TECHNICAL MANUAL - Aqua Lung · This manual provides factory prescribed procedures for the correct service and repair of this Aqua Lung® product. It is not intended to be used as

TECHNICAL MANUAL

SEA-3000 LW & 4500(Survival Egress Air)

Rev. 4/17

Blue = Pantone 2728C

Primary/Preferred Branding

Secondary Branding

Tertiary Branding

2 SEA-3000 LW & 4500 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.

©2017 AQUA LUNG AMERICA. SEA-3000LW & 4500 TECHNICAL MANUAL, PN 103643

You can contact a Technical Adviser via e-mail at: [email protected] [email protected] [email protected]

Warnings, Cautions, & NotesPay special attention to information provided in warnings, cautions and notes that are accompanied by one of these symbols:

Trademark NoticeAqua Lung® is a registered trademark of Aqua Lung America, Inc.

WARNINGS indicate a procedure or situation that may result in serious injury or death if instructions are not followed correctly.

CAUTIONS indicate any situation or technique that will result in potential damage to the product, or render the product unsafe if instructions are not followed correctly.

NOTES are used to emphasize important points, tips and reminders.

3

Introduction ........................................................................................................................................4

Disassembly Procedure .....................................................................................................................5

First Stage Disassembly ..................................................................................................................5

Second Stage Disassembly .............................................................................................................8

Inspection Procedure .........................................................................................................................9

Reassembly Procedure ....................................................................................................................10

First Stage Reassembly .................................................................................................................10

First Stage Adjustment...................................................................................................................15

LP Module Final Assembly ............................................................................................................15

Second Stage Reassembly ...........................................................................................................16

Final Testing ......................................................................................................................................19

Table 1: Troubleshooting Guide First Stage...................................................................................20

Table 2: Troubleshooting Guide Second Stage .............................................................................21

Table 3: List of Tools and Service Kits ...........................................................................................22

Table 4: Torque Specifications ........................................................................................................25

Table 5: Test Bench Specifications ................................................................................................25

Table 6: Recommended Cleaners and Lubricants ........................................................................25

Procedure A: Cleaning and Lubricating .........................................................................................26

SEA First Stage Exploded View ......................................................................................................27

SEA First Parts list ...........................................................................................................................27

SEA LW Second Stage Exploded View ..........................................................................................29

Maintenance Notes ..........................................................................................................................30

CONTENTS

4 SEA-3000 LW & SEA-4500 Technical Manual

IntroductionThis manual provides factory prescribed procedures for the correct service and repair of this Aqua Lung® product. It is not intended to be used as an instructional manual for un-trained personnel. The procedures outlined in 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 Advisor before proceeding any further.

Scheduled ServiceThis 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; once every two years with normal use.

General Guidelines1. 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 non-reusable 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 aluminum, marine brass or plastic and can be permanently damaged by excessive stress.

7. If a part shows signs of damage or excessive wear during inspection, the part must be replaced.

Pinch MethodPress upwards on sides of o-ring to create a protrusion. Grab o-ring or insert o-ring tool at protrusion.

General ConventionsUnless 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, depress the second stage purge button for 5 seconds and release for 5 seconds. Repeat this procedure until the system is depressurized.

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 the manual: LP is Low Pressure; MP is Medium Pressure; and HP is High Pressure.

6. Numbers in parentheses reference the key numbers on the exploded 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) or use a brass or plastic o-ring removal tool. Avoid using hardened steel picks (unless directed), as they may damage the o-ring sealing surface. All o-rings that are removed are discarded and replaced with brand new o-rings.

5

DISASSEMBLY PROCEDURE

First Stage Disassembly

3. Using a 3/16" hex bit socket and flex wrench, unscrew the swivel port plug (41) from the LP body (8). Separate the spacer (37) and MP hose (38) from the swivel port plug. Remove o-rings (39 & 40) from the swivel port plug, using the brass o-ring tool as needed.

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.

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 serviced.

5. Unscrew the handwheel retainer (29) using the notched end of the 5 in 1 tool. Remove the handwheel washer (28), spring (27), handwheel (26), nylon washer (25) from the stem (17). Remove the indicator ring (24) from the bonnet (23).

4. Unscrew the safety plug assembly (35) from the HP module body (13) using a 3/8” socket and flex wrench.

6. Using the 3/4" wrench on the 5 in 1 tool, unscrew the bonnet (23) from the HP module body (13). Pull the stem (17) out of the bonnet.

7. Remove the o-ring (19) from the bonnet (23). Remove the back-up ring (22), o-ring (21), brass stem washer (20) and Teflon washer (18) from the stem (17).

NOTE: It is possible that some or all of the stem assembly parts may have remained inside the bonnet during removal.

1. Open the handwheel (26) and depressurize the system. Ensure the cylinder (42 or 43) is completely empty and it contains no air.

Hose Teeth

2. Pinch the locking slide ring (58) on opposing grips and loosen the hose (38) from the second stage. Carefully remove the o-ring (21) from inside the hose swivel using o-ring tool (PN 10-102-400). Exercise caution not to scratch the o-ring groove. Check the teeth on the second stage end of the MP hose (38), they should be relatively sharp and not excessively worn. Ensure the internal threads are in good condition and the nut spins freely.


9. Remove the dial indicator gauge (14) from the HP module body (13) using a 7/8" crowfoot and flex wrench. Remove o-ring (15) from the dial indicator gauge.

11. Using a 9/16" socket and flex wrench, unscrew the fill port (32) from the HP module body (13). Remove the fill port pin (34) from the fill port.

10. Unscrew the fill port cap (31) from the end of the fill port (32). Remove the o-ring (15) from the fill port cap.

NOTE: Take care not to lose the fill port pin when removing the fill port. It is possible that the fill port pin may have remained in the HP module body during removal.

12. Remove o-ring (15) from the fill port (32) and o-ring (33) from the fill port pin (34).

14. Using a 10mm hex bit socket and flex wrench, unscrew the spring adjuster (2) from the diaphragm clamp (3). Remove the MP spring (4) and the spring carrier (5).

15. Cut the safety wire (36) with diagonal pliers. Unscrew the LP module body (8) from the HP module body (13).

8. Insert the squared end of the stem (17) into the seat & disc retainer (16). Unscrew the seat & disc retainer from the HP module body (13). Use the magnifier tool to inspect the seat & disc retainer crown. There should be no scratches, nicks or dents on the crown seating surface.

Seating Surface 13. Use diagonal pliers to cut strap clamp (60) off the first stage cover (1). Remove first stage cover from LP module body (8).

7

CAUTION: Never remove the diaphragm by prying or dig-ging around the edges of the LP body module with any tool. This will cause irreversible damage to the LP body module.

CAUTION: The balance chamber cannot be removed from the HP module body. Trying to do so will cause irreparable damage to the HP module body.

17. Carefully place the diaphragm clamp tool and flex wrench onto the diaphragm clamp (3). Unscrew the diaphragm clamp from the LP module body (8). Remove the LP module body from the torque tool. Remove torque tool from the vise jaw inserts.

18. Place your finger lightly over the diaphragm (6) and insert a LP air nozzle into the open swivel port in the LP module body (8). Blow a small amount of air into the LP module body to remove the diaphragm. Remove the valve lifter (7) from the LP module body.

20. Remove the HP valve (9) and spring (10) from the HP module body (13). Use a brass o-ring tool to remove o-ring (11) from the balance chamber inside the HP module body (13).

21. Insert cylinder into the vise jaw inserts and tighten until snug. Unscrew the HP module body (13) from the cylinder (42 or 43) using the first stage spanner and flex wrench.

16. Secure vise jaw inserts into shop vise. Secure the LP mod-ule torque tool with the keyhole side up into the vise jaw inserts. Place the LP module body (8) into the LP module torque tool.

CAUTION: Improper alignment of the first stage spanner to the HP module body will cause permanent damage to the body.

CAUTION: The diaphragm clamp tool has three con-nection points that engage the diaphragm clamp, proper alignment is critical to avoid damage. Make sure to apply steady pressure and keep the tool centered when removing the diaphragm clamp.

ConnectionPoints

19. Use the magnifier tool to inspect the HP valve crown. This is located on the bottom side of the LP body module (8). There should be no scratches, nicks or dents on the crown seating surface.

Seating Surface


Second Stage Disassembly

1. Use diagonal pliers to cut the strap clamp (60) and remove the mouthpiece (61) from the box bottom (59). Inspect the mouthpiece to ensure it is free of any tears or cuts that may cause water leakage into the second stage or discomfort during use. Discard the mouthpiece if damage is found.

2. Using your fingers, remove the purge cover (44). Insert the pin spanner on the 5 in 1 tool into the slots of the retainer ring (45) and unscrew it from the box bottom (59).

3. Lift out the front cover (46) and diaphragm (47). Inspect the diaphragm for any tears or pin holes by holding it up to a light and gently stretching around the perimeter.

4. Remove the locking slide ring (58) by gently grasping it and rock it in a side to side motion, while pulling it away from the box bottom (59). Pull the locking slide ring out far enough to clear the box bottom and remain on the inlet fitting (55).

7. Using a 5mm hex bit socket and flex wrench, turn the valve seat (56) clockwise and remove it from the smaller diameter bore of the inlet fitting (55). Remove o-ring (57) from the valve seat.

5. Use the locking slide ring (58) to unscrew inlet fitting (55) from the spindle body (49). Remove the inlet fitting from the box bottom (59). Separate the locking slide ring from the inlet fitting.

NOTE: The valve seat is a reverse thread into the inlet fitting.

6. Inspect the teeth on both sides of the locking slide ring (58). They should be relatively sharp and not excessively worn. Check the locking slide ring is not cracked or warped.

Slide Ring Teeth

8. Inspect the inlet fitting (55) to ensure that it is in good condition. Check there are no cracks or scratch-es in the bores or o-ring groove. Ensure the threads are not damaged.

9. Use the magnif ier tool to inspect the valve seat (56). There should be no scratches, nicks or dents on the seating surface.

Seating Surface

9

10. Use your finger to push the spindle assembly through the inlet fitting hole into the box bottom (59). Grasp the spindle body (49) and lift it out of the box bottom.

CAUTION: DO NOT use the lever to pull the spindle body out of the box bottom, this will bend the lever.

CAUTION: Failure to keep the spring compressed while removing the lever will result in damage to the spindle body.

13. Separate the spring car-rier (50) and spring (52) from the shuttle valve (53). Re-move o-ring (51) from the spring carrier.

15. Unscrew the exhaust valve cap (64) from the box bottom (59). Grasp both sides of the exhaust valve (63) and pull straight out to remove it from the box bottom.

NOTE: Before beginning reassembly, perform parts cleaning and lubrication in accordance with Procedure A: Cleaning and Lubricating.

11. Use your finger to press in on the shuttle valve (53) to compress the spring (52). Carefully pull one of the legs of the lever (48) out of the spindle body (49), then ease the second leg out. Remove the shuttle valve assembly from the spindle body after the lever has been removed.

14. Remove the MP seat (54) from the shuttle valve (53).

12. Check that the spindle body (49) is free of cracks, scratches or d istor t ion. Pay particular attention to excessive wear around the lever holes. Make sure the internal threads are in good condition.

Lever Holes


REASSEMBLY PROCEDURE

First Stage Reassembly

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.

WARNING: Use only genuine Aqua Lung® parts, sub-as-semblies 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: Before proceeding, visually inspect the aluminum cylinder according to Compressed Gas Association (CGA) standards pamphlet (CGA C-6.1--2013, "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.

NOTE: Aluminum cylinders require visual inspection only during service, hydrostatic re-testing is optional.COPV cylinders require visual inspection during service, hydrostatic re-testing is required every 5 years.For more information reference Aqua Lung Technical Bulletin: Hydro Testing #09-001. This information can be found on the Aqua Lung Military and Professional website at www.aqualung.com/militaryandprofessional

1. Install o-ring (30) onto the bottom threads of the HP module body (13). Lubricate the first 4 to 5 threads on the HP module body.

2. Install o-ring (15) over the threads of the fill port cap (31). Set the fill port cap to the side, it will be installed after final testing is completed.

CAUTION: Before proceeding, visually inspect the COPV cylinder according to Worthington Industries publication (A GUIDE TO THE BASIC USE & CARE OF SCI TYPE 3 COMPOSITE PRESSURE VESSELS USER GUIDE). 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. Thread the HP module body (13) into the cylinder (42 or 43) until hand-tight. Secure vise jaw inserts into shop vise. Place the cylinder into the vise jaw inserts and tighten until snug. Attach the first stage spanner to a foot pound torque wrench. While holding the cylinder firmly, torque the HP module body into the cylinder to a value of 25 ft lb (33.9 Nm).

4. Insert the safety plug assembly (35) into the port directly below the safety wire holes on the HP module body (13). Screw the safety plug assembly in by hand until it bottoms out. Attach a 3/8” socket to an inch pound torque wrench and torque to a value of 90 in lb (10.2 Nm).

CAUTION: Improper alignment of the first stage spanner to the HP module body will cause permanent damage to the body.

NOTE: To avoid over-torquing of the safety plug assembly during installation, do not apply any type of lubricant to the safety plug threads.

WARNING: Ensure the proper safety disc is being installed into HP module body. (i.e. 3000 PSI / 207 BAR for aluminum cylinders and 4500 PSI / 310 BAR for COPV cylinders). Failure to do so could result in damage to the product and serious injury or death.

11

5. In the following order, place a new Teflon washer (18), brass washer (20), o-ring (21) and back-up ring (22) onto the stem (17).

NOTE: Before continuing, closely examine the back-up ring. 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, as shown in the picture below.

O-ring

Back-up ring

6. Using the squared end of the stem (17), screw the seat disc & retainer (16) into the port opposite the safety plug assembly (35) on the HP module body (13). Leaving the stem in position, place the handwheel (26) over the stem and tighten the seat disc & retainer until finger-tight. Remove the handwheel from the stem.

7. Install o-ring (19) into the groove located above the threads on the bonnet (23). Lubricate the bonnet threads, then pass the bonnet over the stem and thread it into the HP module body (13) until hand-tight.

8. Attach a 3/4" socket to a inch pound torque wrench and torque the bonnet to a value of 90 in lb (10.2 Nm).

9. Place the nylon washer (25) over the stem (17), so it sits on top of the bonnet (23). Face the round edge on the indicator ring (24) outward and thread the indicator ring onto the bonnet until it bottoms out.

10. When the indicator ring (24) bottoms out, turn it slightly counter-clockwise so the corners of the square shaft of the stem (17) point towards the centers of the square cut outs of the indi-cator ring. Turn an additional 90° counter-clockwise.

11. Place the handwheel (26) over the indicator ring (24). Place the spring (27) into the handwheel, followed by the washer (28). Using the notched end of the 5 in 1 tool, screw the handwheel retainer (29) onto the end of the stem (17) until it will not turn any further.

CAUTION: If resistance is felt while screwing the handwheel retainer onto the stem, stop and start over to avoid cross threading.

NOTE: DO NOT apply any type of lubricant to the seat & disc retainer prior to installation.


13. Install o-ring (15) onto the fill port (32).

14. Install o-ring (33) onto the fill port pin (34). Insert the fill port pin (o-ring side first) into the male threaded end of the fill port (32).

12. Install o-ring (15) onto the dial indicator gauge (14). Install the gauge into the port marked "G" on the HP module body (13). Torque the gauge to a value of 45 in lb (5 Nm) using a 7/8" crowfoot and inch pound torque wrench.

15. Install the fill port (32) into the port opposite the dial indicator gauge (14) on the HP module body (13). Using a inch pound torque wrench and a 9/16” socket, torque the fill port to a value of 90 in lb (10.2 Nm).

16. Use the o-ring tool to seat o-ring (11) into the center of the balance chamber inside the HP module body (13).

17. Install o-ring (12) into the groove below the threads on the HP module body (13).

CAUTION: Do not over-torque the fill port into the HP module body.

18. Install spring (10) into the balance chamber inside the HP module body (13). Place the HP valve (9) through the center of the spring.

19. Insert the valve lifter (7) into the center hole (on the top side) of the LP module body (8). Place the diaphragm (6) over the valve lifter, making sure it lies flat and the edges are seated evenly inside the LP module body.

20. Place the flat side of the spring carrier (5) onto the center of the diaphragm (6). Place the MP spring (4) on top of the spring carrier, making sure it is centered.

WARNING: Ensure the proper gauge is being installed into HP module body. (i.e. 3000 PSI / 207 BAR for aluminum cylinders and 4500 PSI / 310 BAR for COPV cylinders). Failure to do so could result in damage to the product and serious injury or death.

13

21. Screw the diaphragm clamp (3) into the LP module body (8) until hand-tight. Install the spring adjuster (2) into the diaphragm clamp. Use a 10mm hex bit socket and flex wrench, to screw the spring adjuster into the diaphragm clamp until it is flush with the top.

22. Secure the LP module torque tool (keyhole side up) into the vise jaw inserts. Place the LP module body (8) into the LP module torque tool.

23. Careful ly place the diaphragm clamp tool and foot pound torque wrench onto the diaphragm clamp (3). Torque the diaphragm clamp to a value of 15 ft lb (20 Nm).

CAUTION: To avoid damaging the diaphragm clamp, do not exceed 15 ft lb (20 Nm) of torque.

CAUTION: The diaphragm clamp tool has three connection points that engage the diaphragm clamp, proper alignment is crit ical to avoid damage. Make sure to apply steady pressure and keep the tool centered when installing the diaphragm clamp.

ConnectionPoints

24. Lubricate the threads of the HP module body (13). Screw the LP module body (8) all the way down onto the HP module body (13) until it stops. Loosen the LP module body 1/8 of a turn until the safety wire holes line up.

NOTE: The safety wire in the service kit is pre-bent for installation. The pre-bent side of the safety wire faces away from the LP / HP module body during installation.

25. Insert the open ends of the safety wire (36) into the holes on the LP module body (8). Ratchet the safety wire back and forth while pushing it through the holes. This motion bends the wire, allowing it to pass through the holes in the LP / HP module body (8 & 13). Pass enough wire through the holes for the tapered pliers to grip. Straighten the ends of the safety wire that has been passed through the holes.

26. Grasp both ends of the safety wire (36) evenly at a perpendicular angle with the tapered pliers. Pull the safety wire through until the top is flush with the holes on the LP module body (8).

Safety Wire Holes


28. Grasp both ends of the safety wire (36) with the tapered pliers and engage the locking mechanism. Pull the center knob Two Full Rotations (6-8 turns per inch) to twist the safety wire. Disengage the locking mechanism and remove tapered pliers from safety wire. Trim the ends of the safety wire (½ - ¾ inches) enough to fit in the space between the LP / HP module body (8 & 13).

WARNING: Failure to push the safety wire all the way into the space between the LP / HP module body can cause bodily injury due to sharp edges.

29. Grasp the twisted end of the safety wire (36) with the tapered pliers and bend the safety wire 180 degrees to the opposite side. Using the end of the flat brass o-ring tool, push the safety wire all the way into the space between the LP / HP module body (8 & 13) .

27. Grab one wire at a time with the tapered pliers and bend it to the side at a 90 degree angle. Trim the ends of the wire evenly to approximately 1 inch.

30. Install first stage cover (1) onto the LP module body (8). Loosely fasten the strap clamp (60) into the groove at the base of the first stage cover. Align the strap clamp with the fill port and pull tight. Trim the excess strap flush with the tab using diagonal pliers.

15

9. Pass the threaded end of the swivel port plug (41) through the banjo fitting on the MP hose (38). Make sure that both o-rings (40) are covered by the banjo fitting. Insert spacer (37) onto the swivel port plug and thread it into the LP module body. Attach a 3/16" hex bit socket to a inch pound torque wrench and torque the swivel port plug to a value of 60 in lb (6.8 Nm).

• When 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 rises more than 5 PSI (0.34 BAR) in 5-15 seconds after cycling the bleed valve, this indicates a HP leak. Refer to Table 1 : Troubleshooting Guide section of this manual to determine its possible cause.

8. Install o-rings (40) into the grooves on the swivel port plug (41). Install o-ring (39) on the threaded end of the swivel port plug.

10. Install o-ring (21) into the swivel end of the MP hose (38).

NOTE: O-ring for the second stage swivel end of the MP hose is in the second stage overhaul kit.

7. Close the handwheel (26) and open the bleed valve to depressurize the system. Remove the test gauge and 6" yellow from the LP module body (8).

5. Screw the test gauge onto the 6" yellow MP hose until hand-tight. Open the bleed valve on the test gauge and slowly open the handwheel (26). While watching the test gauge, slowly close the bleed valve.

• 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 150 PSI (10 BAR) or "creeps", quick-ly open the bleed valve and close the handwheel as this indicates a HP leak. Refer to Table 1 : Trouble-shooting Guide section of this manual to determine its possible cause.

3. Slowly fill the cylinder to 3000 PSI (207 BAR). Secure the end of the 6" yellow MP hose when filling the cylinder.

4. During the fill process, check for any air leaking from the open end of the MP hose. If a 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 and remove the fill adapter from the fill port (32).

1. Cycle the handwheel (26) several times to ensure the proper function of the indicator ring (24) and seat & disc retainer (16). Close the handwheel when finished.

2. Carefully place the first stage cover (1) over the swivel port on the LP module body (8). Install the 6" yellow MP hose into the swivel port.

First Stage Adjustment and Final Assembly

NOTE: Because the SEA second stage has a ratchet quick release mechanism on the hose, a 6" yellow MP hose (PN 103638) must be used to adjust the medium pressure.

NOTE: The initial first stage testing is done without anything attached to the end of the 6" yellow MP hose. The handwheel should initially be left in the "OFF" position when filling the cylinder to check for any air leaks coming from the open end of the hose.

11. Since there is nothing attached to the end of the MP hose (38) and the cylinder (42 or 43) is fully charged, set the system in a secure place so that the valve cannot be accidentally opened.

6. Insert a 10mm hex bit socket and flex wrench through the cover (1) and into the spring adjuster (2). Slowly turn the 10mm hex bit socket in ⅛ increments (clockwise to increase or counter-clockwise to decrease) to adjust the MP. Cycle the bleed valve and monitor the test gauge after each adjustment. Set the MP to 145 (±5) PSI / 10 (± 0.34) BAR.

NOTE: Correct MP is 145 ±5 PSI (10 ± 0.34 BAR), with an inlet pressure of 3000 PSI (207 BAR).

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.


Second Stage Reassembly

2. Use your fingers to screw the exhaust cover (64) onto the box bottom (59) until hand-tight.

3. Install o-ring (51) onto the spring carrier (50). Insert the spring carrier into one end of the spring (52) and the shuttle valve (53) into the other. Carefully guide the end of the spring carrier into the spindle body (49).

WARNING: Flooding of the second stage may occur if the exhaust valve is folded under or the barb on the stem is not pulled through the hole in the exhaust port all the way.

NOTE: Look into the open end of the spindle body to ensure the legs of the lever are positioned in front of the shuttle valve. This retains the shuttle valve inside the spindle body. Check that the lever has a full range of movement and does not catch on the spindle body.

CAUTION: Ensure the legs of the lever are parallel to each other and not bent. If necessary, gently squeeze the legs together to straighten.

Correct Incorrect

1. Install the exhaust valve (63) into the box bottom (59) by inserting the stem through the center hole of the exhaust port. Pull the stem through until the barb is on the opposite side of the hole in the exhaust port. Examine the flap of the exhaust valve to make sure it is laying flat and is not distorted or folded under. Use a pair of small diagonal pliers to trim the stem so it is only about 1/4" long. Visible

GapCenter Hole

(on Top)

5. Carefully insert the MP seat (54) into the shuttle valve (53). Make sure the MP seat is pos i t ioned correctly and f lush with the end.

4. Position the spindle body (49) with the threaded end to the left and small center hole on top. Using your finger, press in on the shuttle valve (53) to fully compress the spring (52).The shuttle valve should pass the lever holes in the spindle body, creating a small visible gap. Insert the feet of the le-ver (48) one leg at a time into the lever holes, in front of the shuttle valve.

CAUTION: Use the end of your finger to insert the new MP seat into the shuttle valve. Make sure it sits flush with the end and the seat does not get scratched during installation. Damage to the seat will cause the second stage to leak when fully assembled.

17

6. Install o-ring (57) on the valve seat (56). Install the valve seat into the smaller diameter bore of the inlet fitting (55). Using a 5mm hex bit socket and flex wrench turn the valve seat counter-clockwise so that it retracts into the inlet fitting until it stops.

7. Install o-ring (19) onto the outside of the smaller diameter bore of the inlet fitting (55).

8. Insert the threaded end of the spindle body (49) into the inlet fitting hole of the box bottom (59). Ensure the small center hole in the spindle body is facing the diaphragm (47).

CAUTION: DO NOT use the lever to insert the spindle body into the box bottom, this will bend the lever.

9. Screw the fine threaded end of the inlet fitting (55) into spindle body (49) until the notches on the inlet fitting and box bottom (59) are aligned.

10. Align the notches of the locking slide ring (58) to the notches on the inlet fitting (55) and box bottom (59). Use the palm of your hand to carefully push the locking slide ring all the way into place until it clicks.

11. Insert the 5mm hex bit socket and flex wrench into the open end of the inlet fitting (55). Hold the box bottom (59) at eye level and turn the valve seat (56) clockwise until the lever (48) drops just below the rim of the box bottom. Check by gently pushing down and releasing the lever, it should return to its set position. If it sticks then the lever is not squarely seated, positioned correctly or is bent.

CAUTION: Ensure the lever moves freely in the box bottom and does not stick.

12. Place the diaphragm (47) into the box bottom (59), making sure the edges are seated below the threads inside the box bottom. Install the front cover (46) over the diaphragm making sure the front cover slots are positioned horizontally.

NOTE: The valve seat is a reverse thread into the inlet fitting.

CAUTION: DO NOT adjust the lever beyond the recommended height. Screwing the valve seat in too far while adjusting the lever can result in damage to the MP seat. If damaged, the part will require replacement.


15. Refit the hose (38) onto the second stage and tighten the hose nut by hand until it stops. DO NOT use any tools to tighten the hose nut onto the inlet fitting (55). Audible clicks should be heard as the hose nut is tightened into place. Check the hose nut is locked into place and cannot be loosened without squeezing the locking slide ring (58).

NOTE: The mouthpiece can be adjusted to several different user preferred positions. (Reference the User's Manual for more information).

13. Install the retainer ring (45) into the box bottom (59). Insert the pin spanner on the 5 in 1 tool into the slots of the retainer ring and screw it into the box bottom hand-tight. Ensure the front cover (46) slots have remained in a horizontal position. Screw the purge cover (44) onto the box bottom until hand-tight.

14. Install the mouthpiece (61) onto the box bottom (59). Loosely fasten a strap clamp (60) into the groove at the base of the mouthpiece with the tab on the MP hose side. Pull the strap clamp tight and trim the excess strap flush with the tab using diagonal pliers.

19

FINAL TESTING

Subjective Test

2. Press the front cover (46) two times for about five seconds each, with a five second pause between each purge. Ensure no leaks can be heard coming from the second stage. If a leak is detected, refer to Table 2 : Troubleshooting Guide section of this manual to determine its possible cause.

3. Perform a subjective breathing test to ensure the second stage is operating properly using the following procedure:

a. Fully depress the front cover (46) to ensure an adequate volume of air passes through the second stage to clear out any water.b. Inhale slowly but deeply from the second stage. A prop-erly serviced and adjusted regulator should deliver air upon deep inhalation without excessive inhalation effort, free-flow or fluttering of the second stage diaphragm (47). When exhaling, there should be no fluttering or sticking of the exhalation valve (63). If any of these problems occur, refer to Table 1 & 2: Troubleshooting Guides section of this manual to determine its possible cause.

WARNING: It is very critical to ensure that no leakage is present and the SEA has met all requirements in the Final Testing section of this manual. DO NOT issue a SEA which exhibits any signs of leakage or unsatisfactory performance until the problem has been thoroughly diagnosed and repairs have been made as needed, including the possible replacement of a damaged component or subassembly.

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.

1. Slowly open the handwheel (26) to pressurize the system. Check the dial indicator gauge (14) reads 3000 PSI (207 BAR).

1. Ensure the handwheel (26) is in the open position and the system is pressurized. Check the dial indicator gauge (14) reads 3000 PSI (207 BAR).

Immersion Test

NOTE: Do not confuse bubbles from trapped air with a true leak. If a true leak is detected, bubbles will come out in a constant stream.

1. Ensure the system is pressurized with the handwheel (26) in the open position. Check the dial indicator gauge (14) reads 3000 PSI (207 BAR). Set the unit in a stable temperature environment for a minimum of twelve hours. After the time has elapsed, check the dial indicator gauge (14) reads 3000 PSI (207 BAR).

Pressure Drop Test

WARNING: If the dial indicator gauge does not read "3000 PSI / 207 BAR" after 12 hours, refer to Table 1 & 2: Troubleshooting Guides section of this manual to determine its possible cause.

NOTE: The SEA must be cleaned and sanitized as per local instructions before issue.

3. Upon completion of the immersion test, ensure all water is removed from the unit. Wipe the entire system dry with a clean towel. Press the front cover (46) to blow any remaining water out of the second stage.

3. Providing the SEA has passed all testing and the cylinder has been filled to its full capacity as marked, the SEA is now ready for use.

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. If a leak is detected, refer to Table 1 & 2: Troubleshooting Guides section of this manual to determine its possible cause.

2. Refill the cylinder to its full capacity as marked. Close the handwheel (26) when filling is complete and depressurize the system. Screw the fill port cap (31) back into the fill port (32).


SYMPTOM POSSIBLE CAUSE TREATMENT

System will not remain depressurized after handwheel is closed and second stage is purged.

1. The seat disc & retainer (16) is worn or damaged. 1. Replace seat disc & retainer (16).

2. The seat disc & retainer crown in HP module body (13) is worn or damaged. 2. Replace HP module body (13).

High or Unstable MP “Creep”

1. HP valve (9) is dirty, worn or damaged. 1. Clean or replace HP valve (9).

2. HP valve crown in LP module body (8) is worn or damaged. 2. Replace LP module body (8).

3. The seat disc & retainer crown in HP module body (13) is worn or damaged. 3. Replace HP module body (13).

4. The o-ring (11) inside HP balance chamber is worn or damaged. 4. Replace o-ring (11).

5. The HP balance chamber in HP module body (13) is worn or damaged. 5. Replace HP module body (13).

Low MP 1. The MP spring (4) is weakened, damaged or first stage is improperly adjusted.

1. Replace MP spring (4) or check MP adjustment using test gauge.

External Air Leak

1. The diaphragm (6) is worn or damaged. 1. Replace diaphragm (6).

2. The diaphragm seating surface is worn or damaged. 2. Replace LP module body (8).

3. The diaphragm clamp (3) is loose or not torqued properly.

3. Torque diaphragm clamp (3) to proper value.

4. O-ring (12) on HP module body (13) is worn or damaged. 4. Replace o-ring (12).

5. The LP module body (8) is loose. 5. Tighten LP module body (8). Check safety wire (36) has been installed.

6. Safety plug (35) not seated or torqued correctly.

6. Check for damage and re-torque safety plug (35).

Restricted Air Flow or High Inhalation Resistance

1. Handwheel (26) not completely turned to the "ON" position.

1. Turn handwheel (26) to the "ON" position.

TABLE 1: TROUBLESHOOTING GUIDE FIRST STAGE

21

SYMPTOM POSSIBLE CAUSE TREATMENT

Leakage or free-flow from the second stage

1. High first stage MP, should be 145 (±5) PSI / 10 (± 0.3) BAR.

1.Refer to Table 1: Troubleshooting Guide.

2.The MP seat (54) is dirty, worn or damaged. 2. Clean or replace MP seat (54).

3. The lever (48) is set too high. 3. Reset valve seat (56) to preliminary setting and repeat adjustment procedure.

4. The lever (48) is bent. 4. Replace the lever (48).

5. The valve seat (56) seating surface is damaged. 5. Replace the valve seat (56).

6. The spring (52) is worn or damaged. 6. Replace the spring (52).

7. The shuttle valve o-ring (51) is worn or damaged. 7. Replace the o-ring (51).

8. The shuttle valve (53) is damaged. 8. Replace the shuttle valve (53).

Low purge or labored breathing(full cylinder)

1. Low first stage MP, should be 145 (±5) PSI / 10 (± 0.3) BAR.

1.Refer to Table 1: Troubleshooting Guide.

2. The lever (48) is set too low. 2. Reset valve seat (56) to preliminary setting and repeat adjustment procedure.

3. The lever (48) is bent or catching on the spindle body (49).

3. Replace the lever (48) or check it was reassembled correctly.

4. The MP hose is clogged or obstructed. 4. Clean or replace the MP hose (38).

5. The spring (52) is worn or damaged. 5. Replace the spring (52).

External Air Leak(Immersion Test)

1.The MP hose (38) is loose or damaged. 1. Re-tighten MP hose (38) at second stage fitting or replace hose.

2. The MP hose o-ring (21) is damaged. 2. Replace the o-ring (21).

Water entering second stage

1. The mouthpiece (61) is incorrectly fitted or damaged. 1. Refit or replace mouthpiece (61).

2. The diaphragm (47) is damaged. 2. Replace the diaphragm (47).

3. The exhaust valve (63) is damaged or improperly seated.

3. Re-seat or replace the exhaust valve (63).

4.The diaphragm (47) is improperly seated in the box bottom (59).

4. Disassemble and properly reassemble (check for distortion).

5. The box bottom (59) is damaged. 5. Check exhaust valve seating surface and replace box bottom (59).

6. The inlet fitting o-ring (19) is damaged. 6. Replace the o-ring (19).

TABLE 2: TROUBLESHOOTING GUIDE SECOND STAGE

CAUTION: Recommended treatments which require disassembly of this product must be performed during a complete overhaul, according to the prescribed procedures for scheduled service. Do not attempt to perform partial service.

NOTE: This is a partial list of problems and recommended treatments. For more information contact the Aqua Lung Technical Service Department for assistance with problems not described in Table 1 & 2: Troubleshooting Guides.


PART # DESCRIPTION APPLICATION

108509 Tool Kit SEA Tool Kit

820466 Christo-Lube MCG III

Parts lubrication

9-430011030069-43226

Socket (3/8”)Socket (9/16”)Socket (3/4")

Removal / Installation of Safety Plug (35)Removal / Installation of Fill Port Adapter (32)Installation of Bonnet (23)

9-466618367A23103637

Hex Bit Tool (3/16”)Hex Bit Tool (5mm)Hex Bit Tool (10mm)

Removal / Installation of Swivel Port Plug (41)Removal / Installation of Valve Seat (56)Removal / Installation of Spring Adjuster (2)

108512 5 in 1 Tool

Removal / Installation of the following parts:Handwheel Retainer (29)Retainer Ring (45)Bonnet (23)

103636 Pliers, Tapered 3/8” Auto Return

Installation of Safety Wire (36)

AT71DiaphragmClampTool

Removal / Installation of Diaphragm Clamp (3)

944022 O-ring ToolKit

Removal / Installation of o-rings

10-102-400 O-ring Tool Removal of MP hose O-ring (21)

103638 Hose AssyYellow 6”

Testing medium pressure (MP)

TABLE 3: LIST OF TOOLS AND SERVICE KITS

23


9-45171 Diagonal Pliers(small)

Removal of Strap Clamp (60) and Safety Wire (36)

103045Handle, Flex Wrench3/8” Drive

Removal of parts using sockets and crowfoot wrenches

9-43628 Crowfoot (7/8”) Removal / Installation of Dial Indicator Gauge (14)

944014 Pliers, Needle Nose

Removal / Installation of parts

103560 Spanner, 1st Stage Removal / Installation of HP Module Body (13)

103013 Cylinder Light Inspection of Cylinder (42 & 43)

100398 Vise Jaw Inserts Tool

Removal / Installation of HP Module Body (13) from cylinder (42 & 43) using shop vise

9-BA819008 Magnifierw/ Illumination

Inspection of parts

108516 Tool, LP Module Torque

Hold LP Module Body (8) while torquing Diaphragm Clamp (3)

111610 Gauge, Test0-400 PSI

Testing medium pressure (MP)

TABLE 3: LIST OF TOOLS AND SERVICE KITS (CONTINUED)



108325SCUBA Fill Adapter(3000 PSI / 207 BAR Only)

Filling cylinder (42 & 43)

102865HP Fill Adapter(3000 PSI - 4500 PSI)(207 BAR - 310 BAR)

Filling cylinder (42 & 43)(Not included in Tool Kit)

M100656Compressor FillAdapter(3000 PSI / 207 BAR Only)

Filling cylinder (42 & 43) (Not included in Tool Kit)

N/ATorqueWrenchin lb

Apply torque to parts listed in Table 4: Torque Specifications(Not included in Tool Kit)

N/ATorqueWrenchft lb

Apply torque to parts listed in Table 4: Torque Specifications (Not included in Tool Kit)

103554103627103556

Service Kit First Stage (SEA-4500)Service Kit First Stage (SEA-3000)Service Kit Second Stage (SEA-LW)

Maintenance of the SEA-4500 & SEA-3000LW

TABLE 3: LIST OF TOOLS AND SERVICE KITS (CONTINUED)

NOTE: Photos of tools contained in the SEA tool kit are representative. Tool manufacturers and part numbers are subject to change without notice.

25

TABLE 4: TORQUE SPECIFICATIONS

PART # DESCRIPTION / KEY ITEM # TORQUE

103549 HP Module Body (13) 25 ft lb (33.9 Nm)

108305 Swivel Port Plug (41) 60 in lb (6.8 Nm)

054300 / 054232 Safety Plug Assy (35) 90 in lb (10.2 Nm)

108308 Fill Port (32) 90 in lb (10.2 Nm)

103530 / 102810 Dial Indicator Gauge (14) 45 in lb (5 Nm)

108318 Bonnet (23) 90 in lb (10.2 Nm)

AP5752 Diaphragm Clamp (3) 15 ft lb (20 Nm)

TABLE 5: TEST BENCH SPECIFICATIONS

TABLE 6: RECOMMENDED CLEANERS AND LUBRICANTSLUBRICANT/CLEANER APPLICATION SOURCE

Christo-Lube MCG 111All o-rings

Aqua Lung, (PN 820466) orLubrication Technologies 310 Morton Street Jackson, OH 45640 (800) 477-8704

Oakite #31 Acid bath for reusable stainless steel and brass parts.

Oakite Products, Inc. 50 Valley Road Berkeley Heights, NJ 07922

White distilled vinegar Acid bath for reusable stainless steel and brass parts. “Household” grade

Liquid dish washing detergent (diluted with warm water)

Degreaser for brass and stainless steel parts; general cleaning solution for plastic and rubber

“Household” grade

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.

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.

TEST CONDITION SPECIFICATION

Leak Test Inlet 3000 PSI (207 BAR) No leaks allowed

MP Inlet 3000 PSI (207 BAR) 145 ±5 PSI (10 ± 0.34 BAR)

MP Creep Inlet 3000 PSI (207 BAR) 5 psi (0.34 BAR) max between 5 to 15 seconds after cycling regulator (purge)

Opening Effort Inlet 3000 PSI (207 BAR) +2.5 to +3.5 inch H20 (6.2 -8.7 mbar)

Flow Effort MP 145 ±5 PSI (10± 0.34 BAR) +5 inches H20 (12.5 mbar) (maximum) at 8 SCFM (227 LPM)

Purge Flow MP 145 ±5 PSI (10± 0.34 BAR) 5 SCFM (142 LPM) flow rate (minimum)


Cleaning Brass & Stainless Steel Parts1. 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 PartsAnodized 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.

Cleaning Hoses1. Hose fittings: Ultrasonically clean with soapy water*; vinegar OK on tough corrosion – (only brass or stainless 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 DressingAll 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.

PROCEDURE A: CLEANING AND LUBRICATING

CAUTION: Do not place plastic (including hose ends), 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.

CAUTION: Silicone grease and sprays must be strictly avoided, since silicone does not provide adequate lubricity in extreme weather conditions.

27

...... 103628 Service Kit, Second Stage SEA-LW ...... 103557 Second Stage SEA-LW, Spare

44 ...... 103547 Cover, Hard Purge 45 ...... 100119 Ring Retainer Micra 46 ...... 103546 Cover, Front 47 ...... 100181 Diaphragm 2nd Stage Micra 48 ...... 129178 Lever 49 ...... 103561 Body, Spindle 50 ...... AP7584 Spring Carrier 51 ...... 103572P O-ring (10 pk) 52 ...... AP2021 Valve Spring 53 ...... AP5707 Egress Shuttle Valve 54 ...... 129638 Seat MP, Silicone

Key # Part # Description 21 ...... 820010P O-ring (25 pk) 55 ...... AP7586 Inlet Fitting 19 ...... 820015P O-ring (10 pk) 56 ...... AP7563 Egress Valve Seat 57 ...... 103559P O-ring (10 pk) 58 ...... AP7595 Locking Slide Ring 59 ...... 103564 Box Bottom, SEA, Black 60 ...... 104913 Clamp Strap Black 61 ...... 108373 Mouthpiece, LV2 62 ...... 108453 Cover Mouthpiece, LV2 63 ...... 100122 Valve Exhaust, 1.0” 64 ...... 103545 Cap, Exhaust Valve, LV2

Key # Part # Description

Part numbers in BOLD ITALIC indicate standard overhaul replacement part.

44

45

46

47

48 49

505152

5354

55

1956

57 58

64

63

59

60

61

62

SEA LW SECOND STAGE EXPLODED VIEW

21


1

2

3

4

5

6

7

8

9

1011

12

13 14

15 16 1718 19

20 21 22 2324

25 26

27 28 29

30

1532 33

34 15

35

3738

3941

42

40

36

15 ft lb (20 Nm)

45 in lb (5 Nm)

90 in lb (10.2 Nm)

25 ft lb (33.9 Nm)

90 in lb (10.2 Nm)

60 in lb (6.8 Nm)

90 in lb (10.2 Nm)

43

31

SEA FIRST STAGE EXPLODED VIEW

60

29

...... 103554 Service Kit, First Stage, SEA 4500 ...... 103627 Service Kit, First Stage, SEA-3000 ...... 103619 SEA-4500 LW First Stage, w/ Dial Pressure Gauge ...... 103617 SEA-3000 LW First Stage, w/ Dial Pressure Gauge

1 ...... 108478 Cover, Soft, SEA First Stage 60 ...... 104913 Clamp Strap, Black 2 ...... AP5753 Spring Adjuster 3 ...... AP5752 Diaphragm Clamp, Composite 4 ...... AP5754 Spring, MP 5 ...... AP5755 Spring Carrier 6 ...... 103567 Diaphragm, Red, SEA 7 ...... AP5717 Valve Lifter 8 ...... 103550 Body, LP, Module, SEA, (Anodized Aluminum) 9 ...... AP5759 HP Valve 10 ...... AP1415 Spring 11 ...... 820080P O-ring (25 pk) 12 ...... 820017P O-ring (10 pk) 13 ...... 103549 Body, HP Module, SEA, (Anodized Aluminum) 14 ...... 103530 Gauge, Dial Indicator, 4500 PSI, SEA ...... 102810 Gauge, Dial Indicator, 3000 PSI, SEA 15 ...... 820319P O-ring (10 pk) 16 ...... 108322 Seat Disc & Retainer Assembly 17 ...... 108319 Stem, On/Off 18 ...... 108327 Washer, Stem - Bottom Teflon 19 ...... 820015P O-ring (10 pk) 20 ...... 108328 Washer, Stem - Top Brass 21 ...... 820010P O-ring (25 pk) 22 ...... 828009 Ring Back-up 23 ...... 108318 Bonnet, Complete 24 ...... 108317 Ring, On/Off Indicator 25 ...... 108326 Washer, Stem - Top Nylon 26 ...... 108313 Handwheel, On/Off 27 ...... 108316 Spring, On/Off 28 ...... 108329 Washer, Handwheel - Top 29 ...... 108304 Retainer, Handwheel, Black 30 ...... 820016P O-ring (10 pk) 31 ...... 108307 Cap, Fill Port 15 ...... 820319P O-ring (10 pk) 32 ...... 108308 Port, Fill 33 ...... 820304P O-ring (10 pk) 34 ...... 108309 Pin, Fill Port 15 ...... 820319P O-ring (10 pk) 35 ...... 054300 Safety Plug Assy, 4500 PSI, SEA (103554 kit only) ...... 054201 Safety Plug Assy, 3000 PSI, SEA (103627 kit only) 36 ...... 103645 Wire, Form, SEA 37 ...... 108306 Spacer, Swivel, Black 38 ...... 103631 Hose Assy, MP, 20” SEA ...... 103534 Hose Assy, MP, 27” SEA 39 ...... 820311P O-ring (10 pk) 40 ...... 103548 O-ring 41 ...... 108305 Port Plug, Swivel, Black 42 ...... 103524 Cylinder, 4500 PSI, COPV 17.5 in³ ...... 103571 Cylinder, 4500 PSI, COPV 13 in³ 43 ...... 079105 Cylinder, 1.5 ft³, 3000 PSI Black, Aluminum ...... 079120 Cylinder, 2.0 ft³, 3000 PSI Black, Aluminum

Part numbers in BOLD ITALIC indicate standard overhaul replacement part.

Key # Part # Description

SEA FIRST STAGE PARTS LIST


MAINTENANCE NOTES

31

MAINTENANCE NOTES

©2017 Aqua Lung International

SEA-3000 LW & 4500(Survival Egress Air)

Technical Manual

2340 Cousteau Court • Vista, CA 92081Phone (760) 597-5000 • Fax (760) 597-4900www.aqualung.com/militaryandprofessional

Blue = Pantone 2728C

Primary/Preferred Branding

Secondary Branding

Tertiary Branding

Documents

TECHNICAL MANUAL - Aqua Lung · This manual provides factory prescribed procedures for the correct service and repair of this Aqua Lung® product. It is not intended to be used as