Powerline Service Manual
Contents
1. Figure 5 1 3 8 Apply an inch pounds torque wrench with a 16 hex key to tighten the purge rod to a torque measurement of 12 inch pounds 2 Do not overtighten 1 3 9 Insert the narrow stem of the push rod 19 into the small end of the push rod housing and hold it securely in place with the stem protruding from the opposite end 1 3 10 Place the inflator button 22 inside the top of the push rod housing with the opening facing down over the push rod stem Squeeze the push rod and inflator button between thumb and forefinger to fit them securely together see Fig 6 _ Figure 6 1 3 11 Slide the cylindrical screen 18 over the narrow end of the push rod housing until it rests against the base see Fig 7 gt Figure 7 1 3 12 Fit the O ring 20 over the narrow end of push rod housing so that it rests flush against the seating shoulder 1 3 13 Insert the purge rod housing into its opening in the body and press firmly against the button to ensure the O ring seats evenly between the body and the housing 1 3 14 Fit the button cover 23 over the inflator button so that it seats flush against the shoulder of the purge rod housing Sea Quest Powerline Service and Repair Manual 1 3 15 Carefully fit the inflator bezel 24 over the button cover and button assembly and press down while rotating the bezel counter clockwise until a2. 7 1 3 Reassembly Powerline 8 Dual Valve Overhaul Procedures 7 2 1 Disassembly Dual Valve r 10 2 2 Cleaning K 10 2 3 Reassembly Dual 11 Final Inspection 12 Troublesh otin sae dea Ele E aE E E 13 Powerline Parts Lists biceell e a a desea ies 14 Powerline Sche mathe 15 Sea Quest Powerline Service and Repair Manual INTRODUCTION Sea Quest buoyancy compensators and regulators are the prod uct of many years of research and development Sea Quest has utilized proven materials and design to maximize reliability and performance This manual is intended only as a guide for the experienced repair person that has completed a Sea Quest service and repair seminar It is not intended to educate inexperienced repair per sonnel or the consumer in all aspects of Sea Quest regulator and buoyancy compensator repair Sea Quest repair seminars are available periodically to Authorized Sea Quest Dealers Ser
3. sealjuest Powerline Inflator With Dual Valve Service amp Repair Manual for Authorized Sea Quest Service Centers Doc No 42983 1999 Sea Quest Inc 2 Sea Quest Powerline Service and Repair Manual Contents IntPoduetiOn uaa les eae ata Le 3 Safety Precautions te este E a a 3 cach sce dong 3 Maintenance Schedules 2 22 3 Initial Inspection amp Pre Test E 3 Work Arca S amp Required 4 Orrin eaaa ONA EEE EE A shea abate A ean Fas tendons 4 be s sree Soke Reba sched Goa 4 Tools E aae Eees 4 Table 2 Lubricant and Cleaner 5 Powerline Overhaul 6 1 1 015 A aa TEES 6 1 2 Cleaning amp Inspection
4. 1 Using either the pinch method or a plastic O ring removal tool carefully remove the external O rings 32 amp 33 from the valve core retainer Discard both O rings and do not reuse Do not use a brass O ring tool pick or other metal instru ment to remove the O rings from the sealing surfaces of the valve core retainer Doing so may cause permanent damage to the part which will result in leakage if it is not replaced Figure 1 1 1 7 While holding the valve core retainer secure gently apply a pair of needle nose pliers to the valve core 31 and turn it counter clockwise to loosen and remove Discard the valve core and do not attempt to reuse 1 1 8 Closely examine the condition of the valve core retainer to ensure it is completely free of any scratches or damage pay ing particularly close attention to the areas of the external and internal threads and to the O ring sealing surfaces Discard and replace it with new or set it aside to be reused as needed 1 1 9 Mate both pins on the large end of a T Tool P N 42314 into two opposing holes in the inflator bezel 24 See Fig 2 While holding the tool securely engaged turn the bezel counter clockwise to loosen and remove the bezel with the inflator valve subassembly items 18 24 Remove and discard the screen 18 Figure 2 1 1 10 While holding the inflator bezel and button cover 23 secure firmly grasp the push rod housing 21 and pull it stra
5. Valve core 31 corroded or damaged O ring 32 damaged or worn Valve core retainer 34 scratched Inflator body 30 is damaged Replace valve core Replace O ring Replace valve core retainer Replace body Recommended treatments which require disassembly of the inflator must be performed during a complete overhaul according to the prescribed procedures for scheduled annual service Do not attempt to perform partial service For assistance with a problem not described here contact a Sea Quest Technical Advisor 14 Sea Quest Powerline Service and Repair Manual NOTES Sea Quest Powerline Service and Repair Manual 15 REPAIR AND REPLACEMENT PARTS POWERLINE INFLATOR amp DUAL VALVE ASSEMBLY Item Description Part Item Description Part Powerline Dual Valve Airway 42746 20 O ring 15034 Powerline Inflator Assy lower unit 42747 21 Push Rod Housing 15749 n s Dual Valve Assy Acme Thread 42743 22 Button 15747 n s Dual Valve Assy Std Thread 42745 23 Button Cover 15086 n s Overhaul Kit Powerline w Dual Valve 42609 24 Bezel 15746 n s Service amp Repair Manual 42983 25 Mouthpiece 15741 26 Molded Insert 15745 I oap 27 Oral Button 15742 2 Overpressure Spring 15613 28 Gasket 15718 VANE TAIE 9998 29 Oral Valve Spring 15709 4 Gasket 15714 30 Body 15750 5 Body Assy Dual Valve Std Thread 42744 31 Valve Core 45504 Body Assy Dual Valve Acme Thread 42
6. vicing and repair at the repair shop level mainly involves clean ing inspection adjustment and replacement of worn parts If you have any questions on any of the procedures inspec tions or tests please contact Sea Quest at 877 253 3483 SAFETY PRECAUTIONS This manual provides step by step instructions for the disas sembly inspection cleaning reassembly and testing of the Powerline inflation system It is recommended that all steps are followed in the order given Read each section completely PRIOR to beginning work described in that section This will familiarize the repair technician with important precautions to take during each service procedure Pay close attention to all WARNINGS CAUTIONS and NOTES that are intended to draw your attention to items of importance Definition of Warnings Cautions and Notes Indicates a procedure or situation that may result in seri ous injury or death for either the technician or the user if instructions are not followed correctly Indicates any situation or technique that may result in po tential damage to the product or render the product un safe if instructions are not followed correctly Is used to emphasize important points and tips GENERAL PROCEDURES MAINTENANCE SCHEDULES Regulators and inflation systems are subjected to a variety of environmental elements that over time can affect the performance
7. click is felt Then turn the bezel clock wise to engage the threads and continue tightening by hand un til finger snug Be careful to avoid cross threading It is important to rotate the bezel counter clockwise in order to properly seat the threads before tightening it into the body Failure to correctly follow this step may cause permanent dam age to the bezel and the body due to cross threading which could result in leakage if both parts are not replaced 1 3 16 Mate both pins on the large end of the T Tool P N 42314 into two opposing holes in the inflator bezel While holding the tool securely engaged turn the bezel clockwise un til it is flush with the surface of the body see Fig 8 DO NOT overtighten Closely inspect the button cover to ensure that it is seated evenly on all sides and does not appear to be crimped or partially unseated Figure 8 1 3 17 Install the larger external O ring 33 onto the valve core retainer 34 in the groove below the base of the threads Install the smaller O ring 32 over the small end of the retainer so that it rests against the seating shoulder 1 3 18 Insert the valve core 31 into the open end of the valve core retainer with the threaded portion facing up Using a pair of needle nose pliers turn the valve core clockwise to engage the threads of the retainer and tighten further only until it is snug Be careful to avoid cross threading or overtightening
8. is intact and securely attached Discard or set the button aside to be reused as needed 1 1 18 Closely inspect the oral inflator spring under magnifi cation to check for any signs of damage or corrosion If found discard and replace with new 1 1 19 Closely examine the overall condition of the body and inspect all sealing surfaces and female threads under adequate lighting to ensure that the body is free of any scratches cracks or thread damage which may cause leakage or separation from other components If any damage is found discard the body and replace with new 1 2 CLEANING amp INSPECTION 1 2 1 All parts should be cleaned first in a warm not over 120 F mild soap and water solution Use a soft nylon bristle brush to help remove any excess or loose contamination After an initial cleaning in warm soapy water metal parts should be cleaned in an ultrasonic cleaner using the appropriate ultrasonic cleaning solution see Lubricant and Cleaner Table 2 1 2 2 If an ultrasonic cleaner is not available metal parts can be cleaned by soaking the metal parts in a chemical bath solu tion of Oakite 31 see Lubricant and Cleaner Table 2 and agi tating gently for 3 4 minutes Cleaning of metal parts can also be done by soaking in a mild acetic acid solution distilled white household vinegar for 10 15 minutes Cleaning times in excess of those recommended may damage plated parts Never clean parts for longer than specified by t
9. lower barrel of the body Set the ribbed hose aside assembly with a non permanent adhesive It will be necessary to separate this bond prior to performing further disassembly by carefully following the pro cedure outlined below The outer is bonded to the body of the dual valve 2 1 3 Locate the seam that runs along the circumference between the dual valve body and the outer cap 1 where the cap is fastened to the body Using the plastic handle of a medium size screwdriver or similar lightweight blunt instrument rap sharply against all points of the seam to break the adhesive bond see Fig 9 Do not apply excessive force or use a hammer mallet or other heavy instrument Figure 9 2 1 4 While holding the dual valve assembly secure firmly grasp the outer cap and turn it counter clockwise to loosen While maintaining slight inward pressure to counteract the spring pressure inside continue turning the cap until it has disengaged from the valve body and remove the cap and the spring 2 be neath it Closely examine the cap to check for any signs of thread damage distortion cracking or chemical attack that may indicate the use of excessive force or incorrect adhesive during previous service If the cap cannot be turned repeat step 1 to break the adhesive bond 2 1 5 Closely inspect the spring under magnification to check for any signs
10. of the product and as such require frequent tuning and adjust ment As an Authorized Sea Quest Dealer you are advised to inform your staff and customers that Sea Quest regulators and buoyancy compensators require complete servicing at least once a year Under certain circumstances a complete servicing is required every 3 6 months Some of these circumstances are e Frequent or improper use e Inadequate routine freshwater rinsing e Use in dirty or polluted waters e Rental use e Regular use in chlorinated pool water Recommended maintenance schedules are based on average use under normal conditions and assume that recommended pre ventative maintenance and storage procedures have been fol lowed as outlined in the Sea Quest owner s manuals Advise the customer that any adjustments or servicing on Sea Quest regulators and buoyancy compensator inflation systems must be performed by Sea Quest or by an Authorized Sea Quest Dealer that has attended a Sea Quest regulator service seminar INITIAL INSPECTION AND PRE TEST Prior to servicing any B C or regulator Sea Quest recommends that a preliminary inspection of the entire breathing system should be performed This will help the repair technician iden tify any problems that may affect the Powerline Power Inflator Preliminary inspection should include First stage inlet filter If the first stage inlet filter is discol ored or corroded the entire regulator should be completely
11. please contact Sea Quest at 877 253 3483 Sea Quest Powerline Service and Repair Manual 13 3 2 POWERLINE TROUBLESHOOTING SYMPTOM ACTION REQUIRED BC inflates slowly with full tank stable IP Low pressure hose is obstructed Filter 35 is clogged or obstructed Valve core 31 is clogged or corroded Clean or replace hose Replace filter 3 Replace valve core Air does not vent when rapid exhaust valve cable is pulled Rapid exhaust cable 11 is not properly connected to the inflator or dual valve or is damaged Ribbed hose 13 is incorrect length and part number Check condition and connections of cable and correct as needed Verify length and part number of ribbed hose and replace as needed Air leaks continuously from Dual Valve when BC is inflated Dump plug 6 is worn or damaged Dump plug spring 8 is damaged OPRV gasket 4 is damaged OPRV spring 2 is damaged Dual valve body 5 is damaged Replace dump plug Replace dump plug spring Replace gasket Replace spring Replace body External air leakage from inflator O ring 36 33 20 16 is damaged or worn Inflator button cover 23 is damaged or installed incorrectly 3 Push rod 19 is damaged Inflator body 30 is damaged Replace faulty O ring Disassemble and correct as needed Replace purge rod Replace body Internal leakage from inflator
12. 1 3 19 Mate the narrow end of the valve core retainer into the threaded opening of the body and turn clockwise to engage the threads Then apply 16 hex key to the center hole of the retainer and tighten until snug or until the end of the valve re tainer is flush with the surrounding surface of the body Do not overtighten 1 3 20 Lay the inlet filter 35 inside the hole of the body which contains the quick disconnect fitting 37 Check to ensure that it is seated evenly below the threads and reinstall if needed 1 3 21 Install the O ring 36 onto the quick disconnect fitting at the base of the threads Mate the quick disconnect fitting into the inflator body and turn clockwise by hand to engage the threads Continue turning clockwise by hand until it is com pletely threaded into the body and apply a small pair of pliers padded with neoprene or cloth to tighten the fitting until it is snugly seated against the body at the base Do not overtighten directly to the disassembly procedure on the next page and return to perform the following steps when service for the dual valve has been completed If the dual valve assembly requires service proceed 1 3 22 Insert the cable retaining pin 17 partly through one of the holes of the inflator barrel of the body Pull back the lip of the ribbed hose 13 to expose the crimped retainer of the cable 11 and pass the retainer over the pin 1 3 23 When the crim
13. 742 32 O ring 15032 5 1 Connector Seal Gasket 15309 33 O ring 15061 Sump Puy 718559 44 Valve Retainer 15744 7 Poppet Stem 778558 35 Filter 15628 8 Dump Spring 15901 36 O ring 820011 3 Poppet Guide 37 Quick Disconnect Fitting w O ring 090018 10 Cable Hook 15652 11 Cable Assembly 15724 12 Clamp 2 required 15719 13 Ribbed Hose 15734 14 Hose Clip 15735 15 Poppet Oral Valve 15736 16 O ring 15066 17 Cable Pin 15610 18 Filter Screen 15720 19 Push Rod 15743 Items in bold are included in the Overhaul Service Kit 16 Sea Quest Powerline Service and Repair Manual Powerline Schematic 3 m D
14. Grease food grade Chemical Bath Solution Acetic Acid LUBRICANT AND CLEANER TABLE 2 Recommended Type Dow Corning 111 Oakite 31 50 50 mix distilled white vinegar and water Liquid dishwashing detergent Joy diluted with warm water Application All O rings threaded metal parts as indicated Chrome plated brass brass and stainless steel parts Chrome plated brass brass and stainless steel parts General cleaning solution degreaser for plastic and rubber parts leak detection Dow Corning Corp P O Box 1767 T Midland 48640 800 248 2481 Oakite Products Inc 50 Valley Road Berkeley Heights 07922 Local grocery stores Local grocery stores 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 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 evapo rates and provides no lasting benefit 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 deteriora tion of the material Sea Quest Powerline Service and Repair Manu
15. al POWERLINE INFLATOR 1 1 DISASSEMBLY 1 1 1 Firmly grasp the mouthpiece 25 and twist it off the body to remove Closely examine its condition to ensure it is free of any tears or cuts that may cause leakage of water into the sec ond stage or other discomfort Discard or set it aside to be replaced or reused as needed 1 1 2 Snip the clamp 12 which holds the ribbed hose 13 onto the lower valve assembly and work the hose off the power in flator body 30 to expose the cable retaining pin 17 1 1 3 Press the pin out from one side with a pin punch or simi lar tool to release the cable assembly 11 and set the pin and upper dual valve assembly with ribbed hose aside 1 1 4 Using a small pair of pliers which are padded with neo prene or cloth firmly grip the stem of the quick disconnect fit ting 37 and turn the fitting counter clockwise to loosen and remove from the body Remove the O ring 36 from the quick disconnect fitting and discard CAUTION Do not fasten pliers or a wrench onto the nipple of the quick disconnect fitting Doing so may cause permanent damage to the part requiring its replacement 1 1 5 From inside the body or beneath the fitting remove and discard the inlet filter 35 Do not attempt to reuse 1 1 6 Apply 16 hex key to the center of the valve core re tainer 17 While holding the body secure turn the valve core retainer counter clockwise to loosen and remove see Fig
16. e 2 for approved lubricants Sea Quest regulators and inflation systems are intended for use in water temperatures warmer than 45 F 7 C Colder water may cause regulators to be more sensitive to a freeflow condition and can lead to a situation that requires an appro priate response to prevent serious injury or death Users of Sea Quest regulators are advised to ensure that they are ad equately trained to deal with a regulator in a freeflow condi tion or an out of air emergency before attempting to dive ina cold water environment REQUIRED TOOLS POWERLINE INFLATOR TABLE 1 Sea Quest Part No Description 5116236 Seal seat extractor Application Removal installation of crown and filter 778694 Valve Core Tool Removal installation of LP hose valve core 1116 10 test gauge First stage intermediate pressure testing 9440 22 O ring tools Plastic or Brass O ring removal amp installation 41532 LP air nozzle Parts drying 42314 T Tool Removal installation of inflator bezel N A Magnifier w illumination Sealing surface inspection N A Ultrasonic cleaner 60HZ 1 3 amp Brass amp stainless steel parts cleaning N A 946 Hex Key Disassembly assembly of purge rod amp valve retainer N A Inch Pounds Torque Wrench Torque measurement of purge rod Sea Quest Powerline Service and Repair Manual Lubricant Cleaner Silicone
17. et Filter 35 e Valve Core 31 e Screen 18 ment parts are included in the Powerline overhaul All O rings and the above mentioned routine replace service kit Be sure all O rings and other rubber or plastic parts removed before cleaning an ultrasonic cleaner or chemical bath Cleaning solutions may damage these components Sea Quest Powerline Service and Repair Manual 1 3 REASSEMBLY Use only genuine Sea Quest parts subassemblies and com ponents whenever assembling Sea Quest products DO NOT attempt to substitute a Sea Quest 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 1 3 1 Prior to reassembly it is important to perform a final inspection of each part Do not assume that a part is in accept able condition because it has been cleaned or it is new Check all metal parts for excessive wear or corrosion and closely ex amine all sealing surfaces which make contact with O rings for any signs of contamination and or imperfections that may cause leakage past the O ring seal Examine all chrome plated sur faces for any evidence of peeling or flaking of the chrome plat ing Inspect all threads for galling cross threading excessive wear or damage to the chrome plating If any parts show any damage or excess
18. he manufacturer of the solution used After completion of cleaning in any solution thoroughly rinse parts with clean fresh water and blow dry with low pressure 30 psig air Only brass plated brass and stainless steel parts should be immersed in chemical cleaning solutions To avoid injury always use hand and eye protection when handling chemical cleaning solutions 1 2 3 After cleaning all parts should be thoroughly rinsed in fresh water and dried with filtered low pressure 30 psig air to inspect all parts both new and those that are be ing reused to ensure that each part is clean and free of any contamination corrosion or blemish Before performing any reassembly it is important 1 2 4 All O rings should be replaced at every servicing New O rings should be inspected for contamination and or imper fections and lightly dressed with a thin film of approved lubri cant prior to installation See Lubricant and Cleaner Table 2 Do not use any petroleum based lubricants or products or any aerosol silicone sprays on any part of the Powerline In flator or Dual Valve Assembly The petroleum base or pro pellant gas may attack or weaken plastic or rubber parts Refer to Table 2 for a list of approved lubricants 1 2 5 In addition to the O rings the following parts should be routinely replaced at the time of servicing e Clamp 12 e Inl
19. ight away to separate from the bezel Lift out the inflator button 22 from one end and turn the push rod housing over to allow the push rod 19 to drop out Then remove and discard the O ring 20 Closely examine the push rod housing push rod and inflator button to ensure they are in good condition with no visible signs of damage Discard if any damage is found or set these aside if they are in reusable condition 1 1 11 Separate the button cover from the bezel and closely inspect the button cover to check for any signs of damage or wear including tears abrasion or decay If found discard the button cover and do not reuse 1 1 12 Examine the inflator bezel to ensure it is in good condi tion with no signs of cracking or thread damage Discard if any damage is found or set aside if it is in reuseable condition 1 1 13 While holding the oral inflator button 26 completely depressed apply a 16 hex key to the purge rod 15 through the upper barrel of the body and slowly turn the purge rod counter clockwise with steady controlled force until it begins to turn freely see Fig 3 Maintain pressure on the button to prevent the ejection of parts and continue turning the purge rod counter clockwise to loosen and remove Relax the oral infla tor button and set the body with button aside ened a small amount of non permanent thread ad hesive has been applied to the threads during manu facturing or previous service This w
20. ill require that slightly more force should be applied to initially loosen the rod from the threads of the button on the outside of the body ensure that the purge rod does become loos Sea Quest Powerline Service and Repair Manual Figure 3 1 1 14 Using either the pinch method or a plastic O ring re moval tool carefully remove the O ring 16 from the purge rod Discard the O ring and do not reuse Do not use a brass O ring tool pick or other metal instru ment to remove the O ring from the plastic sealing surface of the purge rod Doing so may cause permanent damage to the part which will cause leakage if it is not replaced 1 1 15 Using a plastic O ring tool carefully remove any resi due of thread adhesive from the threads of the purge rod Closely inspect the purge rod for any signs of damage or distortion es pecially around the area of the threads Discard or set the purge rod aside to be replaced or reused as needed 1 1 16 Remove the oral inflator button and spring 29 from the body and separate the gasket 28 from the button Examine the gasket for any signs of wear damage or decay and discard or set it aside to be replaced or reused as needed 1 1 17 Closely inspect the condition of the oral inflator button to check for any signs of damage or distortion and to ensure that the rubber molded insert 26
21. irst in a warm not over 120 F mild soap and water solution Use a soft nylon bristle brush to help remove any excess or loose contamination After an initial cleaning in warm soapy water metal parts should be cleaned in an ultrasonic cleaner using the appropriate ultrasonic cleaning solution see Lubricant and Cleaner Table 2 Sea Quest Powerline Service and Repair Manual 11 Be sure all O rings and other rubber or plastic parts removed before cleaning ultrasonic cleaner or chemical bath Cleaning solutions may damage these components 2 2 2 If an ultrasonic cleaner is not available metal parts can be cleaned by soaking the metal parts in a chemical bath solu tion of Oakite 31 see Lubricant and Cleaner Table 2 and agi tating gently for 3 4 minutes Cleaning of metal parts can also be done by soaking in a mild acetic acid solution 50 50 mix of distilled white household vinegar and water for 10 15 minutes may damage plated parts Never clean parts for longer than specified by the manufacturer of the solution used After completion of cleaning in any solution thoroughly rinse parts with clean fresh water and blow dry with low pressure 30 psig air Only brass plated brass and stainless steel parts should be immersed in chemical cleaning solutions To avoid injury always use hand and eye protection when handling chemical cleaning solutions Cleaning times in exce
22. ive wear they must be replaced with new 1 3 2 Fit the oral inflator gasket 28 over the four guides of the oral inflator button 27 until it is evenly seated at the base of each guide Set the button aside 1 3 3 Install the O ring 16 onto the purge rod 15 into the groove around the base of the large end 1 3 4 Stand the inflator body 30 with the mouthpiece end fac ing up and place the large end of the oral inflator spring 29 inside the opening of the body 1 3 5 Place the oral inflator button directly over the spring and rotate the button as needed to align the indexing tab with the center groove of the body see Fig 4 Depress the oral inflator button and hold it fully depressed while turning the body over so that the barrel faces up Figure 4 1 3 6 Carefully apply only one drop of Loctite brand 425 grade thread adhesive to the center threads of the purge rod stem 1 3 7 Engage the purge rod with a 6 hex key and use the hex key to guide the purge rod through the open barrel of the infla tor body and into the oral inflator button see Fig 5 Slowly turn the purge rod clockwise to engage the threads of the oral inflator button and tighten further until lightly snug Be care ful to avoid cross threading It is imperative to use the specified grade and brand of thread adhesive Other types of thread adhesive may chemically attack the plastic parts and could cause them to separate
23. llar onto the B C manifold Doing so may result in overtightening and or cross threading and could cause permanent damage that will re quire replacement of the entire bladder assembly 3 1 FINAL INSPECTION PROCEDURES Use eye protection while performing the testing procedure Airborne particles can cause eye injury 3 1 1 Verify that the first stage regulator which the Powerline will be used with has been recently serviced and is adjusted to a stable intermediate pressure of 135 147 psi Connect the Powerline to the first stage via the specialty quick disconnect low pressure hose and ensure that a second stage is also connected to function as a safety relief valve in case of an intermediate pressure leak All other first stage ports must be sealed 3 1 2 Connect the first stage to a cylinder that is filled with 3000 psi and slowly open the valve of the supply cylinder to pressurize the regulator 3 1 3 Depress the inflator button of the Powerline inflator several times to ensure that airflow is unobstructed 3 1 4 After releasing the button listen carefully to ensure that the airflow has completely stopped If internal leakage can be heard refer to the Troubleshooting Guide on the following page and correct the problem as needed before proceeding 3 1 5 Hold the inflator button depressed to fully inflate the B C until the overpressure relief valve of the Dual Valve assembly ope
24. ns to release excess pressure inside the bladder of the B C Check the operation of this relief valve by inflating the B C repeatedly to ensure that the valve opens to relieve excess pressure yet closes immediately to allow the bladder of the B C to remain taut and fully inflated 3 1 6 Press the deflation button and pull the rapid exhaust cable to ensure a rapid and unobstructed exhaust using both methods of deflation Fully inflate the B C once again and disconnect the Powerline from the quick disconnect hose to listen closely for any signs of leakage to stand for at least one hour to ensure that none exists If leakage is not immediately detected allow the B C 3 1 7 Ifany leakage is heard or if the B C has begun to deflate within one hour fully inflate the B C once again with the Powerline inflator and hold the entire B C submerge in fresh water for at least one minute to determine the source of leakage During this time carefully observe the Powerline for any signs of bubble formation indicating a leak especially around the inflator buttons and B C connections If a continuous leak is detected the Powerline must be disassembled and examined for damage or contamination of the seals and seating surfaces Refer to the Troubleshooting Table on page 14 and correct as needed The service of the Powerline inflator with Dual Valve is now complete If you have any questions on any of these procedures
25. of damage or corrosion If found discard and replace with new 2 1 6 Remove the valve plate 3 with gasket 4 from the body and remove the gasket from the valve plate Discard the gasket and set the valve plate aside age has been detected from the exhaust valve at the top of the dual valve body Steps 7 9 provide in structions for removing the exhaust valve assembly from the dual valve body for the purposes of replac ing the dump plug 6 Further disassembly is not necessary unless leak 2 1 7 Locate the two holes on opposite sides of the barrel of the dual valve body which hold the arms of the poppet guide 9 To remove the poppet guide and exhaust valve assembly from the dual valve body press the arms of the poppet guide inward by simultaneously inserting two small probes through the op posing holes in the barrel see Fig 10 Figure 10 2 1 8 When the arms of the poppet guide have disengaged from the body firmly grasp the cable and pull the exhaust valve as sembly straight out while holding the body secure This will pull the poppet stem 7 out of the dump plug Remove the dump plug and discard 2 1 9 To replace the dump spring 8 it will be necessary to first remove the cable hook 10 from the cable assembly 11 and then from the poppet stem Pull the poppet stem straight out of the poppet guide and discard the spring 2 2 CLEANING amp INSPECTION 2 2 1 All parts should be cleaned f
26. ped retainer of the cable is securely seated over the pin insert the pin through the opposite hose of the in flator barrel so that it is flush on both sides Fit the ribbed hose over the inflator barrel until it is mated flush at the base of the barrel 1 3 24 Lightly fasten tie strap clamp over the ribbed hose so that it seated evenly inside the groove near the end Pull the end of the tie strap sufficiently snug and snip the excess length with a small pair of scissors or wire cutters 1 3 25 Fit the mouthpiece 25 onto the inflator body so that it is securely seated at the base This concludes the reassembly of the Powerline Inflator If no further disassembly of the Dual Valve is required proceed directly to Section 3 1 Final Inspection Procedures 10 Sea Quest Powerline Service and Repair Manual 2 1 DISASSEMBLY DUAL VALVE the airway perform steps 1 1 2 1 1 3 on page 6 If the Powerline inflator has not been removed from before proceeding with the following procedure 2 1 1 To remove the airway from the B C firmly grip the area of the bladder which surrounds the connection manifold and hold it securely with one hand while turning the retaining collar of the dual valve body assembly 5 counter clockwise to loosen and remove with the other Remove and discard the gasket 5 1 2 1 2 Snip the clamp 12 which holds the ribbed hose 13 onto the body assembly and work the hose off the
27. ser viced Deposits of rust red powder or aluminum oxide gray powder on the filter may indicate that water has entered the SCUBA cylinder and caused internal cylinder corrosion The customer should be notified that their SCUBA cylinder s may be in need of visual inspection cleaning and testing Advise your customers to regularly inspect the inlet filter for any dis coloration or corrosion e High pressure HP and low pressure LP hoses Inspect the hoses carefully for any evidence of cracking tearing or ex cessive abrasion of the outer rubber covering Remove all of the hose protectors and examine the area around the metal fit tings for any damage to the hose Inspect the fittings for signs of excessive corrosion e All chrome plated parts Inspect for any excessive corro sion indicating weak or absent chrome plating Also look for any signs of peeling or flaking of the chrome plating e Regulator pre test A regulator pre test should include all tests outlined in the test section for each regulator A pre test will assist the technician in determining if there are any specific performance deficiencies not mentioned by the customer 4 Sea Quest Powerline Service and Repair Manual INFREQUENTLY USED BUOYANCY COMPENSATORS Do not assume that the Powerline or buoyancy compensator is in good condition because of infrequent use or because it has been in storage Deterioration of the O rings and corrosion can still occ
28. side the dual valve body 2 3 7 Install the gasket 4 onto the valve plate 3 and lay the valve plate inside the dual valve body with the gasket facing down 2 3 8 Place the overpressure spring 2 directly in the center of the valve plate standing up 2 3 9 Carefully apply only one drop of Loctite brand 425 grade thread adhesive to the center thread of the outer cap 1 Mate the cap directly over the spring and valve plate and press down while turning clockwise to engage with the threads of the body Continue turning clockwise by hand until snug 2 3 10 Fit the ribbed hose 13 over the cable assembly and onto the barrel of the dual valve body until it is mated flush at the base of the barrel 2 3 11 Lightly fasten a tie strap clamp over the ribbed hose so that it seated evenly inside the groove near the end Position the end of the clamp to either side where it will not interfere with the connection with the QD hose and pull the end of the tie strap sufficiently snug Snip the excess length with small pair of scissors or wire cutters 2 3 12 Lay the gasket 5 1 flat inside the connection manifold and mate the retaining collar of the body assembly 5 directly over it onto the manifold Gently turn the collar clockwise to engage the threads being careful to avoid cross threading and hold the airway in the desired position while tightening the re taining collar by hand until snug Do not use tools to tighten the retaining co
29. ss of those recommended 2 2 3 After cleaning all parts should be thoroughly rinsed in fresh water and dried with filtered low pressure 30 psig air to inspect all parts both new and those that are be ing reused to ensure that each part is clean and free of any contamination corrosion or blemish Do not use any petroleum based lubricants or products or any aerosol silicone sprays on any part of the Powerline In flator or Dual Valve Assembly The petroleum base or pro pellant gas may attack or weaken plastic or rubber parts Refer to Table 2 for a list of approved lubricants Before performing any reassembly it is important 2 2 5 If overhaul of the dual valve assembly is necessary the following parts should be routinely replaced at the time of ser vicing e Dump Plug 6 e Overpressure Relief Valve Gasket 4 The above mentioned routine replacement parts are included in the Powerline overhaul service kit 2 3 REASSEMBLY DUAL VALVE 2 3 1 Place the dump spring 8 over the poppet stem 7 and insert the poppet stem through the flat side of the poppet guide 9 so that the hole through the end of the stem is visible on the opposite side between the two arms 2 3 2 While holding the poppet secure with the stem extended through the poppet guide press the dump plug 6 onto the barbed tip of the poppet stem until it is securely sea
30. ted flush against the flange that is directly below the barbs 2 3 3 While holding the poppet and poppet guide between thumb and forefinger to compress the poppet spring install the cable hook 10 onto the poppet stem so that it is held inside the single looped end see Fig 11 Figure 11 2 3 4 Install the cable assembly 11 onto the hook by first work ing it over one end and then spread both ends apart to work it over the other see Fig 12a When correctly installed the cable should be held inside the double looped end see Fig 12b Figure 12 12 Sea Quest Powerline Service and Repair Manual 2 3 5 Position the poppet guide with poppet and dump plug outside the barrel of the dual valve body so that the larger rib faces toward the open side of the body away from the collar see Fig 13 Lubricate the dump plug with a small amount of water and align the arms of the poppet guide with the grooves inside the barrel of the body Insert the poppet with dump plug into the barrel only until the ears of the poppet guide rest above the rim MUU UU Figure 13 2 3 6 Squeeze the arms of the poppet guide so that the ears fit inside the barrel and press the poppet guide completely inward until the ears snap into place inside their respective holes Check to ensure that the dump plug has passed through the top of the barrel and remains properly seated over the end of the poppet in
31. ur under these circumstances WORK AREA amp REQUIRED TOOLS Servicing and repair of the Sea Quest Powerline should be car ried out in a clean well lighted work area As each regulator is disassembled all parts should be kept separate from parts of other regulators Some special tools are required for proper disas sembly and reassembly of the Sea Quest Powerline Please see Table 1 below for a list of these tools O RING REMOVAL When removing O rings care must be taken to not damage the regulator surfaces in contact with the O rings Tools used to remove O rings must not have any sharp edges or points that could scratch metal sealing surfaces Sea Quest strongly rec ommends that all O ring removal tools should be made of ei ther brass or plastic LUBRICATION O rings should be lubricated with an approved compound please refer to Table 2 for proper lubricants O rings should be lubri cated only with a very light film of silicone grease Do not use spray aerosol silicone under any circumstances The aerosol propellant may damage the plastic and rubber components of the regulator and the lubricant will quickly evaporate provid ing little or no lasting benefit Do not use any petroleum based lubricants or products or any aerosol silicone sprays to lubricate or clean any part of Sea Quest regulators or inflation systems The petroleum base or propellant gas may attack or weaken the plastic or rubber parts Refer to Tabl
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