LPO Second Stage
Contents
1. AQUALUNG Authorized Dealer SERVICE amp REPAIR MANUAL Contents Introduction Warnings Cautions amp Notes Scheduled Service General Guidelines Initial Inspection Procedure External Inspection Pressure Test Disassembly Procedures Reassembly Procedures Valve Adjustment Procedures Final Assembly amp Testing Procedures Second Stage Air Flow Test Second Stage Opening Effort Test Second Stage Purge Flow Test External Leak Test Subjective Breathing Test Table 1 Troubleshooting Guide Table 3 Standard Parts Replacement Schedule Table 2 Recommended Tool List Table 5 Test Bench Specifications Table 4 Torque Specifications Procedure A Cleaning amp Lubrication Table A Recommended Lubricants amp Cleaners Schematic Drawing LPO Second Stage Doc XXXX XX Service amp Re AQUA LUNG air Manual LPO Second Sta Introduction This manual provides factory prescribed proce dures for the service and repair of the LPO second stage regulator 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 a factory spon sored Aqua Lung Service amp Repair Seminar If you do not completely understand all of the procedures outlined in this manual contact Aqua Lung to speak directly with a Technic2. 5 Replace poppet spring Low purge or excessive work of breathing full cylinder Low intermediate pressure should be 135 140 psi Crown 20 and or locknut 12 adjusted incorrectly lever set too low Intermediate pressure hose 23 clogged or obstructed Refer to first stage Troubleshoot ing Guide Reset crown and locknut to preliminary settings and repeat Adjustment Procedures Clean or replace hose External air leakage Intermediate pressure hose 23 loose Immersion Test 2 Crown O ring 21 damaged 3 Box bottom 15 damaged Tighten to 40 inch Ibs at female second stage fitting 2 Disassemble and replace O ring 3 Disassemble and replace box bottom Water entering second stage Hole in mouthpiece 13 Demand diaphragm 4 damaged Exhaust diaphragm 16 damaged Diaphragm 4 improperly seated between box bottom 15 and retaining ring 3 Box bottom 15 damaged Check exhaust valve sealing surface Valve insert O ring 18 damaged Replace mouthpiece Replace demand diaphragm Replace exhaust diaphragm s Remove color ring 2 and prop erly reassemble sealing ring with diaphragm Check for distortion Disassemble and replace box bottom Disassemble and replace O ring CAUTION Recommended treatments which require disassembly of the regulator must be performed during a complete overhaul according to the presc
3. Parts with damage to their chrome finish should be cleaned separately outside the ultrasonic cleaner to avoid agitation Be certain to isolate more delicate parts such as orifice cones to prevent damage to sealing surfaces CAUTION Harsh acids such as muriatic acid may cause damage to parts and must be strictly avoided White vinegar although less effective is one suitable substitute for ChromeSafe CAUTION Ultrasonic cleaning times in excess of 15 minutes may damage the chrome finish of certain parts Be certain to use a timer and do not leave parts unattended while cleaning NOTE Although ChromeSafe contains a degreasing agent cleaning heavily greased parts in ChromeSafe will shorten the effective life of the solution and require it to be replaced on a more frequent basis Heavily greased parts may be degreased in a solution of warm water and mild dish detergent prior to being placed in the acid bath Fresh Water Rinse If tap water is extremely hard distilled water may be used to prevent any mineral residue Remove parts from the acid bath and place directly into this rinse Agitate lightly and allow to soak for 5 10 minutes Remove and blow dry with low pressure 25 psi filtered air and inspect closely to ensure proper cleaning and like new condition ANODIZED ALUMINUM PLASTIC amp RUBBER PARTS Anodized aluminum parts and parts made of plastic or rubber such as box bottoms box tops dust caps etc may be
4. out being very careful to avoid damaging the poppet Set the seat aside to be used as an aid during reassembly and inspect the head of the poppet to check for any nicks scratches or other signs of damage The through hole beneath the LP seat cavity should be clear and free of any obstructions If any signs of damage are found discard the poppet and do not attempt to reuse 2000 Aqua Lung America Inc LPO Second Stage Service amp Repair Manual Fig 3 Removing Exhaust Diaphragms 15 16 A NOTE The used LP seat is an essential aid to the reassem bly procedure for the valve body Do not discard the seat until the reassembly and final adjustment procedures have both been performed and the regulator is functioning satis factorily Place the handle of the extraction tool directly over the poppet bearing 8 in the top center of the valve body and press downward until the poppet bearing has dropped out Discard the poppet bearing and do not reuse To remove the exhaust valve diaphragms 16 it is not neces sary to remove the exhaust cover 17 Instead use a pair of needle nose pliers to pull each of the diaphragms through the grill of the exhaust cover see Fig 3 Discard both dia phragms and do not reuse CAUTION Aqua Lung recommends that the exhaust cover should not be removed unless it appears to be damaged and requires replacement If removal and replacement is neces sary proceed with caution
5. Lung Regulators LUBRICANT CLEANER APPLICATION SOURCE Christo Lube All O rings seals cylinder valve threads Lubrication Technologies preferred for high pressure DIN systems 310 Morton Street Jackson OH 45640 614 286 2644 Dow Corning 111 All O ring seals Dow Corning Corp pure silicone grease P O Box 1767 T Midland MI 48640 800 248 2481 CAUTION Silicone rubber requires no lubrication or preservative treatment DO NOT apply silicone grease or spray to silicone rubber parts Doing so will cause a chemical breakdown and premature deterioration of the material Silicone Pump General preservative conditioner for McNett Corp non aerosol silicone milk spray hoses instrument console boots etc P O Box 996 Bellingham WA 98227 800 221 7325 CAUTION Aerosol spray silicone should be avoided because 1 common aerosol propellants may attack plastic and rubber parts and 2 because only a slight amount of silicone remains after the solvent evaporates and provides no lasting benefit Anti Seize Lubricant 80208 M A S cylinder adapter female threads Permatex Industrial Corp Micra ADJ adjustment screw 705 N Mountain Rd Newington CT 06111 860 520 5000 ChromeSafe Degreaser and acid bath for reusable Aqua Lung P N 0201 05 ultrasonic cleaning solution stainless steel and brass parts 1 quart Oakite 31 Acid bath for reusable stainless Oakite Products Inc steel and brass parts 50 Valley Road Berkeley
6. and separate these items to closely inspect the diaphragm for any signs of tears deterioration or other damage If deterioration or damage is found discard the diaphragm and do not attempt to reuse 6 While holding the box bottom secure apply a 19mm open end wrench to the inlet fitting 19 Hold the lever 10 de pressed and carefully turn the fitting counter clockwise to loosen and remove Remove and discard the O ring 18 7 Apply a medium blade screwdriver to the slotted head of the crown 20 inside the inlet fitting and hold the inlet fitting 2000 Aqua Lung America Inc 4 LPO Second Stage Service amp Repair Manual secure while turning the crown counter clockwise to disen gage the threads NOTE Because the crown is O ring sealed it will not freely exit the valve body after it has been disengaged The follow ing step must be performed correctly in order to remove the crown without damaging its delicate sealing surface 8 When the crown has been unthreaded from the inlet fitting carefully insert the pin of the extraction tool P N 1094 36 into the opposite end of the inlet fitting and through the center Lam of the crown Gently press the crown out onto a padded M N surface see Fig 1 Remove and discard the O ring 21 E 9 Closely examine the crown with the use of magnifier to check for any scoring nicks or other damage to the polished sealing surface If damag
7. of scissors or wire cutters NOTE Before performing the following procedure refer to Table 5 titled Test Bench Specifications LPO 2nd Stage NOTE If an accurately calibrated airflow test bench is not A available proceed to the Subjective Tuning Procedures provided on the following page SECOND STAGE AIR FLOW TEST 1 Connect the first stage regulator to a calibrated test bench and pressurize the system to 3000 100 psi 2 Place the second stage mouthpiece over the mouthpiece adapter Slowly turn the flowmeter control knob until the flow reaches a minimum of 15 SCFM 425 liters per minute The reading on the Magnahelic gauge inhalation exhalation effort gauge should indicate no more than 6 0 H O If the reading exceeds 6 0 H O refer to refer to Table 1 Trouble shooting for corrective guidelines and specific procedures SECOND STAGE OPENING EFFORT TEST 1 Turn the flowmeter control knob shut and then slowly reopen while watching both the Magnahelic gauge and the intermedi ate pressure gauge 2 When the intermediate pressure gauge begins to drop below the intermediate pressure lockup the Magnahelic gauge should indicate an opening effort of 8 to 1 4 of H O primary or 1 2 to 1 8 octopus If the opening effort is not within this range refer to Table 1 Troubleshooting SECOND STAGE PURGE FLOW TEST 1 Turn off the flowmeter control knob Next while the second stage is still mounted on t
8. 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 Thoroughly blow dry using low pressure filtered air HOSES If buildup of corrosion is severe it is permissible to soak only the hose fittings in ChromeSafe cleaner as needed and not allow any solution to enter the hose Rinse in fresh water and allow to dry with the cleaned ends hanging down Blow filtered air through them prior to installing onto the regulator LUBRICATION AND DRESSING All O rings should be lubricated with either Christo Lube preferred for high pressure systems or Dow Corning 111 food grade silicone grease Dress the O rings with a very light film of grease and remove any visible excess by running the O ring between thumb and forefinger Avoid applying excessive amounts of silicone grease as this will attract particulate matter that may cause damage to the O ring Hoses and other black rubber parts may be dressed and preserved using a clean cloth impregnated with a pump silicone milk CAUTION Aerosol spray silicone must be strictly avoided Do not attempt to use as a substitute for silicone grease CAUTION Do not apply any form of silicone lubricant to silicone rubber parts as this will cause them to deteriorate prematurely 2000 Aqua Lung America Inc 16 LPO Second Stage Service amp Repair Manual Table A Recommended Lubricants amp Cleaners All Aqua
9. 0 psi with no open ports or hoses 2 Listen closely to check for any signs of leakage from the second stage If necessary immerse the second stage in water to locate the source of any leakage found and refer to Table 1 Troubleshooting to determine its possible cause CAUTION If the second stage freeflows uncontrollably immediately shut the cylinder valve and proceed directly to the Disassembly Procedure Do not attempt to further inspect the regulator while pressurized 3 Depress the purge button to determine whether sufficient airflow is provided to clear the second stage of water Imme diately after releasing the purge button listen closely to ensure that no air continues to flow from the second stage 4 Turn the cylinder valve shut and depress the second stage purge button to depressurize the regulator before proceeding to the following Disassembly Procedure 2000 Aqua Lung America Inc LPO Second Stage Service amp Repair Manual 3 Disassembly Procedures NOTE Before performing any disassembly refer to Table 4 which references all mandatory replacement parts These parts must be replaced with new and must not be reused under any circumstances regardless of the age of the regulator or how much use it has received since it was last serviced CAUTION To prevent damage to critical sealing surfaces use only a plastic or brass O ring removal tool P N 9440 22 when removing O rings Once an O ring sealing sur
10. Heights NJ 07922 White distilled vinegar Acid bath for reusable stainless Household grade 100 gr steel and brass parts CAUTION DO NOT use muriatic acid for the cleaning of any parts Muriatic acid even when strongly diluted can harm chrome plating and may leave a residue that is harmful to O ring seals and other parts Liquid dishwashing detergent Degreaser for brass and stainless steel parts Household grade diluted with warm water general cleaning solution for plastic rubber and anodized aluminum parts Snoop Leak testing Nupro Company 400 E 345th St Willoughby OH 44094 440 951 7100 2000 Aqua Lung America Inc LPO Second Stage Service amp Repair Manual 17 LPO Second Stage Key Part Description Key Part Description on 9000 11 Overhaul Parts Kit 14 1049 13 Clamp 15 1009 03 Box Bottom poze ee taia dl 16 1009 22 Exhaust Valve Diaphragm ng 17 1009 07 Exhaust Cover 3 1009 09 Retaining Ring 18 8200 15 O ring Fa on Be 19 1041 06 Inlet Fitting 20 1078 05 Adjustable Crown Be Poppet 21 8200 10 O ring a Spring 22 8200 10 O ring 8 1041 34 Poppet Bearing 23 0900 39 LP Hose 9 1009 45 Valve Body 24 8200 11 O ring 10 1009 23 Lever TE 11 1041 29 Washer 25 1009 24 Hose Retaining Clip 12 1025 10 Locknut FB 13 1058 31 Mouthpiece Part numbers in BOLD ITALICS indicate standard overhaul replacemen
11. N Prior to adjusting and testing the LPO second stage regulator the accompanying first stage must be cor rectly serviced adjusted to a stable intermediate pressure of 135 140 psi and fully tested Refer to the appropriate first stage service manual before attempting to perform the adjustment and testing of the LPO second stage 1 Thread the male fitting of the IP hose into the low pressure port of the first stage and apply a torque wrench with 17mm o crow foot to tighten to 40 inch pounds 2 2 Connect an intermediate pressure test gauge P N 1116 10 to the first stage via a separate low pressure hose Attach the female fitting of the second stage low pressure hose to the Inline Adjustment Tool P N 1001 95 by mating the swivel nut onto the male threaded end of the tool Turn the swivel nut clockwise until finger snug 4 Pull back the knob of the tool to retract the adjusting stem and mate the female threaded end of the tool onto the second stage inlet fitting While holding the tool secure turn the valve assembly clockwise until finger snug see Fig 8 9 5 Slowly open the valve of the air supply to pressurize the valve assembly Press the knob of the inline adjustment tool in ward and gently turn the knob until it can be felt that the adjustment stem has mated into the slotted head of the crown Continue to hold the knob inward in order to prevent it from being pressed outward by the internal air pressure a I
12. al Advisor before proceeding any further Warnings Cautions amp 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 may result in serious injury or death if instructions are not followed correctly A CAUTION indicates any situation or tech A nique that will result in potential damage to the product or render the product unsafe if in structions are not followed correctly A NOTE is used to emphasize important points tips and reminders Scheduled Service Regulators should be given the same care and maintenance as life support equipment It is there fore important to perform scheduled overhaul service for the LPO complete with first stage according to the procedures outlined in this manual at least once a year with normal or infrequent use NOTE A unit that receives heavy or frequent use such as in rental instruction or commer cial applications should be serviced at least twice each year or more often depending on the conditions of use and the manner in which itis maintained Refer to the care and mainte nance procedures outlined in the Regulator Owner s Manual 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 a
13. being careful to avoid damaging the box bottom This concludes the disassembly of the LPO second stage Refer directly to Procedure A and Table A titled Cleaning amp Lubrication before proceeding to the Reas sembly Procedures 2000 Aqua Lung America Inc 6 LPO Second Stage Service amp Repair Manual Reassembly Procedures 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 Check all O rings to ensure they are clean and supple before dressing with either Christo Lube or Dow 111 silicone grease WARNING Use only genuine Aqua Lung parts subassem blies 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 prod uct unsafe and could result in serious injury or death Install each exhaust valve diaphragm 16 into the box bot tom 15 by feeding the stem of the diaphragm through the exhaust cover 17 and into the center hole of the valve in the box bottom Gently pull the stem through the hole on the opposite side inside the box bottom until the barb has passed through and is securely seated against the opposite side Carefully snip off the excess material of each stem with a smal
14. d Stage Service amp Repair Manual Table 4 Torque Specifications PART NUMBER DESCRIPTION KEY NUMBER TORQUE 0900 39 LP Hose Female Fitting 23 40 3 inch Ibs 1041 06 Inlet Fitting 19 50 5 inch Ibs Table 5 Test Bench Specifications CONDITION ACCEPTABLE RANGE Leak test Inlet 2 500 3 000 100 psi None Intermediate pressure Inlet 2 500 3 000 100 psi 135 140 psi Intermediate pressure creep Inlet 2 500 3 000 100 psi 5 psi max between 5 to 15 seconds after cycling regulator purge Opening effort Inlet 2 500 3 000 100 psi 8 to 1 4 inch H 0 primary intermediate pressure 135 140 psi 8 to 1 8 inch H 0 octopus Flow effort Intermediate pressure 135 140 psi 6 inches H 0 maximum at 15 SCFM Purge flow Intermediate pressure 135 140 psi 5 0 SCFM flow rate minimum 2000 Aqua Lung America Inc LPO Second Stage Service amp Repair Manual 15 Procedure A Cleaning amp Lubrication All Aqua Lung Regulators Acid Bath Aqua Lung strongly recommends ChromeSafe regulator cleaner P N 0201 05 for clean ing all reusable brass and stainless steel parts ChromeSafe is a specially formulated cleaner that does not harm rubber or Teflon parts yet effectively removes silicone grease corrosion and grime from metal parts leaving only a brilliant shine For best results soak parts in an ultrasonic cleaner for 5 to 15 minutes unless the chrome finish is chipped or flaking
15. e is found discard the crown and do not attempt to reuse If it is in reusable condition set it aside on a soft surface to prevent damage to the sealing edge Fig 1 Crown Removal 10 Press the valve body 9 with lever assembly into the box bottom by inserting a finger through the inlet opening Gen tly lift the assembly out of the box bottom being careful to avoid pulling or tugging on the lever 10 11 Stand the valve assembly vertical on the head of the poppet with the lever facing up and depress the valve body to expose the locknut 12 While holding the valve body fully de pressed apply a 4 nut driver to turn the locknut counter clockwise until it has disengaged from the threads of the poppet see Fig 2 Remove the locknut washer 11 and lever and slowly relax the valve body to lift it off the pop pet 6 and spring 7 Discard the locknut and do not attempt to reuse 12 Closely inspect the shape and condition of the lever to ensure it is not bent corroded or otherwise damaged If any signs of damage or corrosion are found discard the lever and do not Fig 2 Disassembly of Valve reuse 13 Closely examine the poppet spring with a magnifier to ensure it is not damaged bent or corroded If any signs of damage or corrosion are found discard the spring and do not reuse 14 Using a plastic or brass O ring tool lightly stick the center of the LP seat 5 inside the head of the poppet and lift the seat
16. f airflow cannot be heard slowly turn the crown out counter clockwise only until a very slight leak is present b When a slight leak has been established slowly turn the crown clockwise in very small increments of adjustment while lightly depressing the lever to cycle the regulator Pause to listen after each adjustment to determine whether the airflow has stopped It is important to adjust only until the airflow has stopped c When the airflow is stopped and no leakage can be heard after cycling the regulator proceed to adjust the crown further clockwise exactly 180 degrees Then release the knob of the inline adjustment tool to ensure that it no longer makes contact with the crown Fig 8 Inline Tool Connection 1 2 mm freeplay while pressurized CAUTION Over adjustment of the orifice crown will cause excessive spring load in the second stage valve and may severely degrade the performance of the regulator 6 Apply a hand driver with 4 tapered hex to turn the locknut clockwise in very small increments of adjustment only until the lever stands just below its maximum height with a very slight amount 1 2 millimeters of freeplay see Fig 9 Fig 9 Lever Height Adjustment 2000 Aqua Lung America Inc LPO Second Stage Service amp Repair Manual 9 PP load Fig 10 Installing Valve Assembly Fig 11 Purge Cover Alignment 7 Lightly depress the lever several times to cycle the regulat
17. face has been damaged the part must be replaced with new in order to prevent the possibility of leakage DO NOT use a dental pick or any other type of steel instrument While holding the inlet fitting 19 of the second stage secure with a 19mm open end wrench apply a 17mm 6 open end wrench to the female fitting of the LP hose 23 Turn the fitting counter clockwise to loosen and remove the hose from the second stage Remove the O rings 22 amp 24 from the hose and discard Set the hose aside N Carefully snip the plastic mouthpiece clamp 14 and remove the mouthpiece 13 from the box bottom 15 Inspect the mouthpiece to ensure it is free of any tears or cuts that may cause leakage of water into the second stage or other discom fort Discard the mouthpiece or set it aside to be reused depending on its condition 3 While holding the second stage secure firmly grasp the color ring 2 which holds the purge cover 1 and turn it counter clockwise to loosen and remove from the box bottom 4 While holding the color ring with both hands press inward against the top of the purge cover to remove it from the color ring Closely examine the color ring for any signs of thread damage and inspect the purge cover to check for any signs of deterioration distortion or other damage Replace with new if any damage is found or set these parts aside if they are in reusable condition 5 Lift out the diaphragm 4 with retaining ring 3
18. he arms of the lever 10 inside the groove of the valve body straddling the poppet shaft so that the curved portion of the lever faces towards 12 O clock 11 Place the washer 11 over the poppet shaft followed by the locknut 12 with the flat side facing down Being careful to avoid disturbing the lever turn the locknut clockwise by hand to engage the threads of the poppet and then apply a 1 4 nut driver to turn it further only until 1 thread of the poppet shaft is visible above the top of the locknut see Fig 7 12 Hold the valve body and lever stationary and upright with one hand and slowly unscrew the inlet fitting counter clockwise ps Sa a ee to loosen and remove from beneath it while watching to Fig 7 Locknut Preliminary Setting ensure that the lever rises slightly as the poppet shaft retracts into the valve body Remove and discard the previously used LP seat from the inlet fitting 13 After removing the previously used LP seat reconnect the valve body and inlet fitting and tighten finger snug so that they are flush with each other NOTE This concludes the preliminary reassembly proce dures of the main valve assembly Do not proceed to reas semble the LPO second stage any further until first following the adjustment procedures for the valve assembly outlined in the following section 2000 Aqua Lung America Inc 8 LPO Second Stage Service amp Repair Manual Valve Adjustment Procedures CAUTIO
19. he mouthpiece adapter watch the flowmeter gauge and depress the purge button until the second stage valve is completely open The flowmeter gauge must indicate a minimum of 5 0 SCFM 142 Liters per minute If the purge flow is less than 5 0 SCFM refer to Table 1 Troubleshooting 2 When purge flow is correct remove the second stage from the mouthpiece adapter on the flow test bench Shut the valve of the test bench and purge the second stage to depressurize the system Remove the regulator 2000 Aqua Lung America Inc LPO Second Stage Service amp Repair Manual 11 EXTERNAL LEAK TEST 1 After disconnecting the regulator from the flow bench con nect it to a scuba cylinder filled to approximately 3 000 psi Open the cylinder valve to repressurize the regulator and submerge the entire system in a test tank of clean water 2 Observe any bubbles arising from the submerged regulator over a one minute period The recommended time is neces sary due to slower bubble formation that occurs in smaller leaks Bubbles indicate a leak which requires that the system must be disassembled at the source to check sealing surfaces assembly sequence and component positioning in order to correct the problem s NOTE Extremely small leaks may be better detected by A applying a soap solution or Snoop to the leak area Bubble streams will indicate the source of the leak Before disassembling to correct any leaks rinse the entire reg
20. l pair of scissors to Install the O ring 21 onto the crown 20 and carefully insert the threaded end of the crown into the hose connection of the inlet fitting 19 Gently press it in further with the blunt end of the extraction tool P N 1094 36 until it stops see Fig 4 Apply a medium blade screwdriver to the slotted head of the Fig 4 Crown Installation adjustable crown and turn the crown clockwise to engage the threads Continue turning the crown clockwise to the full extent of its thread engagement and stop turning when resistance is felt Then turn the crown out counter clockwise exactly 2 4 turns counterclockwise to arrive at its correct preliminary setting 4 Stand the inlet fitting vertical on a flat surface with the sealing edge of the crown facing up inside Install the O ring 18 into the groove at the base of the threads just above the hex feature 5 Lay the previously used LP seat inside the inlet fitting over the sealing edge of the crown see Fig 5 NOTE It is essential to use a spare LP seat in order to Fig 5 Using Old LP Seat as Spacer prevent damage to the new seat while performing the follow ing steps of the reassembly procedure 6 Place the poppet bearing 8 over the pin of the extraction tool with the square feature facing up Guide the pin of the tool into the open end of the valve body 9 and out through the square hole in its center While sighting th
21. ll procedures before attempting to disassemble or service the LPO second stage 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 maintaining a professional repair facility 3 Before beginning any disassembly it is impor tant to first perform the Initial Inspection proce dure and refer to Table 1 Troubleshooting to determine the possible cause of any symptoms which may be present 4 As each individual regulator is disassembled reusable components should be segregated to prevent them from mixing with non reusable parts or parts from other regulators Delicate parts and those which contain critical sealing surfaces must be protected and isolated from other parts to prevent damage during the clean ing procedure 5 Use only genuine Aqua Lung parts purchased directly from Aqua Lung when servicing any Aqua Lung product Substitution with another manufacturer s parts constitutes an after market modification of the product and renders the original warranty null and void 6 Do not attempt to reuse mandatory replacement parts under any circumstances regardless of the amount of use the product has received si
22. nce it was manufactured or last serviced 7 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 undue stress caused by overtightening 2 LPO Second Stage Service amp Repair Manual Initial Inspection Procedure EXTERNAL INSPECTION 1 Visually inspect the sintered filter to check for any signs that contaminants may have entered the system such as moisture rust aluminum oxide or charcoal NOTE A green discoloration positively indicates that mois ture has entered the regulator and internal corrosion is therefore likely to be found in the first stage A white or rust colored residue usually indicates that the regulator has been used with a corroded aluminum or steel cylinder Advise the customer of the proper methods for maintaining the regula tor and the possible need to obtain service for their cylinder 2 Slide back the hose protector s to inspect the condition of the LP hose at its fittings and along its length Check closely for any signs of blistering or abrasion or corrosion of the fittings 3 Inspect the condition of the mouthpiece to check for torn bite tabs holes or deterioration PRESSURE TEST 1 Prior to performing any disassembly ensure that the second stage is connected to a first stage with a stable intermediate pressure of 135 14
23. or and listen closely to check for the return of any leakage which may indicate that the locknut has been over adjusted If leakage is detected it is important to return the crown and locknut to their original preliminary settings and then repeat steps 5 6 before proceeding any further CAUTION Over adjustment of the locknut will retract the poppet from the crown resulting in leakage past the LP seat Do not attempt to correct this condition by only readjusting the crown further in clockwise Doing so may increase the opening effort and inhalation resistance of the regulator due to excessive spring load in the second stage valve 8 When the crown and locknut are properly set with no leaks and the lever is standing at its correct height turn the valve of the air source completely shut and lightly depress the lever to depressurize the system Disconnect the in line adjustment tool from the second stage valve assembly 9 While holding the lever partially depressed unscrew the inlet fitting from the valve body and set it aside Final Assembly amp Testing Procedures 1 Lay the valve body and lever assembly inside the box bottom with the lever facing up Mate the valve body into the inlet port of the box bottom until it is seated flush against the wall inside see Fig 10 gt While holding the valve body securely seated inside the box bottom and the lever partially depressed mate the shorter threaded end of the inlet fitting
24. ribed proce dures for scheduled annual service Do not attempt to perform partial service NOTE This is a partial list of possible problems and recommended treatments For more information refer to the second stage troubleshooting guide or contact the Repair Department for assistance with problems not described here 2000 Aqua Lung America Inc LPO Second Stage Service amp Repair Manual 13 Table 2 Recommended Tool List PART NO DESCRIPTION APPLICATION 1116 10 I P test gauge Intermediate pressure testing N A 0 120 inch Ibs torque wrench Inlet amp hose fittings installation 9440 22 O ring tools O ring removal amp installation N A Magnifier w illumination Sealing surface inspection N A Ultrasonic cleaner Brass amp stainless steel parts cleaning N A Medium blade screwdriver Crown removal installation N A 17mm s wrench amp crow foot IP hose fitting N A ya nut driver Valve disassembly assembly adjustment 1094 36 Seat extraction installation tool Crown removal amp installation 1001 95 In line adjustment tool Final adjustment amp tuning Table 3 Standard Parts Replacement Schedule PART NUMBER DESCRIPTION KEY NUMBER 1025 10 Locknut 1041 34 Poppet Bearing 1067 38 LP Seat 8200 11 O ring 8200 10 O ring 8200 15 O ring 1049 13 Clamp 1078 22 Exhaust Diaphragm 2000 Aqua Lung America Inc 14 LPO Secon
25. rough the top of 2000 Aqua Lung America Inc LPO Second Stage Service amp Repair Manual 7 the valve body rotate the tool as needed to align the square feature of the poppet bearing with the square hole and press the tool upward to seat the bearing securely in place see Fig 6 When finished check to ensure that the top of the poppet bearing is flush with the top of the valve body 7 Press the new LP seat 5 into the cavity in the head of the poppet 6 with the smooth side facing out 8 Stand the poppet on its head inside the top of the inlet fitting and place the spring 7 over the poppet shaft 9 Hold the inlet fitting secure and mate the valve body with poppet bearing down over the poppet shaft Press the valve body downward to compress the spring while turning it clockwise to engage the threads of the inlet fitting and then continue turning it slowly until the threaded portion of the poppet shaft stands outside the poppet bearing Fig 6 Poppet Bearing Installation CAUTION If resistance is felt immediately stop and un screw the valve body from the inlet fitting to check the align ment of the poppet shaft and poppet bearing Excessive force and misalignment will otherwise result in damage to the poppet bearing requiring its replacement 10 While the inlet fitting and valve body are laying horizontal rotate both parts until the outlet ports of the valve body face towards 6 O clock Lay t
26. t part 2000 Aqua Lung America Inc AQUA LUNG wy 2340 Cousteau Court Vista California 92083 Phone 760 597 5000 Fax 760 597 4900 www aqualung com
27. through the port of the box bottom Turn the inlet fitting clockwise by hand until finger snug and then apply a torque wrench with a 19mm socket to tighten it to a torque measurement of 50 5 inch pounds Lay the purge cover 1 over the top of the color ring 2 with the logo facing up and align the indexed tab on the side of the purge cover with the slot inside the center of the color ring see Fig 11 Press the purge cover into the color ring beginning with the indexed tab When done check to ensure that it is seated evenly around its entire circumference 4 Lay the diaphragm 4 inside the box bottom directly over the lever with its raised center facing up Check to ensure it is evenly seated over the shoulder on all sides at the base of the threads Then place the retaining ring 3 directly over the diaphragm with the raised shoulder facing up and press it firmly downward to ensure it is seated evenly on all sides at the base of the threads 5 Mate the color ring with purge cover over the box bottom and turn the color ring clockwise to tighten until finger snug 2000 Aqua Lung America Inc 10 LPO Second Stage Service amp Repair Manual 6 Install the mouthpiece 13 onto the box bottom and lightly fasten a clamp 14 onto the groove of the mouthpiece Turn the clamp so that the locking tab is facing toward the inlet side of the box bottom and pull the clamp sufficiently snug Snip the extra length with a small pair
28. ulator thoroughly with fresh water and blow out all residual mois ture with filtered low pressure 50 psi air Disassemble and remedy the problem referring to Table 1 Troubleshooting SUBJECTIVE BREATHING TEST 1 Depress the purge cover fully to ensure that an adequate volume of air needed to clear the second stage flows through the mouthpiece Then inhale slowly but deeply from the mouthpiece A properly serviced and adjusted regulator should deliver air upon deep inhalation without excessive inhalation effort freeflow or fluttering of the second stage diaphragm When exhaling there should be no fluttering or sticking of the exhalation valve If any of these problems occur refer to Table 1 Troubleshooting This concludes annual service procedures for the LPO Second Stage 2000 Aqua Lung America Inc 12 LPO Second Stage Service amp Repair Manual Table 1 Troubleshooting Guide LPO Second Stage SYMPTOM Leakage or freeflow from second stage POSSIBLE CAUSE High first stage intermediate pressure should be 135 140 psi 2 LP seat 5 damaged or worn Crown 20 and or locknut 12 adjusted incorrectly lever set too high Crown 20 sealing surface damaged 5 Poppet spring 7 damaged TREATMENT Refer to first stage Troubleshoot ing Guide 2 Replace LP seat 3 Reset crown and locknut to preliminary settings and repeat Adjustment Procedures Replace crown
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