GLACIA Second Stage Regulator
Contents
1. 17 With the front of the second stage housing facing you and the mouthpiece opening flat against the work surface use a small screwdriver to rotate the vane c clip so the open end is facing you While holding the box bottom secure place the tines of the Micra Pre adjustment Tool P N 100168 squarely against the ends of the circlip 26 as shown in Fig 8 Gently press the circlip straight off the vane adjustment switch 27 and set it aside Fig 8 V A S Circlip Removal 18 Pull the vane adjustment switch straight up and out of the outlet boss of the box bottom Remove and discard the o ring 28 and set the switch aside This concludes the disassembly of the Glacia second stage Refer directly to Procedure A and Table A titled Cleaning amp Lubrication before proceeding to the Reassembly Procedures 2000 Aqua Lung America Inc Glacia Second Stage Service amp Repair Manual 7 REASSEMBLY PROCEDURES NOTE Before starting 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 subassemblies and components whenever assem bling any Aqua Lung product DO NOT attempt to substitute an Aqua Lung part with another man2. 2000 Aqua Lung America Inc 10 Glacia Second Stage Service amp Repair Manual 11 Unscrew the connecting nut 11 from the sheath 13 12 Examine a new low pressure seat 7 One side is flat and one side has a molding dimple Press the low pressure seat into the end of the poppet 8 such that the flat side of the seat is facing outward and it is flush with the poppet see Fig 15 Fig 15 LP Seat Installed in Poppet 13 Place the spring 9 over the shaft of the poppet Insert the poppet threaded end first into the threaded side of the valve body see Fig 16a Press the valve body against the work surface to expose the threaded end of the poppet Thread the connecting nut 11 onto the poppet see Fig 16b Fig 16 Installing Poppet into Valve Body 14 Attach an 8mm socket to an inch pound torque wrench While holding the head of the poppet with an 8mm wrench tight the connecting nut to 10 inch pounds see Fig 17 Fig 17 Torque Nut to Poppet 2000 Aqua Lung America Inc Glacia Second Stage Service amp Repair Manual 11 15 With the front of the second stage body facing you place the valve assembly rounded side facing upward into the second stage and insert it into the hole on the left The valve body is keyed so it can only be inserted one way see Fig 18 Fig 18 Installing Valve Body 16 Hold the lever assembly with the lever facing you and the sheath pointing to the left In
3. 345th St Willoughby OH 44094 440 951 7100 2000 Aqua Lung America Inc Glacia Second Stage Key Part Description Key Part Description naman 900010 Overhaul Parts Kit 21 104129 Washer 22 107822 Exhaust Diaphragm 1 109510 Decal 23 104913 Clamp 2 104107 Purge Button 24 109438 Mouthpiece Comfo Bite 3 104143 Front Cover eee 104138 Mouthpiece Octopus 4 104123 Sealing Ring 25 109512 Lip Shield 5 104109 Diaphragm 26 860137 Circlip 6 104102 Exhaust Tee 27 104113 Vane Adjustment Switch 7 106738 LP Seat 28 820010 O ring 8 109501 Poppet 29 104101 Box Bottom 9 104127 Spring 30 820015 O ring 10 109502 Valve Insert 31 109511 Inlet Fitting 11 109503 Connecting Nut 32 100128 Crown 12 109504 Pin 33 820010 O ring 13 109505 Sheath 34 820010 O ring 14 109506 Lever 35 102035 Hose Cousteau 15 109507 Lever Support eea 090015 Hose Titan 16 109509 Ribbed Plug 4 o1 090027 Hose Octopus Yellow 17 957025 O ring 36 957025 O ring Cousteau 18 109508 Insert eae 820011 O ring Titan Octopus 19 820015 O ring 20 102510 Locknut Part numbers in BOLD ITALICS indicate standard overhaul replacement part TECHNICIAN S NOTES AQUA LUNG
4. refer to refer to Zable 1 Troubleshoot ing for corrective actions SECOND STAGE PURGE FLOW TEST 1 Turn off the flowmeter control knob Next while the second stage is still mounted on the mouthpiece adapter watch the flowmeter gauge and depress the purge button until the second stage valve is com pletely 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 16 Glacia Second Stage Service amp Repair Manual EXTERNAL LEAK TEST 1 After disconnecting the regulator from the flow bench connect it to a scuba cylinder filled to approxi mately 3 000 psi Open the cylinder valve to repressurize the regulator and submerge the entire system 1n a test tank of clean water 2 Observe any bubbles arising from the submerged regulator over a one minute period The recom mended time is necessary due to slower bubble formation that occurs in smaller leaks Bubbles indi cate a leak which requires that the system must be disassembled at the source to check sealing sur faces assembly sequence and component positioning in order to correct the problem s NOTE Extremely small leaks m
5. 2000 Aqua Lung America Inc Glacia Second Stage Service amp Repair Manual 3 DISASSEMBLY PROCEDURES NOTE Before performing any disassembly refer to Table 3 which references all mandatory replace ment parts These parts must be replaced with new and must not be reused under any circum stances 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 944022 when removing o rings Once an o ring sealing surface 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 1 While holding the inlet fitting 31 of the second stage secure with a 19mm open end wrench apply an 11 6 open end wrench to the female fitting of the LP hose 35 See Fig 1 Turn the fitting counterclockwise to loosen and remove the hose from the second stage Remove the o rings 34 amp 36 from the hose and discard Set the hose aside Fig I Removing the Hose 2 Remove the lip shield 25 by gently pulling t over the mouthpiece 24 Carefully snip the plastic mouthpiece clamp 23 and remove the mouthpiece from the box bottom 29 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 dis comfort Discard the mouth
6. crown 32 and turn the crown clockwise to engage the threads Continue turning the crown clockwise until it stops Then turn the crown out counterclockwise exactly four 4 complete turns to arrive at its correct preliminary setting Insert the threaded end of the connecting rod 12 into the threaded side of the sheath 13 as shown in Fig 13a Screw the connecting nut 11 into the sheath until fingertip tight see Fig 13b Do not tighten the connecting nut as it will be removed later in the reassembly procedure o Fig 13 Sheath Assembly a Hold the lever retainer 15 with the rounded side facing upward With the tip of the lever pointing downward insert the feet of the lever 14 into the lever retainer see Fig 14a Lift up on the end of the lever so it 1s pointing upward b While keeping the lever in the up position insert the threaded end of the connecting rod through the squared hole in the front of the lever retainer see Fig 14b c While keeping the sheath pressed against the lever retainer drop the washer 21 over the threaded end of the connecting rod see Fig 14c Place a new locknut 20 rounded side first into the nut driver Screw the locknut onto the connecting rod until it is flush with the end of the connecting rod see Fig 14d Starting from the flush position screw the locknut an addition two full turns see Fig 14e Fig 14 Lever Assembly turns past flush
7. 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 2 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 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 th
8. to increase resistance to freezing Refer to the appropriate first stage service manual before attempting to perform the adjustment and testing of the Glacia second stage Thread the male fitting of the IP hose into the low pressure port of the first stage and apply a torque wrench with 17mm crows foot to tighten to 40 2 inch pounds Attach the female end of the hose to the second stage inlet fitting and tighten until finger tight Connect an intermediate pressure test gauge P N 111610 to the first stage via a separate low pressure hose NOTE The preferred air source for final tuning and testing is a flow bench with accurately calibrated gauges If a flow bench is not available a scuba cylinder may be used following the subjective breathing test provided on page 12 Attach the regulator to a 3000 psi air supply Slowly open the valve of the air supply to pressurize the regulator The second stage leaks when pressurized If the second stage begins to leak turn off the air supply and purge the regulator Loosen the locknut about a half turn and repressurize Repeat this step until the second stage does not leak If after two attempts the leak cannot be stopped by loosening the locknut the adjustable crown is probably not set correctly Turn off the air supply and purge the second stage Remove the hose from the second stage While depressing the lever screw the crown in until it stops then back it out four complete turns Reattach t
9. AQUALUNG Authorized Dealer SERVICE amp REPAIR MANUAL Second Stage Regulator Copyright 2000 Aqua Lung America Inc Contents WIV de Za teen ee waana aaa a a ab ageh APAN EAE ENEE een E E E a Na A eden BAE AA Ae KEN 1 Warnings Cautions amp NOLES ae Ka sah Ba a Ga A an ENT Ba a agak a Ba d aa pa 1 Scheduled SOVICO EE 1 CAE EEEE EE 1 initial Inspection PrOcedUufe u aa a 2 External INSPCCU ON ee E aaa ENG NS 2 Poe SOUL lt 1 ee 2 Disassembly PROCCOUI CS a una 3 Reassembly Procedures nenn nnnennnenen 7 POJUSUMENT PLOCEAUFES une 13 Final ASsembDIy amp TOSTING nennen u 14 second Stage Alf le Test eu ehe 15 Second Stage Opening Effort Jeer nennen 15 second Stage Purge FlOW Test aan a a ANGGE a a Ga a a Gae a a Kaga aaa 15 Sa 15 s bjeelive Breathing TEST E 16 Table 1 Troubleshooting Guide saanane anaa eaaa eaaa anaa nean eea nenen ene 17 Table 2 Recommended Tool Dest 18 Table 3 Standard Parts Replacement Schedule sonnennonnennnnnennenrennennn 18 Table 4 Torgue Specification Sasss hun 19 Table 5 Test Bench Specifications ccccccccccsececseeeseeeeeeeeseeeeseeesaneeseeees 19 Procedure A Cleaning amp Lubrication ass eee eee eea eea een ena e nenen 20 Table A Recommended Lubricants amp Cleanere 21 Schematic Drawing Glacia Second Stage ususe renane nean e eee nennen 22 AQUAGJLUNG Service
10. amp Repair Manual Glacia Second Stage Regulator INTRODUCTION This manual provides factory prescribed procedures for the service and repair of the Glacia 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 sponsored 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 Technical 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 technique that will result in potential damage to the product or render the product unsafe if instructions are not followed correctly AN 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 For normal or infrequent use the Glacia first and second stages should be inspected after one year and fully serviced after two years This yearly rotation of inspection and full service shoul
11. ay be better detected by 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 regulator thoroughly with fresh water and blow out all residual moisture with filtered low pressure 50 psi air Disassemble and remedy the problem referring to Table 7 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 ser viced 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 Glacia Second Stage Regulator 2000 Aqua Lung America Inc Glacia Second Stage Service amp Repair Manual SYMPTOM Leakage or freeflow from second stage Low purge or excessive work of breathing full cylinder Water entering second stage Table 1 POSSIBLE CAUSE High first stage intermediate pressure should be 130 135 psi 2 LP seat 7 damaged or worn 3 Crown 32 and or locknut 20 adjusted incorrectly lever set too high Lever ben
12. completely inside the groove Remove and reinstall the circlip if necessary Fig 11 V A S Circlip Installation CAUTION It is important to ensure that the vane adjustment switch o ring and circlip are cor rectly installed in order to maintain the watertight integrity of the box bottom assembly Improper installation may result in flooding of the second stage 5 Install the exhaust valve diaphragm 22 into the box bottom by gently pulling the stem through the hole in the center of the support spokes until the barb has passed through and is securely seated inside the box bottom Carefully snip off the excess material of the stem 6 Install the exhaust tee 6 onto the box bottom by fitting it over one upper corner of the seating flange and then stretching it over the other Firmly press the lower portion of the tee onto the flange until it is completely seated CAUTION Do not use a tool to install the exhaust tee Doing so may cause serious damage to the seating flange requiring replacement of the box bottom 7 Install anew crown o ring 33 and inlet fitting o ring 30 Carefully insert the threaded end of the crown into the hose connection end of the inlet fitting see Fig 12a Gently press it in further with Fig 12 Crown Installation 2000 Aqua Lung America Inc Glacia Second Stage Service amp Repair Manual 10 Apply a medium blade screwdriver to the slotted head of the adjustable
13. d continue for the life of the regulator NOTE A unit that receives heavy or frequent use such as in rental instruction or commercial LA applications should be serviced at least twice each year or more often depending on the conditions of use and the manner in which it is maintained Refer to the care and maintenance procedures outlined in the Regulator Owner s Manual GENERAL GUIDELINES 1 Inorder 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 or service the Glacia 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 profes sional repair facility 3 Before beginning any disassembly it is important to first perform the Initial Inspection procedure and refer to Table I Troubleshooting to determine the possible cause of any symptoms which may be present 2 Glacia Second Stage Service amp Repair Manual 4 As each individual regulator is disassembled reusable components should be segregated to prevent the
14. he hose and repeat the step The second stage does not leak when pressurized If airflow cannot be heard slowly tighten the locknut until the top of the lever is flush with the top of the second stage case see Fig 23 Slide a straight edge across the face of the second stage to ensure the lever is flus see Fig 24 Do not push in on the locknut while tightening as this will cause the lever to drop Once the lever height is correctly set turn off the air supply and purge the second stage Fig 23 Adjusting Lever Height Fig 24 Checking Lever Height 2000 Aqua Lung America Inc 14 Glacia Second Stage Service amp Repair Manual FINAL ASSEMBLY amp TESTING 1 Install anew o ring 17 onto the ribbed plug 16 Thread the plug into the insert until fingertight Attach a 4mm hex key to a torque wrench and tighten the plug to 20 inch pounds see Fig 25 pr r N p A Fig 25 Tourque Plug to xx Inch Pounds 2 Insert the sealing ring 4 into the diaphragm 5 as shown in Fig 26a Insert the diaphragm assembly into the second stage as shown in 26b Make sure the diaphragm is seat against the box bottom Fig 26 Install Diaphragm Assembly 3 With the purge button decal properly aligned slip the left collar of the purge cover over the inlet fitting see Fig 27a Stretch the right collar over the adjustment port work the top and bottom of the purge cover onto the second stage making sure the pu
15. m from mixing with nonreusable 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 cleaning 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 aftermarket modification of the product and renders the original warranty null and void 6 Donot 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 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 INITIAL INSPECTION PROCEDURE EXTERNAL INSPECTION 1 Visually inspect the first stage 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 moisture has entered the regulator and inter nal 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 cus
16. nd replace o ring CAUTION Recommended treatments which require disassembly of the regulator must be performed during a complete overhaul according to the prescribed 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 18 Glacia Second Stage Service amp Repair Manual Table 2 Recommended Tool List PART NO DESCRIPTION APPLICATION N A 944022 V A V A N A N A 19mm 24 wrench amp crows foot NA V A N A 14 nut driver Valve disassembly assembly adjustment N A V A 107846 100168 109436 Table 3 Standard Parts Replacement Schedule PART NUMBER DESCRIPTION KEY NUMBER 102510 106738 LP Seat 957028 17 6 2000 Aqua Lung America Inc QTY Glacia Second Stage Service amp Repair Manual 19 Table 4 Torque Specifications PART NUMBER DESCRIPTION KEY NUMBER TORGUE 090015 102035 LP Hose Female Fitting 35 40 2 inch lbs 090027 109511 Inlet Fitting 31 85 3 inch lbs 109508 Insert 18 85 3 inch Ibs 109509 Ribbed Plug 16 20 2 inch lbs Table 5 Test Bench Specifications TEST CONDITION ACCEPTABLE RANGE Intermediate pressure Inlet 2 500 3 000 100 psi 130 135 psi Intermediate p
17. other damage If deterioration or damage is found discard the diaphragm and do not attempt to reuse 7 While depressing the lever unscrew the adjustable crown 32 about 6 or 7 full turns see Fig 4 unscrew 6 to 7 full turns Fig 4 Loosen Adjustable Crown Eee ee hih Le depress lever 8 Apply an 8mm wrench to the connecting nut 11 and another 8mm wrench to the sheath 13 See Fig 4 Turn the connecting nut counterclockwise to initially loosen it from the sheath Once loosened use your fingers to fully unscrew the sheath from the connecting nut Fig 5 Loosen Connecting Nut and Sheath 2000 Aqua Lung America Inc 10 11 12 13 14 15 Glacia Second Stage Service amp Repair Manual 5 Using a 19mm 34 wrench turn the inlet fitting 31 counterclockwise and remove it from the second stage Carefully insert the pin of the extraction tool P N 109436 into the opposite end of the inlet fitting and through the center of the crown Gently press the crown out onto a padded surface see Fig 6 Remove and discard the inlet fitting o ring 30 and crown o ring 33 Fig 6 Remove Adjustable Crown Closely examine the crown with the use of a magnifier checking for any scoring nicks or other damage to the polished sealing surface If damage 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
18. piece or set it aside to be reused depending on its condition 3 Remove the exhaust tee 6 by holding the second stage firmly in one hand and with the other hand pulling the exhaust tee from one corner see Fig 2 Remove the exhaust valve 22 by grasping it with your fingers and pulling straight outward CAUTION Do not use a tool to remove the ex haust tee Doing so may cause serious damage to the seating flange requir ing replacement of the box bottom Fig 2 Removal of Exhaust Tee 2000 Aqua Lung America Inc 4 Glacia Second Stage Service amp Repair Manual 4 While holding the second stage secure firmly grasp the collar of the front cover 3 which is seated over the ribbed adjustment port of the box bottom opposite of the inlet side Stretch the collar over the adjustment port see Fig 3 and lift the front cover off the box bottom until the opposite collar can be removed from the inlet fitting Fig 3 Removing Front Cover 5 Ifitis necessary press out the stem of the purge button 2 from inside the front cover Closely exam ine the front cover to check for any tears distortion deterioration or other signs of damage Replace it if found or set it aside if it is in reusable condition 6 Lift out the sealing ring 4 and diaphragm 5 from the box bottom Separate these two parts and closely inspect the diaphragm to ensure that it is perfectly round and free of any tears deterioration or
19. ressure 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 1 0 to 1 6 inch H 0 primary intermediate pressure 130 135 psi Flow effort Intermediate pressure 130 135 psi 6 inches H O maximum at 15 SCFM Purge flow Intermediate pressure 130 135 psi 5 0 SCFM flow rate minimum 2000 Aqua Lung America Inc 20 Glacia Second Stage Service amp Repair Manual Procedure A Cleaning amp Lubrication All Aqua Lung Regulators 1 Acid Bath Aqua Lung strongly recommends ChromeSafe regulator cleaner P N 020105 for cleaning 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 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 sur faces 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
20. rge cover is properly seated around the perimeter see Fig 27b 0 Make sure cover is seated properly at the top and bottom Fig 27 Install Front Cover 2000 Aqua Lung America Inc Glacia Second Stage Service amp Repair Manual 15 4 Attach an Me crows foot to a torque wrench Thread the female end of the hose onto the inlet fitting While holding the inlet fitting with a 19mm wrench tighten the hose to 40 2 inch pounds NOTE Before performing the following procedure refer to Table 5 titled Jest Bench Specifications Glacia 2nd Stage NOTE If an accurately calibrated airflow test bench is not available proceed to the Subjective Tuning Procedures provided on the following page SECOND STAGE OPENING EFFORT TEST 1 Connect the first stage regulator to a calibrated test bench and pressurize the system to 3000 100 psi Slowly open the flowmeter control knob start vacuum while watching both the magnahelic gauge and the intermediate pressure gauge 2 When the intermediate pressure begins to drop indicating the second stage valve is open the magnahelic gauge should indicate an opening effort of 1 0 to 1 6 of H O If the opening effort meets this specification you may skip step 3 below 3 If the opening effort does not meet the specifications in step 2 you must readjust the crown 32 In general turning the crown counterclockwise outward will decrease opening effort and raise the lever height tu
21. rning the crown clockwise inward will increase opening effort and lower the lever height Therefore each time the crown is turned in either direction the lever height must be readjusted so it remains flush with the rim of the box bottom The lever height is adjusted by tightening or loosening the locknut 20 To readjust the regulator you will need to remove the hose 35 front cover 3 diaphragm 5 and ribbed plug 16 Refer to Disassembly Procedures steps 1 4 6 11 respectively a To decrease opening effort Turn the crown 1 4 turn counterclockwise Attach the hose to the sec ond stage and pressurize the system Turn the locknut counterclockwise until the lever is flush with the rim of the box bottom Reassemble the second stage an retest the opening effort Repeat this step until the opening effort meets specification b To increase opening effort Turn the crown 1 4 turn clockwise Attach the hose to the second stage and pressurize the system Turn the locknut clockwise until the lever is flush with the rim of the box bottom Reassemble the second stage an retest the opening effort Repeat this step until the opening effort meets specification SECOND STAGE AIR FLOW TEST 1 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
22. rough them prior to installing onto the regulator LUBRICATION AND DRESSING All o rings should be lubricated with either Christo Lube MCG 111 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 Glacia Second Stage Service amp Repair Manual 21 Table A Recommended Lubricants amp Cleaners All Aqua Lung Regulators LUBRICANT CLEANER APPLICATION 51018 5 6 Christo Lube MCG 111 Lubrication Technologies 310 Morton Street Jackson OH 45640 614 286 2644 All o rings seals cylinder valve threads preferred for high pressure DIN systems Dow Corning Corp P O Box 1767 T Midland MI 48640 800 248 2481 All o ring seals Dow Corning 111 pure silicone grease CAUTION Silicone rubber require
23. s 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 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 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
24. sealing edge Remove the ribbed plug 16 by turning it counterclockwise with a 4mm hex key Remove the o ring 17 from the plug and discard While keeping the lever assembly pressed against the sidewall unscrew the insert 18 by turning it counterclockwise with a 19mm 34 wrench The insert is o ring sealed therefore it will need to be pulled out of the second stage once the threads are disengaged Remove and discard the o ring 19 Gently lift out the lever assembly and valve body assembly from the second stage Remove the locknut 20 located inside the lever retainer by turning it counterclockwise with a 1 4 nutdriver Separate the lever assembly parts including the connecting rod 12 sheath 13 lever 14 lever retainer 15 washer 21 and locknut 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 reuse Remove the connecting nut 11 from the poppet stem by holding the head of the poppet 8 with an 8mm wrench and turning the connecting nut counterclockwise with another 8mm wrench see Fig 7 Fig 7 Loosen Connecting Nut and Sheath 2000 Aqua Lung America Inc 6 Glacia Second Stage Service amp Repair Manual 16 Separate the spring 9 from the poppet Using the brass o ring tool or a safety pin pierce the center of low pressure seat 7 and remove it from the poppet
25. sert the lever assembly into the hole on the right see Fig 19 Fig 19 Installing Lever Assembly 17 Place a new o ring 19 onto the insert 18 While keeping the lever assembly pressed against the sidewall screw the insert into the lever retainer until fingertight Attach a 19mm crows foot adapter to a torque wrench and tighten the insert to 85 3 inch pounds see Fig 20 Fig 20 Installing Retainer 2000 Aqua Lung America Inc 12 Glacia Second Stage Service amp Repair Manual 18 Using your fingers thread the sheath onto the connecting nut until fingertight While holding the sheath with a 8mm wrench tighten the connecting nut with another 8mm wrench see Fig 21 Fig 21 Tightening Connecting Nut to Sheath 19 While keeping the valve body pressed against the sidewall thread the inlet fitting 31 into the valve body see Fig 22 Attach a 19mm Goal crows foot adapter to a torque wrench and tighten the inlet fitting to 8543 inch pounds Fig 22 Install Inlet Fitting 20 Install two new o rings 34 amp 36 onto the IP hose 2000 Aqua Lung America Inc Glacia Second Stage Service amp Repair Manual 13 ADJUSTMENT PROCEDURES A CAUTION Prior to adjusting and testing the Glacia second stage regulator the accompanying first stage must be correctly serviced adjusted to a stable intermediate pressure of 130 135 psi and fully tested This lower I P range is required
26. t 5 Crown 32 sealing surface damaged 6 Poppet spring 9 damaged Low intermediate pressure should be 130 135 psi Crown 32 and or locknut 20 adjusted incorrectly lever set too low Intermediate pressure hose 35 clogged or obstructed Leverbent Hole in mouthpiece 24 Demand diaphragm 5 damaged Exhaust diaphragm 22 damaged Vane Adjustment Switch o ring 29 dirty damaged or worn Diaphragm improperly seated between box bottom 29 and sealing ring 4 Box bottom damaged Check exhaust valve sealing surface 7 Inlet o ring 30 damaged 8 Plug o ring 27 worn or damaged Troubleshooting Guide Glacia Second Stage TREATMENT Refer to first stage Troubleshoot ing Guide 2 Replace LP seat 3 Reset crown and locknut to preliminary settings and repeat Adjustment Procedures 4 Replace lever 4 Replace crown 5 Replace poppet spring Refer to first stage Troubleshoot ing Guide Reset crown and locknut to preliminary settings and repeat Adjustment Procedures Clean or replace hose Replace lever Replace mouthpiece Replace demand diaphragm Replace exhaust diaphragm s Disassemble and replace o ring Remove front cover 3 and prop erly reassemble sealing ring with diaphragm Check for distortion Disassemble and replace box bottom 7 Disassemble and replace o ring Disassemble a
27. tomer of the proper methods for maintaining the regulator 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 130 135 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 Troubleshoot ing 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 Immediately 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
28. ufacturer 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 Install the o ring 28 onto the vane adjustment switch 27 2 Mate the stem of the vane switch into its respective hole in the box bottom 29 above the outlet boss and align the mating pin above the positioning guide see Fig 9 When the switch is correctly aligned press it down and into place so that it is properly seated inside the box bottom Fig 9 VA S Alignment 3 Press the circlip 26 into the recessed ledge in the forks of the Circlip Retaining Ring Tool P N 107846 with its flat side facing down and the open end facing out of the tool see Fig 10 The spring tension of the tool will hold the circlip in place while it is being positioned inside the box bottom Flat side faces down Fig 10 Loading Circlip Tool 2000 Aqua Lung America Inc 8 Glacia Second Stage Service amp Repair Manual 4 While holding the vane switch in place set the box bottom on a flat surface with the open side facing down and the switch at 12 o clock Guide the tool holding the circlip into the outlet boss with the top surface of the tool held flush against the ceiling directly behind the vane Press the circlip evenly onto the groove of the vane stem until it snaps audibly into place see Fig 11 Remove the tool and exam ine closely to ensure the circlip is seated
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