKROS SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

SECOND STAGE, AKROS - XTR - XL

SECOND STAGE, AKROS NITROX Table 18
OCTOPUS AKROS - OCTOPUS XL Updated to 01-04-98

Ref. Code Description Ref. Code Description

19 110106 OR 106 66 110220 OR 2062
19 110402 OR 106 Viton 610-9754 66 110417 OR 2062 Viton 016-9707
21 186023 Seat connector 71 110211 OR 2050
26 186174 Hose high flow black (XL) 71 110413 OR 2050 Viton 014-9707
26 184450 Hose, super high flow black (Akros - XTR) 72 110215 OR 2043
26 186178 Hose, Octopus high flow yellow 72 110415 OR 2043 Viton 013-9707
27 110205 OR 2025 74 184288 By-pass tube
27 110411 OR 2025 Viton O1O-9707 75 110107 OR 2031
28 184282 Hose connector 75 110403 OR 2031 Viton 011–9707
30 184219 Metal poppet body 78 184224 Ring, diaphragm
31 185057 Poppet spring 83 110225 OR 2068
32 184237 Case (Akros) 83 110420 OR 2068 Viton 017–9707
32 184239 Case (Akros - XTR - XL) black 87 184233 Plug seat
33 185051 Lock nut, demand lever 90 184223 Spacer ring
34 185049 Washer, demand lever 91 184281 Poppet housing
35 185104 Demand lever 92 184221 Plastic poppet body
36 184225 Diaphragm 95 184236 Pin vane
39 184275 Porge cover (Akros) 96 184280 Retaining ring, by–pass tube
39 184274 Porge cover (Akros) black
39 184276 Purge cover octopus (Akros) yellow ASSEMBLIES
39 184278 Porge cover (Akros Nitrox)
39 184259 Porge cover (XTR) black G 184296 Akros second stage complete
39 184247 Porge cover (XL) G 184297 Akros J second stage complete
39 184249 Porge cover Octopus (XL) G 184298 Akros second stage complete black
40 184006 Exhaust valve G 184299 Akros J second stage complete black
41 184438 Exhaust tee G 184295 Akros Nitrox second stage complete
42 184235 Vane G 184300 XTR second stage complete
43 157984 Clamp, mouthpiece G 184301 XL second stage complete
44 185086 Mouthpiece black G 184302 Akros Nitrox J second stage complete
45 179904 Hose protector, first stage, black G 184303 XTR Nitrox J second stage complete
46 184210 Hose protector, second stage, black G 184052 XL Nitrox J second stage complete
47 184062 Poppet seat *** 186165 Maintenance kit Akros - XTR - XL 2nd stage
54 186090 Octopus plug (19-27-33-40-43-47-66-71-72-75-83)
63 184289 Safety catch *** 186169 Maintenance kit Akros - XTR - XL Nitrox 2nd stage
64 184234 Case plug (19-27-33-40-43-47-66-71-72-75-83)
 SECOND STAGE
NIKOS
NIKOS SECOND STAGE
 original copywriter 1987 REGULATORS NIKOS SECOND STAGE S 3-1
revised 1998 - printed 1999

D I S A S S E M B LY :
1. Using a 14 mm wrench (B-18), remove the hose 26 from
the first stage (see numbered Nikos schematic).
2. Remove mouthpiece clamp 43 by cutting it with an
appropriate tool, then remove the mouthpiece 44.
3. Remove exhaust tee 41.
4. Slide the hose protector 46 and spacer ring 93 down the
hose away from the second stage.
5. With two wrenches (B-17), remove the hose 26 from hose
connector 28.
6. Remove O-ring 27 from its seat in the swivel connection of
the hose 26.
7. With a 22 mm wrench (B-9), hold the inlet fitting 94 in place
and use a 17 mm wrench (B-17) to remove the hose
connector 28.
8. Remove O-ring 29 from hose connector 28.
9. With a 5 mm Allen wrench (B-4), unscrew seat connector 21
from the hose connector 28.
10. Remove O-ring 27 from seat connector 21.
11. With a narrow slotted screwdriver, gently pry the purge
cover safety catch 63 out and remove from the second stage
case 32.
12. Remove the purge cover 39 with a counter-clockwise
rotation, using Mares special tool B-7 (P/N 106207).
If Mares tool B-7 is not available, snap ring pliers may be
used to remove the purge cover.

NOTE Disassembly of the purge cover (purge button, spring

and cover) is not necessary, unless the cover is severe-
ly scaled, dirty or whenever the purge button does not
return to its normal position. Unless great care is taken,
removal of the purge button may cause damage to the
cover components.
13. If removal of the purge button becomes necessary, gently
compress the four purge button retaining tabs and remove
the purge button and spring. If any damage or wear exists
replace the entire purge cover.
14. Remove the diaphragm ring 78, diaphragm 36 and spacer
ring 90 from the second stage case 32.
15. With a 6 mm Allen wrench (B-8), remove the case plug 64.
16. Remove O-ring 72 from the case plug.
17. Remove the plug seat 87 by gently pressing it into the case.
18. Remove O-ring 83 from its seat in the case.
19. With a 5.5 mm nut driver (B-12), unscrew the demand lever
lock nut 33 from the poppet body 30, then remove the Fig. 1
demand lever 35, and washer 34. (See Fig.1).
S 3-2 NIKOS SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

NOTE The poppet assembly is under spring tension. Cover

the opening of the inlet fitting (94) with one finger to
prevent the poppet assembly and spring (31) from
being ejected when the lock nut (33) is removed.

20. Remove the poppet assembly and spring 31 from inlet

fitting 94.
21. Remove the spring 31 from the poppet assembly.
22. Remove the rubber poppet seat 47 from the plastic poppet
body 92 by grasping the plastic poppet body and the
threaded end of the metal poppet body 30. Then slide the
plastic poppet body towards the threaded end of the metal
poppet body.
23. Remove the plastic poppet body 92 from the metal poppet
body 30.
24. With a 22 mm wrench (B-9), remove the inlet fitting 94
from the poppet housing 91.
25. Remove O-ring-66 from its seat in the poppet housing 91.
26. Gently press the poppet housing 91 into the case, then
remove the O-ring 83 from its seat in the case.
27. Remove the exhaust valve 40.

CLEANING
Cleaning requires all reusable rubber and plastic parts to be care-
fully cleaned by scrubbing with a soft brush in a mild detergent
and water solution. Do not use solvents or acids on rubber or
plastic parts. Metal parts should be cleaned in an ultrasonic
cleaner with fresh water and a mild acid solution (white vinegar
diluited with warm water is recommended). Before reassembly
make sure all parts have been carefully rinsed and dried.

WARNING !
ACIDS MAY CAUSE BURNS OR SKIN, EYE OR RESPIRATORY
IRRITATION. WHEN WORKING WITH ANY KIND OF ACID, PRO-
TECT EYES AND SKIN ADEQUATELY AND WORK IN A WELL
VENTILATED AREA. ACIDS MAY DAMAGE RUBBER AND PLAS-
TIC PARTS. BEFORE CLEANING METAL PARTS, MAKE SURE
THAT ALL RUBBER AND PLASTIC PARTS HAVE BEEN RE-
MOVED.
 original copywriter 1987 REGULATORS NIKOS SECOND STAGE S 3-3
revised 1998 - printed 1999

INSPECTION
The following components should be replaced during routine
service:

Description Reference Part Number Quantity

O-Ring 2025 -27- 110205 2
O-Ring 3-906 -29- 110191 1
O-Ring 2062 -66- 110220 1
O-Ring 2043 -72- 110215 1
O-Ring 2068 -83- 110225 2
Rubber poppet seat -47- 184062 1
Demand lever lock nut -33- 185051 1
Exhaust valve -40- 184006 1
Clamp -43- 157984 1

If the following parts are not replaced, they should be inspected

with a jeweler's loop or similar magnifying device for the flaws
listed below. Replace any part with these flaws.

Description Reference Inspections

Second stage case -32- Inspect the sealing surfaces for cracks, scratches or distortion.
Make sure that the pivoting vane moves freely and returns to its neutral
position.
Diaphragm -36- Inspect for any tears or pin holes, distortion of the outer bead and any signs
of the disk detaching from the diaphragm.
Spacer ring -90- Inspect for cracks or distortion.
Mouthpiece -44- Inspect for deterioration or cuts.
Demand lever -35- Inspect the pivot points for wear and straightness.
Plastic poppet body -92- Inspect the plastic for cracks and wear.
Metal poppet body -30- Inspect the metal for corrosion, loose plating or wear.
Poppet seat -47- Inspect for cuts, cracks or any deformation. If a new poppet seat is not
available, the poppet seat can be reversed, if the surface is not damaged, or
used previously.
Spring -31- Inspect for cracked or broken coils.
Seat connector -21- Inspect the tapered seating surface for nicks, flat spots and deep scratches.
Exhaust valve -40- Inspect for any cracks, tears or deterioration.
Exhaust tee -41- Inspect for cracks or tears.
Second stage hose -26- Inspect for any cracks, blisters, cuts and other signs of damage.
Inspect the hose 0-rings for cuts or foreign matter.
O-rings Inspect for cuts, tears, flat spots or contamination. The presence of any of
these flaws may cause leakage.
S 3-4 NIKOS SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

R E A S S E M B LY
Before reassembly, lightly lubricate all 0-rings with silicone
grease (General Electric Versalube G-322 or equivalent).
Lubricating the 0-rings before reassembly will minimize he risk of
damage during reassembly.

WARNING !
IF THE SECOND STAGE IS USED FOR ENRICHED AIR DIVING, IT
MUST BE PERFECTLY CLEANED AND FREE FROM RESIDUAL
SILICONE OR FROM ANY FOREIGN MATTER. VITON 0-RINGS
CAN BE LUBRICATED WITH SPECIFIC OXYGEN COMPATIBLE
GREASE. DO NOT USE SILICONE GREASE. Fig. 2
1. Carefully install a new exhaust valve 40 by pulling the stem
through the center hole of the exhaust valve seat until it
locks in place. The valve stem should not be pulled
excessively as damage to the valve may occur.
With scissors, cut approximately 7 mm (1/4 in.) off of the
end of the valve stem.
2. From the inside of the case 32, insert the poppet housing 91
through the hole in the side of the case. Align the flat edge
of the poppet housing with the flat molding of the case so
that the hole in the side of the poppet housing is facing the
mouthpiece tube. Then press the poppet housing into place.
(See Fig. 2).
3. Maintain outward pressure against the poppet housing to
prevent it from beign displaced. Place 0-ring 83 in its seat Fig. 3
using Mares special tool (B-6). (See Fig. 3).
4. Place O-ring 66 in the groove of the poppet housing 91.
5. Thread the inlet fitting 94 onto the poppet housing 91 and
tighten with a 22 mm wrench (B-9). When using a torque
wrench, tighten to 8-8.5 N/m (35-40 lb. in.) maximum.
6. Insert the threaded stem of the metal poppet body 30 into
the larger diameter of the plastic poppet body 92. Pull the
metal poppet body through the plastic poppet body until it
is fully seated in the plastic poppet body.
7. Press the poppet seat 47 into the plastic poppet body 92.
8. Place the spring 31 over the poppet assembly.
9. Place the poppet assembly and spring onto Mares special
tool (B-6).
10. Insert poppet assembly and spring into the inlet fitting 94. Fig. 4
Align the square stem of the metal poppet body with the
square hole of the poppet housing 91 and press inward to
compress the spring. (See Fig. 4).
11. Position the demand Iever 35 in the groove of the poppet
housing 91 so that the rounded edge of the demand lever
will be facing the diaphragm 36.
12. Place the demand lever washer 34 over the stem of the
poppet assembly and on top of the demand Iever 35.
 original copywriter 1987 REGULATORS NIKOS SECOND STAGE S 3-5
revised 1998 - printed 1999

13. Place a new demand lever lock nut 33 on the threaded stem
of the poppet assembly and tighten the lock nut, with tool
(B-12) or (B-20), until approximately 1.5 mm (1/16 in.) of
the poppet stem is protruding from the nut. Depress the
demand Iever-35 several times to ensure freedom of
movement. (See Fig. 5).

NOTE Do not over-tighten demand lever lock nut 33. If the

demand lever lock nut is over-tightened, it will cause
the second stage to free flow during intermediate
pressure adjustment.

14. Position the spacer ring 90 into the case 32, with the vane
extending into the mouthpiece tube. Rotate the spacer ring
until the vane is in contact with the poppet housing 91. Fig. 5
15. From the inside of the case 32 insert the plug seat 87
through the hole in the side of the case. Align the flat edge
of the plug seat with the flat molding of the case and press
the plug seat into place.
16. Maintain outward pressure against the plug seat 87 to
prevent it from being displaced. Place O-Ring 83 in its seat
using Mares special tool (B-6).
17. Position the O-Ring 29 on the hose connector 28.
18. Install the O-Ring 27 in the groove of the seat connector 21.
19. With a 5 mm Allen wrench (B-4), thread the seat connector
21 into the hose connector 28 until the tapered end of the
seat connector is even with the end of the hose connector
then continue to turn the Allen wrench three full turns,
resulting in the seat connector protruding from the hose
connector.
20. While depressing the demand Iever 35, thread the hose
connector 28 into the inlet fitting 94. With a 22 mm.
wrench (B-9), hold the inlet fitting 94 in place and use a 17
mm. wrench (B-17) to tighten the hose connector 28.
21. If the purge cover 39 was disassembled, place the larger
diameter of the purge button spring into the purge cover.
Align the purge button logo and the four retaining tabs with
the hole in the purge cover and press into position.
22. Place the o-ring 27 into the swivel connector of the second
stage hose 26.
23. With two 14 mm wrenches (B-17), tighten the hose 26 onto
the hose connector 28.
24. Connect the second stage hose 26 to the first stage port
marked with D.F.C. and tighten with a 14 mm wrench (B-18).
S 3-6 NIKOS SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

ADJUSTMENT AND FINAL ASSEMBLY

NOTE Correct intermediate pressure adjustments are need-
ed for second stage opening pressure to fall within
factory specifications (2.5-3.8 cm/H20 or 1-1.5
in./H20). Second stage sensitivity may be changed by
adjusting intermediate pressure. All second stage
adjustments should be made while the second stage is
supplied with the appropriate intermediate pressure.
1. Connect an intermediate pressure gauge to a 3/8 in. LP port
on the first stage.

WARNING ! EXPLOSION HAZARD

DO NOT CONNECT THE INTERMEDIATE PRESSURE GAUGE TO
THE HIGH PRESSURE PORT OF THE FIRST STAGE.
CONNECTING THE INTERMEDIATE PRESSURE GAUGE TO THE
HIGH PRESSURE PORT OF THE FIRST STAGE WILL CAUSE THE
HOSE AND/ OR INTERMEDIATE PRESSURE GAUGE TO
EXPLODE AND COULD RESULT IN SERIOUS PERSONAL INJURY
OR DEATH.

2. Attach the first stage to a full tank (2000-3000 psi).

(See Fig. 6).
3. Depress the second stage demand lever 35 while slowly
opening the tank valve. When air begins to flow from the
second stage, slowly release the demand lever. If air leakage
is detected after releasing the demand lever, refer to the
troubleshooting section of this manual. if air leakage is not
detected after releasing the demand lever, fully open the
tank valve.
4. Read the intermediate pressure indicated by the gauge. Fig. 6
Intermediate pressure specification for the MR 12 Nikos is
9.8-10.2 bar (142-148 psi). If the intermediate pressure is
incorrect, refer to the MR 12 first stage service manual for
adjustment procedure.

WARNING !
IF THE REGULATOR IS TO BE USED FOR COLD WATER DIVING
(BELOW 40Þ F) OR IS EQUIPPED WITH A CWD KIT, REFER TO
THE COLD WATER DIVING KIT SECTION OF THE MR 12 FIRST
STAGE SERVICE MANUAL FOR INSTALLATION/SERVICING OF
THE CWD KIT AND INTERMEDIATE PRESSURE ADJUSTMENT.
FOR COLD WATER DIVING THE INTERMEDIATE PRESSURE
SPECIFICATION IS 8.8-9.2 BAR (128-132 PSI). FAILURE TO FOL-
LOW THESE INSTRUCTIONS COULD LEAD TO A REGULATOR
ICING SITUATION WHICH COULD LEAD TO SERIOUS PERSON-
AL INJURY OR DEATH.

Due to the second stage case design, the Nikos second stage may
be adjusted by using either of the following procedures.
 original copywriter 1987 REGULATORS NIKOS SECOND STAGE S 3-7
revised 1998 - printed 1999

PROCEDURE A
1. Measure the demand lever height with the Mares demand
lever height gauge (P/N 106230). Position lever height
gauge so that its two ends rest on the edge of the second
stage case. (See Fig. 7)
a. If the demand lever height is too low, tighten the demand
lever lock nut 33, using tool (B-12) or (B-20), until the
demand lever contacts the lower edge of the gauge.
b. If the demand lever height is too high, loosen the demand
lever lock nut 33, using tool (B-12) or (B-20), until the
demand lever just contacts the lower edge of the gauge. Fig. 7

2. Depress and release the demand lever 35 several times to

ensure freedom of movement.
3. Place the diaphragm 36 on the diaphragm ring 78 with
the metal disk of the diaphragm facing away from the
diaphragm ring and the flat surface of the diaphragm ring
facing away from the diaphragm.
4. Place the diaphragm and its ring in the case 32 with the
metal disk of the diaphragm facing the demand lever 35.
5. Install the purge cover 39 with a clockwise rotation using
Mares special tool (B-7) (P/N 106207). If Mares tool (B-7)
is not available, snap ring pliers may be used to install the
purge cover. Position the purge cover logo in the correct
direction and align the two holes for the safety catch (one in
the second stage case and one in the cover).
6. Insert the safety catch 63 into the hole in the case and
press into place.
7. Place the O-ring 72 on the case plug 64. Thread the case
plug into the plug seat 87 and gently tighten with a 6 mm
Allen wrench (B-3). When using a torque wrench, tighten to
90 N/cm (8 lb. in.) maximum.
8. Slide the hose protector 46 and spacer ring 93 into position
on the second stage.
9. After second stage adjustment, depressurize the regulator
and remove the intermediate pressure gauge.
10. Install the exhaust tee 41. Make sure the lip of the exhaust
tee fits fully over the mounting flange.

WARNING !
USE ONLY LIQUID SOAP TO LUBRICATE THE EXHAUST TEE TO
MAKE ASSEMBLY EASIER. DO NOT USE SILICONE GREASE TO
LUBRICATE THE EXHAUST TEE. THE USE OF SILICONE GREASE
MAY CAUSE THE EXHAUST TEE TO COME OFF DURING
OPERATION, WHICH COULD LEAD TO SERIOUS PERSONAL
INJURY OR DEATH.

11. Install the mouthpiece 44 and secure in place with a new

clamp 43. The locking tab of the clamp should be positioned
on the same side as the second stage hose.
S 3-8 NIKOS SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

PROCEDURE B
1. Place the diaphragm 36 on the diaphragm ring 78 with the
metal disk of the diaphragm facing away from the
diaphragm ring and the flat surface of the diaphragm ring
facing away from the diaphragm.
2. Place the diaphragm and its ring in the case 32 with the
metal disk of the diaphragm facing the demand lever 35.
3. Install the purge cover 39 with a clockwise rotation using
Mares special tool (B-7) (P/N 106207). If Mares tool (B-7)
is not available, snap ring pliers may be used to install the
purge cover. Position the purge cover logo in the correct
direction and align the two holes for the safety catch (one in
the second stage case and one in the cover).
4. Insert the safety catch 63 into the hole in the case and press
into place.
5. Insert 5.5 mm nut driver (B-12) through the plug seat 87.
Tighten or loosen the lock nut 33 in order to adjust the
demand lever 35.
a. If the demand lever height is too low, tighten the demand
lever lock nut, using tool (B-12), until depressing the
purge button yelds approximately 1 mm. of travel before
air begins to flow from the second stage.
b. If the demand lever height is too high, loosen the demand
lever lock nut, using tool (B-12), until depressing the
purge button yelds approximately 1 mm. of travel before
air begins to flow from the second stage.
6. Depress the purge button several times to ensure freedom
of movement and to verify correct demand lever height
adjustment.
7. Place the O-ring 72 on the case plug 64. Thread the case
plug into the plug seat 87 and gently tighten with 6 mm
Allen wrench (B-3). When using a torque wrench, tighten to
90 N/cm (8 lb. in.) maximum.
8. Slide the hose protector 46 and spacer ring 93 into position
on the second stage.
9. After second stage adjustment, depressurize the regulator
and remove the intermediate pressure gauge.
10. Install the exhaust tee 41. Make sure the lip of the exhaust
tee fits fully over the mounting flange.

WARNING !
USE ONLY LIQUID SOAP TO LUBRICATE THE EXHAUST TEE TO MAKE ASSEMBLY EASIER. DO NOT USE SILICONE
GREASE TO LUBRICATE THE EXHAUST TEE. THE USE OF SILICONE GREASE MAY CAUSE THE EXHAUST TEE TO COME
OFF DURING OPERATION, WHICH COULD LEAD TO SERIOUS PERSONAL INJURY OR DEATH.

11. Install the mouth piece 44 and secure it in place with a

new clamp 43. The locking tab of the clamp should be
positioned on the same side as the second stage hose.
 original copywriter 1987 REGULATORS NIKOS SECOND STAGE S 3-9
revised 1998 - printed 1999

NIKOS ESCORT SECOND STAGE Table No. 21

NIKOS NITROX SECOND STAGE Updated to 01-04-98

Ref.No. Code Description Ref.No. Code Description

19 110106 OR 106 66 110220 OR 2062
19 110402 OR 106 Viton 610-9707 66 110417 OR 2062 Viton 016-9707
21 186023 Poppet seat 71 110211 OR 2050
26 186174 Hose Hi/Flow, black 71 410413 OR 2050 Viton 014-9707
26 186178 Hose Octopus Hi/Flow, yellow 72 110215 OR 2043
27 110205 OR 2025 72 110415 OR 2043 Viton 013-9707
27 110411 OR 2025 Viton 010-9707 78 184224 Locking ring, diaphragm
29 184282 Hose connector 83 110225 OR 2068
30 184219 Poppet stem, 2nd stage 83 110420 OR 2068 Viton 017-9707
31 185057 Spring 87 184233 Plug seat
32 184232 Case, Nikos 90 184222 Spacer ring, conveyor
32 184231 Case, Nikos, black 91 184218 Poppet housing, Nikos
33 185051 Steel demand lever lock nut 92 184220 Poppet body, 2nd stage Nikos
34 185049 Steel demand lever lock washer 93 184215 Spacer ring Nikos, yellow
35 185104 Lever, CWD 93 184217 Spacer ring Nikos, black
36 184225 Modular diaphragm 94 184216 Inlet fitting Nikos
39 184269 Cover assy Nikos, black
39 184267 Cover assy Nikos Escort, yellow ASSEMBLIES
39 184272 Cover assy Octopus Nikos, yellow
39 184273 Cover assy Nikos, Nitrox G 184293 Second stage assy Nikos (x MR12)
40 184006 Exhaust valve G 184294 Second stage assy Nikos J.(x MR12)
41 184438 Exhaust tee G 186182 Second stage assy Nikos black (xR2)
43 157984 Mouthpiece clamp G 186183 Second stage assy Nikos Escort, black
44 185086 Mouthpiece, black G 186184 Second stage assy Nikos Nitrox
45 179904 Hose protector, 1st stage, black G 184057 Second stage assy Nikos Nitrox J.
46 184210 Hose protector, 2nd stage, black *** 186164 Maintenance kit, 2nd stage assy Nikos
47 184062 Poppet seat (19-27-33-40-43-47-66-71-72-83)
54 186090 Mouthpiece plug Octopus *** 186166 Maintenance kit, 2nd stage assy Nikos Nitrox
63 184289 Safety catch, cover (19-27-33-40-43-47-66-71-72-83)
64 184234 Regulating plug
 SECOND STAGE
III - II
III - II SECOND STAGE
 original copywriter 1987 REGULATORS SECOND STAGE III - II S 4-1
revised 1998 - printed 1999

D I S A S S E M B LY :
1. Using cutting nippers or pliers, cut the mouthpiece clamp
(43) and remove the mouthpiece (44).
2. Remove the exhaust tee (41) from the second stage case.
3. Using two wrenches (B-17), unscrew the hose (26) from the
second stage.
4. Remove the O-ring (27) from the hose (26).
5. Unscrew the seat connector (28) from the second stage,
using wrench (B-17).
6. Remove the O-ring (29) from the seat connector (28).
7. Back off screw (38) on the ring clamp (37).
8. Open the ring clamp (37) and remove it from the second
stage case (32).
9. Remove the cover assembly (39) and the diaphragm (36).

CAUTION !
DISASSEMBLY OF THE PURGE COVER (PURGE BUTTON,
SPRING, BASE) IS NOT NECESSARY UNLESS THE COVER IS
SEVERELY ENCRUSTED WITH RUST OR DIRT, OR WHENEVER
THE PURGE BUTTON FAILS TO RETURN TO ITS NORMAL
POSITION.
REMOVAL OF THE PURGE BUTTON AND BASE MAY CAUSE
DAMAGE TO THE COMPONENTS. EXERCISE THE UTMOST
CAUTION AND CARE DURING THIS OPERATION.
MARES ADVISES AGAINST DISASSEMBLING THESE COMPO-
NENTS IF REPLACEMENT PARTS ARE NOT AVAILABLE.

10. Remove the adjusting nut (33), washer (34) and demand
lever (35), using the special wrench (B-12).

WARNING !
TO PREVENT THE SECOND STAGE SPRING AND POPPET BODY
FROM BEING EJECTED FROM THE INLET FITTING, COVER IT
WITH A FINGER OR HAND.

11. Remove the poppet (30) and spring (31) from the second
stage.
12. Remove the poppet seat (47) from the poppet body (30).

WARNING !
STARTING FROM SECOND STAGE WITH SERIAL NUMBER
0798464- THE SECOND STAGE POPPET BODY HAS BEEN
CHANGED. WITH THE PREVIOUS VERSION IT WAS NOT POSSI-
BLE TO REPLACE ONLY THE RUBBER SEAT. THE OLD POPPET
CAN BE REPLACED WITH THE NEW VERSION.
S 4-2 SECOND STAGE III - II REGULATORS original copywriter 1987
revised 1998 - printed 1999

13. Remove the exhaust valve (40).

WARNING !
DO NOT REMOVE THE METAL FLOW VANE FROM THE SECOND
STAGE CASE, AS THIS MAY DAMAGE THE FLOW VANE,
RESULTING IN IMPROPER OPERATION.

CLEANING

WARNING !
PROTECT EYES AND SKIN ADEQUATELY WHEN WORKING WITH
ANY KIND OF ACID.

For routine cleaning of the components, wash all parts in a mix-

ture of hot water and mild detergent. Make sure that all compo-
nents have been rinsed in fresh water before proceeding with
reassembly. Parts made from chrome-plated brass or stainless
steel can be cleaned with an ultrasonic cleaner in plain water or,
if the necessary equipment is not available, in a mild acid solution
(white vinegar, diluted as required).

WARNING !
ACIDS OR OTHER SOLVENTS MAY DAMAGE PLASTIC AND
RUBBER PARTS. BEFORE CLEANING METAL COMPONENTS,
MAKE SURE THAT THE SEALS AND OTHER PARTS SUBJECT TO
DETERIORATION HAVE BEEN REMOVED.

INSPECTION
Certain components of the second stage should be replaced at
each routine service. Moreover, in view of their relatively low cost,
all the O-rings should also be replaced.
The components to replace are:

Quantity Description Reference Part Number

1 O-ring 2025 (27) - cod. 110205 cod. Viton 110411
1 O-ring 3 - 906 (29) - cod. 110191 cod. Viton 110408
1 2nd stage rubber poppet seat (47) - cod. 185060
1 2nd stage demand lever adjusting nut (33) - cod. 185051
1 exhaust valve (40) - cod. 185052
1 mouthpiece clamp (43) - cod. 157984

If these components are not replaced, they should at least be

inspected with a jeweler’s magnifying glass for the following
defects:
 original copywriter 1987 REGULATORS SECOND STAGE III - II S 4-3
revised 1998 - printed 1999

D O N O T U S E PA RT S W I T H T H E F O L L O W I N G D E F E C T S :

Description Reference Inspections

Second stage case (32) Inspect the sealing surfaces for scratches or breaks. Make sure that the
exhaust valve housing is perfectly clean and undamaged. Check that the
bypass tube is not deformed.
Ring clamp (37) Inspect for breakage or distortion.
Seat connector (28) Inspect the sealing rim and O-ring seat for any damage.
Diaphragm (36) Inspect for tears or pinholes around the metal disk, deformation of the outer
rim or signs of separation of the diaphragm from the metal disk.
O-rings (27-29) Inspect for cuts, chipping or foreign particles. The presence of any of these
defects may result in leakage.
Second stage poppet seat (47) Inspect for cuts, chipping or abrasion of the rubber.

WARNING !
IF THE SURFACE OF THE SECOND STAGE POPPET SEAT IS DAMAGED, IT MUST BE REPLACED. IF A SPARE IS NOT
AVAILABLE, IT CAN ALSO BE TURNED OVER AFTER HAVING CAREFULLY CHECKED THAT THE NEW SURFACE IS PER-
FECTLY SOUND.

Demand lever adjusting nut (33) Verify its self-locking capacity and inspect for rust. It is recommended to
replace it at each routine service.
Mouthpiece (44) Inspect for cuts, tears or deterioration.
Exhaust tee (41) Inspect for signs of damage.
Hose (26) Inspect the hose for splits, blistering, cuts or other signs of damage.
Springs (31) Check for any split or broken coils.

R E A S S E M B LY
Before reassembling, lightly lubricate all the O-rings with silicone
grease (type General Electric Versalube G 322 or equivalent).
Lubrication reduces the likelihood of damage during reassembly.

WARNING !
IF THE SECOND STAGE IS USED FOR DIVING WITH OXYGEN-
RICH MIXTURES, IT MUST BE PERFECTLY CLEANED AND FREE
OF ANY RESIDUAL SILICONE OR OTHER IMPURITIES. VITON
O-RINGS MUST BE LUBRICATED WITH SPECIAL OXYGEN-
COMPATIBLE GREASE. DO NOT USE SILICONE GREASE!

1. Carefully install a new exhaust valve (40), pulling the silicone

stem through the cross hole in the second stage case.

WARNING !
DO NOT PULL TOO HARD ON THE STEM TO AVOID DAMAGING
THE EXHAUST VALVE.

2. Using cutting nippers (or scissors), cut the end of the

exhaust valve (40).
S 4-4 SECOND STAGE III - II REGULATORS original copywriter 1987
revised 1998 - printed 1999

3. Reassemble the rubber seat (47) in the poppet body (30).

4. Position the 2nd stage poppet assembly and its spring (31)
on the special tool (B-6).
5. Exerting a light pressure, correctly position the 2nd stage
poppet and its spring inside the inlet fitting of the 2nd stage
case. (Fig. 1)

WARNING !
IN ORDER TO CORRECTLY POSITION THE 2ND STAGE POPPET,
IT IS RECOMMENDED TO ROTATE THE SECOND STAGE CASE
TO THE RIGHT AND LEFT (FIG. 1). Fig. 1

6. Correctly position the demand lever in the groove of the

second stage case (32), place the washer (34) on the poppet
stem and screw on the new demand lever lock nut (33) by a
few turns, using the special wrench (B-12). (Fig. 2)

NOTE Do not overtighten the demand lever lock nut. If the

lock nut is too tight it may cause air to free flow from
the second stage, interfering with the intermediate
pressure adjustment.

NOTE Press the demand lever a few times to make sure it is Fig. 2
able to move freely.

7. Fit the O-ring (29) on the poppet seat connector (28).

8. Correctly screw the poppet seat connector (28) into the
second stage inlet fitting, locking it down with wrench
(B-17).
9. Reassemble the O-ring (27) in the seat of the swivel fitting of
hose (26).
10. Using two wrenches (B-17), clamp the hose (26) to seat
connector (28).

ADJUSTMENT AND FINAL ASSEMBLY

To ensure sufficiently accurate regulator adjustments, the repair
equipment must be provided with both low- and high-pressure air
supplies. Moreover, a pressure gauge is necessary for checking
the intermediate pressure. (The pressure gauge must have a
maximum full scale value of 30-40 bar - 435-580 p.s.i., for
greater accuracy of adjustment).

1. Screw the intermediate pressure measuring gauge

(cod. 106252) into one of the low pressure ports (3/8”),
using the special wrench (B-18).
2. Using wrench (B-18), assemble the hose with the partially
finished second stage on the port marked D.F.C. (if present).
 original copywriter 1987 REGULATORS SECOND STAGE III - II S 4-5
revised 1998 - printed 1999

WARNING !
MAKE SURE THAT THE INTERMEDIATE PRESSURE GAUGE AND
SECOND STAGE HOSES ARE NOT CONNECTED TO THE HIGH
PRESSURE PORT WHICH IS MARKED HP.
B12
3. Assemble the group on the air valve (of the test bench or
tank). (Fig. 3)
4. Depress the second stage demand lever, slowly open the
LOW PRESSURE
tank valve and, almost at the same time, release the demand (LP) PORT
INTERMEDIATE PRESSURE
CALIBRATION GAUGE
lever. Fig. 3
5. Read the pressure gauge to check whether the calibration of
the first stage is correct.
C-SHAPED GAUGE FOR DEMAND
LEVER HEIGHT INSPECTION
WARNING !
For the correct adjustment stand the gauge on the Second Stage case
THE FIRST STAGE INTERMEDIATE PRESSURE MUST BE MEA- and adjust lever height until it makes contact with the gauge.
SURED WHEN THERE IS NO AIR COMING OUT. FOR CALIBRA-
TION OF THE FIRST STAGE, REFER TO THE SEPARATE MANUAL.
NAVY E BETA
6. Position the Gauge (Fig. 4) perpendicular to the rim of
the second stage case. RUBY / ABYSS
VOLTREX
7. Lock down or back off the demand lever lock nut (33) using
the special wrench (B-12), in order to correctly adjust the
height of the demand lever (35). Fig. 4

WARNING !
THE DEMAND LEVER IS CORRECTLY ADJUSTED WHEN IT JUST
TOUCHES THE GAUGE INDEX CORRESPONDING TO THE SEC-
OND STAGE MODEL (FIG. 4), WITHOUT ANY AIR COMING OUT.

8. Press and release the demand lever a few times.

9. Correctly position the diaphragm (36) with the metal disk
in contact with the demand lever.
10. Correctly orient and position the cover (39) on top of the
diaphragm.
11. Position the ring clamp (37) so that the openings are above
the second stage inlet fitting.
12. Lock down the clamp screw (38).
13. Install the exhaust tee (41) on the second stage supporting
flange.

WARNING !
MAKE SURE THAT THE RIM OF THE EXHAUST TEE IS PROPERLY INSERTED IN THE FLANGE. LIGHT LUBRICATION
WITH LIQUID SOAP OR DETERGENT FACILITATES INSTALLATION. DO NOT USE SILICONE LUBRICANTS, AS THESE
MAY DAMAGE CERTAIN COMPONENTS (DIAPHRAGMS), INCREASING THE LIKELIHOOD OF UNSEATING THE EXHAUST
TEE DURING USE.

14. Correctly install the mouthpiece (44) and secure it with a

new clamp (43).
S 4-6 SECOND STAGE III - II REGULATORS original copywriter 1987
revised 1998 - printed 1999

SECOND STAGE, III Table 25

OCTOPUS III Updated to 01-04-98

Ref. Code Description

19 110106 OR 106
19 110402 OR 106 Viton 610-9754
26 186174 Hose high flow black (XL)
26 186178 Hose, Octopus high flow yellow
27 110205 OR 2025
27 110411 OR 2025 Viton 010-9754
28 185082 Seat connector
29 110191 OR 3-906
29 110408 OR 3-906 Viton 906-9754
30 185058 Poppet body
31 185059 Poppet spring
32 *** Case (see Ref. H)
33 185051 Lock nut, demand lever
34 185049 Washer, demand lever
35 185104 Demand lever CWD
36 185056 Diaphragm
37 185073 Clamp, ring
38 185075 Screw 3x16, clamp ring
39 186070 Cover assy black
39 186072 Cover assy yellow - Octopus
40 185052 Exhaust valve
41 185092 Exhaust tee
42 *** Vane (see Ref. H)
43 157984 Clamp, mouthpiece
44 185089 Mouthpiece
45 179904 Hose protector, first stage, black
47 185060 Poppet seat, rubber
54 186091 Octopus plug

ASSEMBLIES

G 185099 Second stage assy - complete

H 185252 Case assembly w/vane (32-42)
*** 186162 Maintenace kit
(19-27-29-33-40-43-44-47)
 SECOND STAGE
NAVY
NAVY SECOND STAGE
 original copywriter 1987 REGULATORS NAVY SECOND STAGE S 5-1
revised 1998 - printed 1999

D I S A S S E M B LY :
1. Remove mouthpiece clamp (43) by cutting it with an
appropriate tool.
2. Remove mouthpiece (44).
3. Remove exhaust tee (41) from second stage case.
4. Using two wrenches (B17 and B19) remove hose (26)
from second stage.
5. Pull hose connector lock (77) off hose connector (55).
6. Remove hose connector (55) from second stage using
wrench (B19).
7. Remove seat connector (28).
8. Remove O-rings (71) from seat connector (28).
9. Remove O-ring (29) from second stage inlet.

CAUTION !
DO NOT ATTEMPT TO REMOVE THE V.A.D. TUBE FROM THE
SECOND STAGE CASE. DAMAGE TO THE V.A.D. TUBE MAY
RESULT.

10. Depress the second stage safety catch (63).

11. Unscrew the bezel (60).
12. Remove purge cover (39).
13. Remove friction disk (78).
14. Lift safety catch (63) out of second stage case.

NOTE Disassembly of the purge cover (purge button, spring

and cover) is not necessary, unless the cover is severe-
ly encrusted, dirty or whenever the purge button does
not return to its normal position. Unless extreme care
is taken, removal of the purge button may cause dam-
age to the cover components.
15. Remove second stage diaphragm (36).
16. Remove lock nut (33), washer (34) and demand lever (35)
using tool (B20).

CAUTION !
THE POPPET BODY (30) IS UNDER SPRING TENSION. COVER
THE SECOND STAGE INLET FITTING WITH YOUR HAND TO PRE-
VENT THE POPPET BODY (30) AND SPRING (31) FROM BEING
EJECTED WHEN THE LOCK NUT IS REMOVED.

17. Remove poppet body (30) and spring (31) from second
stage inlet.
18. Remove poppet seat (47) from poppet body.
19. Slide the demand lever pad (73) out of the case.
20. Remove exhaust valve (40).
S 5-2 NAVY SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

CLEANING
Cleaning requires all reusable rubber and plastic parts to be care-
fully cleaned by scrubbing with a soft brush in a mild detergent
and water solution. Do not use solvents or acids on rubber or
plastic parts. Metal parts should be cleaned in an ultrasonic
cleaner with fresh water or in a mild acid solution (white vinegar
diluited with warm water is recommended). Before reassembly
make sure all parts have been carefully rinsed and dried.

WARNING !
PROTECT EYES AND SKIN ADEQUATELY WHEN WORKING WITH ANY KIND OF ACID. BEFORE CLEANING METAL
PARTS, MAKE SURE THAT ALL RUBBER AND PLASTIC PARTS HAVE BEEN REMOVED. ACIDS OR OTHER SOLVENTS
MAY DAMAGE RUBBER AND PLASTIC PARTS.

INSPECTION
The following second stage components should be replaced
during routine service:

Quantity Description Reference Part Number

1 Exhaust valve -40- 184006
1 Poppet seat -47- 184062
1 Lock nut -33- 185051
1 Mouthpiece clamp -43- 157984 cod. Viton 110413
2 O-rings seat connector -71- 110211 cod. Viton 110413
1 O-ring hose -27- 110205 cod. Viton 110411
1 O-ring by-pass -24- 110243 cod. Viton 110422

If the following parts are not replaced, they should be inspected

with a jewler's loop for the flaws listed below. Replace any part
with these flaws.

Description Inspections
Seat connector: Inspect the tapered seating surface for nicks, flat spots and deep scratches.
Poppet seat: Inspect for cuts, cracking and any deformation. If a new poppet seat is not available, the
poppet seat can be reversed if the surface is not damaged, or previously used.
Demand lever: Inspect the pivot points for wear and straightness.
Spring: Inspect for cracking or broken coils.
Second stage case: Inspect the case for cracks, distortion or burrs on the case threads and deep scratches on
the exhaust valve seat.
Demand lever pad: Inspect for any sings of wear at the demand lever pivot points.
Exhaust valve: Inspect for any cracks, tears or deterioration.
0-rings: Inspect for cuts, tears, flat spots or contamination. The presence of any of these flaws may
cause leakage.
Diaphragm: Inspect for any tears or pin holes amund the metal disk, for any distortion of the outer bead
or for any signs of the disk detaching from the diaphragm.
Mouthpiece: Inspect for deterioration or cuts.
Exhaust tee: Inspect for cracks or tears.
Second stage hose: Inspect for any cracks, blisters, cuts and other signs of damage. Inspect the hose 0-rings
for cuts or foreign matter.
 original copywriter 1987 REGULATORS NAVY SECOND STAGE S 5-3
revised 1998 - printed 1999

R E A S S E M B LY
Before reassembly, lightly lubricate all 0-rings with silicone
grease (General Electric, Versalube G-322 or equivalent).
Lubricating the 0-rings before reassembly will minimize the risk
of damage during reassembly

WARNING !
IF THE SECOND STAGE IS USED FOR ENRICHED AIR DIVING, IT
MUST BE PERFECTLY CLEANED AND FREE FROM RESIDUAL
SILICONE OR FROM ANY FOREIGN MATTER. VITON 0-RINGS
CAN BE LUBRICATED WITH SPECIFIC OXYGEN COMPATIBLE
GREASE. DO NOT USE SILICONE GREASE.

1. Carefully install a new exhaust valve 40 by pulling the stem

through the center hole of the exhaust valve seat until it
locks in place. The valve stem should not be pulled
excessively as damage to the valve may occur.
Using scissors, cut approximately 7 mm (1/4 in.) off of the
end of the valve stem.
2. Slide demand lever pad (73) into second stage case, making
sure the tapered edge is facing outward
3. Press poppet seat (47) into poppet body (30).
4. Place poppet body (30) onto tool (B6).
5. Place spring (31) over poppet body.
6. Insert poppet body and spring into the second stage inlet.
Align the poppet stem with the hole in the case and press
inward to compress the spring (Fig. 1).
7. Place the demand lever (35) into the demand lever pad
groove.
8. Place the demand lever washer (34) over the second stage Fig. 1
poppet stem and on top of the demand lever.
9. Place a new demand lever lock nut (33) on the second stage
poppet stem and tighten the lock nut, with tool (B20), until
approximately 1/16" of the poppet stem is protruding from
the nut (Fig 2).

NOTE Do not over-tighten demand lever lock nut. If the

demand lever lock nut is over-tightened, it will cause
the second stage to free-flow during intermediate
pressure adjustment.
10. Place O-ring (29) into the seat of the By-pass tube.
11. Place 0-rings (71) on seat connector (28)
12. Slide the seat connector (28) into the second stage inlet,
making sure the tapered seating surface is facing the poppet
seat.
13. Install hose connector (55) and tighten in place with wrench Fig. 2
(B19).
S 5-4 NAVY SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

WARNING !
IF A TORQUE WRENCH IS USED, SET THE TORQUE FOR 4-4.5
N/m (35-40.14 lb. in.).

14. Slide lock connector (77) into place over the hose connector.
15. Connect hose (26) to hose connector using 2 wrenches (B17
and B19).

NAVY SECOND STAGE ADJUSTMENT

NOTE Correct intermediate pressure adjustments are needed

for second stage opening pressures to fall within
factory-set rating. Second stage sensitivity may be
changed by adjusting intermediate pressure. All
second stage adjustments should be made while the
second stage is supplied with the appropriate interme-
diate pressure.

1. Connect an intermediate pressure gauge to a 3/8” LP port on

the first stage.

DANGER ! EXPLOSION HAZARD

DO NOT CONNECT THE INTERMEDIATE PRESSURE GAUGE TO
THE HIGH PRESSURE PORT OF THE FIRST STAGE.
CONNECTING THE INTERMEDIATE PRESSURE GAUGE TO THE
HIGH PRESSURE PORT OF THE FIRST STAGE WILL CAUSE THE
HOSE AND/ OR INTERMEDIATE PRESSURE GAUGE TO
EXPLODE AND COULD RESULT IN SERIOUS PERSONAL INJURY
OR DEATH.

2. Attach the first stage to a full tank (2000-3000 psi).

(See Fig. 3).
3. Depress the second stage demand lever while slowly
opening the tank valve. When air begins to flow from the
second stage slowly release the demand lever and fully open
the tank valve.
4. Read the intermediate pressure indicated by the gauge.
If the intermediate pressure is incorrect refer to the B12
appropriate first stage section of this manual for adjustment
procedure.

NOTE If the regulator is to be used for cold water diving Low pressure
outlet (LP) INTERMEDIATE PRESSURE
(below 47° F) or is equipped with a CWD Kit, refer to
CALIBRATION GAUGE
the cold water diving section of this manual for
Fig. 3
installation/servicing of the CWD Kit and intermediate
pressure specifications.
 original copywriter 1987 REGULATORS NAVY SECOND STAGE S 5-5
revised 1998 - printed 1999

5. Adjust demand lever height using the demand lever height

gauge. The demand lever height gauge sides are marked with C-SHAPED GAUGE FOR DEMAND
LEVER HEIGHT INSPECTION
the second stage model. Place the side of the demand lever
For the correct adjustment stand the gauge on the Second Stage
height gauge marked with the corresponding model across case and adjust lever height until it makes contact with the gauge.
the Second Stage case (Fig. 4).
a. If the demand lever height is too low, tighten the demand
NAVY E BETA
lever lock nut, using tool (B20), until the demand lever
contacts the lower edge of the gauge.
RUBY / ABYSS
b. If the demand lever height is too high, loosen the VOLTREX
demand lever lock nut, using tool (B20), until the demand
lever contacts the lower edge of the gauge.
6. Depress and release the demand lever several times to Fig. 4
ensure freedom of movement.
7. Place the second stage diaphragm (36) on to the second
stage body making sure the metal disk is against the
demand lever.
8. Place the friction disk (78) on the diaphragm with the
rounded side against the diaphragm.
9. Place the purge cover (39) on the friction disk. Position the
purge cover so the logos are properly positioned.
10. Tighten the purge cover bezel (60) until light resistance is felt,
tighten an additional 1/4 to 1/2 turn. Do not over-tighten.
11. Press the second stage safety catch (63) into channel of the
second stage with the tab facing the purge cover bezel.
12. Install mouthpiece (44) and secure in place with a new clamp
(43). The locking tab of the clamp should be positioned to
line up with the V.A.D. tube.
13. Install the exhaust tee (41) over the second stage case
mounting flange. Make sure the lip of the exhaust tee fits fully
over the mounting flange.

NOTE Liquid soap can be used to lubricate the exaust tee to

make assembly easier. Do not use silicone grease to
lubricate the exaust tee. The use of silicone grease
may cause the exhaust tee to come off during
operation.

14. After second stage adjustment, depressurize the regulator

and remove the intermediate pressure gauge.
S 5-6 NAVY SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

SECOND STAGE, NAVY Table 20

OCTOPUS NAVY Updated to 01-04-98

Ref. Code Description

19 110106 O-Ring 106
26 184450 Hose
26 186093 Octopus hose - complete
27 110205 O-Ring 2025
28 184444 Seat connector
29 110243 O-Ring 2975
30 184016 Poppet body
31 185059 Spring
32 - Case (see ref. H)
33 185051 Locknut, demand lever
34 185049 Washer, demand lever
35 185104 Demand lever
36 186029 Diaphragm
39 186060 Cover assy, black
39 186061 Cover assy, yellow - Octopus
40 184006 Exhaust valve
41 184438 Exhaust tee
43 157984 Mouthpiece clamp
44 185089 Mouthpiece
45 179904 Hose proteclor, black
47 184062 Poppet seat, rubber
54 186090 Octopus plug
55 184004 Hose connector
60 184432 Bezel ring, cover
63 184050 Safety catch
71 110211 O-Ring 2050
73 184442 Pad, demand lever
78 184436 Lock, hose connector
184431 Spacer ring, cover

ASSEMBLIES
G 184445 Second stage assy - complete
H 184446 Case assy HT (28-30-31-32-33-34-35-40-41
43-44-47-55-71-77)
186161 Service Kit (19-27-29-33-40-43-47-71)
BETA - MR10
SECOND STAGE
BETA-MR10 SECOND STAGE
 original copywriter 1987 REGULATORS B E TA - M R1 0 S E C O N D S TA G E S 6-1
revised 1998 - printed 1999

D I S A S S E M B LY :
NOTE Always use two wrenches when removing the LP hose
from the second stage. Failure to use two wrenches
will result in damage to the second stage case.

1. Remove mouthpiece clamp (43) by cutting it with an

appropriate tool.
2. Remove mouthpiece (44).
3. Remove exhaust tee (41) from second stage case.
4. Using two wrenches (B17 and B19) remove hose (26)
from second stage (Fig. 1).
4A. On Beta Multi-Air units, gently grasp the Multi-Air adaptor
with pliers (a soft cloth can be wrapped around the adaptor
to protect it from scratching). Using wrench (B19) remove
second stage from Multi-Air adaptor.
5. Pull hose connector lock (77) off hose connector (55).

6. Remove hose connector (55) from the connector case (67)

using two wrenches (B19).
7. Remove seat connector (28).
8. Remove O-rings (71) from seat connector (28).

9. Depress the second stage safety catch (63) towards the

exhaust tee (41) while unscrewing the purge cover bezel (60).
10. Remove the bezel (60). (only Beta Version).
11. Remove purge cover (39).
12. Remove friction disk (78). (72 for MR10).
13. Lift safety catch (63) out of second stage case.

NOTE Disassembly of the purge cover (purge button, spring

and cover) is not necessary, unless the cover is severe-
ly encrusted, dirty or whenever the purge button does Fig. 1
not return to its normal position. Unless extreme care
is taken, removal of the purge button may cause dam-
age to the cover components.
14. Remove second stage diaphragm (36).
15. Remove snap ring (65), using snap ring pliers or a small
screw driver.
16. Depress and hold the demand lever (35) in the down position.
(Fig. 2).
17. Push the connector case inward (towards the second stage
case) until the locking tabs are disengaged from the second
stage case ears (Fig. 2).
18. Keeping the demand lever depressed, rotate the connector
case 90 degrees counter clockwise (Fig. 2).
Fig. 2
19. Pull the connector case out of the second stage (Fig. 2-A).
S 6-2 BETA -MR10 SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

20. Remove the lock nut (33), washer (34) and demand lever
(35) using tool (B12).

NOTE The poppet body (30) is under spring tension. Cover

the connector case inlet fitting with your hand to pre-
vent the poppet body (30) and spring (31) from being
ejected when the lock nut is removed.

21. Remove poppet body (30) and spring (31) from connector
case.
22. Remove poppet seat (47) from poppet body.
23. Remove 0-ring (66) from connector case. Fig. 3

24. Insert tool (B13) into case plug and press inward (towards
the second stage case) (Fig. 3).
25. Rotate the case plug 90 degrees counter clockwise.
26. Push the plug from inside the second stage case to remove.
27. Remove 0-ring (66) from case plug.
28. Remove exhaust valve (40).

CLEANING
Cleaning requires all reusable rubber and plastic parts to be care-
fully cleaned by scrubbing with a soft brush in a mild detergent
and water solution. Do not use solvents or acids on rubber or
plastic parts. Metal parts should be cleaned in an ultrasonic
cleaner with fresh water or a mild acid solution. (White vinegar
diluted with warm water is recommended). Before reassembly
make sure all parts have been carefully rinsed and dried.

WARNING !
PROTECT EYES AND SKIN ADEQUATELY WHEN WORKING WITH
ANY KIND OF ACID. BEFORE CLEANING METAL PARTS, MAKE
SURE THAT ALL RUBBER AND PLASTIC PARTS HAVE BEEN
REMOVED. ACIDS OR OTHER SOLVENTS MAY DAMAGE RUB-
BER AND PLASTIC PARTS.
 original copywriter 1987 REGULATORS B E TA - M R1 0 S E C O N D S TA G E S 6-3
revised 1998 - printed 1999

INSPECTION
The following second stage components should be replaced
during routine service:

Quantity Description Reference Part Number

1 Exhaust valve -40- 184006
1 Poppet seat -47- 184062
1 Lock nut -33- 185051
1 Mouthpiece clamp -43- 157984
2 O-rings seat connector -71- 110211 cod. Viton 110413
2 O-rings connector case -66- 110220 cod. Viton 110417
1 O-ring hose -27- 110205 cod. Viton 110411

If the following parts are not replaced, they should be inspected

with a jewler's loop for the flaws listed below. Replace any part
with these flaws.

Description Inspections
Seat connector: Inspect the tapered seating surface for nicks, flat spots and deep scratches.
Poppet seat: Inspect for cuts, cracking and any deformation. If a new poppet seat is not available, the
poppet seat can be reversed if the surface is not damaged, or previously used.
Demand lever: Inspect the pivot points for wear and straightness.
Spring: Inspect for cracking or broken coils.
Second stage case: Inspect the case for cracks, distorted or broken case ears and deep scratches on the
exhaust valve seat.
Connector case: Inspect the connector case for distortion or burrs on the case threads. Inspect the locking
tabs for any signs of distortion or wear.
Snap ring: Inspect for cracks or distortion.
Case plug: Inspect the locking tabs for any signs of damage.
Exhaust valve: Inspect for any cracks, tears or deterioration.
O-rings: Inspect for cuts, tears, flat spots or contamination. The presence of any of these flaws may
cause leakage.
Diaphragm: Inspect for any tears or pin holes around the metal disk, for any distortion of the outer bead
or for any signs of the disk detaching from the diaphragm.
Mouthpiece: Inspect for deterioration or cuts.
Exhaust tee: Inspect for cracks or tears.
Second stage hose: Inspect for any cracks, blisters, cuts and other signs of damage. Inspect the hose 0-rings
for cuts or foreign matter.
S 6-4 BETA -MR10 SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

R E A S S E M B LY
Before reassembly, lightly lubricate all 0-rings with silicone
grease (General Electric, Versalube G-322 or equivalent).
Lubricating the 0-rings before reassembly will minimize the risk
of damage during reassembly

WARNING !
IF THE SECOND STAGE IS USED FOR ENRICHED AIR DIVING, IT
MUST BE PERFECTLY CLEANED AND FREE FROM RESIDUAL
SILICONE OR FROM ANY FOREIGN MATTER. VITON 0-RINGS
CAN BE LUBRICATED WITH SPECIFIC OXYGEN COMPATIBLE
GREASE. DO NOT USE SILICONE GREASE.

1. Carefully install a new exhaust valve (40) by pulling the stem

through the center hole of the exhaust valve seat until it
locks in place. The valve stem should not be pulled
excessively as damage to the valve may occur.
Using scissors, cut approximately 7 mm (1/4 in.) off of the
end of the valve stem.
2. Place 0-ring (66) on connector case (67) in front of (not in)
the snap ring groove.
3. Press poppet seat (47) into poppet body (30).
4. Place poppet body (30) onto tool (B6).
5. Place spring (31) over poppet body.
6. Insert poppet body and spring into the connector case inlet.
Align the poppet stem with the hole in the connector case
and press inward to compress the spring.

NOTE The connector case has two air jets. When installing
the demand lever, make sure the top (rounded edge)
of the demand is facing away from the air jets.
7. Place the demand lever (35).
8. Place the demand lever washer (34) over the second stage
poppet stem.
9. Tighten the new lock nut, (33) with tool (B12), until the
poppet stem is level with the top of the nut.

NOTE Do not over-tighten demand lever lock nut. If the

demand lever lock nut is over-tightened, it will cause
the second stage to free-flow during intermediate
pressure adjustment.
10. Slide the demand lever through the side hole of the second
stage case.
11. Depress and hold the demand lever in the down position.
12. Align the connector case locking tabs with the slots in the
second stage case.
13. Push the connector case inward (towards the second stage
case) until the locking tabs are past the second stage case
ears.
 original copywriter 1987 REGULATORS B E TA - M R1 0 S E C O N D S TA G E S 6-5
revised 1998 - printed 1999

14. Keeping the demand lever depressed, rotate the connector

case 90 degrees clockwise.
15. Align the connector case locking tabs with the second stage
case ears and pull the connector case outward (away from
the second stage case), until the locking tabs are engaged in
the case ears.
16. Install snap ring (65) in the groove between the connector
case and second stage case.

WARNING !
THE FLAT SIDE OF THE SNAP RING MUST BE AGAINST THE
SECOND STAGE CASE. IMPROPER INSTALLATION MAY CAUSE
THE SNAP RING TO COME OFF DURING USE WHICH MAY
CAUSE REGULATOR FAILURE RESULTING IN SERIOUS INJURY
OR DEATH.

17. Place 0-rings (71) on seat connector (28).

18. Slide the seat connector (28) into the connector case inlet,
making sure the tapered seating surface is facing the poppet
seat.
19. Install hose connector (55) and tighten in place with two
wrenches (B19).

WARNING !
IF A TORQUE WRENCH IS USED, SET THE TORQUE FOR 4-4.5
N/m 2.9 - 3.3 lbs.ft.

20. Place 0-ring (66) on case plug (64) (Fig. 4).

21. Align the second stage plug locking tabs with the slots in the
second stage case.
22. Insert tool (B13) into case plug and press inward (towards
the second stage case).
23. Rotate the case plug 90 degrees clockwise, until the locking Fig. 4
tabs engage the case ears, making sure the "UP" mark on the
plug is facing the purge cover threads on the second stage.
24. Slide lock connector (77) into place over the hose
connector.

NOTE Always use two wrenches when attaching the LP hose

to the second stage. Failure to use two wrenches will
result in damage to the second stage case.

25. Connect hose (26) to hose connector using 2 wrenches

(B17 and B19).
25A.On Beta Multi Air units, gently grasp the Multi Air adaptor
with pliers (a soft cloth can be wrapped around the adaptor
to protect it from scratching). Using wrench (B19) connect
second stage to Multi Air adaptor.
S 6-6 B E TA - M R 1 0 S E C O N D S TA G E REGULATORS original copywriter 1987
revised 1998 - printed 1999

ADJUSTMENT

NOTE Correct intermediate pressure adjustments are needed

for second stage opening pressures to fall within
factory-set ratings. Second stage sensitivity may be
changed by adjusting intermediate pressure. All
second stage adjustments should be made while the
B12
second stage is supplied with the appropriate interme-
diate pressure.

1. Connect an intermediate pressure gauge to a 3/8” LP port on Low pressure

the first stage. outlet (LP) INTERMEDIATE PRESSURE
CALIBRATION GAUGE
Fig. 5
DANGER ! EXPLOSION HAZARD
DO NOT CONNECT THE INTERMEDIATE PRESSURE GAUGE TO
THE HIGH PRESSURE PORT OF THE FIRST STAGE. C-SHAPED GAUGE FOR DEMAND
CONNECTING THE INTERMEDIATE PRESSURE GAUGE TO THE LEVER HEIGHT INSPECTION
HIGH PRESSURE PORT OF THE FIRST STAGE WILL CAUSE THE For the correct adjustment stand the gauge on the Second Stage
HOSE AND/ OR INTERMEDIATE PRESSURE GAUGE TO case and adjust lever height until it makes contact with the gauge.
EXPLODE AND COULD RESULT IN SERIOUS PERSONAL INJURY
OR DEATH.
NAVY E BETA

2. Attach the first stage to a full tank (2000-3000 psi).

RUBY / ABYSS
(See Fig. 5). VOLTREX

3. Depress the second stage demand lever while slowly

opening the tank valve. When air begins to flow from the
second stage slowly release the demand lever and fully open Fig. 6
the tank valve.
4. Read the intermediate pressure indicated by the gauge.
If the intermediate pressure is incorrect refer to the
appropriate first stage section of this manual for adjustment
procedure.

NOTE If the regulator is to be used for cold water diving

(below 47°F) or is equipped with a CWD Kit, refer to
the cold water diving section of this manual for
installation/servicing of the CWD Kit and intermediate
pressure specifications.

5. Adjust demand lever height using the demand lever height

gauge. The demand lever height gauge sides are marked
with the second stage model. Place the side of the demand
lever height gauge marked with the corresponding model
across the second stage case (Fig. 6).
a. If the demand lever height is too low, tighten the demand
lever lock nut, using tool (B-20), until the demand lever
contacts the lower edge of the gauge.
b. If the demand lever height is too high, loosen the demand
lever lock nut, using tool (B-20), until the demand lever
contacts the lower edge of the gauge.
 original copywriter 1987 REGULATORS B E TA - M R1 0 S E C O N D S TA G E S 6-7
revised 1998 - printed 1999

6. Depress and release the demand lever several times to

ensure freedom of movement.
7. Place the diaphragm (36) on to the second stage body
making sure the metal disk is against the demand lever.
8. Place the friction disk (78) on the diaphragm with the
rounded side against the diaphragm.
9. Place the purge cover (39) on the disk. Position the purge
cover so the logos are properly positioned.
10. Tighten the purge cover bezel (60) until light resistance is
felt, tighten an additional 1/4 to 1/2 turn.
Do not over-tighten. (only Beta version)
11. Press the second stage safety catch (63) into channel of the
second stage with the tab facing the purge cover bezel.
12. Install mouthpiece (44) and secure in place with a new
clamp (43). The locking tab of the clamp should be
positioned facing the second stage hose.
13. Install the exhaust tee (41) over the second stage case
mounting flange. Make sure the lip of the exhaust tee fits
fully over the mounting flange.
14. After second stage adjustment, depressurize the regulator
and remove the intermediate pressure gauge.

CHANGING THE HOSE CONNECTION FROM RIGHT TO LEFT OR VICE VERSA

The BETA second stage offers the unique possibility of changing

the hose connector from the right to left side of the second stage
and vice versa. (Fig. 7)

WARNING !
IF PERFORMING ONLY THE CONVERSION FROM RIGHT TO
LEFT-HAND ASSEMBLY, OR VICE VERSA, IT IS NOT NECESSARY
TO DISASSEMBLE THE HOSE (26) AND THE HOSE CONNECTOR
(55).

D I S A S S E M B LY :

1. Using a small flat-blade screwdriver, remove the safety clip

(63).
2. Completely unscrew the cover ring (60) (BETA version only)
3. Remove the cover (39).
4. Remove the spacer (78) (72 for MR 10).
5. Remove the second stage diaphragm (36)
6. Remove the snap ring (65) using snap ring pliers or a small Fig. 7
flat-blade screwdriver.
S 6-8 BETA -MR10 SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

WARNING !
DO NOT EXPAND THE SNAP RING EXCESSIVELY.

7. Press the demand lever (35). (Fig. 2)

8. Push the case assembly connector group (Fig. 2 - A) into the
second stage case to release the tabs from the anti-rotation
grooves. (Fig. 2)
9. Keeping the demand lever (35) pressed, rotate the case
assembly connector through 90° in an counter-clockwise
direction (Fig. 2).
10. Remove the case assembly connector (67) from the second
stage case (32).

WARNING !
CHECK THE CONDITION OF THE O-RING (66) AND REPLACE IF
NECESSARY.

12. Insert the Allen wrench (B-13) and exert a light pressure on
the cover (64). (Fig. 3).
13. Using wrench (B-13), rotate the cover (64) through 90° in a
counter-clockwise direction. (Fig. 3).
14. Push cover (64) from the inside and remove it from the
second stage case.

WARNING !
CHECK THE CONDITION OF THE O-RING (66) AND REPLACE IF
NECESSARY.

R E A S S E M B LY
1. If previously disassembled, position O-ring (66) on the case
assembly connector (67).
2. After choosing the desired position, correctly align the tabs
of the case assembly connector (67) with the grooves in the
second stage case (32).
3. Insert the connector group (67) all the way into the hole of
the second stage case (32), keeping the demand lever (35)
in the horizontal position.

WARNING !
NEVER FORCE INSERTION OF THE CONNECTOR INTO THE
SECOND STAGE CASE.
 original copywriter 1987 REGULATORS B E TA - M R1 0 S E C O N D S TA G E S 6-9
revised 1998 - printed 1999

4. Keeping the demand lever (35) pressed, rotate the case

assembly connector (67) through 90° in a clockwise
direction, bringing the tabs of the connector above their
corresponding grooves in the second stage case.
5. Pull the case assembly connector (67), checking that the
tabs lock into the grooves of the 2nd stage case.
6. Correctly fit the snap ring (65) in its seat on the connector.

DANGER !
MAKE SURE THAT THE SNAP RING IS CORRECTLY POSI-
TIONED: INCORRECT POSITIONING CAN RESULT IN
DANGEROUS AND EVEN FATAL ACCIDENTS.

7. If previously disassembled, position O-ring (66) on the cover

(64). (Fig. 4)
8. Correctly align the tabs of the cover (64) with the grooves of
the second stage case (32).
9. Push the cover (64) into the second stage case.

WARNING !
NEVER FORCE THE INSERTION OF THE COVER INTO THE
SECOND STAGE CASE.

10. Insert the Allen wrench (B-13) into the housing of cover (64)
and rotate through 90° in a clockwise direction.

CAUTION !
THE COVER (64) IS CORRECTLY POSITIONED WHEN THE “UP”
MARKING ON THE COVER COINCIDES WITH THE THREAD OF
THE SECOND STAGE CASE.

11. Press and release the demand lever a few times.

12. Correctly position the diaphragm (36) with the metal disk in
contact with the demand lever.
13. Position the spacer (78) (72 for MR 10).

BETA version only

The rounded side of the spacer must be in contact with the
diaphragm

13. Fit the cover assembly (39) on the spacer (78), correctly
orienting the logo on the cover.
14. Firmly lock down the ring (60) without exerting excessive
force. (BETA version only).
15. Engage the safety clip (63) in its seat in the second stage
case, checking that, once it has been installed, the projection
is directed toward the ring.
S 6-10 BETA -MR10 SECOND STAGE REGULATORS original copywriter 1987
revised 1998 - printed 1999

Table 31
R2 BETA - BETA ESCORT - OCTOPUS BETA SECOND STAGE Updated to 01-04-98

Ref.N. Code Description Ref. Code Description

19 110106 OR 106 47 184062 Rubber seat
19 110402 OR 106 Viton 610-9754 54 186090 Yellow OCTOPUS mouthpiece plug
26 186174 Black hi-flow hose 55 184004 HT Hose connector
26 186178 Yellow Beta Escort-Octopus hi-flow hose 60 184432 BETA cover ring
27 110205 OR 2025 63 184050 Safety clip
27 110411 OR 2025 Viton 010-9754 64 184154 Case plug
28 184282 Seat connector 65 184155 Case assembly connector snap ring
30 184219 Poppet body 66 110220 OR 2062
31 185057 Poppet spring 66 110417 OR 2062 Viton 014-9754
32 *** 2nd stage case (see H) 67 184157 Case assembly connector
33 185051 Demand lever lock nut 71 110211 OR 2050
34 185049 Washer 71 110413 OR 2050
35 185104 Demand lever (CWD) 77 184436 Case assembly connector lock
36 186029 Black diaphragm 78 184431 BETA cover spacer
39 186080 Blue BETA cover assembly
39 186085 Black cover assembly for R2 ASSEMBLIES
39 186083 Yellow BETA ESCORT cover assembly G 184053 BETA 2nd stage assembly
39 186082 Yellow OCTOPUS cover assembly G 184056 BETA ESCORT 2nd stage assembly
40 184006 Exhaust valve H 184165 2nd stage case with vane 96
41 184438 Exhaust tee L 184475 Connector assembly
43 157984 Mouthpiece clamp (28-30-31-33-34-35-47-55-66-67-71)
44 185089 Clear mouthpiece *** 186163 2nd stage maintenance kit
45 179904 Black hose protector (19-27-29-33-40-43-44-47)
 original copywriter 1987 REGULATORS B E TA - M R1 0 S E C O N D S TA G E S 6-11
revised 1998 - printed 1999

Table 25
MR 10 REGULATOR Updated to 30-01-91

Ref. Code Description Ref. Code Description

1 184065 Body 19 110106 OR 106
2* 185015 Snap ring - int. f 13 26 185098 Complete hose f 4.5
3 185208 Yoke 27 110205 OR 2025
8 184071 Poppet spring 28 184051 Poppet seat
9 184070 Poppet 30 184156 Poppet body
12 184072 Poppet pin 31 184078 Spring
13 185032 Poppet button 32 Second stage case (see H)
14 185022 Diaphragm 33 185051 Demand lever lock nut
15 185034 Spring base plate 34 185049 Washer
16 185023 Diaphragm spring 35 185050 Demand lever
17 184069 Diaphragm retaining nut 36 185056 Diaphragm
18 184073 Spring adjusting nut 39 184085 Cover assembly, black (line)
19 110106 OR 106 39 184086 Cover assembly, lime
20 185204 UNF 3/8” port plug 39 184087 Cover assembly, pink
22* 185014 Sintered filter 39 184130 Cover assembly, white
22 184074 Sintered filter (DIN) 39 184131 Cover assembly, orange
23 110117 OR 115 39 184132 Cover assembly, blue
24 185009 Protection cap 40 184006 Exhaust valve
25 184076 Yoke retainer knob 41 184438 Exhaust tee
48 183005 DIN connector body (DIN) 43 157984 Mouthpiece clamp
49 183006 Threaded locking ring (DIN) 44 185089 Clear mouthpiece
50 110203 OR 2018 45 179902 Black hose protector
51 179261 DIN connector coupling (DIN) 47 184062 Poppet seat, rubber
52 110108 OR 108 55 184009 Hose connector
53 185205 7/16” HP port plug 56 110247 OR 3043
57 185300 Body (EPK) 63 184050 Safety clip
58 185301 Diaphragm (EPK) 64 184154 Case plug
59 185302 Ring ((EPK) 65 184155 Case assembly snap ring
68 184067 Poppet seat 66 110220 OR 2062
69* 184063 Yoke retainer nut 67 184157 Case assembly connector
70 184066 Cap 72 184077 Antifriction disk
71 110211 OR 2050 77 184042 Case assembly connector lock
79 183007 DIN connector wheel
COMPLETE ASSEMBLIES COMPLETE ASSEMBLIES
A 184081 complete 1st stage G 184058 complete 2nd stage RH
A 184064 complete DIN 1st stage G 184059 complete 2nd stage LH
I 185306 complete EPK kit H 184158 case with vane
*** 185261 Cpl. seal kit L 184079 connector assembly
*** 185262 Cpl. repair kit (28-30-31-33-34-35-47-55-66-67)
 FINAL CHECKS
TROUBLESHOOTING
CHECKS / TROUBLESHOOTING
 original copywriter 1987 REGULATORS S E C OND S TA G E C HE C KS S 7-1
revised 1998 - printed 1999

FINAL CHECKS AND ADJUSTMENTS

The checks described below are designed to verify the perfect
operation of the regulator. The specified values are applicable to
regulators subject to annual service.

“CRACKING” PRESSURE VALUES FOR SECOND STAGES

MODEL Inch of H20 cm of H20
PRIMARY SECOND STAGE 1 - 1.5 2.5 - 3.8
OCTOPUS SECOND STAGE 1.2 - 1.6 3.0 - 4
tab. A

1. Position the regulator on the air valve (of a test bench or

tank).
2. Using the laboratory Test Bench (cod. 7855501) or the
RUBY · ABYSS · VOLTREX – III · II
portable Test Bench (cod. 785510), after calibrating the first

RUBY - ABYSS - VOLTREX

stage, breath in through the mouthpiece and read the
“cracking” pressure (value required to trigger air delivery)
on the U gauge, at the instant when the gauge detects a drop
in the intermediate pressure. H20

III - II
WARNING !
IN THE ABSENCE OF A TEST BENCH IT IS POSSIBLE TO RUN AN
APPROXIMATE CHECK ON THE CRACKING PRESSURE USING A A
BASIN OF WATER AND FOLLOWING THE PROCEDURE BELOW:
XTR · XL · AKROS – NIKOS
a. Slowly submerge the second stage in the water with the

XTR · XL · AKROS · – NIKOS

mouthpiece facing up, without allowing water to go inside.
b. When the water level, measured on the mouthpiece
connector with reference to the point indicated in the
diagram (Fig. 1), falls between the cracking values indicated H20
in the table (see table A), the air must start to flow.

SECOND STAGE MODEL POINT OF REFERENCE B

RUBY - ABYSS - VOLTREX STARTING FROM AND
NAVY – BETA
INCLUDING THE RING CLAMP
(37) (A)
AKROS - XTR - XL - NIKOS STARTING FROM THE
SECOND STAGE CASE (32) (B)
NAVY – BETA

III - II STARTING FROM AND H 20

EXCLUDING THE RING CLAMP
(37), (A)
NAVY - BETA STARTING FROM AND
INCLUDING THE COVER RING
(60) (C) C Fig. 1
S 7-2 SECOND STAGE CHECKS REGULATORS original copywriter 1987
revised 1998 - printed 1999

3. If the cracking pressure does not fall between the values

specified in the table, proceed as follows:
a. If the cracking pressure is greater, it is necessary to
reduce the loading on the spring.
- If the second stage is equipped with the connector
(28) with adjustable seat (21), reduce the projection
using Allen wrench (B-4).
- If the second stage does not permit adjustment of the
loading, the spring (31) must be replaced.
b. If the cracking pressure is lower, it is necessary to
increase the loading on the spring.
- If the second stage is equipped with the connector
(28) with adjustable seat (21), increase the projection
(max. 3.8 mm) using an Allen wrench (B-4).
- If the second stage does not permit adjustment of the
loading, the spring (31) must be replaced.

WARNING !
AFTER CARRYING OUT THE OPERATIONS DESCRIBED IN STEP
(3), ALWAYS REPEAT THE ADJUSTMENT OF THE DEMAND
LEVER (35) AS DESCRIBED IN THE MANUALS.

4. Submerge the second stage in water with the mouthpiece

facing up, allowing water to enter the exhaust tee and
keeping it in the water for about 30 seconds.
5. Remove the second stage from the water and then turn the
mouthpiece downward.
6. Check for any traces of water

WARNING !
IF MORE THAN A FEW DROPS OF WATER COME OUT OF THE
SECOND STAGE, CHECK WATERTIGHTNESS OF THE MOUTH-
PIECE CLAMP, THE EXHAUST VALVE AND THE RIM OF THE
DIAPHRAGM.

7. Press the purge button, making sure that it operates

smoothly and does not jam.
8. Completely submerge the second stage in water (allowing
water to enter the mouthpiece) and check for any air leaks.
 original copywriter 1987 TROUBLESHOOTING S E C OND S TA G E S 8-1
revised 1998 - printed 1999

S E C O N D - S TA G E T R O U B L E S H O O T I N G

PROBLEM MODEL PROBABLE CAUSE SOLUTION

RUBY-ABYSS 1) Second stage valve pad dirty or damaged 1) Clean, invert or replace
VOLTREX- 2) Sealing surface of valve seat dirty or damaged 1) Clean or replace
AKROS-XTR-XL 3) Intermediate pressure too high 1) Adjust intermediate pressure
NIKOS 4) Demand lever set too high 1) Adjust correctly
-1- NAVY-BETA
CONSTANT OR III - II 5) Second stage valve spring incorrectly 1) Position correctly or replace
INTERMITTENT positioned or damaged
AIR LEAKS RUBY-ABYSS 6) Adjustable seat O-ring in connector dirty or 1) Clean and replace
FROM SECOND VOLTREX damaged
STAGE AKROS-XTR-XL
NIKOS 7) Adjustable seat in connector too low 1) Adjust correctly
8) Valve seat O-ring dirty or damaged 1) Clean and replace
NAVY-BETA
9) Cover spacer missing or damaged 2) Position correctly or replace
1) Demand lever set too low 1) Adjust correctly
RUBY-ABYSS 2) Intermediate pressure too low 1) Adjust correctly
VOLTREX 3) Hole for second stage valve in second stage 1) Clean thoroughly
AKROX-XTR-XL body obstructed
NIKOS 4) Tank valve not fully open 1) Open the tank valve completely
NAVY-BETA
5) Second stage spring deformed and/or damaged 1) Replace
-2- III - II
6) First stage filter clogged 1) Service first stage and replace the filter
EXCESSIVE
AKROS-XTR-XL 7) Pivoting flow vane dirty and/or damaged 1) Clean and/or replace the damaged
BREATHING components
EFFORT
RUBY-ABYSS
VOLTREX
8) Loading of valve spring too high 1) Correctly adjust and replace spring if
AKROS-XTR-XL necessary
NIKOS

NAVY-BETA 10)Loading of valve spring too high 1) Replace the spring or remove the
III - II washer if present

RUBY-ABYSS
VOLTREX 1) Intermediate pressure too high 1) Adjust correctly
AKROS-XTR-XL
NIKOS
-3- NAVY-BETA 2) Second stage spring deformed and/or damaged 1) Replace
BREATHING III - II
EFFORT
RUBY-ABYSS
TOO LOW 3) Loading of spring too low 1) Adjust correctly and replace spring if
VOLTREX
AKROX-XTR-XL necessary
NIKOS
NAVY-BETA 4) Loading of spring too low 1) Add a spacer (max one) or replace
the spring
III - II 5) Loading of spring too low 1) Replace the spring

-4- RUBY-ABYSS
AIR LEAK VOLTREX 1) Swivel hose coupling O-ring defective 1) Replace the O-ring
BETWEEN AKROS-XTR-XL
SWIVEL HOSE NIKOS
2) Sealing surface of hose connector O-ring 1) Clean or replace the hose connector
COUPLING NAVY-BETA dirty or damaged
AND 2ND STAGE III - II
HOSE 3) O-ring of valve seat dirty or damaged 1) Clean and replace
CONNECTOR NAVY-BETA
4) Valve seat dirty or damaged 1) Clean or replace
S 8-2 S ECOND STAGE TROUBLESHOOTING original copywriter 1987
revised 1998 - printed 1999

S E C O N D - S TA G E T R O U B L E S H O O T I N G

PROBLEM MODEL PROBABLE CAUSE SOLUTION

1) Exhaust valve dirty, incorrectly positioned or 1) Clean, position correctly or replace

RUBY-ABYSS damaged
VOLTREX- 2) Exhaust valve seat dirty or damaged 1) Clean or replace the second stage case
AKROS-XTR-XL 3) Diaphragm dirty, incorrectly positioned or 1) Clean, position correctly or replace
NIKOS damaged
NAVY-BETA
4) Mouthpiece loose or damaged 1) Tighten with a new clamp strap or replace
III - II
5) Seat-connector O-ring defective 1) Replace
RUBY-ABYSS 6) Cover clamp strap loose or damaged 1) Tighten or repair
VOLTREX 7) Spacer ring incorrectly positioned or damaged 1) Check the position of the spacer ring
III - II or replace
8) Ring clamp incorrectly positioned or damaged 1) Check position of the ring clamp or
replace
- 5- 1) Correctly clamp the cover and lock
9) Cover incorrectly clamped
TRACES OF AKROS-XTR-XL with the pin
WATER INSIDE NIKOS 10)Sealing surfaces and O-rings of the plug, 1) Inspect and clean all sealing surfaces,
SECOND STAGE between the threaded block and the second replacing O-rings, and defective
stage case, and between the union and the components.
second stage case.
11)O-ring seals and seats between the bypass tube 1) Inspect and clean the sealing
AKROS-XTR-XL and second stage union dirty or defective surfaces, replacing the O-rings and
defective components.

12)Defective seal between bypass and second 1) Replace with the second stage
stage body incorporating a bypass tube.
NAVY
13) O-ring seal between bypass and union dirty or 1) Clean and replace the O-ring
damaged

NAVY-BETA 14)Cover ring clamp insufficiently tightened 1) Lock down the ring clamp.

15)O-ring in valve seat defective 1) Replace the O-ring

BETA 16)O-rings in union and plug dirty or damaged 1) Clean seats and replace O-rings

RUBY-ABYSS
-6- 1) Seat of purge button dirty 1) Clean
VOLTREX
SECOND STAGE
AKROX-XTR-XL
PURGE
NIKOS
BUTTON STICKS 2) Defective spring 1) Replace spring
NAVY-BETA
III - II

RUBY-ABYSS
-7- 1) Diaphragm incorrectly positioned 1) Position correctly
VOLTREX
VIBRATION
AKROS-XTR-XL 2) Demand lever incorrectly adjusted 1) Adjust correctly
DURING
NIKOS
INHALATION
NAVY-BETA 3) Valve spring incorrectly positioned or defective 1) Position correctly or replace.
III - II
 original copywriter 1987 LP INFLATOR SERVICE INTRODUCTION VII
revised 1998 - printed 1999

LP INFLATOR SERVICE

GENERAL
Servicing at the repair shop level mainly involves disassembly,
cleaning, replacement of necessary parts, and reassembly.
Numerous o-rings are used throughout the inflator. Cleanliness is
of the utmost importance in obtaining effective o-ring seals.
To insure optimum performance and reliability, use only MARES
replacement parts and accessories.

SERIALIZATION
All Mares LP inflators are identified by individual serial numbers.
The LP inflator serial number is located on the inflator body.

WARRANTY
The warranty card is packaged with the BCD/inflator and is to be
given to the buyer at the time of sale. The dealer, at the time of
sale, should complete all three parts. The “MARES” copy should
be mailed to Mares. The “STORE” copy should be retained by the
retailer for their records. The “CUSTOMER” copy should be given
to the purchaser. The warranty policy, as stated in the warranty,
shipped with the BCD/inflator, is the final authority.

ROUTINE CARE
Following the recommended care and maintenance procedures
will provide many years of trouble-free use. The following instruc-
tions will help increase the life and proper function of the Ergo LP
inflator.
1. After disconnecting the LP hose from the inflator, always
install the dust cap on the male QD fitting.
2. After each dive always rinse the inflator with fresh water.
3. Do not use any solvents for cleaning.
4. Avoid prolonged exposure under direct sunlight.

SERVICE REQUIREMENTS
As stated in the owners manual, the LP Inflators should be
inspected and serviced annually or every 100 hours of use,
whichever comes first. With extraordinary use, inspection and
service may be required at more frequent intervals. Inspection
involves disassembly, cleaning, replacement of parts as needed,
and reassembly. Inspection and servicing should not be perfon-
ned by the user, rather by a MARES AUTHORIZED SERVICE
CENTER or by MARES.
VIII SPECIAL TOOL ERGO LP I NFLATOR SERVICE original copywriter 1987
revised 1998 - printed 1999

Special Tool ERGO

Purge button-tool (Ergo)

Code 106190
 INTERNATIONAL
MULTI AIR
INFLATOR
MULTI AIR
INTERNATIONAL INFLATOR
 original copywriter 1987 MULTI AIR - INTERNATIONAL INFLATOR B 1-1
revised 1998 - printed 1999

D I S A S S E M B L I N G T H E S E C O N D S TA G E
(if present, for MULTI AIR version only)

1. Unscrew the second stage group from the second stage

adapter kit (code 159086).
2. Using a 4-mm Allen wrench, unscrew the second stage
adapter kit (code 159086) from the LP inflator assembly (A).

NOTE If the second stage is not present, it is necessary to

disassemble the plug (12) and the o-ring (9) with a
4-mm allen wrench.

3. Remove the O-rings from the adapter kit connector.

DISASSEMBLING THE COMPLETE CORRUGATED HOSE GROUP FROM THE BC

1. Disassemble the corrugated hose group (C), complete with
R.E. valve and LP inflator, from the BC bag, unscrewing the
locking ring of the R.E. valve (E).
2. Remove the seal of the locking ring on the BC.

DISASSEMBLING THE INFLATOR UNIT

1. Using cutting nippers or pliers, remove the clamp (41) and
separate the inflator body (1) from the corrugated hose (39).
2. Lightly grip the inflator body (1) in a vice with plastic jaws.
3. Using two small flat-head screwdrivers, simultaneously
press the tabs on the cord-anchor bushing (3) and remove
it from the inflator body (1).

DISASSEMBLING THE QUICK COUPLING

1. Disassemble the protection cap (23).
2. Using wrench (B-18), unscrew the male quick coupling (13).

NOTE For the multi air version a 15 mm wrench is necessary.

3. Remove the O-ring (9) from the quick coupling (13).

4. Remove the filter O-ring (24) and the fabric filter (22) from
the inflator body (1).

WARNING !
DO NOT USE SHARP OR POINTED TOOLS FOR REMOVING THE
FILTER.

NOTE The fabric filter is fitted on new models (as of 1989).

B 1-2 MULTI AIR - INTERNATIONAL INFLATOR original copywriter 1987
revised 1998 - printed 1999

DISASSEMBLING THE DEFLATION GROUP

1. Unscrew the locking ring (11) to release the toothed ring
(10).
2. Using a pair of snap ring pliers, squeeze the tabs of
mouthpiece (28) to separate it from toothed ring (10),
releasing locking ring (11) and O-ring (29).

WARNING !
DISASSEMBLE THE MOUTHPIECE (28) FROM THE LOCKING
RING (11) ONLY WHEN ABSOLUTELY NECESSARY.

3. Remove the group composed of the diaphragm holder (7),

diaphragm (6) and O-ring (8) from the seat in the inflator
body (1).
4. Remove the spring base ring (5) and the tapered spring (4).

DISASSEMBLING THE LP INFLATOR CONTROL GROUP

1. Unscrew the locking ring (14), and remove from the inflator
body (1) the diaphragm (15) with the pin (16) and washer
(17) inside.
2. Remove the spring (18).
3. With the help of a caliper tool (or snap ring pliers), unscrew
the servo control cap (18). (Fig. 1)
4. Remove the 4-hole rubber disk (19), the disk clamp ring (20)
and the servo control disk (21) from the seat in the servo
control cap (18).

Fig. 1

DISASSEMBLING THE R.E. VALVE

1. Unscrew the cover (69) using a caliper tool or snap ring
pliers. (Fig. 2)
2. Remove the diaphragm-holder (7) with the diaphragm (6)
from the cover (69).
3. Remove the seal (67).

DISASSEMBLING THE CORRUGATED HOSE

NOTE It is recommended to disassemble the corrugated hose Fig. 2

only when absolutely necessary.

1. Untie the cord (66) from the anchor bushing (3).

2. Pull out the cord (66) with valve (63) and remove the spring
(64).
 original copywriter 1987 MULTI AIR - INTERNATIONAL INFLATOR B 1-3
revised 1998 - printed 1999

3. Remove the cord (66) from the valve (63).

4. Remove the clamp (41) using a pair of pliers (e.g. cutting
nippers).
5. Separate the corrugated hose (39) from the R.E. valve body
(E).

CLEANING

WARNING !
ADEQUATELY PROTECT EYES AND SKIN WHEN WORKING WITH
ANY KIND OF ACID.

For routine cleaning of reusable rubber components, wash all

parts in a mixture of hot water and mild detergent, scrubbing if
necessary with a soft brush. Do not use solvents or acids on rub-
ber components. Chrome plated brass and stainless steel parts
can be cleaned with an ultrasonic cleaner in fresh water or, if the
necessary equipment is not available, in a mild acid solution (for
example white vinegar, diluted with hot water as required).
Make sure that all components have been rinsed and dried before
proceeding with reassembly.

WARNING !
ACIDS OR OTHER SOLVENTS MAY DAMAGE PLASTIC AND
RUBBER PARTS. BEFORE CLEANING METAL COMPONENTS,
MAKE SURE THAT ALL SEALS AND OTHER PARTS SUBJECT TO
DETERIORATION HAVE BEEN REMOVED.

INSPECTION
Certain key components of the corrugated hose group should be
replaced at each routine service. Moreover, in view of their
relatively low cost, all the O-rings should also be replaced.
The components to replace are:

Description Reference Part Number

LP filter (22) - cod. 159146
O-ring 2106 (8) - cod. 110245
O-ring 2037 (51) - cod. 110117
3 O-rings 106 (9) - cod. 110106
O-ring 2025 (2nd stage kit) (*) - cod. 110205
4-hole rubber disk (19) - cod. 159081
pin (16) - cod. 159078
diaphragm (15) - cod. 159077
B 1-4 MULTI AIR - INTERNATIONAL INFLATOR original copywriter 1987
revised 1998 - printed 1999

WARNING !
MARES RECOMMENDS REPLACING THE O-RING (COD.
110107) INSIDE THE LP HOSE COUPLING.

If these components are not replaced, they should at least be

inspected with a jeweler’s magnifying glass for the following
defects.

DO NOT USE PARTS WITH THE FOLLOWING DEFECTS:

Description Reference Inspections

Quick coupling (13) Inspect for scratches, corrosion or damaged plating.
LP filter (22) Check for any deposits of dirt on the surface.
Inflator body (1) Inspect for signs of breakage and check the integrity of all the O-ring sealing
surfaces. Check the threads for signs of damage and remove any foreign
particles from the sealing surfaces and air holes of the inflator body.
Diaphragm (15) Inspect the surface for any pinholes, flaws or buckling.
Pin (16) Inspect for signs of rust, deformation or breakage.
4-hole rubber disk (19) Check that the center point in contact with the pin is not excessively indented
or damaged.

WARNING !
TO OBTAIN GOOD SENSITIVITY OF THE INFLATION BUTTON, IT
IS ADVISABLE TO REPLACE THE 4-HOLE RUBBER DISK.

Servo control disk (21): Use a pin to check for foreign particles inside the capillary hole.
O-rings: Inspect for cuts, deformation or foreign particles. The presence of any of
these defects may result in leakage.
Mouthpiece: Check the integrity of its attachment to the locking ring.
Cord (66): Inspect for signs of fraying.
Corrugated hose (60): Inspect for small holes or signs of damage.
R.E. valve body (E): Inspect the body for signs of breakage, and for damaged threads and/or seats.
Valve (63): Inspect the sealing surface for scratches or damage.
Seal (67): Inspect for deformation, damage or the presence of foreign particles.
LP diaphragm holder (7): Inspect for scratches on the surface or the presence of foreign particles.
Deflation diaphragm (6): Inspect for incrustations of salt or foreign particles.
Cover (69): Inspect the grooves on the cover for signs of damage and check the
soundness of the threads.
O-ring seats: Inspect all metal surfaces which come into contact with the O-rings or other
seals, and check for any scratches, chipping, deteriorated plating or foreign
particles.
Springs: Inspect for cracked, deformed or broken coils.
 original copywriter 1987 MULTI AIR - INTERNATIONAL INFLATOR B 1-5
revised 1998 - printed 1999

R E A S S E M B LY
Prior to reassembly, lightly lubricate all O-rings with silicone
grease (type General Electric Versalube G 322 or equivalent).
Lubrication reduces the likelihood of damage during reassembly.

WARNING !
EXERCISE THE UTMOST CARE WHEN REASSEMBLING THE
THREADED METAL COMPONENTS IN THEIR PLASTIC SEATS.

ASSEMBLING THE LP INFLATOR CONTROL GROUP

1. Insert the rubber servo control disk (21) into the seat of the
disk clamp ring (20).

WARNING !
MAKE SURE THAT THE CENTER RELIEF ON ONE SIDE OF THE
RUBBER SERVO CONTROL DISK IS FACING OUTWARD.

2. Position the 4-hole rubber disk (19) inside the servo control
cap (18).

WARNING !
IF THE 4-HOLE RUBBER DISK CANNOT BE REPLACED, IT MUST
BE REASSEMBLED INSIDE THE SERVO CONTROL CAP IN THE
SAME POSITION AS BEFORE. DO NOT OVERTURN IT.

3. Position components (20+21) inside components (18+19).

4. After turning over the LP inflator body (1), insert
components (21 - 20 - 19 - 18) working from the bottom up.
Hold the components in place and turn the inflator body
through 180°.
5. Screw on the servo control cap (18), using a caliper tool
(or snap ring pliers).

WARNING !
EXERCISE GREAT CARE AND ATTENTION WHEN SCREWING ON
THE SERVO CONTROL CAP TO AVOID DAMAGING THE
THREADS OF THE INFLATOR BODY.

6. Insert the pin (16) in diaphragm (15).

WARNING !
DO NOT USE ANY TYPE OF LUBRICANT TO INSTALL THE PIN
INSIDE THE DIAPHRAGM.
B 1-6 MULTI AIR - INTERNATIONAL INFLATOR original copywriter 1987
revised 1998 - printed 1999

7. Fit the washer (17) on pin (16), with the bevel of the washer
facing upward.
8. Position the spring (25) with its smaller end centered on the
servo control cap (18).
9. Fit the diaphragm assembly (15) in the seat in inflator body
(1), centering the pin in the large end of the spring (25).
10. Screw the locking ring (14) into the inflator body (1), locking
down fully by hand.

WARNING !
EXERCISE EXTREME CARE AND CAUTION TO AVOID DAMAG-
ING THE DIAPHRAGM WHEN SCREWING ON THE LOCKING
RING.

A S S E M B L I N G T H E D E F L AT I O N G R O U P
1. Position the deflation diaphragm (6) and the O-ring (8) on
the diaphragm holder.

WARNING !
CHECK THAT THE SEALING RIM OF THE DIAPHRAGM RESTS
ON THE UNMARKED SURFACE OF THE DISK.

2. Position the spring (4) with its smaller end inside the seat of
body (1).
3. Insert the centering relief of ring (5) in the larger diameter of
spring (4).
4. Rest the diaphragm holder assembly (7) on the ring (5), with
the diaphragm (6) in contact with the ring itself.
5. Position the mouthpiece assembly (10-11-28-29) so that the
toothed ring (10) rests on the diaphragm (6).
6. Screw on the threaded ring (11), locking it down by hand.

WARNING !
DO NOT ATTEMPT TO ROTATE THE MOUTHPIECE AFTER
HAVING LOCKED DOWN THE RING.

ASSEMBLING THE COUPLING

1. Position the O-ring (9) on the quick coupling (13).
2. Fit the fabric filter (22) inside the seat of body (1).
3. Position the O-ring (24) on the filter.
4. Screw the quick coupling on the inflator group body (1)
using wrench (B-18 version INT) or a 15-mm wrench (Multi
Air version).
 original copywriter 1987 MULTI AIR - INTERNATIONAL INFLATOR B 1-7
revised 1998 - printed 1999

NOTE If using a torque wrench, set the torque for 4 N/m.

35 lb. in.

5. Assemble the cap (23).

A S S E M B L I N G T H E R . E . VA LV E G R O U P
1. Secure the cord (66) to the valve (63).
2. Thread the cord (66) connected to valve (63) into the
smaller diameter of the spring (64).

WARNING !
MAKE SURE THAT THE SMALLER DIAMETER OF THE SPRING
(64) IS IN CONTACT WITH THE VALVE (63).

3. Pass the cord (66) on the roller of the R.E. valve body (E),
pulling it out through the hole for the corrugated hose.
4. Position the spring (64) inside the R.E. valve body, and the
valve (63) on top of the spring.

WARNING !
MAKE SURE THAT THE LARGER DIAMETER OF THE SPRING
(64) IS IN THE SEAT OF R.E. VALVE BODY (E).

5. Assemble the deflation diaphragm (6) on the diaphragm

holder (7).

WARNING !
CHECK THAT THE SEALING RIM OF THE DIAPHRAGM (6) IS IN
CONTACT WITH THE DIAPHRAGM HOLDER (7) ON THE
UNMARKED SIDE.
AFTER REASSEMBLING THE DIAPHRAGM (6), CUT OFF ITS
STEM BY ABOUT 8 MM.

6. Insert the diaphragm assembly (6 + 7) inside the cover (69).

WARNING !
CHECK THAT THE AIR EXHAUST FROM THE DEFLATION
DIAPHRAGM IS TOWARD THE OUTSIDE OF THE COVER.

7. Correctly assemble the seal (67) on the cover assembly (69)

and screw the components into the R.E. valve body (E) using
a caliper tool (or snap ring pliers).

WARNING !
IN ORDER TO CORRECTLY POSITION THE SEAL (67) ON THE
COVER (69) THE RELIEF OF THE CENTER HOLE ON THE SEAL
MUST BE FACING TOWARD THE VALVE (63).
B 1-8 MULTI AIR - INTERNATIONAL INFLATOR original copywriter 1987
revised 1998 - printed 1999

A S S E M B L I N G T H E C O R R U G AT E D H O S E
1. Thread the cord (66) through the corrugated hose (39) and
position the corrugated hose on the R.E. valve assembly (F).
2. Fix the corrugated hose (39) on the R.E. valve assembly (F)
with clamp (41).
3. Secure the cord-anchor bushing (3) to the cord (66),
checking the length of the cord.

WARNING !
THE CORRECT POSITION OF ANCHOR BUSHING (47) ON THE
CORD (66) IS ACHIEVED WHEN, AFTER SECURING THE CORD,
THE ENTIRE LENGTH OF THE BUSHING PROTRUDES FROM THE
CORRUGATED HOSE.

4. Insert the cord-anchor bushing (3) into the inflator assembly

(1).

WARNING !
CHECK THAT THE TABS OF THE ANCHOR BUSHING ARE
CORRECTLY ENGAGED IN THE SEATS ON THE INFLATOR UNIT.

5. Fit the corrugated hose (39) on the inflator unit (1) and
secure it with clamp (41).

WARNING !
THE CONTROL GROUP IS CORRECTLY POSITIONED WHEN THE
HOSE COUPLING IS FACING OUTWARD. (SEE DRAWING 65
AND 70).

A S S E M B L I N G T H E S E C O N D S TA G E
(Multi Air version only)
1. Position the two O-rings (code 110106 and 110205) on the
adapter kit connector.
2. Screw the second stage adapter kit assembly (code 159086)
into the LP inflator assembly (A) using a 4-mm Allen wrench.
3. Screw on the second stage.

NOTE If the second stage is not assembled, it is necessary to

assemble the plug (12) with the o-ring (9) using a
4-mm allen wrench.

ASSEMBLING THE CORRUGATED HOSE ON THE BC

1. Fit a new seal in the BC seat.
2. Position the corrugated hose (C) complete with R.E. valve
and LP inflator on the BC bag, screwing down the ring of the
R.E. valve.
 original copywriter 1987 MULTI AIR - INTERNATIONAL INFLATOR B 1-9
revised 1998 - printed 1999

FINAL CHECKS

DANGER !
DO NOT CONNECT THE INFLATOR HOSE TO THE HIGH PRES-
SURE PORT OF THE FIRST STAGE, TO PREVENT EXPLOSIONS
WHICH MAY RESULT IN SERIOUS INJURY OR EVEN DEATH.

1. Connect the inflator hose (45) to the low pressure port (3/8”)
of the first stage.
2. Connect the inflator hose (45) to the quick coupling (13) of
the inflator assembly (A).
3. Slowly open the tank valve and submerge the corrugated
hose in water, checking for any air leaks or spontaneous
inflation of the BC.
4. Press the inflation diaphragm (15) until the BC is fully
inflated and the over-expansion relief valve opens.
5. Submerge in water, checking for air leakage from the
corrugated hose.
6. Deflate using the R.E. valve and the exhaust button, and
re-inflate a few times, to make sure that both the
over-expansion relief valve (R.E. valve) and the seals are
operating correctly.

NOTE In the event of air leaking from the second stage (Multi
Air version) refer to the relevant section of the second
stage manual.

7. Leave the BC inflated for about 2 hours to check the

tightness of the valves and detect the presence of cuts or
small holes.

NOTE Cuts or small holes in the BC buoyancy bag can be

repaired using a special adhesive (for example,
“Aquasure”).
B 1-10 MULTI AIR - INTERNATIONAL INFLATOR original copywriter 1987
revised 1998 - printed 1999

MULTI AIR - INTERNATIONAL INFLATOR Table 70

WITH R.E. VALVE Updated to 12-11-93

Ref. Code Description Ref. Code Description

A 159164 Multiair assembly without LP hose 18 159080 Servo control cap
A 159039 Multiair assembly with LP hose (A-D) 19 159081 4-hole rubber disk
A 159670 Int. Inflator assembly without LP hose 20 159082 Servo control disk clamp ring
A 159671 Int. Inflator assembly with LP hose (A-45) 21 159083 Rubber servo control disk
C 159036 Multiair corrugated hose assembly with LP hose (A-D-F-39-41) 22 159146 Filter
C 159041 Multiair corrugated hose assembly without LP hose (A- F-39-41) 23 159147 Male coupling protection cap
C 159675 Int. Inflator corrugated hose assembly without LP hose (A-F-39-41) 24 110204 OR 2021
D 159063 LP hose with female quick coupling 25 159075 Pin return spring
E 159142 R.E. valve body, partially finished 26 159062 Multiair female quick coupling
F 159135 R.E. valve assembly for corrugated hose 27 159653 M12 Int Inflator cap
(E-3-6-7-63-64-66-67-69-70) 28+ 159660 Int. Inflator mouthpiece
1 159163 Multiair inflator body with insert 89 29+ 110212 OR 3087
1 159650 Inflator 91 body 30 110110 OR 2037
3 159141 Cord-anchor bushing 31 110107 OR 2031 Int Inflator
4 159068 Spring 39 157985 Corrugated hose, D. 29
5 159069 Spring base ring 41 157984 Corrugated hose clamp
6 159070 Deflation diaphragm 45 159090 Multiair hose
7 159071 Diaphragm holder 45 159680 Int. Inflator hose
8 110245 OR 2106 63 159131 R.E. valve
9 110106 OR 106 64 185078 Exhaust button spring
10+ 159655 Int Inflator toothed deflation ring 66 169822 Black cord without core D. 1,75
11+ 159073 Deflation group locking ring 67 159133 R.E. valve seal
12 185204 3/8” UNF Multiair plug 69 159130 R.E. valve cover
13 159074 Multiair male quick coupling 70 184321 Cover label
13 159659 Int. Inflator male quick coupling 93 179902 Black hose protector
14 159076 Inflator threaded locking ring
15 159077 Diaphragm ACCESSORIES
16 159078 Inflator pin * 159086 2nd stage LP inflator adapter kit
17 159079 Inflator pin washer + 159061 Multiair mouthpiece kit (10-11-28-29)
 LP INFLATOR
ERGO
ERGO LP INFLATOR
 original copywriter 1987 ERGO LP INFLATOR B 2-1
revised 1998 - printed 1999

L P I N F L AT O R R E M O V A L

1. Unscrew the rapid exhaust valve (RE) locking nut and

remove the entire inflator system from the BC.

2. Remove the gasket from the BC collar.

D I S A S S E M B LY Fig. 1

1. Gently pry off the mouthpiece (61) (see numbered Ergo LP

inflator diagram) using a slotted screwdriver.

2. Press the power inflate button (54). Insert a 1/8” pin

punch into the small round hole near the manual quick
disconnect (QD) fitting, then push the pin (53) until it
comes out completely (Fig. 1).

3. Remove the inflate button (54) and 0-ring (55).

4. Remove 0-ring (55) from inflate button (54).

Fig. 2
5. Remove spring (48).

6. Remove the valve holder unit by inserting flat-nose

pliers into the notches of the valve holder (57). Pull the valve
holder (57) straight out of the inflator body (Fig. 2 and 3).

7. Remove the two 0-rings (58) from the valve holder.

8. With suitable pliers, cut clamp (59) and remove the

corrugated hose (60) from the inflator (46).
By lightly clamping LP inflator (46) in a vice with plastic
jaws, use two small screwdrivers to depress the two tabs on
the anchoring bushing (47), then remove the anchoring Fig. 3
bushing from the inflator body (Fig. 4).

9. Remove spring (48) from the anchoring bushing (47).

Fig. 4
B 2-2 ERGO LP INFLATOR original copywriter 1987
revised 1998 - printed 1999

10. With special tool (P/N 106190 Fig. 5) or needle nose pliers,
compress the deflate button retaining tabs and remove
deflate button (52) from bushing (49) (Fig. 6).

11. Remove O-ring (50) from bushing (49).

12. Remove O-ring (5 1) from deflate button (52).

13. Remove the male QD cap (27) from the male QD ( 13) and Fig. 5
using a 14 mm hex wrench, unscrew the male QD
connector.

14. Remove O-ring (9) from the connector.

15. Remove the filter (22) from the inflator body.

16. Remove the male QD cap (27) and LP hose clip (62) from
the corrugated hose (60) only if the male QD cap, LP hose
clip or corrugated hose are to be replaced.

17. If the anchoring bushing (47), corrugated hose (60), RE

valve plate (63) or actuating cable (66) are to be replaced, Fig. 6
cut the cable near the anchoring bushing.

NOTE Once the actuating cable has been cut it must be

replaced. The actuating cable should be cut only if the
anchoring bushing (47), corrugated hose (60), RE
valve plate (63) or actuating cable (66) are to
replaced.

18. Remove anchoring bushing (47) from actuating cable (66).

19. With suitable pliers, cut clamp (59) and remove the
corrugated hose (60) from the RE valve (F).
Fig. 7
20. Unscrew the RE cap (69) and remove (Fig. 7).

21. Remove the exhaust diaphragm (6) and housing (7) from
RE cap (69).

NOTE It is not necessary to remove the exhaust diaphragm

(6) from the housing (7), unless the exhaust
diaphragm or housing are to be replaced.

22. Remove gasket (67) from RE housing.

23. Remove the RE valve plate (63) from the RE housing and
unthread the actuating cable (66), detaching it from RE
valve plate (63).

24. Remove spring (64) from RE housing.

 original copywriter 1987 ERGO LP INFLATOR B 2-3
revised 1998 - printed 1999

CLEANING
Cleaning requires all reusable rubber and plastic parts to be care-
fully cleaned by scrubbing with a soft brush in a mild detergent
and water solution. Do not use solvents or acids on rubber or
plastic parts. Metal parts should be cleaned in an ultrasonic clean-
er with fresh water or a mild acid solution. (White vinegar diluted
with warm water is recommended). Before reassembly make sure
all parts have been carefully rinsed and dried.

WARNING !
ACIDS MAY CAUSE BURNS, OR SKIN, EYE OR RESPIRATORY
IRRITATION. WHEN WORKING WITH ANY KIND OF ACID
PROTECT EYES AND SKIN ADEQUATELY AND WORK IN A WELL
VENTILATED AREA. ACIDS MAY DAMAGE RUBBER AND
PLASTIC PARTS. BEFORE CLEANING METAL PARTS, MAKE
SURE THAT ALL RUBBER AND PLASTIC PARTS HAVE BEEN
REMOVED.

INSPECTION
The following components should be replaced during routine
service.
Description Part Number
Filter (22) 159146
0-ring, male QD (9) 110106
0-ring, bushing (50) 110241
0-ring, deflate button (51) 110117
0-ring, inflate button (55) 110210
0-ring, valve holder (58) 110221

If the following parts are not replaced, they should be inspected

with a jeweler's loop or similar magnifying device, for the defects
listed below. Replace any part with these defects.

Male OD fitting (13): Inspect for wear, corrosion or loose plating.

Filter (22): Inspect the filter surface for any foreign matter or deposits.

Inflator body (46): Inspect the body for any signs of cracks and check all surfaces in contact with 0-rings.
Inspect the QD threads for any signs of damage.

Inflate button (54): Inspect for wear or cracking.

Pin (53): Inspect for wear or distortion.

Valve holder (57): Inspect the valve for any signs of contamination or corrosion. Inspect the holder for any
signs of scratches on O-ring surfaces or cracking. The valve and holder are replaced as
an assembly.

Deflate button (52): Inspect the deflate button retaining tabs for any signs of distortion or breakage.
B 2-4 ERGO LP INFLATOR original copywriter 1987
revised 1998 - printed 1999

Bushing (49): Inspect for wear or cracking.

Anchoring bushing (49): Inspect the locking tabs and actuating cable attaching hole for wear or cracking.

Actuating cable (66): Inspect the knots for tightness and any signs of frayed cable.

Corrugated hose (60): Inspect for wear or cracking.

RE housing (E): Inspect the housing for cracks and all thread surfaces for damage.

RE valve plate (63): Inspect for wear or scratches on the gasket sealing surface.

Gasket (67): Inspect for cracking, brittleness and splits.

Exhaust diaphgram seat (7): Inspect for wear or cracking

Exhaust diaphgram (6): Inspect for wear or cracking.

Cap (69): Inspect threads for damage.

Springs: Inspect for cracking or broken coils.

0-rings: Inspect for cuts, tears, flat spots or contamination.

The presence of any of these defects may cause leakage.

0-ring seats: Inspect all surfaces in contact with 0-rings and other seals for chipping, scratches
or contamination.

CAUTION
REPLACE ANY PARTS WITH DAMAGED THREADS. ALL THREAD-
ED PARTS MUST BE CLEAN AND IN GOOD CONDITION.
INSTALLING ANY PART WITH DAMAGED THREADS MAY CAUSE
IT TO CROSS THREAD RESULTING IN DAMAGE TO THE LP
INFLATOR.

R E A S S E M B LY
Before reassembly, slightly lubricate all 0-rings with silicone
grease (General Electric, Versalukie G-322 or equivalent).
Lubricating the 0-rings before reassembly will minimize the risk
of damage during reassembly.

1. If the actuating cable (66) is to be replaced. cut the

replacement cable to a length of 51 cm. (20 in.) and tie a
knot at one end.
2. Thread the actuating cable (66) through the RE valve plate
(63) so that the end of the actuating cable without the knot
is protruding from the center hole of the RE valve plate. Pull
the actuating cable through the center hole of the RE valve
plate until the knot is fed into the seat of the RE valve plate.
3. Thread the actuating cable through the spring (64) so the
smaller diameter of the spring faces the RE valve plate (63).
 original copywriter 1987 ERGO LP INFLATOR B 2-5
revised 1998 - printed 1999

4. Thread the actuating cable through the RE housing (F), over

the internal pin and out through the hose connector
opening. Pull the loose end of the actuating cable until the
Spring (64) and RE valve plate (63) are positioned inside the
RE Valve body (E).

5. Install the exhaust diaphragm (6) onto the housing (7) and
trim the exhaust diaphragm stem.

NOTE The exhaust diaphragm (6) must be against the flat

smooth side of the seat (7).

6. Insert the exhaust diaphragm (6) and housing (7) into the
RE Valve cap (69) with the diaphragm facing the cap.

7. Position the gasket (67) onto the cap (69), with the
stepped side of the gasket facing the cap.

8. Thread the cap (69) with the exhaust diaphragm (6), hous-
ing (7) and gasket (67) into the RE housing (F) and tighten.

9. If the male QD cap (27) or LP hose clip (62) were removed

from the corrugated hose (60) or if the corrugated hose was
replaced, install the male QD cap and LP hose clip on the
corrugated hose.

10. Thread the actuating cable through the corrugated hose

(60).

11. Slide the corrugated hose (60) onto the RE housing (F) and
secure with clamp (59).

12. Thread the actuating cable (66) through the anchoring

bushing (47) and tie a knot in the actuating cable in a
location that will allow the base of the anchoring bushing to
just protrude from the corrugated hose.

13. Place o-ring (51) into the o-ring groove of the deflate button
(52).

14. Insert the deflate button (52) with o-ring (51) into the Fig. 8
inflator body (46).

15. Place 0-ring (50) on bushing (49).

16. With special tool (P/N 106190 Fig. 5) or needle nose pliers,
insert bushing (49) with 0-ring (50), facing the deflate
button, into the inflator body until the deflate button
retaining tabs engage the bushing (Fig. 8-9).

17. Place the spring (48) on the anchoring bushing (47) and
insert the anchoring bushing with spring into the inflator
body until the locking tabs engage the inflator body. Depress
the deflate button and release. The deflate button should
return to its original position. If it does not return to its
original position repeat steps 12-16 making sure all parts Fig. 9
are in the correct location.
B 2-6 ERGO LP INFLATOR original copywriter 1987
revised 1998 - printed 1999

18. Slide the corrugated hose (60) onto the inflator body (46)
and secure with clamp (59).

19. Insert filter (22) into the inflator body inlet.

NOTE A plastic rod may be a useful aid in positioning the

filter.

20. Place 0-ring (9) on male QD fitting (13).

21. Thread male QD fitting into inflator body (46) and gently
tighten.

CAUTION
DO NOT OVER-TIGHTEN THE MALE QD FITTING. OVER-TIGHT-
ENING OF THE MALE QD FITTING MAY DAMAGE THE THREADS
IN THE INFLATOR BODY AND COULD RESULT IN LEAKAGE.

22. Install the two 0-rings (58) in the o-ring grooves of the valve
holder (57).

23. Align the notches of the valve holder (57) and push the valve
holder straight into the inflator body.

24. Position the spring (48) in the center of the valve holder.

25. Place 0-ring (55) into the 0-ring groove of the inflator
button (54).

26. Position the inflate button (54) over the spring (48), align
the hole in the inflator button with the holes in the inflator
body. Press the inflator button and insert the pin (53)
through the mouthpiece opening. Press the pin in the
inflator body until its head makes contact.

27. Align the mouthpiece tab with the flange on the inflator body
and press the mouthpiece (61) into place.

L P I N F L AT O R I N S TA L L AT I O N

1. Place a new gasket in the BC collar.

2. Align the RE valve with the BC collar and tighten the RE

valve locking nut.
 original copywriter 1987 ERGO LP INFLATOR B 2-7
revised 1998 - printed 1999

FINAL INSPECTION

WARNING ! EXPLOSION HAZARD

DO NOT CONNECT THE LP INFLATOR HOSE TO THE HIGH
PRESSURE PORT OF THE FIRST STAGE. CONNECTING LP
INFLATOR HOSE TO HIGH PRESSURE PORT OF THE FIRST
STAGE WLLL CAUSE THE HOSE AND/OR LP INFLATOR TO
EXPLODE AND COULD RESULT IN SERIOUS PERSONAL
INJURY OR DEATH.

1. Connect the Ergo LP hose (45) to a low-pressure (LP) port

of the first stage.

2. Connect the female quick disconnect to the male quick

connector (13) by pulling back the knurled flange of female
quick disconnect with thumb and index finger, slide the
female QD over the male connector and release the knurled
flange.

3. Slowly open the air supply from the scuba cylinder. Minor
leaks may be detected by submerging the LP inflator and/or
BC in water or by using soapy water. When the air supply is
turned on there should not be any air leakage or
spontaneous BC inflation. If any air leakage or spontaneous
BC inflation occur refer to the trouble shooting section of
this manual .

4. Inflate the BC by Pressing the inflate button several times

until the BC vest is fully inflated and the over-pressure valve
begins to release excess air.

5. Press the deflate button several times, releasing a small

amount of air each time and inspect for any signs of
leakage. Re-inflate the BC if necessary.

6. Release a small amount of air by slightly pulling the

corrugated hose several times, to release air through the
rapid exhaust valve (RE) and inspect for any signs of
leakage. Re-inflate the BC where necessary.

7. Fully inflate and deflate the BC several times using both the
RE valve and the deflate button and inspect for any signs of
leakage.

8. After service or repair, let the inflated BC set for

approximately 1 hour. The BC should remain inflated
without any pressure loss.

NOTE If any malfunction is detected with the LP inflator,

refer to the troubleshooting section of this manual.
Any cuts or holes in the BC should be repaired with a
water proof rubber cement prior to leak testing the
BC.
B 2-8 ERGO INFLATOR ASSY WITH R.E. VA LV E original copywriter 1987
revised 1998 - printed 1999

Table No. 75
ERGO INFLATOR ASSY WITH R.E. VALVE Updated to 01-04-98

Ref.No. Code Description

2 159020 Whistle
6 159070 Exhaust diaphragm, Lp Inflator
7 159071 Diaphragm housing,Lp Inflator
9 110106 OR 106
13 159659 LP male quick connector
22 159146 LP filter
27 159712 Dust cap, Ergo male connector
45 159680 Hose, LP Int. Assy
46 159700 Body, LP Ergo
47 159702 Line retainer ERGO
48 185011 Spring, 1st stage MR 12
49 159701 Bushing, exhaust OR ERGO
50 110241 OR 2-109
51 110117 OR 115
52 159708 Exhaust button, ERGO
53 159707 Pin, inflation button ERGO
54 159706 Inflation button ERGO
55 110210 OR 2056
57 159715 Bushing and poppet ERGO
58 110221 OR 2081
59 179863 Clamp, corrugated hose D. 23
60 159709 Corrugated hose D. 23
61 159705 Mouthpiece LP ERGO
62 159711 Hose retainer ERGO
63 159131 Poppet, R.E. Valve
64 185078 Spring, exhaust button
66 169822 Spring, black D. 1,75
67 159133 Gasket, R.E. Valve
69 159130 Cover, R.E. Valve
70 184321 Cover label R.E. Valve

ASSEMBLIES
A 159720 LP inflator assy w/o hose, ERGO
A 159723 LP inflator assy with hose, ERGO (A - 45)
C 159728 Inflator ERGO with hose
( A -F -2-27-59-60-62)
E 159724 Body, R.E. Valve D. 23 P.F.
F 159725 Body, R.E. Valve assy
(E-6-7-63-64-66-67-69-70)
*** 159719 Maintenance kit ERGO
(9-22-50-51-55-57-58-59)
 TROUBLESHOOTING
INFLATOR
TROUBLESHOOTING INFLATOR
 original copywriter 1987 TROUBLESHOOTING MULTI-AIR INTERNATIONAL INFLATOR B 3-1
revised 1998 - printed 1999

M U LT I A I R - I N T E R N AT I O N A L I N F L AT O R T R O U B L E S H O O T I N G
PROBLEM MODEL PROBABLE CAUSE SOLUTION

1) Hose coupling O-ring dirty or damaged 1) Replace O-ring

-1-
AIR LEAK FROM MULTI AIR
2) Inflator quick coupling damaged or scratched 1) Replace quick coupling of inflator
QUICK COUPLING INTERNATIONAL
3) O-ring seal of inflator body dirty or damaged 1) Replace O-ring

1) Deflation diaphragm dirty or damaged 1) Clean or replace the diaphragm

-2- 2) Diaphragm holder damaged 1) Replace diaphragm holder

AIR LEAK FROM MULTI AIR 3) Spring defective or damaged 1) Replace the spring
DEFLATOR INTERNATIONAL
BUTTON 4) Diaphragm-holder O-ring dirty or damaged 1) Replace the O-ring

5) Seat in inflator body damaged 1) Replace the inflator body

-3- 1) Diaphragm dirty or damaged 1) Clean or replace the diaphragm

AIR LEAK FROM MULTI AIR
2) Diaphragm locking ring loose 1) Correctly lock down the ring
INFLATION INTERNATIONAL
DIAPHRAGM 3) Servo control cap loose 1) Tighten correctly

-4-
AIR LEAK FROM
MOUTHPIECE MULTI AIR 1) O-ring dirty, damaged or absent 1) Clean or replace the O-ring
DURING ORAL INTERNATIONAL
INFLATION

-5- 1) Seal dirty or damaged 1) Clean or replace the seal

AIR LEAK MULTI AIR 2) Valve disk dirty or damaged 1) Clean or replace the valve disk
FROM INTERNATIONAL
R.E. VALVE 3) Cord length too short 1) Replace cord or correct its length
-6- 1) Clamp missing or loose 1) Replace the clamp
AIR LEAK FROM MULTI AIR
CORRUGATED HOSE INTERNATIONAL 2) Corrugated hose dirty or damaged 1) Clean or replace corrugated hose

-7- 1) Seal dirty or damaged 1) Clean or replace the seal

AIR LEAK BETWEEN MULTI AIR
R.E. VALVE AND BC INTERNATIONAL 2) R.E. valve group incorrectly positioned on BC 1) Disassemble the R.E. valve group and
CONNECTOR threaded connector position it correctly

-8-
R.E. VALVE
FAILS TO OPEN MULTI AIR 1) Cord broken or damaged 1) Replace the cord
WHEN INFLATOR IS INTERNATIONAL
OPERATED

-9- 1) 4-hole rubber disk damaged 1) Replace 4-hole rubber disk

WHEN INFLATION
BUTTON PRESSED MULTI AIR 2) Pin damaged 1) Replace pin
BC INFLATES INTERNATIONAL
SLOWLY OR
NOT AT ALL 3) Filter dirty 1) Replace filter

1) 4-hole rubber disk damaged 1) Adjust intermediate pressure

- 10 -
CONTINUOUS
2) Servo control cap seat dirty or damaged 1) Clean or replace the servo control cap
AIR FLOW INTO MULTI AIR
BC WITHOUT INTERNATIONAL 3) Servo control rubber disk dirty or damaged 1) Clean or replace the rubber servo
PRESSING
control disk
INFLATION
BUTTON 4) Seats in inflator body dirty or damaged 1) Clean or replace
 original copywriter 1987 TROUBLESHOOTING ERGO LP INFLATOR B 4-1
revised 1998 - printed 1999

TROUBLESHOOTING
Troubleshooting should be performed only after the inflator has been assembled.
Failure to solve any problems following these procedures indicates that the inflator should be returned to the factory for
service:

MALFUNCTION PROBABLE CAUSE REMEDY

Air leaks at male QD fiting. Dirty or damaged 0-ring. Clean or replace 0-ring.
Damaged male QD fitting. Replace male QD fitting.

Air leaks at deflate button. Dirty or damaged 0-ring. Clean or replace 0-ring.
Weak or damaged spring Replace spring.
Damaged inflator body. Replace inflator body.

Air leaks at inflate button. Dirty or damaged 0-ring. Clean or replace 0-ring.
Damaged inflator body. Replace inflator body.

Air leaks from mouthpiece Mouthpiece tab not positioned in flange of Remove mouthpiece and place the tab
during oral inflation. inflator body. into the flange of the inflator body.

Air leaks from RE valve. Dirty or damaged gasket or valve plate. Clean or replace gasket or valve plate.
Actuating cable too short. Replace with correct length.

Air leaks from corrugated hose. Loose clamps. Replace clamps.

Damaged corrugated hose. Replace corrugated hose.

Air leaks from RE housing to Dirty or damaged gasket. Clean or replace gasket.
BC collar connection. RE housing not correctly positioned on BC collar. Remove RE housing and reposition.

BC inflates without activating Damaged valve or valve holder. Replace valve holder.
inflate button. Dirty or damaged valve holder o-rings . Clean or replace valve holder 0-rings .
Damaged inflator body. Replace inflator body.

BC does not inflate or inflates Damaged valve. Replace valve holder.

slowly when inflate button is Clogged filter. Replace filter.
activated.

RE valve does not activate. Broken actuating cable. Replace actuating cable.
 original copywriter 1987 GUN SERVICE INTRODUCTION IX
revised 1998 - printed 1999

GENERAL INFORMATION GUN SERVICE

GENERAL
Servicing at the repair shop level mainly involves cleaning,
inspection, replacement of necessary parts, pressurizing and
adjustment of the speargun.
Numerous O-rings are used throughout the speargun. Cleanliness
is of the utmost importance in obtaining effective O-rings seals.
Tools required for maintenance and repair are shown in the spe-
cial tools section of this manual.
To insure optimum performance and reliability use only MARES
replacement parts and accessories.

SERIALIZATION
All Mares spearguns are identified by individual serial numbers.
The speargun serial number is embossed on the tank, near the
handle.

WARRANTY
The warranty card is packaged with the speargun and is to be
given to the buyer at the time of sale. The dealer, at the time of
sale, should complete all three parts. The "MARES" copy should
be mailed to Mares. The "STORE" copy should be retained by the
retailer for their records. The "CUSTOMER" copy should be given
to the purchaser. The warranty policy, as stated in the warranty,
shipped with the speargun is the final authority.

ROUTINE CARE
Mares Pneumatic Spearguns are exceptionally powerful and
accurate spearguns. Following the recommended care and main-
tenance procedures will provide many years of trouble-free use.
1. Thoroughly rinse the speargun and shaft, especially around
the muzzle and power adjustment lever, after each use with
fresh water.
2. Check the loader for wear and replace if necessary.
3. If the shaft becomes bent replace it. Do not attempt to force it
into the gun, this can damage the gun intemally.
4. The speargun should be stored in a dark cool place. Do not
expose the speargun to heat or direct sunlight.
5. Make sure the power adjustment lever is in the maximum
power position when storing the speargun.
6. All MARES pneumatic spearguns should be stored in a muzz-
le down, handle up position. This allows oil in the barrel to
keep the piston lubricated while not in use. Small amounts of
oil deposits can be expected to appear at the muzzle end.
X INTRODUCTION GUN SERVICE original copywriter 1987
revised 1998 - printed 1999

SERVICE REQUIREMENTS
As stated in the owners manual, the pneumatic spearguns should
be inspected and serviced annually. With extraordinary use
inspection and service may be required at more frequent
intervals. Inspection involves disassembly, cleaning, replacement
of parts as needed, reassembly, pressurizing and adjustment.
Inspection and servicing should not be performed by the user,
rather by a MARES AUTHORIZED SERVICE CENTER or by
MARES.
 original copywriter 1987 GUN SERVICE SPEARGUN MAINTENANCE KIT XI
revised 1998 - printed 1999

Speargun maintenance kit Code 775007

Head and barrel clamping jaws O-ring fitting cone

(power adjustment rods)

(A-1) (A-12)
Code 106101 Code 106112

Tank clamping jaws (all models) Connecting plunger positioning rod

(A-3) (A-13)
Code 106103 Code 106113

Valve disassembling wrench Catch hook positioning rod

(A-16)
(A-4) Code 163608 Sten Line
Code 106104 Code 164209 Cyrano Line

O-ring fitting cone for spearguns Assembling tool to fit handle on barrel
Insert for barrel plastic insert
Cyrano

(A-7) (A-18)
Code 106107 Code 106118

O-ring fitting cone for spearguns Screwdriver for connecting plunger grup screw
Insert for barrel plastic insert
Sten

(A-9) (A-22)
Code 106109 Code 106122
 PNEUMATIC
SPEARGUN

CYRANO
CYRANO AND SPARK
PNEUMATIC SPEARGUNS
 original copywriter 1987 CYRANO AND SPARK PNEUMATIC SPEARGUNS G 1-1
revised 1998 - printed 1999

D I S A S S E M B LY :
1. Remove protective cover (6) (if any) from head (1-2-3-5).
2. Unscrew inlet cap (33) using the special loader (Fig. 1)
[not available in North America] or 6 mm. Allen wrench.

WARNING !
ALWAYS EXHAUST ALL AIR FROM THE SPEARGUN WITH THE
POWER ADJUSTMENT LEVER IN THE MAXIMUM “HIGH”
POWER POSITION BEFORE PERFORMING ANY MAINTENANCE
OR REPAIRS REQUIRING DISASSEMBLY (FIG. 1). FAILURE TO Fig. 1
EXHAUST ALL AIR FROM THE SPEARGUN IN THE MAXIMUM
"HIGH" POWER POSITION CAN CAUSE PARTS TO BE EXPELLED
FROM THE SPEARGUN AT HIGH VELOCITY WHICH MAY CAUSE
SERIOUS INJURY OR DEATH.

3. Set the power adjustment lever (38) to maximum "high"

power position (Fig. 2).
4. With a metal rod (approximately 1.5 mm. diameter),
depress the inlet valve ball, until all the air is fully released
from the speargun (Fig. 3).

NOTE It is normal for a small amount of oil to be present as Fig. 2

the air is released from the speargun. Before releasing
the air, position the speargun in a muzzle down posi-
tion for several minutes. This will minimize the amount
of oil released when the inlet valve ball is depressed. A
shop rag positioned over the inlet valve may be useful
in capturing any oil which may be released during this
procedure.

5. Using a vise, clamp the head (1-2-3-5) in the 24 mm. jaws

(A-1) ( Fig. 4). Remove the head by holding the handle and
the nose cone and simultaneously turning them counter
clockwise using equal effort (Fig. 5).
Fig. 3

CAUTION !
THE HANDLE AND NOSE CONE MUST BE TURNED SIMULTANE-
Ø 18
OUSLY USING EQUAL EFFORT OR INTERNAL DAMAGE TO THE
GUN WILL RESULT (FIG. 5).

Ø 24
6. Clamp the head in the 24 mm. jaws (A-1) (Fig. 4) and
remove head tip (5) from head body (1) with a 19 mm.
wrench (Fig. 6). Ø 16

7. Remove shock absorber (2) and insert (3) from head body.
Fig. 4
8. Remove shock absorber (2) from shock absorber insert (3).
G 1-2 CYRANO AND SPARK PNEUMATIC SPEARGUNS original copywriter 1987
revised 1998 - printed 1999

9. Remove piston (19) from the barrel. If necessary a shaft

may be used to aid in the removal of the piston (Fig. 7).
10. Remove oil wiper (19) and o-ring (18) from piston.
11. Using a rotating motion, remove the nose cone (4) and
o-ring (20).
12. Slide the nose cone reinforcement (23) forward (toward
the muzzle) and drain the oil contained in the speargun into
a suitable container. Dispose of waste oil properly by taking Fig. 5
it to a waste oil recycling facility. (only CYRANO version)
13. Slide the nose cone reinforcement back into its original
position, then using a rotating motion remove the tank (25),
using clamping jaws (A-3) if needed. (only CYRANO version)
14. Place the barrel in the 16 mm. jaws (A) (Fig. 4) and clamp
into vise (Fig. 8).
15. Remove barrel o-ring (22) with tool A-7.
16. Using snap ring pliers remove the barrel bushing (21).
17. Remove the nose cone reinforcement (23) and o-ring (29) Fig. 6
from barrel. (only CYRANO version)
18. Remove the remaining barrel o-ring (22) with tool A-7.
19. Using snap ring pliers remove the remaining barrel bushing
(21) from barrel. (only CYRANO version)
20. Remove the grip pin (62) using a pin punch, then remove
grip (61).
21. Remove trigger pin (3) using a pin punch, then remove
trigger (48-52). Fig. 7
22. Remove the trigger adjustment screw (48) from trigger
body (52) with a 6 mm. wrench.

NOTE It is not necessary to remove the trigger adjustment

(48) or the trigger insert (75) from the trigger body
(52) during routine servicing, unless they are to be
replaced.

23. Remove the safety bar retainer (58) by depressing the latch
with a small screwdriver (Fig. 9).
24. Remove safety bar (59) with o-ring (60) from handle (41). Fig. 8
25. Remove o-ring (60) from safety bar.
26. Remove connecting plunger (45) with special tool A-13
(Ø 1,5 mm) or needle nose pliers.
27. Remove bushing (47) with tool A-22, then remove o-ring
(46) and guide bushing (51) (Fig. 10).

CAUTION !
IF GUIDE BUSHING (51) DOES NOT COME OUT DURING STEP
27, DO NOT ATTEMPT TO REMOVE IT. PLIERS OR POINTED
TOOLS WILL DAMAGE THE BUSHING OR ITS SEAT. Fig. 9
 original copywriter 1987 CYRANO AND SPARK PNEUMATIC SPEARGUNS G 1-3
revised 1998 - printed 1999

NOTE The guide bushing (51) for the 1.5 mm. diameter
connecting plunger is fitted in the handles of apnea
system Cyrano 700 and Cyrano 970 spearguns and in
the handles of all Cyrano models starting from serial
number 94336001.
28. Remove line retainer pin (43) with a pin punch, then
remove line retainer (42).

NOTE It is not necessary to remove the line release during

routine service unless the line release is worn, dam-
aged or does not swivel freely on the line release pin.
Fig. 10
29. Remove inlet valve (32-46-65-66-67) with inlet valve
wrench (A 4).
30. With a Philips screwdriver, remove the inlet bushing (67)
and spring (66) (Fig. 11).
31. Remove ball (65) from the inlet valve body (32).
32. Remove o-ring (46) from the inlet valve body.
33. Slide handle (41) rearward off of the barrel (26).
34. Remove o-ring (37) from o-ring seat (39) of the power
adjustment rod (Fig. 12).
35. With a 7 mm wrench, unscrew power adjustment rod
(34-35-37-39) from power adjustment lever (38). Fig. 11

NOTE If the o-ring seat (39) unscrews from power adjust-

ment rod (35), the rod must be completely removed
from power adjustment lever (38) by clamping the rod
with plastic jaws. After removing the power adjust-
ment rod put a drop of thread compound (Loctite 270)
in the threaded hole of o-ring seat (39) and tighten it
securely on the power adjustment rod (35).
36. Remove power adjustment rod (35-39) and spring (34)
from handle (41).
37. Remove spring (34) from power adjustment rod.
38. Remove power adjustment lever (38) from handle (41).
39. Remove the power adjustment rod bushing (36) and o-ring Fig. 12
(37) from handle.
40. Remove 0-ring (20).
41. With a pin punch, remove catch hook pin (57), catch hook
(50) and spring (44) from the barrel (26).
42. Slide the power regulating block (20-68-69-70) off of the
barrel.
43. Remove one-way housing (69) and one-way seat (68) from
power regulating block (Fig. 13).
44. Remove o-ring (20) from power regulating block.
45. Remove o-ring (71) from barrel with tool A-7. Fig. 13
G 1-4 CYRANO AND SPARK PNEUMATIC SPEARGUNS original copywriter 1987
revised 1998 - printed 1999

46. Remove snap ring (72).

NOTE It is not necessary to remove the snap ring (72) dur-

ing routine service, unless it or the barrel is to be
replaced.
47. Remove barrel (26) from the jaws.

CLEANING
The parts used to manufacture MARES spearguns do not require
special cleaning. Acids or solvents should not be used to clean
any speargun parts. A clean shop rag can be used to remove any
oil or grease that remains on the parts prior to inspection.

INSPECTION
All o-rings should be replaced during routine servicing (mainte-
nance kit part # 164290). If the following parts are not replaced,
they should be inspected with a jeweler's loop for the flaws listed
below. Replace any part with these flaws.

Barrel (26) Inspect for any scratches or foreign material inside the barrel. Then check the
(part # depending on the model) outer surface for scratching and/or chipping around the 0-ring sealing areas.
Barrel bushing (21) Inspect for any signs of cracking, distortion or brittleness.
(part # 164204)
Snap ring (72) Inspect for any signs of cracking, distortion or brittleness.
(part # 164212)
Piston (17) Inspect for any cracks or distortion.
(part # 164209)
Oil wiper (19) Inspect for any cuts, distortion or foreign material. Any of these flaws may
(part # 164208) cause leakage.
Shock absorber (2) Inspect for any signs of cuts or distortion.
(part # 163856)
Shock absorber insert (3) Inspect for any cracks or distortion.
(part # 164207)
Power regulating block (70) Inspect for any cracks or distortion.
(part # 164213)
One-way seat (68) Inspect for any signs of cuts or distortion.
(part # 163635)
Power adjustment rod (35) Inspect the surface of the rod for scratching, distortion or cracking. Also make sure
(part # 163328) that the 0-ring seat (39) is securely tightened on the power adjustment rod.
Handle (41) Inspect for any cracks or distortion. Check all 0-ring seating surfaces for
(part # 164231) any signs of scratching, distortion or cracking.
Connecting plunger (45) Inspect the surface for distortion or scratching.
(part # 164282, 1.5 mm.)
(part # 163344, 3 mm.)
Catch hook (50) Inspect the surface of the catch hook that engages the piston for any signs of wear.
(part # 163377) Replace the catch hook if any signs of wear are present.
Inlet valve (32) Inspect the seating and sealing surfaces for cracks, scratches, distortion or
(part # 164221) foreign material.
 original copywriter 1987 CYRANO AND SPARK PNEUMATIC SPEARGUNS G 1-5
revised 1998 - printed 1999

Springs Inspect for any signs of distortion.

O-rings Inspect for any cuts, distortion or foreign material. Any of these flaws
(maintenance kit part # 163979) may cause leakage.
Shaft Inspect the shaft for straightness and corrosion. Check the tapered shaft sleeve,
(part # depending on the model) washer and line retainer for wear and replace with original Mares parts if necessary.

CAUTION !
REPLACE ANY PARTS WITH DAMAGED THREADS. ALL
THREADED PARTS MUST BE CLEAN AND IN GOOD CONDITION.
INSTALLING ANY PART WITH DAMAGED THREADS MAY CAUSE
IT TO CROSS-THREAD RESULTING IN DAMAGE TO THE
SPEARGUN.

R E A S S E M B LY
NOTE Before reassembly, lightly lubricate all o-rings with
MARES grease (MOBIL PLEX 47 or equivalent).
Lubricating o-rings before installation will minimize
the risk of damage to the o-rings during reassembly.

1. Place the barrel in the 16 mm. jaws (A-1) (Fig. 3) and clamp
into vise (Fig. 14).

Fig. 14

2. Install one barrel bushing (21) in the inner groove of the

barrel with tool A-7 (Fig. 14-A). (only Cyrano version)
3. Place one o-ring (22) against the barrel bushing (21) with
tool A-7 (Fig. 14-A). (only Cyrano version)
4. Place o-ring (29) on the nose cone reinforcement (23).
(only Cyrano version)
G 1-6 CYRANO AND SPARK PNEUMATIC SPEARGUNS original copywriter 1987
revised 1998 - printed 1999

5. Slide the nose cone reinforcement (23) into position over

o-ring (22) (Fig. 14-A). (only Cyrano version)
6. Install the remaining barrel bushing (21) in the outer
groove of the barrel with tool A-7 (Fig. 14-B).
7. Place the remaining o-ring (22) against the barrel bushing
(21) with tool A-7 (Fig. 14-B).
8. Install the snap ring (72) into the groove of the barrel, with
the square tab facing the front (muzzle end) of the barrel
with tool A-7 (Fig. 14-C).
9. Place o-ring (71) in the groove of the barrel next to the snap
ring (72) with tool A-7 (Fig. 14-C).
10. Insert the one-way seat (68) into the power regulating block
(70) (Fig. 13).
11. Position the one-way housing (69) over the one-way seat
(68) and press into place (Fig. 13).
12. Place o-ring (20) into the groove of the power regulating
block (70) (Fig. 13).
13. Slide the power regulating block into position over o-ring
(71). Rotate the snap ring and/or power regulating block as
needed to align the one-way housing (69) with the snap ring
seat. (Fig 14-C).
14. Install spring (44) on to catch hook (50) (Fig. 14-D).
15. Install catch hook (50) with spring (44) attached, into the
barrel and align the hole in the catch hook with the holes in
the barrel and install the catch hook pin (57) (Fig. 14-D).
16. Using an appropriate length shaft with piston (A-16, part #
164209) attached, slide the piston and shaft into the barrel
until it latches into the catch hook. Make sure that the catch
hook spring is positioned into its seat.
17. Place o-ring (20) into the groove of the handle (41).
18. Slide spring (24) onto power adjustment rod.

NOTE If the o-ring seat (39) was removed from the power
adjustment rod (35), put a drop of thread compound
(Loctite 270) in the threaded hole of o-ring seat (39)
and tighten it securely on the powed adjustment rod
(35).
19. Slide power adjustment rod bushing (36) onto the power
adjustment rod, with the smaller diameter facing away from
the o-ring seat (39).
20. Place o-ring (37) onto power adjustment rod against the
power adjustment rod bushing (36).

NOTE Place a drop of thread compound (Loctite 242) on the

threads of the power adjustment rod.

21. Insert the power adjustment rod into its hole in the handle
(41), press o-ring (37) and power adjustment rod bushing
(36) into handle.
 original copywriter 1987 CYRANO AND SPARK PNEUMATIC SPEARGUNS G 1-7
revised 1998 - printed 1999

22. Insert the power adjustment lever (38) into its housing in
the handle, then with a 7 mm wrench, gently tighten the
power adjustment rod onto the power adjustment lever.
23. Place o-ring (37) into the groove of the o-ring seat (39)
using tool (A-12).
24. Slide handle (41) onto barrel (26).

NOTE Position the handle (41) with the trigger seat above the
catch hook (50) (Fig. 15-A). Align the power adjustment
rod with the corresponding hole in the power regulating
block. If necessary, rotate the power regulating block,
making sure the one-way housing remains in the snap
ring seat (Fig. 15-B). Push the handle against the power
regulating block and make sure that the power regulat-
ing block tabs are positioned in their seats in the handle.
Fig. 15
(Fig. 16)

25. Position o-ring (46) in inlet valve body (32) seat, with tool
(A-13) (Fig. 11).
26. Center the inlet ball (65) on o-ring (46).
27. Place spring (66) inside of the inlet bushing (67).

NOTE Applying a small amount of grease on the spring (66)

will retain the spring in the inlet bushing (67) during
assembly.

28. Tighten inlet bushing (67) into valve body (32) using a
Philips screwdriver

NOTE Apply two or three drops of thread compound (Loctite Fig. 16

242) to the threads of the inlet valve.

29. Insert the inlet valve into handle using the inlet valve wrench
(A4) and tighten securely.

WARNING !
FAILURE TO SECURELY TIGHTEN THE INLET VALVE MAY
CAUSE PARTS TO BE EXPELLED FROM THE SPEARGUN AT
HIGH VELOCITY, WHEN THE GUN IS PRESSURIZED, WHICH
MAY CAUSE SERIOUS INJURY OR DEATH.

30. Align the hole in the line release (42) with the hole in the
handle and install line release pin (43):
31. Place bushing (47), 0-ring (46) and guide bushing (51)
(if any) on tool A-22 (Fig. 17). Fig. 17

NOTE The guide bushing (51) for the1.5 mm. diameter con-
necting plunger is fitted in the handle of apnea system
Cyrano 700 and Cyrano 970 spearguns and in the han-
dles of all Cyrano models starting from serial number
94336001.
G 1-8 CYRANO AND SPARK PNEUMATIC SPEARGUNS original copywriter 1987
revised 1998 - printed 1999

32. Insert bushing (47), 0-ring (46) and guide bushing (51) (if
any) into the handle (41). Gently tighten the bushing (47)
into its housing in the handle with tool A-22 (Fig. 10).

CAUTION !
TORQUE BUSHING (47) TO 140 N/CM. (12.5 lbs. in. approx.)
OVER TIGHTENING THE BUSHING MAY RESULT IN DAMAGE TO
THE HANDLE CAUSING LEAKAGE.
33. Insert the rounded end of the connecting plunger (45) into
the bushing (47) using a special tool A-13 (Ø 1.5 mm) or
needle nose pliers. Fig. 18

34. Place o-ring (60) into groove of safety bar (59).

35. Insert the safety bar (59-60) into the handle from the
opposite side that contains the power adjustment lever.
36. Align the safety bar retainer (58) and press it into the safety
bar until the latch engages.
37. Install trigger adjustment screw (48) into trigger body (52)
(Fig. 18-A). With a 6 mm wrench, tighten trigger adjustment
screw (48) into trigger body (52), until it protrudes
approximately 4 mm. (Fig. 18-B).
38. Align the hole in the trigger with the holes in the handle (41)
and install trigger pin (53).
39. Position the grip (61) on the handle (41) and install grip pin
(62), from the power adjustment lever side.
40. Pull trigger and remove shaft with piston (A-16) attached.
41. Remove piston (A-16, part # 164209) from the shaft.
42. Open the jaws and remove barrel (26).
43. With a rotating motion, install tank (25) using jaws (A-3) if
necessary.
44. Fill the barrel (26) with oil according to the quantities
shown in the table below.

CAUTION !
USE ONLY CORROSION AND RUST PREVENTING OILS, SUCH
AS MOBIL DTE OIL LIGHT OR SAE 10 W OILS SUITABLE FOR
USE IN HYDROPNEUMATIC SYSTEMS. DO NOT USE GRAPHITE
BASE OILS! THE USE OF OILS NOT SPECIFIED FOR USE IN
HYDROPNEUMATIC SYSTEMS MAY LEAD TO PREMATURE GUN
DAMAGE DUE TO INTERNAL CORROSION.

SPEARGUN OIL QUANTITY IN CC

CYRANO 550 - SPARK 550 20
CYRANO 700 - SPARK 700 25
CYRANO 850 - SPARK 850 25
CYRANO 970 - SPARK 970 30
CYRANO 1100 - SPARK 1100 Pipin 30
 original copywriter 1987 CYRANO AND SPARK PNEUMATIC SPEARGUNS G 1-9
revised 1998 - printed 1999

45. Install 0-ring (18) into the groove of the piston body (17)
(Fig. 7)
46. Install the oil wiper (19) on piston making sure that the lip
of the oil wiper faces the metal post of the piston.
47. Insert piston into barrel using caution not to damage oil
wiper.
48. Install o-ring (20) into the o-ring groove of the nose cone
(4).
49. Using a rotating motion insert the nose cone (4) into tank
(25) and align the nose cone fluorescent sight with the sight
on the handle.
50. Insert the shock absorber insert (3) into the shock absorber
(2) (Fig. 6).
51. Install shock absorber (2) and shock absorber insert (3) into
the head body (1) with the shock absorber facing the head
tip (5) (Fig. 6).
52. Block head into jaws (24mm) (A1) (Fig. 6).
53. Lubricate head ferrule threads (5) (Fig. 6).
54. Thread head ferrule (5) into head body (1) using a 19 mm
wrench (Fig. 6).
55. Clamp the head (1-2-3-5) in the 24 mm. jaws (A-l) ( Fig. 4).
Tighten the head by holding the handle and the nose cone
and simultaneously tuming them clockwise using equal
effort (Fig. 5).

CAUTION !
THE HANDLE AND NOSE CONE MUST BE TURNED SIMULTANE-
OUSLY USING EQUAL EFFORT OR INTERNAL DAMAGE TO THE
GUN WILL RESULT (FIG. 5).

56. Remove speargun from jaws .

57. The speargun is now ready to be pressurized. Follow the
instructions in the Pressurizing section of this manual.

NOTE Perform steps 58 and 59 below, after pressurizing,

testing trigger adjustment (if any), as described in the
following sections of this manual.

58. Install inlet valve cap (33) using the special loader ( Fig. 1)
[not available in North America] or a 6 mm Allen wrench.
59. Install protective cover (6) (if any) on head (1-2-3-5).
G 1-10 CYRANO AND SPARK PNEUMATIC SPEARGUNS original copywriter 1987
revised 1998 - printed 1999

TAHITIAN SHAFT SERVICE

NOTE The Tahitian shaft should only be disassembled if it

becomes necessary to replace the line retainer or
washer.

Fig. 18

D I S A S S E M B LY

1. Clamp the shaft in a vise.

2. Unscrew the tapered shaft sleeve with pliers.
3. Remove washer (14) and line retainer (12) from the shaft
(Fig. 18).

R E A S S E M B LY

1. Position the line retainer (12) and washer (14) on the shaft
as shown in fig. 22.

NOTE To prevent the tapered shaft sleeve from becoming

loose, place a drop of thread compound (Loctite 270)
on the shaft threads.

2. Using pliers, securely tighten the tapered shaft sleeve on the

shaft.
3. Remove the shaft from the vise.
 original copywriter 1987 CYRANO AND SPARK PNEUMATIC SPEARGUNS G 1-11
revised 1998 - printed 1999

PRESSURIZING
Cyrano pneumatic spearguns can be pressurized using the Mares
gun charging yoke (part # 691503) or a Mares hand pump (part
# 691101).

WARNING !
ALWAYS PRESSURIZE THE SPEARGUN WITH THE POWER
ADJUSTMENT LEVER IN THE MAXIMUM “HIGH” POWER POSI-
TION (FlG. 2). NEVER EXCEED THE MAXIMUM 30 BAR PRES-
SURE. FAILURE TO PRESSURIZE THE SPEARGUN IN THE MAX-
IMUM “HlGH” POWER POSITION, OR OVER-PRESSURIZATION
MAY CAUSE THE SPEARGUN TO RUPTURE WHICH MAY CAUSE
SERIOUS INJURY OR DEATH.

P R E S S U R I Z I N G U S I N G M A R E S G U N C H A R G I N G Y O K E ( PA RT # 6 9 1 5 0 3 )

1. Set the power adjustment lever (38) to maximum "high"

power position (Fig. 2).
2. Connect the yoke to the valve of a scuba cylinder.
3. By hand, thread the pressure gauge body into the inlet valve
of the speargun, until the pressure gauge body o-ring seals
against the inlet valve body. Do not tighten with a wrench.
4. Close the purge valve by rotating the thumb wheel
clockwise.
5. Slowly open the valve on the scuba cylinder and read the
pressure value on the pressure gauge. When the desired
value is reached, close the valve on the scuba cylinder.

WARNING !
PNEUMATIC SPEARGUNS ARE HIGHLY PRESSURIZED. NEVER
POINT THE SPEARGUN AT YOURSELF OR ANYONE ELSE.
VIOLATION OF THIS WARNING COULD RESULT IN SERIOUS
INJURY OR DEATH.

6. Open the purge valve by rotating the thumb wheel clockwise

and allow any residual air to escape from the hose.
7. Remove the pressure gauge body from inlet valve.
8. Remove the yoke from the valve of the scuba cylinder.
G 1-12 CYRANO AND SPARK PNEUMATIC SPEARGUNS original copywriter 1987
revised 1998 - printed 1999

P R E S S U R I Z I N G U S I N G M A R E S H A N D P U M P ( PA RT # 6 9 1 1 0 1 )

WARNING !
ALWAYS PRESSURIZE THE SPEARGUN WITH THE POWER ADIUSTMENT LEVER IN THE MAXIMUM “HIGH” POWER
POSITION (FlG. 1). NEVER EXCEED THE MAXIMUM 30 BAR PRESSURE. FAILURE TO PRESSURIZE THE SPEARGUN IN
THE MAXIMUM “HIGH” POWER POSITION OR OVER-PRESSURIZATION MAY CAUSE THE SPEARGUN TO RUPTURE
WHICH MAY CAUSE SERIOUS INJURY OR DEATH.

1. Set the power adjustment lever (38) to maximum “high”

power position (Fig. 2).
2. By hand, thread the hand pump into the inlet valve of the
speargun, until the hand pump o-ring seals against the inlet
valve body.
3. The following pressure table shows the approximate
number of pump strokes required to obtain the pressure
values listed.

CYRANO VERSION

PRESSURE IN BAR
DESCRIPTION 10 15 20 25 30
NUMBER OF PUMP STROKES (Approx.)
CYRANO 550 125 185 250 330 410
CYRANO 700 150 230 310 390 480
CYRANO 850 210 330 450 580 710
CYRANO 970 260 395 575 755 925
CYRANO 1100 320 510 700 870 1055
SPARK VERSION

PRESSURE IN BAR
DESCRIPTION 10 15 20 25 30
NUMBER OF PUMP STROKES (Approx.)
SPARK 550 181 268 363 479 595
SPARK 700 218 334 450 566 696
SPARK 850 305 479 653 841 1030
SPARK 970 377 573 834 1095 1341
SPARK 1100 Pipin 464 740 1015 1262 1530

WARNING !
THE NUMBER OF PUMP STROKES LISTED IN THE PRESSURE TABLE REFER TO A COMPLETELY EMPTY SPEARGUN
TANK. IF IT IS NOT POSSIBLE TO DETERMINE THE EXISTING PRESSURE IN THE SPEARGUN, ALL PRESSURE MUST
BE RELEASED FROM THE SPEARGUN PRIOR TO PRESSURIZING IT. IF THE EXISTING PRESSURE IN THE SPEARGUN
IS KNOWN AND IT BECOMES NECESSARY TO ADD PRESSURE, ONLY INCREASE IT THE AMOUNT OF THE DIFFERENCE.
FOR EXAMPLE, TO INCREASE THE PRESSURE OF A CYRANO 700 FROM 20 BAR TO 30 BAR, 170 PUMP STROKES ARE
REQUIRED. NOT THE FULL 480 PUMP STROKES SHOWN IN THE TABLE. NEVER EXCEED THE MAXIMUM 30 BAR PRES-
SURE. OVER-PRESSURIZATION MAY CAUSE THE SPEARGUN TO RUPTURE WHICH MAY CAUSE SERIOUS INJURY OR
DEATH. PNEUMATIC SPEARGUNS ARE HIGHLY PRESSURIZED. NEVER POINT THE SPEARGUN AT YOURSELF OR ANY-
ONE ELSE. VIOLATION OF THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH.
4. Remove the hand pump from the inlet valve.
 original copywriter 1987 CYRANO AND SPARK PNEUMATIC SPEARGUNS G 1-13
revised 1998 - printed 1999

SPEARGUN INSPECTION AND ADJUSTMENT

To make sure the gun is functioning correctly, inspection and
adjustment may be needed. The following inspection and adjust-
ment procedures must be performed with the greatest care and
attention.

O.K. NO
WARNING !
FOR THE NECESSARY INSPECTION TO BE PERFORMED, THE
SHAFT MUST BE INSERTED INTO THE SPEARGUN. FOR YOUR
SAFETY, FASTEN THE SHAFT INTO A FLOOR BASE. WHEN THE
SHAFT IS INSERTED, ALWAYS MAINTAIN PRESSURE ON THE
Fig. 20
SPEARGUN WITH BOTH HANDS AND KEEP THE HANDLE
UNDER YOUR SHOULDER (FlG. 20-A), NEVER UNDER YOUR
FACE (FIG. 20-B). DO NOT PERFORM ANY ADJUSTMENT OR
LEAVE THE GUN UNATTENDED WHEN THE SHAFT IS INSERTED.
FAILURE TO FASTEN THE SHAFT INTO A FLOOR BASE OR MAIN-
TAIN PRESSURE ON THE SPEARGUN WITH BOTH HANDS AND
KEEP THE HANDLE UNDER YOUR SHOULDER (FlG. 20-A) WHEN
THE SHAFT IS INSERTED, COULD RESULT IN THE SPEAR
SHAFT AND/OR SPEARGUN BEING PROPELLED UNCONTROL-
LABLY, IF THE TRIGGER IS PULLED OR THE SPEARGUN FIRES
UNEXPECTEDLY AND COULD RESULT IN SERIOUS INJURY OR
DEATH.

A floor base can be made from a piece of metal that is 120 mm.
(4.75 in.) in diameter and 30 mm. (1.25 in.) thick. Locate the cen-
Fig. 21
ter point of the floor base and drill a hole 16 mm. (5/8 in.) in
depth with a 6.20 mm. bit. Thread the hole using a M 7 x 1 tap
(Fig. 21).

NOTE The various inspection steps may be performed con-

secutively.

O-RING INSPECTION
1. Immerse the speargun in water and watch for signs of air
leakage from o-rings and sealing items.

TRIGGER STROKE INSPECTION

1. Using a floor base, insert the shaft until the piston engages
the catch hook (Fig. 20-A).
2. Pull the trigger until the piston disengages. Measure the
trigger stroke. The trigger stroke should be a minimum of
3 mm. to a maximum of 7 mm. If the trigger stroke does not
fall within 3 mm. minimum to 7 mm. maximum, the trigger
sensitivity will need to be adjusted.
3. Remove shaft from speargun.
G 1-14 CYRANO AND SPARK PNEUMATIC SPEARGUNS original copywriter 1987
revised 1998 - printed 1999

TRIGGER SENSITIVITY ADJUSTMENT

WARNING !
FOR CORRECT TRIGGER RELEASE SENSITIVITY, THE TRIGGER STROKE SHOULD BE SET FROM 3 MM MINIMUM (Fig.
22). WHENEVER TRIGGER SENSITIVITY IS ADJUSTED, MAKE SURE THAT THE PISTON FULLY ENGAGES THE CATCH
HOOK. OVER-ADJUSTMENT MAY CAUSE THE PISTON NOT TO ENGAGE OR TO PARTIALLY ENGAGE THE CATCH HOOK
AND MAY CAUSE THE SPEARGUN TO DISCHARGE UNEXPECTEDLY WHICH MAY CAUSE SERIOUS INJURY OR DEATH.

1. Move the safety bar to the “safe” position.

2. Insert a small screwdriver into the trigger adjustment screw
(48).
a. Turn the trigger adjustment screw counterclockwise to
decrease sensitivity. (Fig. 23)
b. Turn the trigger adjustment screw clockwise to increase
sensitivity. (Fig. 23)
3. Measure trigger stroke and repeat steps as needed to obtain
the correct adjustment.

SAFETY BAR INSPECTION

1. Using a floor base, insert the shaft until the piston engages Fig. 22
the catch hook (Fig. 20-A).
2. Move the safety to the "safe" position.
3. Pull the trigger. The trigger should be locked in position and
the speargun should not fire.
4. Move the safety to the “fire” position.
5. Pull the trigger and remove the shaft from the speargun.

P O W E R R E G U L AT O R I N S P E C T I O N
1. Set the power adjustment lever (38) to minimum "low"
power position (Fig. 2).
2. Using a floor base, insert the shaft until the piston engages
the catch hook (Fig. 20-A).
3. Pull the trigger, take note of the effort exerted by the
speargun and remove the shaft from the speargun.
4. Leave the power adjustment lever (38) in minimum “low”
power position (Fig. 2), for approximately 2 hours.
Fig. 23
5. Using a floor base, insert the shaft until the piston engages
the catch hook (Fig. 20-A). The effort exerted by the
speargun should be the same as it was 2 hours previous.
A decrease in the effort would indicate a leak in the
speargun. An increase in effort would indicate an internal
leak past the power regulating block.
6. Pull the trigger and remove the shaft from the speargun.
7. Set the power adjustment lever (38) to maximum “high”
power position (Fig. 2).
 original copywriter 1987 CYRANO AND SPARK PNEUMATIC SPEARGUNS G 1-15
revised 1998 - printed 1999

Table 205
CYRANO SPEARGUNS LINE Updated to 01-04-98

Ref. Code Description Ref. Code Description

1 164205 Head body 44 163313 Spring catch hook
2 163856 Shock absorber , rubber 45 164282 Connecting plunger 1,5 - Apnea System
3 163207 Shock absorber insert 46 110242 O–Ring – R/ 1
4 164200 Nose cone blue 47 164284 Housing – connecting plunger Apnea System
5 164206 Head ferrule 48 164240 Trigger adjustment screw
6 164008 Protective cap - head 49 110242 O-ring 2-003 Apnea System
7 163968 Rubber ring - shock 50 163377 Catch hook
8 164201 View finder 51 164286 Spacing sleeve, Apnea System
11 169821 Shock line - m 3 52 164283 Trigger , Apnea System
11 169818 Shock line - m 5 53 163337 Pin 4x23
12 164004 Line retainer for shaft Ø 7 mm 57 163338 Pin 4x20 - catch hook
14 163503 Washer for shaft Ø 7 mm 58 164237 Safety stop
17 164209 Piston body 59 164236 Safety body
18 110107 O-ring 2031 - piston 60 110106 O-ring 106
19 164208 Oil wiper piston 61 164232 Handle
20 110208 O-ring tank - special OR 62 164233 Pin - handle
21 164204 Bushing 65 163808 Ball bearing - inlet valve
22 110228 O-ring 3062 66 163807 Spring - inlet valve
23 164202 Nose cone insert 67 164220 Bushing - inlet valve
25 164225 Tank Cyrano 550 68 163635 Seat, one way valve
25 164226 Tank Cyrano 700 69 163636 Housing, one way valve
25 164227 Tank Cyrano 850 70 164213 Power regulator block
25 164228 Tank Cyrano 970 71 110227 O-ring 3056
25 164229 Tank Cyrano 1100 72 164212 Circlip Ø 16 - power regulator
26 164215 Barrel Cyrano 550
26 164216 Barrel Cyrano 700 ASSEMBLIES
26 164217 Barrel Cyrano 850 A 164210 Head assy
26 164218 Barrel Cyrano 970 D 164214 Power regulator assy (68-69-70)
26 164219 Barrel Cyrano 1100 E 164285 Trigger assy Apnea System (48-52)
29 110245 O-ring 2106 H 164287 Handle assy Apnea System
32 164221 Body - inlet valve (38-41-42-43-46-47-61-L)
33 164223 Cap - inlet valve L 163937 Power adjustment assy (34-35-36-37-39)
34 163325 Spring - power adjustment M 164222 Inlet valve assy (32-46-65-66-67)
35 163328 Rod - power adjustment N 164211 Piston assy Ø 16 (17-18-19)
36 163628 Bushing - power adjustment *** 164290 Complete set of O-rings
37 110102 O-ring 2015 - power adjustment (18-19-20-22-29-37-46-60-71 )
38 164234 Lever power adjustment
39 163324 O-ring housing - power adjustment REMARKS
41 164231 Handle From serial no.94336001 all Cyrano’ spearguns have
42 163668 Line release, black the Apnea System type handle. For repairs of previous
43 163614 Pin - line release guns, please replace the handle with the new one.
G 1-16 CYRANO AND SPARK PNEUMATIC SPEARGUNS original copywriter 1987
revised 1998 - printed 1999

SPARK SPEARGUNS Table 208

SPARK 110 - (Pipin line) Updated to 01-04-98

Ref. Code Description Ref. Code Description

1 164205 Head body 48 164240 Trigger adjustment screw
2 163856 Shock absorber , rubber 49 110242 O-ring 2-003 Apnea System
3 163207 Shock absorber insert 50 163377 Catch hook
4 164301 Nose cone 51 164286 Spacing sleeve, Apnea System
5 164206 Head ferrule 52 164242 Trigger
6 164008 Protective cap - head 53 163337 Pin 4x23
7 163968 Rubber ring - shock 57 163338 Pin 4x20 - catch hook
11 169821 Shock line - m 3 58 164310 Safety stop Spark yellow
11 169818 Shock line - m 5 58 164324 Safety stop Spark blue (Pipin line)
12 164004 Line retainer for shaft Ø 7 mm 59 164309 Safety body Spark yellow
14 163503 Washer for shaft Ø 7 mm 59 164323 Safety body Spark blue (Pipin line)
17 164209 Piston body 60 110106 O-ring 106
18 110107 O-ring 2031 - piston 61 164300 Handle Spark yellow
19 164208 Oil wiper piston 61 164326 Handle Spark black (Pipin line)
20 110208 O-ring tank - special OR 62 164233 Pin - handle
21 164204 Bushing 65 163808 Ball bearing - inlet valve
22 110228 O-ring 3062 66 163807 Spring - inlet valve
25 164302 Tank Spark 550 67 164220 Bushing - inlet valve
25 164303 Tank Spark 700 68 163635 Seat, one way valve
25 164304 Tank Spark 850 69 163636 Housing, one way valve
25 164305 Tank Spark 970 70 164213 Power regulator block
25 164306 Tank Spark 1100 (Pipin line) 71 110227 O-ring 3056
26 164215 Barrel Spark 550 72 164212 Circlip Ø 16 - power regulator
26 164216 Barrel Spark 700
26 164217 Barrel Spark 850 ASSEMBLIES
26 164218 Barrel Spark 970 A 164210 Head assy (1-2-3-5)
26 164219 Barrel Spark 1100 (Pipin line) D 164214 Power regulator assy (68-69-70)
32 164221 Body - inlet valve E 164230 Trigger assy Spark (48-52)
33 164311 Cap - inlet valve yellow H 164308 Handle assy Spark
33 164325 Cap - inlet valve blue (Pipin line) (38-41-42-43-46-47-61-L)
34 163325 Spring - power adjustment H 164322 Handle assy Spark (Pipin line)
35 163328 Rod - power adjustment (38-41-42-43-46-47-61-L)
36 163628 Bushing - power adjustment L 163937 Power adjustment assy (34-35-36-37-39)
37 110102 O-ring 2015 - power adjustment M 164222 Inlet valve assy (32-46-65-66-67)
38 164234 Lever power adjustment N 164211 Piston assy Ø 16 (17-18-19)
39 163324 O-ring housing - power adjustment *** 164290 Complete set of O-rings
41 164231 Handle (18-19-20-22-29-37-46-60-71 )
42 163668 Line release, black
43 163614 Pin - line release REMARKS
44 163313 Spring catch hook From serial no.94336001 all Spark’ spearguns have
45 164282 Connecting plunger 1,5 - Apnea System the Apnea System type handle. For repairs of previous
47 164284 Housing – connecting plunger Apnea System guns, please replace the handle with the new one.
 COMPETITION
PNEUMATIC
SPEARGUN
COMPETITION
PNEUMATIC SPEARGUN
 original copywriter 1987 COMPETITION PNEUMATIC SPEARGUN G 2-1
revised 1998 - printed 1999

D I S A S S E M B LY :
1. Remove protective cover (6) (if any) from head (1-2-3-5) MIN MAX
(see numbered Competition schematic).
2. Unscrew inlet cap (33) using a 6 mm. Allen wrench.

WARNING ! Power Adjustment

Lever
ALWAYS EXHAUST ALL AIR FROM THE SPEARGUN WITH THE
POWER ADJUSTMENT LEVER IN THE MAXIMUM “HIGH”
POWER POSITION BEFORE PERFORMING ANY MAINTENANCE
OR REPAIRS REQUIRING DISASSEMBLY (FIG. 1). FAILURE TO
EXHAUST ALL AIR FROM THE SPEARGUN IN THE MAXIMUM Fig. 1
“HIGH” POWER POSITION CAN CAUSE PARTS TO BE EXPELLED
FROM THE SPEARGUN AT HIGH VELOCITY WHICH MAY CAUSE
SERIOUS INJURY OR DEATH.

3. Set the power adjustment lever (38) to maximum "high"

power position (Fig. 1).
4. With a metal rod (approximately 1.5 mm. diameter),
depress the inlet valve ball, until all the air is fully released
from the speargun (Fig. 2).

NOTE It is normal for a small amount of oil to be present as

the air is released from the speargun. Before releasing
Fig. 2
the air, position the speargun in a muzzle down posi-
tion for several minutes. This will minimize the amount
of oil released when the inlet valve ball is depressed. A
shop rag positioned over the inlet valve may be useful
in capturing any oil which may be released during this Ø 18
procedure
5. Using a vise, clamp the head (1-2-3-5) in the 24 mm. jaws
(A-1) (Fig. 3). Remove the head by holding the handle and Ø 24

the nose cone and simultaneously turning them counter-

clockwise using equal effort (Fig. 4).
Ø 16

Fig. 3

CAUTION !
THE HANDLE AND NOSE CONE MUST BE TURNED SIMULTANE-
OUSLY USING EQUAL EFFORT OR INTERNAL DAMAGE TO THE
GUN WILL RESULT FIG. 4.

Fig. 4
G 2-2 COMPETITION PNEUMATIC SPEARGUN original copywriter 1987
revised 1998 - printed 1999

6. Clamp the head in the 24 mm. jaws (A-1) (Fig. 3) and

remove head tip (5) from head body (1) with a 19 mm.
wrench (Fig. 5).
7. Remove shock absorber (2) and insert (3) from head body.
8. Remove shock absorber (2) from shock absorber insert (3).
9. Remove piston (17-18-19) from the barrel. If necessary a
shaft may be used to aid in the removal of the piston
(Fig.6).
10. Remove oil wiper (19) and O-ring (18) from piston (Fig. 6).
11. Using a rotating motion, remove the nose cone (4) and Fig. 5
O-ring (20).
12. Drain the oil contained in the speargun into a suitable
container. Dispose ofwaste oil properly by taking it to a
waste oil recycling facility.
13. Using a rotating motion remove the tank (25), using
clamping jaws (A-3) if needed.
14. Place the barrel in the 18 mm. jaws (A-1) (Fig. 3) and
clamp into vise.
15. Remove barrel 0-ring (22) with tool A-7.
16. Using snap ring pliers remove the barrel bushing (21).
Fig. 6
17. If necessary remove the grip by gently sliding it off the
handle.
18. Remove trigger pin (53) using a pin punch, then remove
trigger (48-52-75).
19. Remove the trigger adjustment screw (48) from trigger
body (52) with a 6 mm. wrench.
20. Remove the trigger insert (75) by depressing the locking
tab and sliding it out of the trigger body (52).

NOTE It is not necessary to remove the trigger adjustment

(48) or the trigger insert (75) from the trigger body Fig. 7
(52) during routine servicing, unless they are to be
replaced.

21. Remove the safety (49) by sliding it out of the handle (41).
22. Remove connecting plunger (45) with special tool A–13
(Ø 3 mm) or needle nose pliers.
23. For Competition Line Spearguns starting from serial
number 92296000 forward, remove connecting plunger
bushing (47) using tool A22 (Fig. 7).
24. For Competition Line Spearguns with serials numbers
92289000 and prior, remove snap fork (74) by inserting,
simultaneously, 2 small screwdrivers or punches through
the holes on either side of the handle. Slightly depress snap
fork with screwdrivers or punches and lift upward (Fig. 8).
Fig. 8
25. Remove connecting plunger O-ring (77).
 original copywriter 1987 COMPETITION PNEUMATIC SPEARGUN G 2-3
revised 1998 - printed 1999

26. Remove line retainer pin (43) with a pin punch, then
remove line retainer (42).
NOTE It is not necessary to remove the line release during
routine service unless the line release is worn, dam-
aged or does not swivel freely on the line release pin.
27. Remove inlet valve (32-46-65-66-67) with inlet valve
wrench (A 4).
28. With a Philips screwdriver, remove the inlet bushing (67)
and spring (66) (Fig. 9).
29. Remove ball (65) from the inlet valve body (32).
30. Remove O-ring (46) from the inlet valve body. Fig. 9

31. Slide handle (41) rearward off of the barrel (26).

32. Remove 0-ring (37) from 0-ring seat (39) of the power
adjustment rod.
33. With a 7 mm wrench, unscrew power adjustment rod
(34-35-37-39) from power adjustment lever (38).

NOTE If the o-ring seat (39) unscrews from power adjust-

ment rod (35), the rod must be completely removed
from power adjustment lever (38) by clamping the rod
with plastic jaws and rotating the handle counter-
clockwise to unscrew the power adjustment rod. After
removing the power adjustment rod put a drop of
o-ring compound (Loctite 270) in the threaded hole of Fig. 10
o-ring seat (39) and tighten it securely on the power
adjustment rod (35).
34. Remove power adjustmnent rod (35-39) and spring (34)
from handle (41).
35. Remove spring (34) from power adjustment rod.
36. Remove power adjustment lever (38) from handle (41).
37. Remove the power adjustmnent rod bushing (36) and
O-ring (37) from handle.
38. Remove 0-ring (20) from handle.
39. With a pin punch, remove catch hook pin (53), catch hook
(50) and spring (44) from the barrel (26).
40. Slide the power regulating block (20-68-69-70) off of the
barrel.
41. Remove one-way housing (69) and one-way seat (68)
from power regulating block (Fig. 10).
42. Remove 0-ring (20) from power regulating block.
43. Remove 0-ring (71) from barrel with tool A-7.
44. Remove snap ring (72).

NOTE It is not necessary to remove the snap ring (72) dur-

ing routine service, unless it or the barrel is to be
replaced.
45. Remove barrel (26) from the jaws.
G 2-4 COMPETITION PNEUMATIC SPEARGUN original copywriter 1987
revised 1998 - printed 1999

CLEANING
The parts used to manufacture MARES spearguns do not require special cleaning. Acids or solvents should not be used
to clean any speargun parts. A clean shop rag can be used to remove any oil or grease that remains on the parts prior to
inspection.

INSPECTION
All O-rings should be replaced during routine servicing (maintenance kit part # 163979). If the following parts are not
replaced, they should be inspected with a jeweler's loop or similar magnifying device, for the flaws listed below. Replace
any part with these flaws.

Barrel (26) Inspect for any scratches or foreign material inside the barrel. Then check
(part # depending on the model) the outer surface for scratches and or chips around the o-ring sealing areas.
Barrel bushing (21) Inspect for any signs of cracks, distortion or brittleness.
(part # 163665)
Snap ring (72) Inspect for any signs of cracks, distortion or brittleness.
(part #163518)
Oil wiper (19) Inspect for any cuts, distortion or foreign material. Any of these flaws may cause
(part # 163866) leakage.
Shock absorber (2) Inspect for any signs or cuts or distortion.
(part # 163856)
Shock absorber insert (3) Inspect for any cracks or distortion.
(part # 163409)
Piston (17) Inspect for any cracks or distortion.
(part # 163608)
Power regulating block (70) Inspect for any cracks or distortion.
(part # 163637)
One-way seat (68) Inspect for any signs of cracks or distortion.
(part # 163635)
Power adjustment rod (35) Inspect the surface of the rod for scratches, distortion or cracks. Also make sure
(part # 163328) that the o-ring seat (39) is securely tightened on the power adjustmment rod.
Handle (41) Inspect for any cracks or distortion. Check all o-ring seating surfaces for any
(part # 163657 w/power adjustment) signs of scratches, distortion or cracks.
(part # 163658 w/power adjustment)
Connecting plunger (45) Inspect the surface for distortion or scratches.
(part # 163674, 2 mm.)
(part # 163344, 3 mm.)
Catch hook (50) Inspect the surface of the catch hook that engages the piston for any signs
(part # 163377) of wear. Replace the catch hook if any signs of wear are present.
Inlet valve (32) Inspect the seating and sealing surfaces for cracks, scratches, distortion or
(part # 163429) foreign material.
Springs Inspect for any signs of distortion.
O-rings Inspect for any cuts, distortion or foreign material. Any of these flaws
(maintenance kit part # 163979) may cause leakage.
Shaft Inspect the shaft for straightness and corrosion. Check the tapered shaft sleeve,
(part depending on the model) washer and line retainer for wear and replace with original Mares parts if necessary.
 original copywriter 1987 COMPETITION PNEUMATIC SPEARGUN G 2-5
revised 1998 - printed 1999

CAUTION !
REPLACE ANY PARTS WITH DAMAGED THREADS. ALL
THREADED PARTS MUST BE CLEAN AND IN GOOD CONDITION.
INSTALLING ANY PART WITH DAMAGED THREADS MAY CAUSE
IT TO CROSS THREAD RESULTING IN DAMAGE TO THE SPEAR-
GUN.

R E A S S E M B LY
NOTE Before reassembly, lightly lubricate all O-rings with
MARES grease (MOBIL PLEX 47 or equivalent).
Lubricating O-rings before installation will minimize
the risk of damage to the o-rings during reassembly.

1. Place the barrel in the 16 mm. jaws (A-1) (Fig. 3) and clamp
into vise (Fig. 11).
2. Install the barrel bushing (21) in the groove of the barrel with
tool A-9, being sure that the side of the bushing with the
smaller diameter is towards the handle of the gun.
(Fig. 11–A).
3. Place O-ring (22) against the barrel bushing (21) with tool
A-9 (Fig. 11-A).
4. Using tool A–7, install the snap ring (72) into the groove of
the barrel, with the square tab facing the front (muzzle end)
of the barrel (Fig. 11-B).

Fig. 11
G 2-6 COMPETITION PNEUMATIC SPEARGUN original copywriter 1987
revised 1998 - printed 1999

5. Place o-ring (71) in the groove of the barrel next to the snap
ring (72) with tool A-7 (Fig. 11-B).
6. Insert the one–way seat (68) into the power regulating block
(70) (Fig. 10).
7. Position the one–way housing (69) over the one-way seat
(68) and press into place (Fig. 12).
8. Place O-ring (20) into the groove of the power regulating
block (70) (Fig. 12).
9. Slide the power regulating block into position over O-ring
(71). Rotate the snap ring and/or power regulating block as
needed to align the one-way housing (69) with the snap
ring seat. (Fig 11-B).
10. Install spring (44) onto catch hook (50) (Fig. 11-C).
Fig. 12
11. Install catch hook (50) with spring (44) attached, into the
barrel and align the hole in the catch hook with the holes in
the barrel and install the catch hook pin (53) (Fig. 11-C).
12. Using an appropriate length shaft with piston (A-16, part #
163608) attached, slide the piston and shaft into the barrel
until it engages the catch hook. Make sure that the catch
hook spring is positioned into its seat.
13. Place O-ring (20) into the groove of the handle (41).

NOTE If the O-ring seat (39) was removed from the power
adjustment rod (35), put a drop of thread compound
(Loctite 270) in the threaded hole of o-ring seat (39)
and tighten it securely on the power adjustment rod
(35).
Fig. 13
14. Slide spring (24) onto power adjustment rod.
15. Slide power adjustment rod bushing (36) onto the power
adjustment rod, with the smaller diameter facing away from
the O-ring seat (39).
16. Place O-ring (37) onto power adjustment rod against the
power adjustment rod bushing (36).

NOTE Place a drop of thread compound (Loctite 242) on the

threads of the power adjustment rod.

17. Insert the power adjustment rod into its hole in the handle
(41), press O-ring (37) and power adjustment rod bushing
(36) into handle.
18. Insert the power adjustment lever (38) into its housing in
the handle, then with a 7 mm wrench, gently tighten the
power adjustment rod onto the power adjustment lever.
19. Place O-ring (37) into the groove of the O-ring seat (39)
using tool (A-12).
20. Slide handle (41) onto barrel (26).
 original copywriter 1987 COMPETITION PNEUMATIC SPEARGUN G 2-7
revised 1998 - printed 1999

NOTE Position the handle (41) with the trigger seat above the
catch hook (50) (Fig. 12-A). Align the power adjust-
ment rod with the corresponding hole in the power
regulating block. If necessary, rotate the power regu-
lating block, making sure the one-way housing
remains in the snap ring seat (Fig. 14-B). Push the
handle against the power regulating block and make
sure that the power regulating block tabs are posi-
tioned in their seats in the handle.

21. Position o-ring (46) in inlet valve body (32) seat, with tool
(A-13) (Fig. 9).
22. Center the inlet ball (65) on o-ring (46).
23. Place spring (66) inside of the inlet bushing (67).

NOTE Applying a small amount of grease on the spring (66)

will retain the spring in the inlet bushing (67) during
assembly.

24. Tighten inlet bushing (67) into valve body (32) using a
Philips screwdriver.

NOTE Apply two or three drops of thread compound (Loctite

242) to the threads of the inlet valve.

25. Insert the inlet valve into handle using the inlet valve wrench
(A4) and tighten securely.

WARNING !
FAILURE TO SECURELY TIGHTEN THE INLET VALVE MAY
CAUSE PARTS TO BE EXPELLED FROM THE SPEARGUN AT
HIGH VELOCITY WHEN THE GUN IS PRESSURIZED, WHICH
MAY CAUSE SERIOUS INJURY OR DEATH.

26. Insert the line release (42) into the handle with the line
release lever oriented towards the same side as the power
adjustment lever. Align the hole in the line release (42) with
the hole in the handle and install line release pin
27. On Competition Line guns starting from serial number
92296000 forward, place bushing (47) and o-ring (46) on
tool A-22 (Fig. 15).
28. Insert bushing (47) and o-ring (46) into lhe handle (41).
Gently tighten the bushing (47) into its housing in the
handle with tool A-22.

CAUTION !
TORQUE BUSHING (47) TO 80 N/CM. (7 lbs.in. approx.)OVER
TIGHTENING THE BUSHING MAY RESULT IN DAMAGE TO THE
HANDLE CAUSING LEAKAGE.
G 2-8 COMPETITION PNEUMATIC SPEARGUN original copywriter 1987
revised 1998 - printed 1999

29. On guns prior to serial number 92289000, place the o-ring

(46) into the handle insuring that it is positioned in its seat
then install the snap fork (74). Be sure that the snap fork
locks into place.
30. Insert the rounded end of the connecting plunger (45) into
the bushing (47) or snap fork (74) using special tool A-13
(Ø 3mm) or needle nose pliers.
31. Insert the safety with the fluorescent tab oriented towards
the same side as the power adjustment lever, making sure
that the notch in the safety faces the trigger.
Fig. 14
32. Install trigger adjustment screw (48) and trigger insert (75)
into trigger body (52) (Fig. 14). With a 6 mm wrench,
tighten trigger adjustment screw (48) into trigger body (52),
until the 6 mm. hex protrudes approximately 4 mm.
33. Align the hole in the trigger with the holes in the handle
(41) and install trigger pin (53).
34. If the grip was removed gently slide it onto the handle.
35. Pull trigger and remove shaft with piston (A-16) attached.
36. Remove piston (A-16, part # 163608) from the shaft.
37. Open the jaws and remove barrel (26).
38. With a rotating motion, install tank (25) using jaws (A-3) if
necessary.
39. Fill the barrel (26) with oil, according to the quantities
shown in the table below.

CAUTION !
USE ONLY CORROSION AND RUST PREVENTING OILS, SUCH
AS MOBIL DTE OIL LIGHT OR SAE 10 W OILS SUITABLE FOR
USE IN HYDROPNEUMATIC SYSTEMS. DO NOT USE GRAPHITE
BASE OILS! THE USE OF OILS NOT SPECIFIED FOR USE IN
HYDROPNEUMATIC SYSTEMS MAY LEAD TO PREMATURE GUN
DAMAGE DUE TO INTERNAL CORROSION.

SPEARGUN OIL QUANTITY IN CC

STEN-MINIMINI 15
STEN-MINI 20
STEN-MEDI 20
OTHER MODELS 30

41. Install the oil wiper (19) on piston making sure that the lip
of the oil wiper faces the metal post of the piston.
42. Insert piston into barrel using caution not to damage oil
wiper.
43. Install o-ring (20) onto the nose cone (4).
44. Using a rotating motion insert the nose cone (4) into tank
(25) and align the nose cone sight with the sight on the
handle.
 original copywriter 1987 COMPETITION PNEUMATIC SPEARGUN G 2-9
revised 1998 - printed 1999

45. Insert the shock absorber insert (3) into the shock absorber
(2) (Fig. 5).
46. Install shock absorber (2) and shock absorber insert (3) into
the head body (1) with the shock absorber facing the head
tip (5) (Fig. 5).
47. Clamp the head body in the 24 mm. jaws (A-1) (Fig. 3)
48. Apply anti-corrosion grease to the threads of the head tip
(5). Tighten the head tip into head body (1) with a 19 mm.
wrench (Fig .5).
49. Apply anti-corrosion grease to the threads of the head body
(1) and install head.
50. Clamp the head (1-2-3-5) in the 24 mm. jaws (A-1) (Fig. 3).
Tighten the head by holding the handle and the nose cone
and simultaneously turning them clockwise using equal
effort (Fig. 4).

CAUTION !
THE HANDLE AND NOSE CONE MUST BE TURNED SIMULTANE-
OUSLY USING EQUAL EFFORT OR INTERNAL DAMAGE TO THE
GUN WILL RESULT (FIG. 4).

51. Remove speargun from jaws .

52. The speargun is now ready to be pressurized. Follow the
instructions in the Pressurizing section of this manual.

NOTE Perform steps 53 and 54 below, after pressurizing,

testing and trigger adjustment (if any), as described in
the following sections of this manual.

53. Install inlet valve cap (33) using a 6 mm Allen wrench.

54. Install protective cover (6) (if any) on head (1-2-3-5).

PRESSURIZING

Competition pneumatic spearguns can be pressurized using the

Mares gun charging yoke (part # 691503) or a Mares hand pump
(part # 691101).

WARNING !
ALWAYS PRESSURIZE THE SPEARGUN WITH THE POWER
ADJUSTMENT LEVER IN THE MAXIMUM “HIGH”POWER
POSITION (FlG. 1). NEVER EXCEED THE MAXIMUM 30 BAR
PRESSURE. FAILURE TO PRESSURIZE THE SPEARGUN IN THE
MAXIMUM "HlGH" POWER POSITION OR OVER PRESSURIZA-
TION MAY CAUSE THE SPEARGUN TO RUPTURE WHICH MAY
CAUSE SERIOUS INJURY OR DEATH.
G 2-10 COMPETITION PNEUMATIC SPEARGUN original copywriter 1987
revised 1998 - printed 1999

P R E S S U R I Z I N G U S I N G M A R E S G U N C H A R G I N G Y O K E ( PA RT # 6 9 1 5 0 3 )

1. Set the power adjustment lever (38) to “maximum high”

power position (Fig. 1).
2. Connect the yoke to the valve of a scuba cylinder.
3. By hand, thread the pressure gauge body into the inlet valve
of the speargun, until the pressure gauge body o-ring seals
against the inlet valve body. Do not tighten with a wrench.
4. Close the purge valve by rotating the thumb wheel clockwise.
5. Slowly open the valve on the scuba cylinder and read the
pressure value on the pressure gauge. When the desired
value is reached, close the valve on the scuba cylinder.

WARNING !
PNEUMATIC SPEARGUNS ARE HIGHLY PRESSURIZED. NEVER
POINT THE SPEARGUN AT YOURSELF OR ANYONE ELSE. VIO-
LATION OF THIS WARNING COULD RESULT IN SERIOUS
INJURY OR DEATH.

6. Open the purge valve by rotating the thumb wheel clockwise

and allow any residual air to escape from the hose.
7. Remove the pressure gauge body from inlet valve.
8. Remove the yoke from the valve of the scuba cylinder.

P R E S S U R I Z I N G U S I N G M A R E S H A N D P U M P ( PA RT # 6 9 1 1 0 1 )

WARNING !
ALWAYS PRESSURIZE THE SPEARGUN WITH THE POWER
ADJUSTMENT LEVER IN THE MAXIMUM “HIGH” POWER POSI-
TION (FlG. 1). NEVER EXCEED THE MAXIMUM 30 BAR PRES-
SURE. FAILURE TO PRESSURIZE THE SPEARGUN IN THE MAX-
IMUM “HIGH” POWER POSITION OR OVER-PRESSURIZATION
MAY CAUSE THE SPEARGUN TO RUPTURE WHICH MAY CAUSE
SERIOUS INJURY OR DEATH.

1. Set the power adjustment lever (38) to maximum “high”

power position (Fig. 1).
2. By hand, thread the hand pump into the inlet valve of the
speargun, until the hand pump o-ring seals against the inlet
valve body.
3. The following pressure table shows the approximate
number of pump strokes required to obtain the pressure
values listed.
 original copywriter 1987 COMPETITION PNEUMATIC SPEARGUN G 2-11
revised 1998 - printed 1999

PRESSURE TANK (bar)

MODEL LENGTH
CM 10 15 20 25 30
NUMBER OF PUMP (Approx.)
STEN–MINIMINI 42 50 75 100 130 170
STEN–MINI 58 100 150 200 250 310
STEN–MEDI 71,5 100 150 250 350 470
STEN LONG 84 150 200 275 375 520
STEN 92 200 250 300 400 570
SUPERSTEN 100 300 350 400 500 660
STEN L 119 345 400 460 575 715
STEN 133 126 300 400 500 600 810

WARNING !
THE NUMBER OF PUMP STROKES LISTED IN THE PRESSURE TABLE REFER TO A COMPLETELY EMPTY SPEARGUN
TANK. IF IT IS NOT POSSIBLE TO DETERMINE THE EXISTING PRESSURE IN THE SPEARGUN, ALL PRESSURE MUST
BE RELEASED FROM THE SPEARGUN PRIOR TO PRESSURIZING IT. IF THE EXISTING PRESSURE IN THE SPEARGUN
IS KNOWN AND IT BECOMES NECESSARY TO ADD PRESSURE, ONLY INCREASE IT THE AMOUNT OF THE DIFFERENCE.
FOR EXAMPLE, TO INCREASE THE PRESSURE OF A FRONTIERSMAN FROM 20 BAR TO 30 BAR, 200 PUMP STROKES
ARE REQUIRED NOT THE FULL 470 PUMP STROKES SHOWN IN THE TABLE. NEVER EXCEED THE MAXIMUM 30 BAR
PRESSURE. OVER-PRESSURIZATION MAY CAUSE THE SPEARGUN TO RUPTURE WHICH MAY CAUSE SERIOUS
INJURY OR DEATH. PNEUMATIC SPEARGUNS ARE HIGHLY PRESSURIZED. NEVER POINT THE SPEARGUN AT YOUR-
SELF OR ANYONE ELSE. VIOLATION OF THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH.

4. Remove the hand pump from the inlet valve.

SPEARGUN INSPECTION AND ADJUSTMENT

To insure the gun is functioning correctly, inspection and adjust-
ment may be needed. The following inspection and adjustment
procedures must be performed with the greatest care and atten-
tion.

WARNING !
FOR THE NECESSARY INSPECTION TO BE PERFORMED, THE
SHAFT MUST BE INSERTED INTO THE SPEARGUN. FOR YOUR
SAFETY, FASTEN THE SHAFT INTO A FLOOR BASE. WHEN THE
SHAFT IS INSERTED, ALWAYS MAINTAIN PRESSURE ON THE
SPEARGUN WITH BOTH HANDS AND KEEP THE HANDLE
UNDER YOUR SHOULDER (FlG. 15-A), NEVER UNDER YOUR O.K. NO
FACE (FIG. 15-B). DO NOT PERFORM ANY ADJUSTMENT OR
LEAVE THE GUN UNATTENDED WHEN THE SHAFT IS INSERTED.
FAILURE TO FASTEN THE SHAFT INTO A FLOOR BASE OR MAIN-
TAIN PRESSURE ON THE SPEARGUN WITH BOTH HANDS AND
KEEP THE HANDLE UNDER YOUR SHOULDER (FlG. 15-A) WHEN
THE SHAFT IS INSERTED, COULD RESULT IN THE SPEAR Fig. 15
SHAFT AND/OR SPEARGUN BEING PROPELLED UNCONTROL-
LABLY, IF THE TRIGGER IS PULLED OR THE SPEARGUN FIRES
UNEXPECTEDLY AND COULD RESULT IN SERIOUS INJURY OR
DEATH.
G 2-12 COMPETITION PNEUMATIC SPEARGUN original copywriter 1987
revised 1998 - printed 1999

A floor base can be made from a piece of metal that is 120 mm.
(4.75 in.) in diameter and 30 mm. (1.25 in.) thick. Locate the cen-
ter point ofthe floor base and drill a hole 16 mm. (5/8 in.) in depth
with a 6.20 mm. bit. Thread the hole using a M 7 x 1 tap (Fig. 16).

NOTE The various inspection steps may be performed con-

secutively.

O-RING INSPECTION
1. Immerse the speargun in water and watch for signs of air Fig. 16
leakage from o-rings and sealing items.

TRIGGER STROKE INSPECTION

1. Using a floor base, insert the shaft until the piston engages
the catch hook (Fig. 15-A).
2. Pull the trigger until the piston disengages. Measure the
trigger stroke. The trigger stroke should be a minimum of
3 mm. to a maximum of 7 mm. If the trigger stroke does not
fall within 3 mm. minimum to 7 mm. maximum, the trigger
sensitivity will need to be adjusted.
3. Remove shaft from speargun.

TRIGGER SENSITIVITY ADJUSTMENT

WARNING !
FOR CORRECT TRIGGER RELEASE SENSITIVITY, THE TRIGGER
STROKE SHOULD BE SET FROM 3 MM MINIMUM TO 7 MM
MAXIMUM. WHENEVER TRIGGER SENSITIVITY IS ADJUSTED,
MAKE SURE THAT THE PISTON FULLY ENGAGES THE CATCH
HOOK. OVER-ADJUSTMENT MAY CAUSE THE PISTON NOT TO
ENGAGE OR TO PARTIALLY ENGAGE THE CATCH HOOK AND
MAY CAUSE THE SPEARGUN TO DISCHARGE UNEXPECTEDLY
WHICH MAY CAUSE SERIOUS INJURY OR DEATH.

1. Move the safety to the “safe” position.

2. Insert a small screwdriver into the trigger adjustment screw
(48).
a. Turn the trigger adjustment screw counterclockwise to
decrease sensitivity.
b. Turn the trigger adjustment screw clockwise to increase
sensitivity.
3. Measure trigger stroke and repeat steps as needed to obtain
the correct adjustment.
 original copywriter 1987 COMPETITION PNEUMATIC SPEARGUN G 2-13
revised 1998 - printed 1999

SAFETY INSPECTION

1. Using a floor base, insert the shaft until the piston engages
the catch hook (Fig. 15-A).
2. Move the safety to the "safe" position.
3. Pull the trigger. The trigger should be locked in position and
the speargun should not fire.
4. Move the safety to the “fire” position.
5. Pull the trigger and remove the shaft from the speargun.

P O W E R R E G U L AT O R I N S P E C T I O N

1. Set the power adjustment lever (38) to minimum "low"

power position (Fig. 1).
2. Using a floor base, insert the shaft until the piston engages
the catch hook (Fig. 15-A).
3. Pull the trigger, take note of the effort exerted by the
speargun and remove the shaft from the speargun.
4. Leave the power adjustment lever (38) in minimum “low”
power position (Fig. 1), for approximately 2 hours.
5. Using a floor base, insert the shaft until the piston engages
the catch hook (Fig. 15-A). The effort exerted by the
speargun should be the same as it was 2 hours previous.
A decrease in the effort would indicate a leak in the
speargun. An increase in effort would indicate an internal
leak past the power regulating block.
6. Pull the trigger and remove the shaft from the speargun.
7. Set the power adjustment lever (38) to maximum “high”
power position (Fig. 1).
G 2-14 COMPETITION PNEUMATIC SPEARGUN original copywriter 1987
revised 1998 - printed 1999

SPEARGUNS STEN Table 216

70 - 115 - 133 “Pipin line” Updated to 01-04-98

Ref. Code Description Ref. Code Description

1 164100 Head body 42 163613 Line release, black
1 164100 Head body A/S (Pipin line) 43 163614 Pin - line release
2 163856 Shock absorber , rubber 44 163313 Spring catch hook
3 163409 Shock absorber insert 45 163344 Connecting plunger 3x17,5
4 164101 Nose cone blue 46 110201 O–Ring – R/ l
4 164009 Nose cone black A/S (Pipin line) 47 164024 Housing – connecting plunger
5 164102 Head ferrule 48 164240 Trigger adjustment screw
6 164138 Protective cap - head 49 164150 Safety, orange
7 163968 Rubber ring - shock 49 164109 Safety, blue
8 163410 Float for Sten 130 50 163377 Catch hook
11 169821 Shock line - m 3 52 163611 Trigger body
11 169818 Shock line - m 5 52 164283 Trigger , Apnea System
12 163355 Line retainer for shaft Ø 8 mm 53 163337 Pin 4x23
13 163354 Spring for shaft Ø 8 mm 54 163682 Leg sheath, Miniministen
14 163505 Washer for shaft Ø 8 mm 55 163366 Short strap with buckle
17 163608 Piston body 56 163381 Long strap with buckle
18 110110 O-ring 2037 - piston 58 163208 Rear Sten 130
19 163866 Oil wiper piston 59 163402 Shackle Sten 130 support
20 110208 O-ring tank - special OR 60 163404 Pin shackle Sten 130 support
21 163665 Bushing 61 *** Screw for shackle Sten 130
22 110206 O-ring 122 bis 62 *** Seeger for pin ø 5 Sten 130
25 164113 Tank, Sten Minimini 65 163808 Ball bearing - inlet valve
25 164114 Tank, Sten Mini 66 163807 Spring - inlet vaive
25 164115 Tank, Sten Medisten 67 163806 Bushing - inlet valve
25 164116 Tank, Sten Long 68 163635 Seat, one way valve
25 163401 Tank Sten 100 Blue 69 163636 Housing, one way valve
25 163347 Tank Sten 115 (Pipin line) 70 163637 Power regulator block
25 163412 Tank Sten 130 Blue 71 110220 O-ring 2062
25 164013 Tank Sten 133 Black (Pipin line) 72 163518 Circlip, power regulator block
26 163362 Barrel, Miniministen
26 163361 Barrel, Ministen
26 163639 Barrel, Medisten
26 163640 Barrel, Medisten L ASSEMBLIES
32 163429 Body - inlet valve A 164103 Head assy blue (1-2-3-5)
33 163679 Cap - inlet valve, orange A 164017 Head assy A/S (Pipin line) (1-2-3-5)
33 164159 Cap - inlet valve, yellow fluo D 163638 Power regulator assy (68-69-70)
33 163432 Cap - inlet valve, black E 163613 Trigger assy (48-52)
33 164039 Cap - inlet valve, blue (Pipin line) G 164153 Handle assembly w/o power adjustment, blue.
34 163325 Spring - power adjustment (41-42-43-46-47-49)
35 163328 Rod - power adjustment H 164155 Handle assembly with power adjustment, blue.
36 1 6362 Bushing - power adjustment H 164031 Handle assembly with power adjustment, black
37 110102 O-ring 2015 - power adjustment (Pipin line). (L-38-41-42-43-46-47-49)
38 163701 Lever, power adjustment black L 163937 Power adjustment assy (34-35-36-37-39)
38 164112 Lever, power adjustment fluo M 163941 Inlet valve assy (32-46-65-66-67)
39 163324 Housing power adjustment N 163629 Piston assy (17-18-19)
41 164120 Handle with power adjustment, blue *** 163979 Complete set O-rings (18-19-20-22-37-46-71)
41 164119 Handle w/o power adjustment, blue *** 163403 Trasparent film (only STEN 130)
 TROUBLESHOOTING
SPEARGUN
TROUBLESHOOTING SPEARGUN
 original copywriter 1987 TROUBLESHOOTING SPEARGUN G 3-1
revised 1998 - printed 1999

SPEARGUN TROUBLESHOOTING

PROBLEM MODEL PROBABLE CAUSE SOLUTION

-1- CYRANO 1) Piston O-ring dirty, defective or damaged. 1) Replace O-ring

AIR LEAK FROM SPARK 2) Piston cap dirty, defective or damaged. 1) Replace piston cap
SPEARHEAD STEN 3) Barrel scratched or damaged 1) Replace barrel
-2- 1) O-ring on power control dirty, defective or 1) Replace O-ring
AIR LEAK CYRANO damaged
FROM POWER SPARK 2) Power control rod scratched or damaged 1) Replace power control rod
CONTROL STEN 3) O-ring seat in handle dirty, defective or damaged 1) Clean or replace the handle
1) Foreign particles in the recharge valve body. 1) Clean recharge valve body
-3-
CYRANO 2) Recharge valve O-ring dirty, defective or damaged. 1) Replace O-ring
AIR LEAK FROM
SPARK
RECHARGE 3) Recharge valve sphere defective or damaged. 1) Replace sphere
STEN
VALVE 4) Seat of O-ring in recharge valve dirty, defective or 1) Clean or replace valve body
damaged.
1) Connecting piston O-ring dirty, defective or 1) Replace O-ring
-4- damaged .
CYRANO
AIR LEAK
SPARK 2) Connecting piston scratched or damaged 1) Replace connecting piston
FROM
STEN 3) Seat of O-ring in handle dirty, defective or 1) Clean or replace the handle
TRIGGER
damaged.
-5- CYRANO 1) O-ring dirty, defective or damaged 1) Replace O-ring
AIR LEAK BETWEEN SPARK 2) Tank damaged 1) Replace tank
TANK AND NOSE STEN 3) Seat of O-ring in nose defective or damaged. 1) Replace nose
-6- CYRANO 1) O-ring dirty, defective or damaged 1) Replace O-ring
AIR LEAK BETWEEN SPARK 2) Tank damaged 1) Replace tank
TANK AND HANDLE STEN 3) O-ring seat in handle defective or damaged. 1) Replace handle
-7- CYRANO 1) Power control in “minimum power” position 1) Place on “maximum power” setting
INSUFFICIENT SPARK 2) Speargun pressure low 1) Check for leaks in the speargun and
POWER STEN repair and/or load the gun
-8-
SHAFT ACCIDENTALLY CYRANO 1) Correctly adjust trigger sensitivity
1) Trigger sensitivity too high
DISCHARGED WITHOUT SPARK
PRESSING TRIGGER STEN

-9-
SHAFT NOT CYRANO
SPARK 1) Trigger sensitivity too low 1) Correctly adjust trigger sensitivity
DISCHARGED WHEN
TRIGGER PRESSED STEN

- 10 -
PRESSING TRIGGER CYRANO 1) Safety catch damaged or defective 1) Replace safety catch
WITH THE SAFETY SPARK
CATCH ON RELEASES STEN 1) Replace trigger
2) Trigger damaged or defective
THE PISTON

- 11 - 1) Speargun excessively pressurized 1) Unload rifle and pressurize correctly

DIFFICULTY CYRANO 2) Piston defective or damaged 1) Replace piston
LOADING SPARK 1) Replace shock absorber bushing
3) Shock absorber bushing defective or damaged
THE SPEARGUN STEN
4) Shaft damaged or bent 1) Replace the shaft
- 12 - 1) Shaft housing in the piston damaged 1) Replace piston
CYRANO
SHAFT DOES NOT 1) Replace shaft tail
SPARK 2) Shaft tail damaged or defective
REMAIN INSIDE THE
STEN 3) Non-original shaft 1) Replace with original shaft
PISTON