LOW PRESSURE INFLATION SYSTEM (LPIS) DRY SUIT INFLATION SYSTEM (DSIS) TECHNICAL MANUAL

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1 LOW PRESSURE INFLATION SYSTEM (LPIS) DRY SUIT INFLATION SYSTEM (DSIS) TECHNICAL MANUAL Rev. 6/17

2 2 LPIS / DSIS Technical Manual COPYRIGHT NOTICE This manual is copyrighted, all rights reserved. It may not, in whole or in part, be copied, photocopied, reproduced, translated or reduced to any electronic medium or machine-readable format without prior consent in writing from Aqua Lung America. It may not be distributed through the internet or computer bulletin board systems without prior consent in writing from Aqua Lung America AQUA LUNG AMERICA. LPIS./DSIS TECHNICAL MANUAL, PN You can contact a Technical Adviser via at: sreilly@aqualung.com grubin@aqualung.com jbutner@aqualung.com Trademark Notice Aqua Lung is a registered trademark of Aqua Lung America, Inc. Warnings, Cautions, & Notes Pay special attention to information provided in warnings, cautions and notes that are accompanied by one of these symbols: A WARNING indicates a procedure or situation that, if not avoided, could result in serious injury or death to the user. A CAUTION indicates any situation or technique that could cause damage to the product and could subsequently result in injury to the user. A NOTE is used to emphasize important points, tips and reminders.

3 3 CONTENTS Introduction...4 Disassembly Procedure...5 Reassembly Procedure...8 Swivel Relief Test Procedure...11 Final Testing Procedure...12 Table 1: Troubleshooting Guide...13 Table 2: List of Tools and Service Kits...14 Table 3: Torque Specifications...17 Table 4: Test Bench Specifications...17 Table 5: Recommended Cleaners and Lubricants...17 Procedure A: Cleaning and Lubricating...18 LPIS / DSIS Exploded View...19 Maintenance Notes...20

4 4 LPIS / DSIS Technical Manual Introduction This manual provides factory prescribed procedures for the correct service and repair of the Aqua Lung product described in this manual. It is not intended to be used as an instructional manual for untrained personnel. The procedures outlined within this manual are to be performed only by personnel who have received Factory Authorized training through an Aqua Lung Service & Repair Seminar. If you do not completely understand all of the procedures outlined in this manual, contact Aqua Lung to speak directly with a Technical Adviser before proceeding any further. Scheduled Service This product should be given the same care and maintenance as life support equipment. It is therefore important to perform scheduled overhaul service for the complete unit, according to the procedures outlined in this manual on a regularly scheduled basis; annually with normal use. Overhaul service may need to be performed more frequently depending on the amount of use it received and environmental condition in which it is used. General Guidelines 1. In order to correctly perform the procedures outlined in this manual, it is important to follow each step exactly in the order given. Read over the entire manual to become familiar with all procedures before attempting to disassemble the product in this manual and to learn which specialty tools and replacement parts will be required. Keep the manual open beside you for reference while performing each procedure. Do not rely on memory. 2. All service and repair should be carried out in a work area specifically set up and equipped for the task. Adequate lighting, cleanliness and easy access to all required tools are essential for an efficient repair facility. 3. As each unit is disassembled, reusable components should be segregated and not allowed to intermix with nonreusable parts or parts from other units. Delicate parts, including inlet fittings and crowns which contain critical seating surfaces, must be protected and isolated from other parts to prevent damage during the cleaning procedure. 4. Use only genuine Aqua Lung parts provided in the overhaul parts kit for this product. DO NOT attempt to substitute an Aqua Lung part with another manufacturer s regardless of any similarity in shape or size. 5. Do not attempt to reuse mandatory replacement parts under any circumstances, regardless of the amount of use the product has received since it was manufactured or last serviced. 6. When reassembling, it is important to follow every torque specification prescribed in this manual, using a calibrated torque wrench. Most parts are made of either marine brass or plastic and can be permanently damaged by excessive stress. General Conventions Unless otherwise instructed, the following terminology and techniques are assumed: 1. When instructed to remove, unscrew, or loosen a threaded part, turn the part counter-clockwise. When instructed to install, screw, or tighten a threaded part, turn the part clockwise. 2. When instructed to OPEN the handwheel, turn the handwheel counter-clockwise. The red indicator ring will not be visible in the handwheel window, this indicates the unit is in the ON position. When instructed to CLOSE the handwheel, turn the handwheel clockwise. The red indicator ring will be visible in the handwheel window, this indicates the unit is in the OFF position. 3. When instructed to depressurize the system, close the handwheel and connect the MP hose to an inflation device. Depress the inflator button on the device for 5 seconds and release for 5 seconds. Repeat this procedure until the system is depressurized. Remove MP hose from inflation device when done. 4. When instructed to fill or refill the cylinder, 3000 PSI (207 BAR) will be the standard fill pressure used for testing purposes in this manual. Upon completion of all testing, fill the cylinder to its full capacity as marked. (Reference the Filling Procedures section of the User s Manual). 5. The following acronyms are used throughout this manual: MP is Medium Pressure; HP is High Pressure: LP is Low Pressure. 6. Numbers in parentheses reference the key numbers on the exploded view parts schematics. For example, in the statement,...remove the o-ring (7) from the crown (8)..., the number 7 is the key number to the crown o-ring. 7. When instructed to remove an o-ring, use the pinch method (see illustration below) if possible, or use a brass or plastic o-ring removal tool. Avoid using hardened steel picks, as they may damage the o-ring sealing surface. All o-rings that are removed are discarded and replaced with brand new o-rings. Pinch Method Press upwards on sides of o-ring to create a protrusion. Grab o-ring or insert o-ring tool at protrusion.

5 5 DISASSEMBLY PROCEDURE NOTE: Before performing any disassembly, refer to the exploded parts drawing, which references all mandatory replacement parts. These parts should be replaced with new service kit parts. Old parts should not be reused under any circumstances, regardless of the regulator age or how much use it has received since it was last used. 4. Using a 9/16" deep socket and flex wrench, unscrew the swivel relief plug assy (17) from the first stage body (32). Separate the MP hose (13) and spacer (12) from the swivel relief plug assy. CAUTION: Use only brass o-ring removal tools when removing o-rings to prevent damaging critical sealing surfaces. Even a small scratch across an o-ring sealing surface could result in leakage. Once an o-ring sealing surface has been damaged, the part must be replaced with new. DO NOT use a dental pick or any other steel instrument, except where instructed. 5. Remove o-rings (14 & 15) from the swivel relief plug (17d). NOTE: Certain components are available in a black or chrome finish. Components in either finish are interchangeable. 6. Hold the swivel relief plug (17d) with a 9/16" wrench. Using a 5 mm hex bit socket and flex wrench, remove the relief valve screw (17a). Black Chrome 1. Open the handwheel (21) and depressurize the system. Ensure the cylinder (39) is completely empty and it contains no air. CAUTION: The relief valve screw (17a) is under spring tension. Use caution when disassembling. 2. Remove the o-ring (10) from inside the MP hose (13) QD fitting using the stainless steel o-ring tool (PN ). 7. Remove the spring (17b), relief valve (17c) and o-ring (16) from the swivel relief plug (17d). Using a magnifier, inspect the internal sealing surface of the relief valve for debris or damage. 3. Remove the hose hat (8) (if equipped) from the MP hose (13). Using the valve core tool, unscrew the schrader valve (9) from the end of the MP hose.

6 6 LPIS / DSIS Technical Manual 8. Unscrew the safety plug (11) from the first stage using a 3/8 socket and flex wrench. 12. Remove the o-ring (25) from the bonnet (24). 9. Unscrew the handwheel retainer (18) using the modified screwdriver. Remove the washer (19), spring (20), handwheel (21), nylon washer (22) and indicator ring (23) from the stem (30). 13. Insert the squared end of the stem (30) into the seat & disc retainer (31) and unscrew it from the first stage body (32). 10. Using the 3/4" socket and flex wrench, unscrew the bonnet (24) from the first stage body (32). Pull the stem assembly out of the bonnet. 14. Using a magnifier, inspect the condition of the crown. There should be no scratches, nicks or dents on the crown seating surface. Crown 15. Remove the pressure gauge (38) using a 7/8 crowfoot and flex wrench. Remove o-ring (35) from the pressure gauge. CAUTION: Be careful not to damage the fill port (36) with the wrench while removing the pressure gauge (38). 11. Remove the back-up ring (26), o-ring (27), brass washer (28) and Teflon washer (29) from the stem (30). NOTE: It is possible that some or all of these parts have remained in the bonnet (24). Check Bonnet 16. Using your fingers, unscrew the fill port cap (34) from the fill port (36). Remove the o-ring (35) from the fill port cap.

7 7 17. Using a 9/16 socket and flex wrench, unscrew the fill port (36) from the first stage body (32). Remove the fill port pin (37) from the fill port. 21. Separate the piston (4) from the retainer cap (2). Remove the spring (7) from the first stage body (32). NOTE: Take care not to lose the fill port pin (37) when removing the fill port (36). It is possible that the fill port pin may have remained in the fill port during removal. 22. Remove o-rings (3 & 5) from the piston (4). Insert the seat extraction tool into the open end of the piston and push out the HP seat (6). 18. Remove the o-ring (35) from the fill port (36) and o-ring (16) from the fill port pin (37). 19. Using your fingers, peel the retainer cover (1) off the retainer cap (2). 23. Secure the strap wrench to the cylinder (39). Using a 1 3/16 crowfoot and flex wrench, unscrew the first stage body (32) from the cylinder. Remove o-ring (33) from the first stage body. 20. Insert the pins on the adjustable spanner wrench into the two holes on top of the retainer cap (2). Unscrew the retainer cap from the first stage body (32). CAUTION: Ensure that the crowfoot is aligned with the wrench flats on the first stage body (32). Do not position the crowfoot over the bonnet opening as this will cause damage, resulting in replacement of the first stage body. NOTE: Before beginning reassembly, perform parts cleaning and lubrication in accordance with Procedure A: Cleaning and Lubricating.

8 8 LPIS / DSIS Technical Manual REASSEMBLY PROCEDURE NOTE: Before performing any reassembly, it is important to inspect all parts, both new and those that are being reused, to ensure that every part and component is perfectly clean and free of any dust, corrosion or blemishes. Before dressing each o-ring with Christo-Lube, check to ensure it is clean, supple and free of any blemish. 2. Thread the first stage body (32) into the cylinder (39) until hand-tight. Secure the strap wrench to the cylinder. Using a 1 3/16 crowfoot and foot pound torque wrench, apply of 25 ft-lbs (33.9 Nm) of torque to the first stage body. WARNING: Use only genuine Aqua Lung parts, sub-assemblies and components whenever assembling any Aqua Lung product. DO NOT attempt to substitute an Aqua Lung part with another manufacturer s, regardless of any similarity in shape, size or appearance. Doing so may render the product unsafe and could result in serious injury or death. CAUTION: Ensure that the crowfoot is aligned with the wrench flats on the first stage body (32). Do not position the crowfoot over the bonnet opening as this will cause damage, resulting in replacement of the first stage body. CAUTION: Before proceeding, visually inspect the cylinder according to Compressed Gas Association (CGA) standards pamphlet (CGA C , "STANDARDS FOR VISUAL INSPECTION OF HIGH PRESSURE ALUMINUM COMPRESSED GAS CYLINDERS"). This inspection requires a visual inspection light. If the cylinder does not pass the visual inspection, it must be serviced or replaced with a new cylinder before it can be assembled and filled. 3. Install o-ring (3) and o-ring (5) onto the piston (4). Closely inspect the edges of new HP seat (6). One edge is sharp and one edge has a bevel. Using your fingers, press the HP seat into the piston with the beveled edge facing out. The HP seat should be flush with the end of the piston. If you are unable to press the HP seat into the piston, place the HP seat on a flat, clean surface (beveled side down) and press the piston shaft down over it. NOTE: Certain cylinders (39) will require hydrostatic re-testing every 5 years. For more information reference Aqua Lung Technical Bulletin: Hydro Testing # This information can be found on the Aqua Lung Military and Professional website at 1. Install o-ring (33) over the threads on the first stage body (32). Lubricate the first 4 to 5 threads on the first stage body with Christo-lube. 4. Place the spring (7) into the first stage body (32). Lightly lubricate the threads on the first stage body. Press the piston (4) into the retainer cap (2) so that the piston head is seated flat against the cap.

9 9 5. Insert the shaft of the piston (4) into the spring (7). Press down on the retainer cap (2) and tighten the cap onto the first stage body (32) until hand tight. Insert the pins on the adjustable spanner wrench into the two holes on top of the retainer cap and tighten until snug. 9. Install o-ring (35) onto the pressure gauge (38). Screw the pressure gauge into the upper HP port on the first stage body (32) until hand tight. Using a 7/8 crowfoot and inch pound torque wrench, tighten the pressure gauge to a value of 45 in-lbs (5 Nm). CAUTION: Be careful not to damage the fill port (36) with the crowfoot while torquing the pressure gauge (38). 6. Install o-ring (16) onto the shaft of the fill port pin (37) and o-ring (35) onto the fill port cap (34). Set the fill port cap to the side, it will be installed after final testing. 10. Install safety plug (11) into the lower port on the first stage body (32) (the side opposite of the fill port 36). Using a 3/8" socket and inch pound torque wrench, torque the safety plug to a value of 90 in-lbs (10.2 Nm). 7. Install o-ring (35) onto the fill port (36). Insert the fill port pin (37), o-ring side first, into the male-threaded end of the fill port. NOTE: DO NOT apply any type of lubricant to the safety plug (11). This will result in the over-torquing of the safety plug. 8. Install the fill port (36) into the lower HP port on the first stage body (32). Using a 9/16 socket and inch pound torque wrench, torque the fill port to a value of 90 in-lbs (10.2 Nm). CAUTION: To avoid damaging the fill port (36), do not over torque. NOTE: Before continuing, closely examine the back-up ring (26). You will note that it has a flat side and a concave side. For correct assembly, the concave side should be against the o-ring (27), as shown in the picture below. O-ring Back-up ring 11. In the following order, place a new Teflon washer (29), brass washer (28), o-ring (27) and back-up ring (26) onto the stem (30).

10 10 LPIS / DSIS Technical Manual 12. Using the squared end of the stem (30), screw the seat & disc retainer into the first stage body (32). Leave the stem in the seat & disc retainer. Place the handwheel (21) over the stem and tighten the seat & disc retainer until finger tight. Remove the handwheel from the stem. 17. Place the handwheel (21) over the indicator ring (23). Place the spring (20) into the handwheel, followed by the washer (19). Using the modified screwdriver, screw the handwheel retainer (18) onto the end of the stem (30) until it will not turn any further. NOTE: DO NOT apply any type of lubricant to the seat & disc retainer prior to installation. 13. Install o-ring (25) onto the bonnet (24) so that the o-ring fits into the groove located above the larger threads. Lubricate the bonnet threads, then pass the bonnet over the stem (30) and thread it into the first stage body (32). CAUTION: If resistance is felt while screwing the handwheel retainer (18) onto the stem (30), stop and start over to avoid cross threading. 18. Using the valve core tool, screw the schrader valve (9) into the QD fitting on the MP hose (13) until hand-tight. Install o-ring (10) into groove inside the QD fitting. The end of the seat extractor tool can be used to push the o-ring into place. Install the hose hat (8) (if equipped) over the QD fitting on the MP hose. 14. Attach a 3/4" socket to a inch pound torque wrench and torque the bonnet (24) to a value of 90 in-lbs (10.2 Nm). 19. Install o-ring (16) onto the relief valve (17c). Place the relief valve (o-ring end first into the relief valve screw end of the swivel relief plug (17d). 15. Place the nylon washer (22) over the stem (30), so it sits on top of the bonnet (24). Face the round edge on the indicator ring (23) outward and thread the indicator ring onto the bonnet until it bottoms out. 16. When the indicator ring (23) bottoms out, turn it slightly counter-clockwise so the corners of the square shaft of the stem (30) point towards the centers of the square cut outs of the indicator ring. Turn an additional 90 counter-clockwise. 20. Place the spring (17b), onto the relief valve (17c).

11 Place a small amount of Christo-Lube onto the threads of the relief valve screw (17a). Use your fingers to install the relief valve screw onto the swivel relief plug (17d) until hand tight. CAUTION: The relief valve screw (17a) is under spring tension. Use caution when assembling. 25. Increase the MP on the first stage regulator to 170 +/- 5 PSI (11.7 +/- 0.3 BAR). During this time the MP should remain stable and no air should leak past the relief holes on the swivel relief plug (17). Increase the MP on the first stage to 205 +/- 5 PSI (14.1 +/- 0.3 BAR). The swivel relief plug can start venting air above 175 PSI (12 BAR) and must vent air by 210 PSI (14 BAR) in order to pass this testing procedure. Turn off the supply cylinder and open the bleed valve on the test gauge to depressurize the system. Remove the swivel relief plug and MP hose assembly from the first stage. Remove the QD adapter and test gauge from the MP hose after testing has been completed. 22. Hold the swivel relief plug (17d) with a 9/16" wrench. Using a 5 mm hex bit socket and inch pound torque wrench, torque the relief valve screw (17a) to a value of 45 in-lbs (5.1 Nm). 23. Install o-rings (15), onto the grooves located on either side of the center hole of the swivel relief plug (17d). Install o-ring (14) onto the threaded end of the swivel relief plug. 26. Pass the threaded end of the swivel relief plug assembly (17) through the swivel on the MP hose (13), followed by the spacer (12). Make sure that both o-rings (15) are covered by the hose swivel. Thread the swivel relief plug assembly into the open port on the first stage body (32). Using a 9/16" deep socket and inch pound torque wrench, torque the relief plug swivel (17d) to a value of 60 in-lbs (6.8 Nm). SWIVEL RELIEF TEST PROCEDURE NOTE: This test will require the use of a first stage regulator with adjustable MP capability, such as the Conshelf XIV. 24. Install the swivel relief plug assembly and MP hose (13) into a MP port on a regulator first stage regulator that is adjusted to a MP of 140 +/- 5 PSI (9.6 +/- 0.3 BAR). Attach the QD adapter and test gauge to the end of the MP hose. Connect the regulator first stage to a supply cylinder filled to 3000 PSI (207 BAR). Slightly open the bleed valve on the test gauge and slowly turn on the supply cylinder. Close the bleed valve and verify the MP is stable. Cycle the bleed valve on the test gauge, let the regulator stand for 30 seconds and re-check the MP after each adjustment.

12 12 LPIS / DSIS Technical Manual FINAL TESTING PROCEDURE WARNING: Compressed air can be highly explosive and is dangerous if misused. Ensure the cylinder valve is opened slowly. Use eye and ear personal protective equipment when performing any tests involving compressed air. First Stage Testing 1. Cycle the handwheel (21) several times to ensure the proper function of the indicator ring (23) and seat & disc retainer (31). Close the handwheel when finished. 2. Install the QD adapter and test gauge onto the end of the MP hose (13). Leave the bleed valve on the test gauge slightly open. 3. Attach the SCUBA fill adapter to the fill port and slowly fill the DSIS / LPIS to 3000 PSI (207 BAR). Do not exceed a fill rate of 500 PSI (34 BAR) per minute. Secure the MP hose (13) and test gauge during the fill process. 4. During the fill process, check for any air leaking from the bleed valve on the test gauge. If an air leak is detected, immediately stop the filling process and refer to Table 1: Troubleshooting Guide section of this manual to determine its possible cause. If no leak is detected, finish filling the cylinder (39) and remove the SCUBA fill adapter from the fill port (36). 5. Ensure the bleed valve on the test gauge is slightly open and slowly open the handwheel (21). While watching the test gauge, slowly close the bleed valve. NOTE: Correct medium pressure for the LPIS / DSIS is 135 ±20 PSI (9.3 ± 1.4 BAR), with an inlet pressure of 3000 PSI (207 BAR). If a stable MP has been achieved, note the pressure indicated on the test gauge. Cycle the bleed valve several times and closely monitor the test gauge for several minutes, making sure the MP has remained stable. If the MP exceeds 155 PSI (10.7 BAR), quickly open the bleed valve and close the handwheel (21). Refer to Table 1 : Troubleshooting Guide section of this manual to determine its possible cause. If the MP rises more than 5 PSI (0.35 BAR) in 5-15 seconds after cycling the bleed valve or "creeps", this indicates a HP leak. Refer to Table 1 : Troubleshooting Guide section of this manual to determine its possible cause. 6. Close the handwheel and open the bleed valve on the test gauge to depressurize the system. Remove the test gauge and QD adapter from the MP hose (13). Immersion Test 1. Slowly open the handwheel and check the pressure gauge (38) reads 3000 PSI (207 BAR) indicating a full cylinder (39). 2. Submerge the entire system in a test tank of clean water. Shake the unit to remove trapped bubbles. Observe any bubbles rising from the submerged system over a five minute period. The recommended time is necessary due to slower bubble formation that occurs in smaller leaks. Bubbles indicate a leak, which requires the system to be disassembled at the source to check sealing surfaces, assembly sequence and component positioning in order to correct the problem. NOTE: Do not confuse bubbles from trapped air with a true leak. If there is an air leak, bubbles will come out in a constant stream. Pressure Drop Test 1. Ensure the unit pressurized with the handwheel (21) in the open position. Check the pressure gauge (38) reads 3000 PSI (207 BAR) indicating a full cylinder. Set the unit in a stable temperature for a minimum of twelve hours. After the time has elapsed, check the pressure gauge reads 3000 PSI (207 BAR). WARNING: If the pressure gauge (38) does not read 3000 PSI (207 BAR) after 12 hours, refer to Table 1: Troubleshooting Guide section of this manual to determine its possible cause. 2. Upon completion of the pressure drop test, ensure all water is removed from unit. Blow clean LP air through the cap (2) holes and fill port (36) to remove excess water. After the unit is dry, refill the unit to 3000 PSI (207 BAR). Close the handwheel (21) when filling is complete and depressurize the unit. 3. Once completely dry, install retainer cover (1) and fill port cap (34). 4. Providing the unit has passed all testing and the cylinder has been filled to 3000 PSI (207 BAR), the LPIS/DSIS is ready for use.

13 13 TABLE 1: TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSE TREATMENT System will not remain depressurized after valve is shut and QD hose is vented. 1. The seat & disc retainer (31) is worn or damaged. 2. The seat & disc retainer crown in first stage body (32) is worn or damaged. 1. The seat & disc retainer (31) is worn or damaged. 2. The seat & disc retainer crown in first stage body (32) is worn or damaged. 1. Replace seat & disc retainer (31) 2. Replace body (32) 1. Replace seat & disc retainer (31) 2. Replace body (32) High or Unstable MP Creep 3. The spring (7) is weakened or damaged. 3. Replace spring (7) 4. The HP seat (6) is worn or damaged. 4. Replace HP seat (6) 5. The HP crown seating surface in first stage body (32) is worn or damaged. 5. Replace body (32) Low MP 1. The spring (7) is weakened or damaged. 1. Replace spring (7) External Air Leak 1. The piston head o-ring (3) or shaft o-ring (5) is worn or damaged. 2. The o-ring grooves on the piston (4) are worn or damaged. 3. The piston head o-ring sealing surface in the retainer cap (2) is worn or damaged. 4. The piston shaft o-ring sealing surface in the first stage body (32) is worn or damaged. 5. Swivel relief plug o-rings (14 & 15) are worn or damaged. 1. Replace o-rings (3 & 5) 2. Replace piston (4) and o-rings (3 & 5) 3. Replace retainer cap (2) 4. Replace first stage body (32) 5. Replace o-rings (14 & 15) QD Hose Fitting leaking Swivel Relief Plug leaks 1. Schrader valve (9) is worn or damaged. 1. Replace schrader valve (9) 2. O-ring (10) in QD is worn or damaged. 2. Replace o-ring (10) 1. O-ring (16) on relief valve (17c) is worn or damaged. 1. Replace o-ring (16) 2. Relief valve (17c) is worn or damaged. 2. Replace relief valve (17c) 1. Spring (17b) is weakened or damaged. 1. Replace spring (17b) Swivel Relief Plug will not set 2. O-ring (16) is worn or damaged. 2. Replace o-ring (16) 3. Relief valve (17c) is worn or damaged. 3. Replace relief valve (17c) NOTE: This is a partial list of problems and recommended treatments. For more information contact your Aqua Lung Technical Service Department for assistance with problems not described in the Table 1 Troubleshooting Guide. CAUTION: Recommended treatments which require disassembly of the DSIS / LPIS must be performed during a complete overhaul, according to the prescribed procedures for scheduled service. Do not attempt to perform partial service.

14 14 LPIS / DSIS Technical Manual TABLE 2: LIST OF TOOLS AND SERVICE KITS PART # DESCRIPTION APPLICATION SEA MK Tool Kit (Tools in addition to those listed below are included in the tool kit. Additional tools are for SEA MK & LV2 service). Tools Kit for servicing LPIS / DSIS and SEA MK / LV Tool Pouch SEA MK Carrying Tools Test Gauge psi Checking medium pressure Repair Mat Service and maintenance Soft Cases MP Test Gauge Cover for MP Test Gauge SCUBA Fill Adaptor Filling Cylinder (39) O-ring Tool (Brass) Removal / Installation of O-rings O-ring Tool SS Removal of MP Hose O-ring (10) Seat Extractor Tool Removal of HP Seat (6) Cylinder Light Inspection of Cylinder (39)

15 15 TABLE 2: LIST OF TOOLS AND SERVICE KITS (CONTINUED) PART # DESCRIPTION APPLICATION 9-BA Magnifier w/illumination Inspection of parts Christo-Lube MCG oz. Parts lubrication Screwdriver Medium Blade (Modified) Removal / Installation of Handwheel Retainer (18) 54325A22 Strap Wrench Retains Cylinder (39) during removal / installation of First Stage Body (32) Flex Wrench 3/8 Drive Removal / Installation of parts FC38A /16 Crowfoot 7/8 Crowfoot Removal / Installation of First Stage Body (32) Removal / Installation of Pressure Gauge (38) /4 Socket 9/16 Socket 3/8 Socket Installation of Bonnet (24) Installation of Fill Port (36) & Swivel Relief Plug (17d) Removal / Installation of Safety Plug (11) Adjustable Spanner Wrench Removal / Installation of Retainer Cap (2) Wrench (9/16 ) Retain Swivel Relief Plug (17d) while removing Relief Valve Screw (17a)

16 16 LPIS / DSIS Technical Manual TABLE 2: LIST OF TOOLS AND SERVICE KITS (CONTINUED) PART # DESCRIPTION APPLICATION 8367A23 5 mm Hex Bit Socket Removal / Installation of Relief Valve Screw (17a) (Not included in SEA MK Tool Kit) Valve Core Tool Removal / Installation of Schrader Valve (9) (Not included in SEA MK Tool Kit) Insert, Tool Vise Jaws Retains Cylinder (39) during removal / installation of First Stage Body (32) (1.5 ft³ cylinder only) (Not included in SEA MK Tool Kit) QD Adapter Test Gauge Adapter - Use in conjunction with Test Gauge (PN ) (Not included in SEA MK Tool Kit) N/A Torque Wrench in-lbs Apply torque to parts listed in Table 4: Torque Specifications (Not included in SEA MK Tool Kit) N/A Torque Wrench ft-lbs Apply torque to parts listed in Table 4: Torque Specifications (Not included in SEA MK Tool Kit) LPIS / DSIS Service Kit Replacement Service Kit Parts NOTE: Photos of tools contained in the SEA tool kit are representative. Tool manufacturers and part numbers are subject to change without notice.

17 17 TABLE 3: TORQUE SPECIFICATIONS PART # DESCRIPTION / KEY ITEM # TORQUE First Stage Body (32) 25 ft-lbs (33.9 Nm) / Screw, Relief Valve (17a) 45 in-lbs (5.1 Nm) / Swivel Plug, w/ Relief (17d) 60 in-lbs (6.8 Nm) Safety Plug (11) 90 in-lbs (10.2 Nm) Bonnet (24) 90 in-lbs (10.2 Nm) Fill Port (36) 90 in-lbs (10.2 Nm) Pressure Gauge (38) 45 in-lbs (5.1 Nm) TABLE 4: TEST BENCH SPECIFICATIONS TEST CONDITION SPECIFICATION Leak Test Inlet 2,500-3,000 psi No leaks allowed MP Inlet 2,500-3,000 psi 135±20 psi Swivel Relief Test 170+/- 5 psi /- 5 psi 170 +/- 5 psi for 30 seconds; no leak. Pressure release can occur from 175 psi minimum and must release by 210 psi maximum to be accepted. TABLE 5: RECOMMENDED CLEANERS AND LUBRICANTS LUBRICANT/CLEANER APPLICATION SOURCE Christo-Lube MCG 111 All o-rings Aqua Lung, PN , or Lubrication Technologies 310 Morton Street Jackson, OH (800) CAUTION: Silicone rubber requires no lubrication or preservative treatment. DO NOT apply grease or spray to silicone rubber parts. Doing so may cause a chemical breakdown and premature deterioration of the material. Oakite #31 Acid bath for reusable stainless steel and brass parts. Oakite Products, Inc. 50 Valley Road Berkeley Heights, NJ CAUTION: Do not use muriatic acid for the cleaning of any parts. Even if strongly diluted, muriatic acid can harm chrome plating and may leave a residue that is harmful to o-ring seals and other parts. White distilled vinegar Liquid dish washing detergent (diluted with warm water) Acid bath for reusable stainless steel and brass parts. Degreaser for brass and stainless steel parts; general cleaning solution for plastic and rubber Household grade Household grade

18 18 LPIS / DSIS Technical Manual Cleaning Brass & Stainless Steel Parts PROCEDURE A: CLEANING AND LUBRICATING 1. Pre-clean in warm, soapy water* using a nylon bristle tooth brush. 2. Thoroughly clean parts in an ultrasonic cleaner filled with soapy water. If there are stubborn deposits, household white distilled vinegar (acetic acid) in an ultrasonic cleaner will work well. DO NOT place plastic, rubber, silicone or anodized aluminum parts in vinegar. 3. Remove parts from the ultrasonic cleaner and rinse with fresh water. If tap water is extremely hard, place the parts in a bath of distilled water to prevent any mineral residue. Agitate lightly and allow to soak for 5-10 minutes. Remove and blow dry with clean, low pressure filtered air and inspect closely to ensure proper cleaning and like-new condition. Cleaning Anodized Aluminum, Plastic & Rubber Parts Anodized aluminum parts and parts made of plastic, rubber or silicone such as box bottoms, box tops, dust caps, diaphragms, etc., may be soaked and cleaned in a solution of warm water mixed with mild dish soap. Use only a soft nylon toothbrush to scrub away any deposits. Rinse in fresh water and thoroughly blow dry, using low pressure filtered air. CAUTION: Do not place plastic, rubber, silicone or anodized aluminum parts in acid solutions. Doing so may alter the physical properties of the component, causing it to prematurely degrade and/or break. Cleaning Hoses 1. Hose fittings: Ultrasonically clean with soapy water*; vinegar OK on tough corrosion (only hose ends). 2. Run soapy water through hose if needed. 3. Thoroughly rinse with fresh water (hang with hose ends down). 4. Blow out hose before installing. Lubrication and Dressing All o-rings should be lubricated with Christo-Lube MCG 111. Dress the o-rings with a very light film of lubricant and remove any visible excess by running the o-ring between thumb and forefinger. Avoid applying excessive amounts of Christo-Lube MCG 111, as this will attract particulate matter that may cause damage to the o-ring. *Soapy water is defined as household grade liquid dishwashing detergent diluted in warm water. CAUTION: Silicone grease and sprays must be strictly avoided, since silicone does not provide adequate lubricity in extreme weather conditions.

19 19 LPIS / DSIS EXPLODED VIEW in-lbs (5.1 Nm) c 17b 17a 45 in-lbs (5.1 Nm) d in-lbs (6.8 Nm) in-lbs (10.2 Nm) in-lbs (10.2 Nm) ft-lbs 25 (33.9 Nm) 90 in-lbs (10.2 Nm) Key # Part # Description Key # Part # Description Kit Service LPIS/DSIS First Stage, Spare Cover, Retainer Cap, Retainer P O-ring (10 pk) Piston P O-ring (20 pk) HP Seat Spring Hose Hat, MP Hose Valve, Schrader P O-ring (10 pk) Safety Plug Spacer, Black Spacer, Chrome 13a...AP0154/1BLK33 Hose Assy, LPIS, 33 QD 13b...AP0154/1BLK Hose Assy, DSIS, 20 QD 13c...AP0154/1BLK6 Hose Assy, DSIS, 6 QD 13d...AP0154/1BLK9 Hose Assy, DSIS, 9 QD P O-ring (10pk) P O-ring (10pk) P O-ring (10pk) Swivel Plug Assy, w/ Relief, Black Swivel Plug Assy, w/ Relief, Chrome 17a Screw, Relief Valve, Black Screw, Relief Valve, Chrome 17b Spring, Relief Valve 17c Valve, Relief 17d Plug, Swivel w / Relief, Black Plug, Swivel w / Relief, Chrome Retainer, Handwheel, Black Washer, Handwheel Spring, Handwheel Handwheel Washer, Nylon Ring, On-Off Indicator Bonnet P O-ring (10 pk) Ring, Back-up P O-ring (25 pk) Washer, Brass Washer, Teflon Stem, On / Off Seat & Disc Retainer Assy Body, First Stage P O-ring (10 pk) Cap, Fill Port P O-ring (10 pk) Port, Fill Pin, Fill Port Pressure Gauge 3000 psi, Black Cylinder, 3.0 ft³ Black, AL Cylinder, 6.0 ft³ Black, AL Cylinder, 1.5 ft³ Black, AL

20 20 LPIS / DSIS Technical Manual MAINTENANCE NOTES

21 MAINTENANCE NOTES 21

22 22 LPIS / DSIS Technical Manual MAINTENANCE NOTES

23 MAINTENANCE NOTES 23

24 LOW PRESSURE INFLATION SYSTEM (LPIS) DRY SUIT INFLATION SYSTEM (DSIS) 2340 Cousteau Court Vista, CA Phone (760) Fax (760) Aqua Lung International

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