SOPRAS SUB JUPITER DIAPHRAGM FIRST STAGE

MAINTENANCE INSTRUCTIONS

Tools required
“C spanner 42 x 3mm (Part No RE 013350007301), 4mm hex wrench, 6mm hex wrench,
25mm ring spanner, 14, 15, 22 mm open ended spanners, intermediate pressure gauge (Part
No RE100260 or RE100265).
Disassembly
1. R emove all hoses and 3/8 plugs (25), 7/16 plugs (26) and O rings (39) and (43)
2. C lamp the valve body (76) vertically in a soft jawed vice with diaphragm end facing
upwards.
3. R emove the adjuster (20) with a 6mm hex wrench. With a “C spanner “ remove end
cap (48).
4. R emove the spring (18) and spring support pad (17).
5. R emove the thrust washer (15) and diaphragm (14) taking care not to damage the
sealing surface in the valve body (76).
6. L ift out the valve needle support pad (13) and the valve needle (72).
7. I nvert the valve body (76) so that the balance chamber (75) is facing upwards.
8. U sing a 6mm hex wrench remove the balance chamber (75)
9. R emove O ring (40) and (43) from the balance chamber (75) then remove the O ring
(9) and the backup ring (8) from inside the balance chamber (75) taking care not to
scratch or damage the sealing surface.
10. Remove the O ring bush (10), control spring (11) and piston assembly (12 & 12b) from
inside the valve body (76). Pull the O ring bush (10) from the control spring (11).
11. Slide the guide bush (12b) from the piston (12).
12. Turn the valve body (76) in the vice so that the yoke is facing upwards.
13. For the “A” clamp version: With a 25mm ring spanner, remove the yoke bolt (27).
Remove the saddle (34), dust cap (0) and yoke (2). Unscrew the hand wheel (1) from
the yoke (2).
14. Remove snap ring (3), filter (4) and two O rings (38) from yoke bolt (27).

13a. For the DIN connector version: With a 6mm hex wrench remove the hand wheel
connector (21). Remove O rings (41) and (42). Pull off the Hand wheel (22).
14a.With a 22mm spanner, remove the hand wheel post (28) and lift off the saddle (34).
Remove filter (23) and O ring (38) from the hand wheel post (25).

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The Regulator is now completely disassembled
Cleaning
All plastic and rubber parts should be washed in warm soapy water and rinsed and dried
thoroughly.

All metal parts should be cleaned in an ultra sonic cleaner using a mild degreaser followed by
a mild acid (citric 5% solution), rinsing thoroughly between baths.
Optimum temperature 60o C.

Note: Protect critical surfaces such as valve orifices and piston knife-edges from contact with
other components (and the cleaning container if not plastic) during ultrasonic cleaning.
Rinse all components thoroughly and blow dry in a clean dry air stream.
Lubrication
Lightly lubricate all O rings, sliding surfaces and any threads exposed to ingress of water.
Replacement parts

Fit a service kit, which contains: All essential O rings, diaphragm (14), thrust washer (15)
backup ring (9), piston (12), Filter (4) (or (23) if DIN).
Reassembly

1. C lamp the valve body (76) in a soft jawed vice with balance chamber end facing
upwards. Fit a 7/16 blanking plug (26) to stop the body slipping.
2. F it the guide bush (12b) onto the piston (12), making sure that the large end of the
piston (12) is enclosed and the sealing surface is visible.
Note: incorrect assembly of the guide bush and piston can result in damage to
the valve orifice.
3. D rop the piston assembly (12 & 12b) into the valve body (76) so that the seal face
contacts the orifice and the piston stem is centralised and pointing upwards.
4. P ush the spring bush (10) into the control spring (11) then drop this assembly, with the
spring bush (10) facing upwards into the valve body (76).
5. F it O ring (40) up to the shoulder of, and O ring (43) into the groove half way along the
balance chamber body (75).
6. Push the backup ring (8) and O ring (9) into the balance chamber (75)
7. S crew the balance chamber (75) into the valve body (76), locking firmly with a 6mm
hex wrench.
Note: The balance chamber should screw all the way in with no resistance. If any
resistance is felt, remove it and check the order and alignment of the
components carefully.

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 8. For the “A” clamp version: Turn the valve body (76) in the vice until the yoke
position is facing upwards. Press O ring (38) into the filter end of the yoke bolt (27)
followed by the filter (4). Push the snap ring (3) into it’s locating groove above the filter:
this is achieved by feeding one corner of the snap ring (3) into its groove, then pressing
the second corner into place. Press the second O ring (38) into the bottom of the yoke
bolt (27).
Note: the snap ring has two tabs that are offset to one side; these should press
down onto the filter.
9. I nsert the yoke bolt (27) through the yoke (2) and the saddle (34), and then screw it
into the valve body (76) tightening to 37 – 42 Nm with a torque wrench. Screw the
hand wheel (1) into the yoke (2) and fit the dust cap (0).
8a. For DIN connector version: Turn the valve body (76) in the vice so that the
connector position is facing upwards. Put O ring (38) into the groove in the end of the
hand wheel post (28), screw the hand wheel post (28) into the valve body (76).

9a. Slide the hand wheel (22) with it’s thread facing upwards onto the hand
wheel post (28). Drop the DIN filter (23) into the hand wheel post (28)
Fit O ring (42) onto the hand wheel connector (21), screw the hand wheel
connector (21) into the hand wheel post (28) and tighten with a 6mm hex key.
Fit the O ring (41) into the hand wheel connector (21).
10. Turn the valve body (76) so that the diaphragm end is facing upwards. Push the valve
needle (72) through the hole in the centre of the valve body (76) and into the piston
(12). Fit the valve needle support pad (13) over the valve needle (72). Press the needle
support pad (13) with two thumbs to ensure that the valve operates.
11. Push the diaphragm (14) and thrust washer (15) under the lip in the valve body (76)
making sure that they are fully seated and the thrust washer (15) is not trapped in the
threads inside the valve body (76).
12. Place and centralise the spring support pad (17) onto the diaphragm. Sit the main
spring (18) onto the support pad (16)
Note: on C90models prior to 2002 there is an isolating washer (15) fitted between the
spring (18) and spring support pad (17)
13. Screw the adjuster (20) into the end cap (48) leaving two threads showing, then screw
the end cap assembly (20 & 48) into the valve body (76) taking care not to disturb the
spring (18) and spring support Pad (17). Tighten the end cap firmly with a “C spanner”.
14. Fit O rings (39) on to 3/8 plugs and low pressure hoses and O rings (43) onto 7/16
plugs and hoses. Screw into appropriate ports ensuring correct hose orientation.
The valve is now fully assembled.

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Final adjustment

1. U sing a 0 – 20 bar gauge connect the regulator to a 200 bar supply

2. The intermediate pressure is adjusted by screwing the adjuster (20) in/out using a
6mm hex key until the valve locks up at 9.5 bar. Purge the regulator 2 or 3 times, then
check again, adjusting to 9.5 bar as necessary. Leave the regulator pressurised for 1
minute, the interstage pressure should not have crept more than x bar. Purge the
regulator fully.
3. A djust the supply pressure to 20 bars; the interstage pressure should not be less than
9.0 bars.
4. F inally, immerse the valve connected to a small cylinder in a water bath and check for
air leaks.

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 SOPRAS SUB JUPITER FIRST STAGE PARTS

Italiano English
No. Position
Codice
Denominazione number
Name
0 Tappo antipolvere 0 Dust cap
01 Galletto nylon 01 Hand wheel
02 Nuovo Staffa Int. 02 Yoke
03 Clips tenuta filtro 0 3 Snap ring
04 Filtro conico int 0 4 Conical filter (“A” clamp)
08 BK antiestrusione 08 Backup ring
09 O ring 2.90 X 1.78 mm 09 O ring 2.90 X 1.78 mm
10 Boccola fermo O ring 10 O ring bush
11 Molla ritorno pistoncino 11 Control spring
12 Pistoncino (pat system) 1 2 Piston (patented)
12b Boccola guida 12b Guide bush
13 Piattello spinta 13 Needle support pad
14 Membrana 14 Diaphragm
15 Rondella membrana 15 Thrust washer
17 Ghiera porta molla 1 6 Spring support pad
18 Molla taratura 18 Main spring
20 Ghiera regolazione 20 Adjuster
25 Tappo LP 3/8 25 LP plug 3/8 UNF
26 Tappo HP 7/16 26 HP plug 7/16 UNF
27 Bloccastaffa 2 7 Yoke bolt
34 Sella “compact” 3 4 Nylon saddle
38 O ring 9.19 X 1.78 mm 38 O ring 9.19 X 1.78 mm
39 O ring 7.66 X 1.78 mm 39 O ring 7.66 X 1.78 mm
40 O ring 14.0 X 1.78 mm 40 O ring 14.0 X 1.78 mm
43 O ring 8.73 X 1.78 mm 43 O ring 8.73 X 1.78 mm
48 Cappellotto 48 End cap
72 Astina guida 72 Valve needle
75 Camera billanc monolit 75 Balance chamber housing
76 Corpo MF 4 76 Valve body
DIN connector version
21 Raccordo volantino 21 Hand wheel connector
22 Volantino DIN 200 Bar 22 Hand wheel (200 bar DIN)
23 Filtro conico DIN 23 Conical filter DIN
28 Fermo Volant 200 bar 28 Hand wheel post (DIN 200 bar)
41 O ring 11.91 X 2.63 mm 41 O ring 11.91 X 2.63 mm
42 O ring 10.82 X 1.78 mm 42 O ring 10.82 X 1.78 mm

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 SOPRAS SUB VENUS SECOND STAGE

MAINTENANCE INSTRUCTIONS

Tools required: 17 & 18mm open ended spanners, 5mm hex key, large bent nose
tweezers, 11mm straight screwdriver, nose pliers and in line adjusting tool RE 100425.
Disassembly

1. D isconnect the regulator from its hose; slide back the hose protector (13), hold the
lock-nut (12) with an 18mm spanner, then turn the hose connector with a 17mm
spanner.
2. U nscrew the cover-retaining ring (28) from the case (3) and remove the cover
assembly (25-27).
3. R emove the diaphragm (24).
4. T o release the purge button (27) from inside the front cover (25), push the open end
of a 10mm socket against the tabs on the purge button (27). Lift out the conical
spring (26).
5. C ut the mouthpiece clip (2) then pull off the mouthpiece (1) from its spigot.
6. Turn the regulator case (2) so that the exhaust tee (30) is uppermost and the
diaphragm opening is facing you. Prise the exhaust tee (30) up and off its locating
peg, and then pull it towards you so that it disengages from the tab on the regulator
body (2).
7. P ull out the exhaust valves (29) X 2
8. R emove the handgrip locking screw (22) using a 5mm hex key, then pull off the
handgrip (21).
9. U sing a 11mm straight screwdriver, unscrew and remove the spring adjusting screw
(20) and the spring (19). Remove the O ring (11) from the spring adjusting screw
(20).
10. With a pair of nose pliers pull out the spring clip (16) from the flow regulator (18)
inside the regulator case (3).
11. Slide the flow regulator (18) out of the case (3) by pulling firmly. Remove the O ring
(17) from the flow regulator (18).
12. Lift out the lever (23).
13. Rotate the venturi nozzle (15) towards the diaphragm position and slide it towards
the flow regulator opening so that it disengages from the demand valve connector
(14), then lift it out of the case (3).
14. With an 18mm spanner remove the locknut (12), then slide the valve housing (8)
inwards and remove it from the case (3).
15. Gently pull the demand valve connector (14) off the piston stem (6).

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 16. Using a pair of large pointed tweezers, unscrew the bearing (5) form the valve
housing (8). Remove piston (6) from of the valve housing (8). Remove O ring (9)
form the valve housing (8).
17. Remove the seat (7) from the piston (6).
18. Unscrew the valve orifice (10) from the housing (8) and remove its O ring (11).
Finally remove the O ring (9) from the valve housing (8).

The regulator is now completely disassembled.

Cleaning
All plastic and rubber parts should be washed in warm soapy water, rinsed, and dried
thoroughly.

All metal parts should be cleaned in an ultra sonic cleaner using a mild degreaser followed
by a mild acid (e.g. citric 5% solution), rinsing thoroughly between baths.
Optimum bath temperature 60o C.

Note: Protect critical surfaces such as the valve orifice knife-edge from contact with other
components (and the cleaning container if not plastic) during ultrasonic cleaning.
Rinse all components thoroughly and blow dry in a clean dry air stream.
Inspection

1. I nspect the exhaust sealing surfaces of the case (3) for damage. Inspect all moving
parts for wear, distortion and damage.
2. I nspect sealing surfaces, particularly of the valve orifice (10) for damage.
3. C heck the case (2) for cracks and the mouthpiece (1) for holes and cuts.
4. C heck the diaphragm (24) for swelling, holes and distortion.

Replace
The service kit contains all essential O rings, exhaust valves, seat (7) diaphragm (24) and
a mouthpiece. All other parts should be reused or replaced as indicated by inspection.
Lubrication
Do not lubricate the orifice O ring (10) all other O rings, sliding surfaces and threads
exposed to ingress of water should be lightly lubricated.
Reassembly

1. F it the two exhaust valves (29) by pulling their extension beads through the holes in
the case (3) from the exhaust side. Ensure that the sealing edges of the exhaust
valves are sitting evenly on the sealing surfaces of the case.
2. F it O ring (11) to the valve orifice (10) and then push the valve orifice into the valve
housing (8) from the hose connection side, screw it in with a 5mm hex key until it is
approximately 10.4mm from the edge of the valve housing to the face of the orifice.
3. F it the O ring (9) to the valve housing (8).

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4. F it a new seat (7) to the piston (6). Push the piston (6) through the bearing (5) so
that the two holes in the bearing (5) are facing away from the seat (7).
5. S crew the piston and bearing assembly (5 -7) into valve housing (8) until the face of
the bearing (5) is level with bottom of the central (deepest) notch in the valve
housing (8). Make sure that the piston moves freely.
Note: If the bearing (5) is allowed to protrude above or sit below the level of
the deep notch in the valve housing (8) correct operation of the regulator will
be impeded.
6. P ush the valve housing assembly (5-11) into the inside of the case (3) ensuring that
the central notch is to the back of the case so that the lever slot will be parallel with
the diaphragm. Screw the locknut (12) onto the housing (8) and tighten firmly (15-20
Nm).
Note: make sure that the turned edge of the locknut (12) faces the regulator
case.
7. P ush the demand valve connector (14) over the piston (6) whilst locating its tab into
the bottom (deepest) notch in the valve housing (8).
8. P ush the blind end of the injector (15) into the flow adjuster opening in the case (3)
and slide the open end over the demand valve connector (14).
9. E nsure that the tab on the demand valve connector (14) is located in the central
(deepest) notch in the valve housing (8)
Note: make sure that the tab remains engaged in this notch throughout the
following assembly procedure.
10. Fit the O ring (17) into the inner (widest) groove in the flow regulator (18).
11. Hold the regulator case so that the regulator housing/injection assembly is vertical
with the hose connector pointing downwards. Fit the lever (23) into its groove in the
valve housing (8) and under the valve connector (14).
Note: make sure that the lever tabs remain in the groove throughout the
following assembly procedure.
12. When the lever (23) is securely in place, rotate the injector nozzle (15) into the
mouthpiece opening in the case (3).
13. Push the flow regulator (18) into the regulator case (3) so that the two tabs engage
with the angular protrusion on the injector (15). Make sure that the regulator body
(18) is pushed fully in and that its lug is engaged in the notch in the regulator case
(3).
14. Using a pair of nose pliers, push the spring clip (16) with its long side facing
outward into the groove in the flow regulator.
15. Fit the O ring (11) onto the spring adjusting screw (20) then drop the spring into the
flow regulator (18) making sure that it engages on the shoulder of the injector (15).
16. Screw in the adjusting screw (20) until its face is 2mm below the edge of the flow
regulator (18).

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 17. Turn the flow regulator backwards and forwards two or three times while watching
the moving components to ensure that they are correctly engaged and properly
fixed.
18. Press the lever (23) two or three times to ensure its free movement.
19. Refit the exhaust tee (30) by engaging the tapered edge of the slot in the exhaust
tee with the tab on the regulator case, and then press the hole in the exhaust tee
over the peg on the bottom of the regulator case (3).

Set the lever height

20. With no air turned on, hold the valve case (3) horizontal and put the diaphragm (24)
(without the front cover and locking ring) into position on the case. With a 5mm hex
key turn the valve orifice (10) in or out, until the lever just touches the diaphragm’s
wear plate.
21. Put the conical spring (26) with its wide end inwards into the front cover (25).
Holding the cover so that the open wave styling is at the top. Ensuring the name is
horizontal; Press the purge button (27) into place.
22. Place front cover (25) into the retaining ring (28) push the diaphragm (24) into the
front cover assembly (25-28) so that the wear plate is facing outwards (towards the
lever) (23).
23. Screw the front cover assembly (24-28) onto the regulator case (3) making sure that
the name on the purge button (27) is horizontal. Tighten firmly, hand tight.
24. Fit the mouthpiece (1) and lock in place with a clip (2)
Note: Do not fit adjusting hand wheel (21) and its screw (22) until final adjustments
are complete.
The regulator is now reassembled for final adjustment (See final adjustment 6).

Final adjustments
1. C onnect a first stage with a 200bar supply and 9.5 bar intermediate pressure to the
second stage regulator.
2. If there is any airflow from the second stage valve turn off, purge and disconnect the
hose, then screw valve orifice (10) 15 minutes clockwise and then reconnect the
hose and turn on the supply. There should not be any airflow.
3. C onnect a manometer or magnahelic gauge to the mouthpiece, the inhalation
resistance should be approximately 40mm H2O, if not, adjust the spring adjusting
screw (20) in, to increase or out to decrease the inhalation resistance.
4. W ith the air supply turned on shake the valve gently from front to back. There
should be no rattling sound caused by the lever being set too low and striking the
wear plate, if there is, switch off the air supply, purge and disconnect the hose; turn
the orifice (10) anticlockwise until the rattle just disappears. Recheck with the air
supply turned on.
5. R echeck the breathing resistance and if necessary readjust by turning the spring
adjusting screw (20) as above.

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 6. F inally, fit the adjusting hand wheel (21) and insert the screw (22) tightening it
snugly against the adjusting hand wheel.
Note: do not over tighten this screw (22) as it may distort the hand wheel (21) and change
the setting of the spring adjusting screw (20).
7. Dry Test: turn off the air supply and purge, and then inhale firmly on the
mouthpiece. There should be no sensation of air being drawn into the second
stage.
8. Wet test: connect the regulator first stage to a small cylinder and immerse the
assembly in water. Check for leaks from all connections, covers and plugs and from
the second stage mouthpiece. There should be none.
If all is ok, the service is complete.

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