5.4 PRELIMINARY ASSEMBLY OF THE SECOND STAGE
5.4.1 Ensure that all parts are clean. To determine the identity of each O-ring in the Second Stage Service
Kit, remove them from the bag and use the O-ring Identification Chart on the back page of this section. Lay
each O-ring over its corresponding picture on the page and read the description.
Before installing new O-rings into the regulator, lightly lubricate the O-rings with Dow-Corning 111® Silicone
Grease or LTI Christo-Lube 111® (EXCEPT O-ring (9) that goes over the valve tube (21) male threaded
end).
5.4.2 Install the exhaust valve (14) into the case by inserting the nipple into the square hole from the outside
of the case. Reach inside the case and pull the nipple firmly with the fingers until you hear or feel it “click”
into place. Inspect the exhaust valve to see that it is properly seated. Take care not to get any lubricating
grease on the exhaust valve during this procedure.
5.4.3 Install a new O-ring (27) onto the outside of the valve tube (21).
5.4.4 If the lever (19) was removed, carefully re-fit it into the valve tube (21). To orient the
lever properly, hold the valve tube with the external threads to the left. Turn the valve tube until you can see
the hole where the air exits the valve tube (indicated by the arrow in photo). The lever is inserted so that
it hangs down and curves leans to the right. See Photo 9. Work the lever into the valve tube one foot at a
time so the lever legs are spread outwards as little as possible.
5.4.5 Insert the new seating seal (22) into the white piston (23).
5.4.6 Install the lubricated small O-ring (24) onto the piston tip.
5.4.7 Install the spring (25) onto the piston and the balance cylinder (26) onto the piston to make the shuttle
valve assembly.
5.4.8 Insert the shuttle valve assembly you have just assembled, into the valve tube (21) at the end with the
raised collar (opposite the external threaded end). See Photo 10.
Photo 9
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