1. Prestige ex 2000 TECHNICAL MANUAL 2ND STAGE
A Manual for Repair and Maintenance Technicians

2. CAUTION
This manual is designed to help technicians who are already experienced
in workshop procedures and know how to handle tools.
Only experienced technicians should attempt to use this manual.
Improper use of tools could result in personal injury to the user, the
technician or at the least damage to the regulator.
To use this presentation effectively a parts exploded view must be on hand to determine the correct assembly order plus to check if any parts are missing prior to reassembly.

3. ex 2000 TOOLING REQUIREMENTS Apollo seat carrier adjusting tool
P/No
6” Flat blade screwdriver
O ring pick
Tweezers
12mm open end spanner
11/16” open end spanner
3/4” open end spanner
Apollo valve cone adjusting tool
P/No
ex 2000

4. (Adjust Inhalation Effort)
FEATURES
VENTURI CONTROL
(Adjust Airflow)
SENSATIVITY CONTROL
(Adjust Inhalation Effort)

5. DISASSEMBLY The ‘ex 2000’ has a unique ball and socket swivel hose.
To remove the hose, first
slide back the rubber cover.

6. DISASSEMBLY An 11/16” open end spanner and 3/4“
spanner are used to remove the hose
from the 2nd stage.
Disconnect the hose from the
2nd stage.

7. DISASSEMBLY To remove the front cover a small metal lock must be
disengaged. The lock is shown
inside the red circle.
Use a small screw driver or an
o ring pick and gently prise the
lock towards the hose fitting.
At the same time turn the cover
one quarter turn counter-clockwise.

8. DISASSEMBLY Remover the cover and place to one side.
The diaphragm snap ring is
removed next. A screw driver
can be used to engage the lock
ring as shown.
Turn the lock counter-clockwise.

9. DISASSEMBLY Remove the snap ring, then remove the diaphragm cover

10. DISASSEMBLY Lift out the diaphragm. Use an 11/16“ spanner and
undo the valve cone holder.
NB: If tight use two spanners,
one on the cone holder and one
to hold the valve housing.

11. DISASSEMBLY The valve cone is inside the holder,
(sometimes called a hose connector)
place the cone and holder to one side.
The valve cone will be removed later
for cleaning and inspection.
The seat carrier adjusting tool
Part No is used
to compress the valve seat
carrier spring to enable removal
of the demand lever.

12. DISASSEMBLY Carefully remove the demand lever one leg at the time.
Remember to keep the spring
compressed until the lever is
completely removed.

13. DISASSEMBLY The valve and spring can now be removed by tilting the
housing.
Remove the two seat carrier
o rings and discard.

14. DISASSEMBLY The tip of the valve will have a slight
witness mark plus a hole due to the
moulding process. This hole is not
cause for rejection. With normal
use the valve has a life expectancy
of approx. 3 years.
To take off the adjusting knob
the screw cover must be removed.
Gently prise up the cover using an
o ring pick.

15. DISASSEMBLY Place the cover to one side.
Using a flat blade screw driver
remove the knob retaining screw.

16. DISASSEMBLY Remove the knob and place to one side.
Remove the exhaust cover. This is
accomplished by depressing the
metal lock below the mouthpiece
and turning the cover a quarter turn
counter clockwise.

17. DISASSEMBLY Remove the cover and place to one side.
Use a 12mm open end spanner to
undo the bonnet. If the bonnet is
very tight use an 11/16“ spanner
to hold the opposite end of the
valve housing.

18. DISASSEMBLY Remove the bonnet, the adjusting
shaft and nut as a sub-assembly
and place to one side.
Next slide the valve housing
from the bottom box.
Take care not to damage the air
flow tube, it is held in position by
the valve housing.

19. DISASSEMBLY Slide the air flow tube off the
air flow adjuster to remove.
The air flow adjuster is held in
position by a spring clip.
Grasp the head of the clip with
tweezers and simply pull to
remove.

20. DISASSEMBLY The air flow adjuster is removed
through the top of the bottom box.
Push from underneath, it could be
tight due to o ring friction.
The disassembly is complete except for the following sub-assemblies.

21. DISASSEMBLY Separate the adjusting assy. From
the bonnet. Then separate the nut
from the shaft.
DO NOT separate the plastic balance cylinder from
the adjusting nut unless either part is damaged.
Separate the valve cone from the
valve cone holder. Turn counter-
clockwise with a screw driver until
the thread is disengaged.
Push the valve cone out using a soft
probe so as not to damage the tip.

22. INSPECTION & CLEANING
A quick check of parts to be reused is carried out prior to cleaning.
This will ensure you do not clean obviously defective parts.
All metal parts are cleaned using white vinegar. The vinegar may
be diluted using water, however diluting usually only means a
longer soak period before the parts are clean.
Only leave the parts in the vinegar bath until clean, do not leave in
the bath for prolonged periods. Eg; hours or over night.
The parts must be rinsed in warm to hot fresh water after removal
from the acid bath, this helps to neutralise the acid.
Blow dry with clean filtered air.
Metal parts must now be carefully inspected prior to refitting.

23. INSPECTION & CLEANING
Non-metal parts eg; exhaust valve, bottom box, diaphragm etc.
are cleaned by washing in warm water and a mild liquid detergent.
Gentle scrubbing with a tooth brush will help remove stains.
Parts should be rinsed in fresh water after washing.
Parts must be carefully inspected for defects before refitting.
Ensure ALL parts are inspected prior to refitting.
Following are some areas presenting common problems.

24. INSPECTION Inspect the demand lever for distortion and misalignment
of the legs.
Gently stretch the diaphragm,
hold it towards the light and
check for perforations.
Next check for swelling due to
chemical contamination.

25. INSPECTION Carefully examine the tip of the valve
cone for damage or imperfections.
Check to ensure the air flow adjuster
stop pin is not missing or damaged.

26. ASSEMBLY
All o rings and threads should be lubricated prior to assembly.
Dynamic o rings should be liberally lubricated, static o rings
and threads should be very lightly lubricated.
DO NOT lubricate all parts and then assemble, lubrication
should be carried out immediately prior to assembly.
(This avoids collecting dust particles.)
DO NOT use silicone spray as a lubricant.
DO NOT spray plastic components with silicone spray.
Suitable lubricants for Apollo 2nd stages are ‘Food grade’
silicone grease or ‘Christo-lube’ except where mentioned in
the text.

27. ASSEMBLY Sub-assemblies will be assembled first.
Lightly lubricate and install the o ring
into it’s groove on the valve cone holder.
Lubricate and install the o ring on the
valve cone. Lightly lubricate the thread.

28. ASSEMBLY Install the valve cone into the holder,
there is no need to screw the valve
home at this time. Place this sub-assy.
to one side.
Install the teflon washer onto the
adjusting shaft.

29. ASSEMBLY Lubricate and install the o ring into
the groove on the adjusting shaft.
The shaft o ring and the adjusting
thread are dynamic ensure they
are well lubricated.

30. ASSEMBLY The adjusting nut, together with the
balance cylinder are now installed
onto the adjusting shaft.
This is a left hand thread,screw the
shaft into the nut until it bottoms but
do not tighten.

31. ASSEMBLY The bonnet o ring is now installed.
The adjusting shaft sub-assy. is
now fitted to the bonnet.

32. ASSEMBLY The completed sub-assy. should
appear as the picture on the right.
Next install the o ring onto the
valve housing.
Remember to ensure the o ring
is against the shoulder as shown.

33. ASSEMBLY Lubricate and install the air flow adjuster shaft o ring.
Be sure to fit it to the correct groove.
Install the air flow adjuster into the
bottom box, aligning the stop pin.

34. ASSEMBLY Secure the air flow adjuster by
installing the spring clip as shown.
The air flow tube can now be fitted.
Ensure the round hole in the tube is
facing the diaphragm. The elliptical
hole faces the mouthpiece.

35. ASSEMBLY Ensuring the air flow tube does not
become dislodged install the valve
housing.
The housing outlet hole MUST be
engaged with air flow tube.
Fitting upside down will result in
poor performance.
Install the bonnet and adjusting
shaft assembly and tighten using
a 12mm open end spanner.

36. ASSEMBLY Two new valve seat carrier o rings
are to be fitted to the grooves in
the seat carrier end.
NOTE: These are self lubricating.
The carrier spring is installed onto
the carrier.
NOTE: The spring is tapered, the
small diameter slides onto the carrier
and rests against the shoulder as
shown.

37. ASSEMBLY The carrier and spring are placed into the valve housing.
2nd stage Adjusting wrench Part
No is used to
compress the carrier spring.

38. ASSEMBLY When compressing the spring the adjusting wrench must be hard
against the valve housing as shown.
Failure to observe this rule will result
in the incorrect positioning of the
demand lever.
While holding the carried spring
compressed install the demand
lever, gently fitting one leg at a time.
If any doubt exists whether the lever
legs have been bent the lever must
be removed inspected and refitted.

39. ASSEMBLY Depress the lever several times to ensure smooth operation.
Next install the valve cone holder
assembly.
Tighten the valve cone holder using
an 11/16” spanner.

40. ASSEMBLY At this point the valve cone can be roughly adjusted.
Using a screw driver turn the cone
clockwise until the demand lever
starts to drop.
This will require readjusting later.
Fit the adjusting knob to the
adjusting shaft.

41. ASSEMBLY Install the adjusting knob retaining
screw and tighten using a screw
driver.
The adjusting knob cap is now
gently pressed into position.

42. ASSEMBLY The adjusting knob cap should be flush around the edges if
fitted correctly.
The 2nd stage diaphragm is installed.
NOTE: Use no lubricants or sprays on
the diaphragm or it’s seating area.

43. ASSEMBLY The cover ring is placed on top of the diaphragm.
Install the diaphragm snap ring,
the four legs face upper most.

44. ASSEMBLY Tighten the snap ring using a screw driver as shown.
The front cover can now fitted.
The cover has a quarter turn
bayonet type screw.
Engage as shown and turn
clockwise until the metal lock
engages.

45. ASSEMBLY The exhaust tee is refitted, again
with a quarter turn clockwise until
the metal lock engages.
The basic assembly is now complete.
The 2nd stage must now be tuned and
tested. Ideally the first stage used for
the test and tuning should be the same
first stage the unit will be used with for
diving.

46. TEST & TUNING Adjusting tool Part No. 319-02-00-014
is used for tuning the 2nd stage.
A standard hose assembly must be
used with this tool. The o ring sealing
surfaces are different on the new ball
joint hose.

47. TEST & TUNING NOTE: If you have already fitted the
bonnet o ring shown, it must be
removed for using the adjusting tool.

48. TEST & TUNING Install the adjusting tool to the 2nd stage.
Remember to use a standard hose.
The adjusting knob must be pre-set
prior to tuning the valve cone.
The adjusting knob is turned counter-
clockwise until it stops, then turned
clockwise one half turn.

49. TEST & TUNING Couple the hose assembly to the
1st stage. (Ensure the correct
intermediate pressure 9.8 kg/cm2)
With the air supply ‘on’ push the tool hand
wheel in against the pressure and engage
the screw driver slot. Turn the hand wheel
counter clockwise until a slight free flow is
heard, then turn back to stop the free flow.
Purge the 2nd stage several times, listen for
free flowing. If free flow is present, re-adjust.

50. ASSEMBLY The adjusting tool must be removed to
carry out the flow (breathing) test.
Lightly lubricate and install the bonnet
o ring as shown.

51. ASSEMBLY Install the ball joint hose assembly
and tighten using an 11/16” and 3/4”
spanners
Slide the rubber boot assembly
back into position.

52. The assembly is now complete.
Final testing involves checking for
air leaks and carry out the flow test.
The flow test is simply turning the
flow adjuster and checking that
the regulator has a venturi flow.
If NO venturi flow occurs:
Check your air source is
turned fully on.
Check the intermediate
pressure is correct.
Check the valve cone is
adjusted correctly.

53. HOSE ASSEMBLY (Appendix)
If necessary the ball joint hose
maybe dismantled, cleaned and
lubricated as follows.
Two 3/4” open spanners are used
to split apart the ball housing.

54. HOSE ASSEMBLY (Appendix)
Remove the coupling section of the
housing.
Check the o ring and thread for damage.

55. HOSE ASSEMBLY (Appendix)
To gain access to the o ring behind the
ball, slide the housing towards the hose.
The o ring shown sits against the rear
shoulder. Carefully remove with an
o ring pick. Take care NOT to scratch
the sealing area.
The coupling cannot be completely removed from the hose end.
The hose ends and metal parts may be placed in your acid bath
for cleaning etc.

56. HOSE ASSEMBLY (Appendix)
Lightly lubricate the o rings before fitting.
Care must be taken to ensure the o ring
behind the ball is sitting correctly on the
shoulder. If not, the o ring will be pinched
and damaged when tightening the coupling
halves together.
Lightly lubricate the thread and fit the
coupling to the hose end.

57. HOSE ASSEMBLY (Appendix)
Tighten the coupling using two 3/4”
open end spanners. The fitting must
be firm only, do not over tighten
The hose assembly is now ready
for service.