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1. 6 Immersion Leak Test 6 Intermediate Over Bottom Pressure Test 7 Disassembly Procedures 7 First Stage Disassembly 7 Cylinder Adapter Disassembly 10 Second Stage Disassembly Left Hand Model 10 Second Stage Disassembly Right Hand Model 12 Reassembly Procedures 15 Cylinder Adapter Reassembly 15 First Stage Reassembly 15 Second Stage Reassembly Left and Right Hand Model 17 Second Stage Reassembly Left Hand Model 18 Second Stage Reassembly Right Hand Model 20 Final Adjustment amp Testing Procedures 22 First Stage Adjustment 0 cc eee 22 Second Stage Adjustment 24 Final Assembly Second Stage RH amp LH Models 25 Final Testing Procedures 25 Pressure Gauge Installation amp External Leak Test 26 Table 1 Troubleshooting Guide Second Stage 27 Table 2 Troubleshooting Guide First Stage Valve Assembly 29 Table 3 Recommended Tool List
2. 30 Table 4 Standard Parts Replacement Schedule 31 Table 5 Torque Specifications 31 Table 6 Test Bench Specifications 32 Procedure A Cleaning amp Lubrication 33 Table A Recommended Lubricants amp Cleaners 34 Exploded Diagram First Stage with Cylinder Assembly 35 Exploded Diagram Second Stage LH Version 36 Exploded Diagram Second Stage RH Version 37 Maintenance Notes 4 38 LUNG H A B D Service amp Repair Manual CHANGE RECORD Change No Title and or brief Change made by description 10 001 3 NOV 10 Adjustment screw 11 clarification 5 Introduction This manual provides factory prescribed procedures for the correct service and repair of the Helicopter Aircrew Breath ing Device H A B D It is not intended to be used as an instructional manual for untrained personnel The proce dures outlined within this manual are to be performed only by personnel who have received factory authorized training through an 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 Warning
3. c77 NOTE If the pin is a Rev A part PN 105323 it is important to discard it and install the SRU40A P retrofit kit PN 100699 which includes a Rev B pin PN 1028 23 Rev A Rev B Figure 9 Rev A 8 Rev B Identification 18 Secure the vise mounting tool in the vise once again so that the high pressure valve body 28 faces straight Up 19 Apply a 3 4 open end wrench over the flat hex surface of the valve body just above the threaded portion of the first stage body Slowly turn the wrench counterclock wise to loosen and remove the valve body from the first stage body being careful to prevent the sudden ejection of internal parts beneath the valve body which are under spring pressure see Figure 10 K Figure 10 Removal of the valve body AQUA LUNG I PT boo 20 Remove the O ring 27 from the male threads and the O ring 30 and backup ring 29 from the stem of the valve body Discard these items and do not reuse 21 Closely examine the seat material inside the end of the valve body stem to check for any excessive wear or damage such as a deep circular indentation in its center If the seat material exhibits any signs of exces sive wear or damage or if the valve exhibited leakage during the initial inspection discard the valve body and do not reuse 22 Loosen the vise to remove the vise mounting tool and first stage Turn the first stage over to allow the spring 26 spring block
4. Figure 6 Loosening indicator ring While holding the cylinder secure turn the first stage as sembly counterclockwise by hand to loosen and remove from the cylinder adapter Lift straight off to remove us ing caution to avoid damaging the high pressure seat of the valve body Gently pull the indicator ring off the stem of the valve assembly Remove the set screw and set both items aside Install a vise mounting tool PN 100395 or a discharged CO cartridge PN 13220 connected to a HP port adapt er PN 102085 into the larger HP port of the first stage body Ensure it is fully seated CAUTION DO NOT use a CO cartridge which may have been discharged Doing so may cause the cartridge to rupture resulting in serious per sonal injury 8 I PT ri 11 Secure the vise mounting tool in a vise so that the low pressure side of the first stage faces straight up see Figure 7 Figure 7 Adjustment screw removal 12 Apply a 5 16 blade screwdriver to the adjustment screw 1 and turn counterclockwise to loosen and remove from the spring retainer 2 Set the adjustment screw aside Lift out the washer 3 and the main spring 4 Examine the main spring with the use of a magnifier checking closely for any signs of pitting rusting or other corro sion which permeates the surface of the metal If per manent corrosion is found discard the spring and do not attempt to reuse _ CAUTION If permanen
5. AQUA CZ LUNG Military amp Professional Operations Authorized Technician SERVICE amp REPAIR MANUAL H A B D Helicopter Aircrew Breathing Device REVISED 02 11 H A B D Service amp Repair Manual COPYRIGHT NOTICE This owner s manual is copyrighted all rights reserved It may not in whole or in part be copied photocopied reproduced translated or reduced to any electronic medium or machine readable form without prior consent in writing from Aqua Lung America Inc 2011 AQUA LUNG AMERICA HABD TECHNICAL MANUAL P N 780303 You can contact a Technical Adviser via e mail at rbedard aqualung com dstancil aqualung com dsumian aqualung com TRADEMARK NOTICE Aqua Lung America is a registered trademark of Aqua Lung America Inc Warnings Cautions amp Notes PAY SPECIAL ATTENTION TO INFORMATION PROVIDED IN WARNINGS CAUTIONS AND NOTES THAT ARE ACCOMPANIED BY ONE OF THESE SYMBOLS WARNING indicates a procedure or situation that if not avoided could result in serious injury or death to the user A CAUTION indicates any situation or technique that A could cause damage to the product and could subsequently result in injury to the user cs NOTE is used to emphasize important points tips and reminders AQUA gt Change ROCOTO AAP 4 Tai 6 6 5 ene oe a a a ee es AA 5 Initial Inspection Procedure 6 External Inspection
6. 4 0 SCFM 142 L P M If the purge flow is less than 44 0 SCFM refer to Table 1 Troubleshooting When purge flow is correct remove the second stage from the mouthpiece adapter on the flow test bench H A B D Service amp Repair Manual 26 4 Subjective Breathing Test Inhale from the second stage while the system is pressurized with 3 000 psi A properly serviced and adjusted H A B D should deliver air upon deep inhalation without freeflow hesitation or fluttering of the second stage diaphragm When ex haling there should be no noticeable resistance felt If any of these problems occur refer to Table 1 Trouble shooting Also depress the purge cover fully to ensure that an adequate volume of air needed to clear the sec ond stage flows through the mouthpiece Sterilize regulator IAW local instructions prior to storage or issue WARNING The H A B D is designed to assist helicopter crewmembers and passengers in emergency egress situations from submerged aircraft It is very critical to ensure that no leak age is present and that the unit has met all re quirements in the Final Testing Procedures out lined above DO NOT issue to a crewmember or passenger any H A B D which exhibits any signs of leakage or unsatisfactory performance until the problem has been thoroughly diag nosed and repairs have been made as needed including the possible replacement of a dam aged component or subassembly PRESSURE GA
7. hex key to the cap plug 9 and turn it counterclockwise to loosen and remove Remove the O ring 10 from either the cap plug or the box bottom and discard Apply a 1 8 blade screwdriver to the slotted head of the black adjustment screw 11 and turn it counterclockwise to loosen and remove Remove the small red washer 12 from the stem of the adjustment screw Inspect these items for any signs of damage If found discard the damaged part and do not reuse Remove the poppet spring 13 and examine it closely through a magnifier Discard if it is found to be damaged or corroded 10 Before proceeding stand the lever 5 up and out of the box bottom and ensure that it is kept standing while performing the following step N CAUTION Failure to stand the lever up before at tempting to move the valve body may result in per manent damage to the box bottom 11 11 12 13 14 While holding the box bottom secure press the male threaded inlet side of the valve body 23 into the box bottom until it stops exposing the recessed head of the lever retaining pin 6 See Figure 13 Turn the box bottom over to drop out the pin and then pull the lever straight down and out of the valve body to remove In spect the lever and pin for any signs of bending distor tion or excessive wear of the plating If any of these conditions are found discard and do not reuse PIN Figure 13 Removal
8. 8 100109 Exhaust Cover DT 100136 Hex Nut 3 4 9 100162 Cap Plug Right Black 28 820310P O ring 10 pk 10 820016P O ring 10 pk 11 100123 Adjustment Screw white Part numbers in BOLD ITALICS indicate standard overhaul replacement parts 12 100173 Washer Red 13 100134 Spring 14 100127 Poppet 15 106738 Disc Seat H A B D Service amp Repair Manual Maintenance Notes 38 39 Maintenance Notes AQUA DLUNC Helicopter Aircrew Breathing Device H A B D Service and Repair Manual AQUA ZI LUNG Aqua Lung 2340 Cousteau Court Vista CA 92081 Telephone 760 597 5000 Fax 760 597 4900 www aqualung com militaryandprofessional ff PN 780303 Rev 02 11
9. Remove and dis card the O ring 21 and set the vane aside H A B D Service amp Repair Manual 12 20 Place a medium blade screwdriver approximately 1 2 This concludes the disassembly of all H A B D components inside the top corner of the exhaust cover 8 and press Refer directly to Procedure A and Table A titled Cleaning amp the exhaust cover between thumb and screwdriver see Lubrication before proceeding to the Reassembly Proce Figure 16 While holding the box bottom horizontal and dures secure sharply pull the exhaust cover out and away from the box bottom only until that corner of the exhaust SECOND STAGE DISASSEMBLY cover is disengaged Right Hand Model 1 While holding the hex nut 27 of the second stage secure with a 3 4 open end wrench apply an 11 16 open end wrench to the female fitting of the IP hose 19 Turn the fitting counterclockwise to loosen and remove the hose from the second stage Remove the O ring 28 from the hose and discard 2 Remove the mouthpiece cover 18 if present and care fully snip the plastic mouthpiece clamp 17 to remove the mouthpiece 19 from the box bottom 22 Inspect the mouthpiece to ensure it is free of any tears or cuts Figure 16 Removal of exhaust cover Step 1 that may cause leakage of water into the second stage or 21 Turn the box bottom vertical and press the disengaged other discomfort Discard the mouthpiece or set it aside side of the exhaust cov
10. of the test gauge Monitor the test gauge while adjusting in this manner until the intermediate pressure locks up at 140 5 psi Turn the cylinder valve completely shut and ensure that the H A B D valve remains shut to the OFF position Open the bleed valve of the test gauge to depressurize and loosen the yoke screw of the fill adapter to remove the H A B D from the supply cylinder Turn the bleed valve of the test gauge completely shut before proceed ing to the next step 9 Attach the H A B D to a supply cylinder that is filled with 3 000 psi via the SCUBA fill adapter 10 With the H A B D cylinder held supported slowly open 11 the supply cylinder valve At the same time it is impor tant to continue monitoring the IP test gauge to ensure that the immediate pressure does not rise above 145 psi If the intermediate pressure rises above 145 psi immediately reopen the bleed valve of the test gauge and shut the valve of the supply cylinder Refer directly to Table 1 Troubleshooting and remedy as needed before proceeding Repeat the adjustment procedure given above to adjust the H A B D first stage intermediate pressure to exactly 140 psi Repeatedly open and shut the bleed valve at least 10 times to ensure that the intermediate pressure locks up consistently and remains stable with no signs of creeping or fluctuation CAUTION Failure to cycle the regulator during ad justment can result in a false readin
11. of lever Turn the box bottom so that the squared end of the valve body faces downward allowing the poppet 14 which contains the LP seat 15 to drop out Lightly stick the center of the LP seat with a plastic or brass O ring tool and lift the seat out being very careful to avoid damag ing the poppet Discard the seat and inspect the poppet for any nicks scratches or wear of the lever groove The through hole beneath the LP seat cavity should be clear and free of any obstructions Discard the poppet or set it aside to be reused depending on its condition While holding the box bottom secure press against the squared side of the valve body to slide it back out Grasp the valve body by the male threaded inlet and pull it completely out of the box bottom Remove and discard the valve body O ring 24 and set the box bot tom aside While holding the valve body secure apply a medium blade screwdriver to the slotted head of the crown 25 and turn the crown counterclockwise until its threads have completely disengaged from the valve body Cg NOTE Because the crown is O ring sealed it will not freely exit the valve body after it has been dis engaged The following step must be performed correctly in order to remove the crown without dam aging its delicate sealing surface AQUA DLUNG ho I Lo Fr kaan 15 When the crown threads have been disengaged from the valve body carefully insert the pin of the seat ex trac
12. por tions mate In order to maintain the correct orienta tion of these parts it is necessary for the retaining pin hole of the valve body to be facing straight up and out of the box bottom while the elliptical hole for the lever faces towards the exhaust valve 10 While holding the lever up gently press the valve body into place until the indexed shoulder is securely seated flush with the surrounding outer surface of the box bot tom If necessary first use the lever to rotate the valve body slightly in either direction until its indexed feature is properly aligned with the box bottom CAUTION Do not apply undue force to press the A valve body into place Doing so may cause the O ring 24 to bind up and become unseated which may allow water to leak into the box bottom see Figure 47 If bind up occurs remove the valve body and check to ensure that the O ring has been dressed with a sufficient amount of lubricant AQUA LUNG Figure 47 O ring bind up 11 Insert the poppet spring 13 into the open end of the valve body and check to ensure that it seats evenly over the stem of the poppet outside 12 Install the red washer 12 onto the stem of the white adjustment screw 11 Mate the stem of the adjustment screw through the open end of the valve body and into the center of the spring and turn it clockwise by hand to engage the threads until it is perfectly flush with the end of the valve body 13 Apply
13. the cap plug 9 clockwise into the valve body and apply the blade of the Micra Retaining Ring Tool PN 100188 to tighten the cap nut snug so that it is seated flush against the box bottom While holding the box bottom secure apply a torque wrench with 13 16 socket LH or 3 4 socket RH to tighten the hex nut snug to a torque measurement of 45 2 inch Ibs Connect the female fitting of the IP hose to the sec ond stage inlet While holding the hex nut of the second stage secure with a 13 16 or 3 4 open end wrench apply a torque wrench with 11 16 crow foot to tighten the IP hose fitting to a torque measurement of 45 3 inch Ibs Install the diaphragm 4 into the box bottom with its raised center facing up and check to ensure it is evenly seated onto the shoulder at the base of the threads Place the purge cover 3 directly over the diaphragm and rotate it as needed to align the holes horizontally straight After rinsing the retaining ring in soapy water fit the re taining ring 2 down over the purge cover with the slotted side facing up and apply one pin of the Micra retaining ring tool PN 100188 to one of the slots While holding the purge cover securely in place turn the retaining ring clockwise until it is lightly snug see Figure 54 Check to ensure that the purge cover has not rotated and correct if necessary before applying both pins of the tool to tighten the retaining ring completely sn
14. time 2 Lay the LP seat 15 into the cavity on the end of the poppet 14 checking first to ensure that the perfectly smooth side of the seat is facing out and press the seat firmly into place 3 Position the valve body horizontally so that the male threaded inlet faces directly to the right and the two outlet ports in the center of the barrel face directly up Locate the small pin hole that is adjacent to these on the right in the raised feature on the inlet side of the valve body 4 Examine the length of the poppet to locate the side which contains an elliptical hole centered between two of the Figure 34 Circlip installation ribs Align the poppet to the left of the squared end of the valve body with the LP seat facing in so that the elliptical CAUTION It is important to ensure that the vane hole is perfectly in line with the center of the outlet ports O ring and circlip are correctly installed in order to and the pin hole in the valve body see Figure 36 maintain the watertight integrity of the box bottom assembly Improper installation may result in flood a KHAN 7 ing of the second stage aaa EY ka HEE c7 NOTE If a pre adjustment tool is not available the Figure 36 Poppet 8 valve body alignment circlip can be pressed into place with the use ofa 5 Slide the poppet completely into the valve body and medium blade screwdriver while the box bottom is check to ensure that the alignment has not been
15. to be come familiar with all procedures before attempting to disassemble the H A B D 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 AQUA JLuNG All service and repair should be carried out in a work area specifically set up and equipped for the task Adequate lighting cleanliness and easy access to all required tools are essential for an efficient repair facility Before beginning any disassembly it is important to first perform the Initial Inspection procedure and refer to Table 1 Troubleshooting to determine the possible cause of any symptoms which may be present As each unit is disassembled reusable components should be segregated and not allowed to intermix with non reusable parts or parts from other units Delicate parts including inlet fittings and crowns which contain critical sealing surfaces must be protected and isolated from other parts to prevent damage during the cleaning procedure Use only genuine Aqua Lung parts provided in the H A B D overhaul parts kits DO NOT attempt to sub stitute an Aqua Lung part with another manufacturer s regardless of any similarity in shape or size Substitution with other manufacturer s parts constitutes an after mar ket modification of the product and renders all warran ties null and void Do not attempt to reuse mandatory replace
16. with the blunt end of the seat extraction tool PN 109436 until it stops see Figure 44 Figure 44 Crown installation Cg NOTE Do not attempt to thread the crown into the valve body at this time Install the O ring 24 into the groove of the valve body near the threaded inlet Lay the LP seat 15 into the cavity on the end of the poppet 14 checking first to ensure that the perfectly smooth side of the seat is facing out and press the seat firmly into place Position the valve body horizontally so that the male threaded inlet faces directly to the left and the two outlet ports in the center of the barrel face directly up Locate the small pin hole that is adjacent to the left of these between the chamber and the groove Examine the length of the poppet to locate the side which contains an elliptical hole centered between two of the ribs Align the poppet to the right of the valve body with the LP seat facing in so that the elliptical hole is perfectly in line with the center of the outlet ports and the pin hole in the valve body see Figure 45 Inlet NG W Heek CM Figure 45 Poppet and valve body alignment Slide the poppet completely into the valve body and check to ensure that the alignment has not been dis turbed If necessary gently rotate the poppet with a blunt probe through the outlet ports of the valve body to correct the alignment With the inlet end of the valve body tilted
17. 25 seat spring 22 and high pres sure seat 21 to drop out Discard the high pressure seat and do not reuse Allow the pin to fall out 22a Alternative Method Using the seat extractor PN 109437 insert it in the body carefully so not to dam age the HP crown and push the diaphragm out Review Step 17a and confirm the pin is correct 23 Closely examine both springs to check for any signs of corrosion that may have resulted from moisture entering the first stage If corrosion is found discard and do not reuse 24 Carefully remove the O ring 23 and backup ring 24 from inside the balancing chamber of the spring block using a brass or plastic O ring removal tool to prevent any damage to the internal sealing surface of the spring block 25 With the use of a magnifier closely examine the seal ing surface inside the balancing chamber of the spring block to check for any signs of permanent corrosion scoring or other damage If found discard the spring block and do not reuse CAUTION The slightest scratch or scar across the sealing surface inside the spring block may cause leakage and could prevent the regulator from achieving a stable lock up of intermediate pres sure N 26 With the use of a magnifier closely inspect the seating surface of the orifice crown inside the first stage body checking to ensure that it is free of any signs of damage or corrosion Cg NOTE Minor blemishes on the crown sealing s
18. 7 inside the body and gently tap it down until it is evenly seated at the base of the female threads Lay the thrust washer 6 inside the body and press it firmly down until it is seated evenly over the diaphragm Lay the spring pad 5 in the center of the diaphragm with the mating tab facing up lubricate the threads of the spring retainer 2 and thread the spring retainer 2 clockwise into the body by hand until snug Install a vise mounting tool PN 100395 or a discharged CO2 cartridge PN 13220 connected to a HP port adapter PN 102085 into the larger HP port of the first stage body Secure the vise mounting tool in a vise with the in let boss of the first stage body facing straight up Apply a torque wrench with 3 4 crow foot or deep socket to tighten the valve body to a torque measurement of 60 5 inch Ibs See Figure 29 i 1 LL Figure 29 Torque measurement of valve body Re secure the first stage inside the vise with the spring retainer facing straight up Apply a torque wrench with 1 crow foot or socket to tighten the spring retainer to a torque measurement of 25 2 ft Ibs See Figure 30 16 20 16 Figure 30 Torque measurement of spring retainer After checking to ensure that the spring pad is positioned over the center of the diaphragm install the main spring 4 into the spring retainer followed by the washer 3 on top of the spring Lightly lubricate the lower thr
19. UGE INSTALLATION amp EXTERNAL LEAK TEST This concludes annual service procedures for the H A B D After final reassembly and adjustment of the H A B D is completed fill the H A B D with 3 000 psi directly from the flow bench or according to the procedures outlined in the H A B D Owner s Manual Turn the H A B D valve to the OFF position and depressurize the air supply and H A B D second stage before removing the fill adapter Mate the threaded end of the pressure gauge assembly into the open HP port and turn clockwise by hand until finger snug Apply a torque wrench with 11 16 socket to tighten the pressure gauge assembly to a torque mea surement of 45 3 inch Ibs DO NOT OVERTIGHT EN Turn the H A B D valve to the ON position to repres surize and check the pressure gauge to ensure that the H A B D cylinder is completely filled to 3 000 psi Submerge the entire system in a test tank of clean water while pressurized in the ON position Observe any bub bles arising from the submerged system over a minimum one minute period The recommended time is necessary 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 As a final test leave the unit pressurized in the ON position at a stable temp
20. aianst the hole of the valve assembly Apply a 1 16 hex key to tighten the set screw clockwise until snug 28 While holding the cylinder secure turn the first stage valve assembly further clockwise until lightly snug The indicator pin should be inside the aperture cutout of the indicator ring marked OFF Resistance should be felt before the indicator pin reaches the far right side of the OFF aperture If not reposition the indication ring Be careful to avoid overtightening 29 Place the banjo fitting of the hose directly over the port swivel and firmly press straight down until it is seated at the base 30 Closely examine the retaining ring 20 to identify that it is flat on one side and slightly rounded on the other Ap ply external circlip pliers to install the retaining ring onto the port swivel with its flat side facing out and check to ensure that it is snugly fastened inside the groove CAUTION Be careful to avoid stretching the retain ing ring while installing and do not use a retaining ring that has become stretched SECOND STAGE REASSEMBLY Left Hand and Right Hand Models 1 Install the O ring 28 into the second stage fitting of the IP hose and set the first stage cylinder assembly aside 2 Install the O ring 21 onto the anti venturi vane 20 3 Mate the stem of the anti venturi vane into its respec tive hole in the box bottom 22 above the mouthpiece boss and align the indi
21. amp testing instructions Readjust crown 25 per final tun ing amp testing instructions Disassemble second stage and replace lever Disassemble second stage and reinstall poppet spring Clean or replace hose Tighten to 45 inch Ibs at second stage fitting Disassemble and replace O ring Replace hose H A B D Service amp Repair Manual SYMPTOM Water entering second stage T 8 Table 1 Continued POSSIBLE CAUSE Hole in mouthpiece 18 Demand diaphragm 4 damaged Exhaust diaphragm 7 damaged Anti venturi vane O ring 21 dirty damaged or worn Diaphragm improperly seated between box bottom 22 and purge cover 3 Box bottom damaged Check exhaust valve sealing surface Valve body O ring 24 damaged End cap O ring 10 damaged 28 TREATMENT Replace mouthpiece Replace demand diaphragm Replace exhaust diaphragm s Replace O ring Disassemble and properly assemble Check for distortion Replace box bottom Disassemble and replace O ring Disassemble and replace O ring P NOTE This is a partial list of possible problems and recommended treat ments For more information refer to the first stage troubleshooting guide or contact Aqua Lung s Technical Services Department for assistance with problems not described here CAUTION Recommended treatments which require disassembly of the regulator must be performed during a complete overhaul accordin
22. cator pin in its locked position When the vane is correctly aligned press it down and into place so that it is properly seated inside the box bot tom see Figure 33 Figure 33 Anti venturi vane installation H A B D Service amp Repair Manual 18 NOTE If the box bottom was identified as a Revi SECOND STAGE REASSEMBLY sion A part during disassembly it is important to Right Hand Model replace it with Revision B box bottom provided in the SRU 40A P retrofit kit Cg NOTE If the second stage is a right hand model 4 While holding the anti venturi vane in place turn the box please refer to the reassembly procedure on page bottom upside down with the open side facing away Lay 21 the circlip 16 inside the mouthpiece boss with its flat the open end directly behind the stem of the vane insert the threaded end of the crown into the inlet end of the valve body 23 Gently press it in further with the 5 Place the tines of the Micra pre adjustment tool PN blunt end of the seat extraction tool PN 109436 until it 100168 squarely behind the circlip and press the circlip stops see Figure 35 evenly onto the groove of the vane stem until it audibly snaps into place see Figure 34 Examine closely to en sure that the circlip is seated evenly over the stem of the vane inside the groove Figure 35 Crown installation Cg NOTE Do not attempt to thread the crown into the valve body at this
23. d male stem of the cylinder adapter 32 2 Lightly lubricate the first two male threads of the adapter with Christo Lube Thread the adapter clockwise into the cylinder 34 until handtight 3 Place bottle in a bottle vise PN 100397 vise insert PN 100398 or place a strap wrench onto the cylinder to hold it secure while it is turned in a counterclockwise direction See Figure 27 Figure 27 Installation of cylinder adapter 4 While holding the cylinder secure apply a torque wrench witha 1 1 8 crow foot or socket to tighten the cylinder adapter to a torque measurement or 25 2 ft Ibs 5 Lightly lubricate the female threads of the cylinder adapter with food grade U S D A approved anti seize lubricant AQUA LUNG CAUTION Be careful to prevent any O rings from coming in contact with the anti sieze lubricant which can cause premature deterioration of nitrile buna and EPDM materials FIRST STAGE REASSEMBLY 1 Install the O ring 13 onto the pressure gauge 14 at the base of the male threads Set the pressure gauge assembly aside 2 Install the backup ring 24 and then O ring 23 into the chamber of the spring block 25 Set this assembly aside 3 While holding the high pressure seat 21 by its stem gently lower it into the inlet boss of the first stage body until it rests flat on top of the orifice crown 4 Place the spring 22 over the stem of the high pressure seat 5 Insert
24. d of the tool onto in very small increments to lower the lever or counter the second stage inlet fitting While holding the tool se clockwise to raise it When the lever is set perfectly flush cure turn the second stage clockwise until lightly snug with the bottom of the gauge release the knob of the see Figure 52 adjustment tool to ensure that it no longer makes contact with the crown Check to ensure that no leakage can be heard 7 Apply a 1 8 slotted blade screwdriver to turn the adjust ment screw 11 counterclockwise to initiate a very slight leak Then turn the adjustment screw back clockwise in very small increments of adjustment only until the exact point where the leak stops Purge the second stage to ensure the leak does not return and then turn the ad justment screw exactly three 360 full turns clockwise further from the point where the leak stopped CAUTION Over adjustment of the adjustment screw can cause excessive spring load in a second Figure 52 Inline adjustment tool connection i i Ha RH model stage valve and may severely degrade the perfor mance of the regulator 4 With the H A B D cylinder held supported slowly open 8 Purge the second stage regulator several times and lis the supply cylinder valve to pressurize the system Lis ten for any leaks Check the lever height again and ten to determine whether air is flowing from the second perform any follow up adjustments as needed to e
25. dis turned upside down Be careful however to avoid turbed If necessary gently rotate the poppet with a blunt damaging the box bottom or vane probe through the outlet ports of the valve body to correct the alignment 6 Install each exhaust valve diaphragm 7 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 against the opposite side Carefully snip off the excess material of each stem with a small pair of scissors leaving about a 1 4 showing 6 Without disturbing the alignment of the poppet inside stand the valve body vertically with the squared end fac ing up While holding it secure in this position closely examine the four flat surfaces to identify one which is slightly narrower than the others Compare this feature to the squared opening in the box bottom to determine how these parts are indexed to fit together see Figure 37 19 AQUA JLuNG maggie a nog umh pen kabatak Figure 38 Installation of lever 10 Press the squared end of the valve body inward in order to hold the retaining pin in place 11 Insert the poppet spring 13 into the open end of the valve body and check to ensure that it seats evenly over the stem of the poppet inside 12 Install the red washer 12 onto the stem of the black adjustment screw 11 Mate the stem of the adjustment screw through the open end of the valve b
26. e Exhaust 1 0 Exhaust Cover Cap plug Left Chrome O ring 10pk Adjustment Screw black Washer Red Spring Poppet Disc Seat Key Part Description 16 860137 Retaining Ring 17 104913 Clamp Strap Black 18 100653 Mouthpiece Cover 19 105831 Mouthpiece 20 100108 Vane Adjusting Anti Venturi 21 820310P O ring 10 pk 22 102844 Box Bottom 6 spokes 23 100245 Valve Body Left 24 820015P O ring 10 pk 25 100128 Crown Orifice 26 820310P O ring 10 pk 27 100236 Hex Nut 13 16 Left 28 820310P O ring 10 pk Part numbers in BOLD ITALICS indicate standard overhaul replacement parts AQUA LUNG 37 Ly l Poo H A B D Second Stage RH Version Key Part Description Key Part Description 211961 Overhaul Second Stage CF MAS RH 16 860137 Retaining Ring 10PK 17 104913 Clamp Strap Black 100699 Retrofit Kit SRU 40A P B 100653 Mouthpiece Cover 19 105831 Mouthpiece Black 1 100652 Cover Hard Purge Guard 20 100108 Vane Adjusting Anti Venturi 2 100119 Ring Retainer 21 820310P O ring 10 pk 3 100104 Cover Front 22 102844 Box Bottom 6 spokes 4 100181 Demand Diaphragm DF in 100145 Valve Body 5 100157 Lever Teflon Coated 24 820314 O ring 6 100132 Pin 25 100128 Crown Orifice 7 100122 Exhaust Valve 1 0 26 820310P O ring 10 pk
27. e body back and forth during assembly 16 Thread the hex nut 27 clockwise onto the inlet end of the valve body and turn by hand until it is finger snug and seated flush against the box bottom 17 Examine the exhaust cover 8 and the box bottom to identify the locking tabs and slots of each respective part Press one corner of the exhaust cover onto the box bottom until the mating tab audibly snaps into place Press the center tab next followed by the tab of the op posite corner and check to ensure that all three tabs are securely locked into their slots 18 Install a mouthpiece 19 onto the box bottom and light ly fasten a mouthpiece clamp 17 onto the groove of the mouthpiece Turn the clamp so that the locking tab is aligned with the air inlet of the box bottom and pull the clamp sufficiently snug Snip the extra length with a small pair of wire cutters cg NOTE The cap plug 9 O ring 10 diaphragm 4 purge cover 3 and retaining ring 2 should not be installed until after the final adjustments and testing procedures have been completed This concludes the reassembly of all H A B D components Refer directly to the section titled Final Adjustment 4 Testing on page xx 20 SECOND STAGE REASSEMBLY Right Hand Model 1 2 6 Install the O ring 26 onto the crown 25 and carefully insert the threaded end of the crown into the inlet end of the valve body 23 Gently press it in further
28. eads with Christo Lube and mate the adjustment screw 1 over the spring and washer and turn it clockwise to engage the threads Apply a 5 16 blade screwdriver to turn the adjustment screw further until it is flush with the top of the spring retainer see Figure 31 Figure 31 Adjustment screw preliminary setting Reposition the first stage horizontal inside the vise and place a new gasket 11a inside the smaller high pres sure port marked HP followed by a new burst disc 11b with the red side facing out Use a non metallic probe to seat these items evenly at the base of the fe male threads Mate a new safety plug 11c into the port and thread clockwise by hand unti snug Apply a torque wrench with 1 2 hex socket to tighten the safety plug to a torque measurement of 90 5 inch Ibs STOP Allow a waiting period of at least 12 hours before proceeding further and then repeat steps 15 amp 19 17 riod of at least twelve 12 hours before proceed ing further and then re torque the spring retainer 2 and safety plug 11c according to steps 15 amp N CAUTION It is important to allow a waiting pe 19 These parts may otherwise lose their original torque values after the seals have become slightly compressed which could result in leakage of air 21 Install the O ring 16 onto the port swivel 17 at the base of the male threads Install the other two O rings 18 into the two gro
29. er 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 must be lubricated only with Christo Lube MCG 111 grease which meets requirements for extreme weather conditions Dress every O ring with a visible film of grease but avoid applying excessive amounts as this will attract particulate matter that may cause damage to the O ring CAUTION Silicone grease and sprays must be strictly avoided for the H A B D since silicone does not provide adequate lubricity in extreme weather conditions H A B D Service amp Repair Manual 34 Io _ Loo I Loo er EE Table A Recommended Lubricants amp Cleaners H A B D LUBRICANT CLEANER APPLICATION SOURCE Christo Lube MCG 111 All O ring seals cylinder valve PN 820466 2 0 oz tube or threads Lubrication Techologies 310 Morton Street Jackson OH 45640 800 477 8704 CAUTION Silicone rubber requires no lubrication or preservative treatment DO NOT apply grease or spray to silicone rubber parts Doing so may cause a chemical break down and premature deterioration of the material Anti Seize Lubricant 80208 H A B D cylinder adapter Permatex Industrial Corp female threads 10 Columbus Blvd Hartford CT 06106 860 520 5000 CAUTION Anti seize lubricant can cause premature deterioration of O ring materials Be careful when apply
30. er up from below rotating it over to be reused depending on its condition the box bottom until the opposite side disengages see 3 Turn the purge guard 1 counterclockwise by hand to Figure 17 loosen and remove from the second stage box bottom 22 4 Mate both pins of the Micra retaining ring tool PN 100188 securely into two opposite slots of the retaining ring 2 Turn the tool counterclockwise to loosen and remove the retaining ring together with the purge cover 3 and demand diaphragm 4 See Figure 19 Figure 17 Removal of exhaust cover Step 2 22 Remove and discard the two exhaust valve diaphragms 7 23 Closely examine the exhaust valves inside the box bot tom and count the number of spokes in each valve to identify whether the box bottom is a Revision A part three spokes or Revision B six spokes See Figure 18 Figure 19 Removal of retaining ring 5 Separate the retaining ring purge cover and diaphragm a lin i ay dh i ser tal Ce x 4 and inspect each of the items closely to ensure that they Ay PA i a oes FF are perfectly round and free of any tears corrosion or kh fe zr A other damage If damage or deterioration is found dis 1 Re i NG mg pA card the item s and do not reuse UN EEN See 6 Apply a 3 4 open end wrench to the hex nut and turn it ai Rw B counterclockwise to loosen and remove Figure 18 Rev A amp Rev B Identification 7 Apply the blade side of t
31. erature for a period of at least twelve hours and check the pressure gauge to deter mine whether any air loss occurs 27 SYMPTOM Leakage or freeflow from second stage Low purge or excessive work of breathing full cylinder External air leakage Immersion Test Table 1 Troubleshooting Guide H A B D Second Stage POSSIBLE CAUSE High first stage intermediate pres sure should be 140 5 psi LP seat 15 damaged or worn Adjustment screw 11 incorrectly adjusted Lever 5 set too high Lever 5 damaged Crown 25 sealing surface damaged or worn Poppet 14 damaged or worn Poppet spring 13 damaged Low intermediate pressure should be 140 5 psi Poppet spring adjustment screw 11 incorrectly adjusted Lever 5 set too low Lever 5 bent Poppet spring 13 incorrectly installed Intermediate pressure hose clogged or obstructed Intermediate pressure hose loose IP hose O ring 28 damaged IP hose leaking AQUA LUNG TREATMENT Refer to first stage Troubleshoot ing Guide Replace LP seat Readjust adjustment screw per final tuning amp testing instructions Readjust crown 25 per final tuning amp testing instructions Disassemble second stage and replace lever Replace crown Replace poppet amp LP seat Replace poppet spring Refer to first stage Troubleshoot ing Guide Readjust adjustment screw per final tuning
32. following step must be performed correctly in order to remove the crown without dam aging its delicate sealing surface 15 When the crown has been disengaged from the valve body carefully insert the pin of the seat extraction tool PN 109436 through the opposite end of the valve body and through the opening in the center of the crown Gently press the crown out see Figure 22 Remove and discard the O ring 26 Figure 22 Removal of crown 16 Closely examine the crown with the use of a magnifier checking for any scoring nicks or other damage to the 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 sealing surface 17 Stand the box bottom upside down with the mouthpiece boss facing forward so that the circlip 16 which holds the anti venturi vane 20 secure is clearly visible If necessary gently turn the circlip with a small probe until both ends are facing toward the open side of the box bottom H A B D Service amp Repair Manual 14 CE NOTE To prevent the circlip from becoming lost in the process of removal place a shop rag over the mouthpiece boss ofthe box bottom before per forming the following step 18 While holding the box bottom secure place the tines of the Micra pre adjustment tool PN 100168 or two medium blade screwdrivers if this specialty tool is not available
33. g of the interme diate pressure 12 Turn the supply cylinder valve completely shut and check to ensure that the H A B D valve remains shut to the OFF position Open the bleed valve of the test gauge to depressurize and remove the test gauge from the IP hose H A B D Service amp Repair Manual 24 SECOND STAGE ADJUSTMENT Cg NOTE Before performing the following procedure refer to Table 6 titled Test Bench Specifications H A B D 1 If necessary connect the H A B D to a flow test bench or a cylinder containing 3 000 psi via the SCUBA fill adapter 2 Attach the female fitting of the intermediate pressure hose to the In Line Adjustment Tool PN 100195 by mat ing the swivel nut onto the male threaded end of the tool Figure 53 Lever height setting RH model Turn the swivel nut clockwise by hand until finger snug 6 To adjust the orifice crown press the knob of the adjust NOTE It will be necessary to hold the valve body ment tool inward and gently turn the knob until it can be secure throughout this procedure in order to pre felt that the adjustment stem has mated into the slotted vent it from exiting the box bottom head of the orifice Continue to hold the knob inward to prevent it from being pressed outward by the internal air 3 Pull back the knob of the tool to retract the adjusting pressure Turn the knob of the adjustment tool clockwise stem and mate the female threaded en
34. g to the prescribed procedures for scheduled annual service Do not attempt to perform partial service 29 SYMPTOM System will not remain depressurized after valve is shut and second stage is purged High or unstable intermediate pressure Low intermediate pressure External air leakage Immersion Test Table 2 Troubleshooting Guide AQUA JLuNG H A B D First stage Valve assembly 1 POSSIBLE CAUSE Indicator ring 15 set incorrectly Valve body 28 is damaged or worn Crown sealing surface of cylinder adapter 32 orifice is damaged First stage improperly adjusted HP seat 21 damaged or worn Spring block O ring 23 damaged or worn Spring block 25 internal surface damaged Crown sealing surface of first stage body 10 damaged Springblock springs 22 amp 26 weakened or damaged Adjustment screw 1 incorrectly adjusted Main spring 4 weakened or damaged Spring retainer 2 loose Spring retainer 2 loose Diaphragm 7 worn or damaged Diaphragm seating surface inside first stage body 10 damaged TREATMENT Loosen set screw 12 and reset indicator ring Replace valve body Replace cylinder adapter Readjust adjustment screw 1 Replace HP seat Replace spring block O ring Replace spring block Polish w tool PN 105997 or replace first stage body Replace springblock springs Readjust adjustment screw per final tuning amp test
35. gns of bending distortion or excessive wear of the plating If any of these conditions are found discard and do not attempt to reuse Figure 21 Removal of lever AQUA DLUNC CE NOTE If corrosion or salt crystals are present it may be necessary to press out the small end of the pin by inserting the pin of the extraction tool PN 109436 through the mouthpiece boss and the opposite side of the valve body 12 Continue pressing the valve body until it can be pulled out and removed from the opposite side of the box bot tom Tilt the female threaded end of the valve body down to drop out the poppet 14 that contains the LP seat 15 Remove and discard the valve body O ring 24 13 Lightly stick the center of the LP seat with a plastic or brass O ring tool and lift the seat out being very careful to avoid damaging the poppet Discard the seat and inspect the poppet for any nicks scratches or wear of the lever groove The through hole beneath the LP seat cavity should be clear and free of any obstructions Dis card the poppet or set it aside to be reused depending on its condition 14 While holding the valve body secure apply a medium blade screwdriver to the slotted head of the crown 25 and turn the crown counterclockwise until its threads have completely disengaged from the valve body Cg NOTE Because the crown is O ring sealed it will not freely exit the valve body after it has been dis engaged The
36. he retaining ring tool to the cap CF NOTE If the box bottom is a Revision A part PN plug 9 and turn it counterclockwise to loosen and re 100644 it is important to discard it and install the move see Figure 20 Remove the O ring 10 from ei SRU4OA P retrofit kit PN 100699 which includes ther the cap plug or the box bottom and discard a Revision B box bottom PN 102844 13 Paa Figure 20 Removal of cap plu 8 Apply a 1 8 blade screwdriver to the slotted head of the white adjustment screw 11 and turn it counterclockwise to loosen and remove Remove the small red washer 12 from the stem of the adjustment screw Inspect these items for any signs of damage If found discard the damaged part and do not reuse 9 Remove the poppet spring 13 and examine it closely through a magnifier Discard if it is found to be damaged or corroded 10 Before proceeding stand the lever 5 up and out of the box bottom and ensure that it is kept standing while performing the following step f CAUTION Failure to stand the lever up before at tempting to move the valve body may result in per manent damage to the box bottom 11 While holding the box bottom secure press against the male threaded inlet side of the valve body 23 until the head of the lever retaining pin 6 is visible see Figure 21 Turn the box bottom over to drop out the pin and then remove the lever Inspect the lever and pin for any si
37. ing instructions Replace main spring Tighten to 25 2 ft lbs Tighten to 25 2 ft lbs Replace diaphragm Replace first stage body af NOTE This ts a partial list of possible problems and recommended treat ments For more information contact Aqua Lung s Technical Services Department for assistance with problems not described here CAUTION Recommended treatments which require disassembly of the A regulator must be performed during a complete overhaul according to the prescribed procedures for scheduled annual service Do not attempt to perform partial service H A B D Service amp Repair Manual 30 EL Lo I I ML I LN hes EE Table 3 Recommended Tool List H A B D PART NO DESCRIPTION APPLICATION N A N A Can be used instead of vise mounting tool N A N A N A N A N A N A N A N A N A N A N A 31 AQUA gt es Loo l o Table 4 Standard Parts Replacement H A B D PART NO DESCRIPTION KEY NUMBER QTY 33 1st stage 30 1st stage 21 26 amp 28 2nd stage 17 2nd stage Table 5 Torque Specifications H A B D PART NO DESCRIPTION KEY NUMBER TORQUE 1006 05 25 4 2 1028 22 1006 27 25 2 90 5 inch Ibs 1028 12 1006 25 IP hose 19 1st Stage 45 3 inch Ibs 1001 36 Hex Nut 24 2nd Stage 45 3 inch Ibs 1002 62 Cap Plug 9 2nd Stage Left Hand 30 2 inch Ibs es ur ur Lu Lu Na Na LUNG H A B D Service amp Repa
38. ing to remove any excess and clean hands afterward if neces sary before handling other parts to prevent any contact between residue and O rings Oakite 31 Acid bath for reusable stainless Oakite Products Inc steel and brass parts 50 Valley Road Berkeley Heights NJ 07922 White distilled vinegar 100 gr Acid bath for reusable stainless Household grade 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 harm ful to O ring seals and other parts Liquid dishwashing detergent Degreaser for brass and stain Household grade diluted with warm water less steel parts general cleaning solution for plastic rubber and anodized aluminum parts 35 Key Part 102881 211962 102871 1 106023 2 100627 3 845097 4 105327 5 101728 6 103425 A 7 103425 B 8 101727 9 102823 10 100601 11 050241 12 100623 13 820319P 14 102873 15 100614 16 820311P 17 102812 18 820312P Description Overhaul Kit 1st STG HABD SRU 40B P Overhaul Service Kit HABD First Stage 10pk CF MAS 1st Stage Assy HABD SRU 40B Spare Adjustment Screw Spring Retainer Washer Nylon Main Spring Main Spring Spring Pad Thrust Washer Diaphragm Pin Support Pin Body First Stage Safety Di
39. ir Manual 32 Table 6 Test Bench Specifications H A B D TEST CONDITION ACCEPTABLE RANGE Leak test Inlet 2 500 3 000 4 100 psi Intermediate Inlet 2 500 3 000 100 psi 140 5 psi pressure Intermediate Inlet 2 500 3 000 100 psi 5 psi max between 5 to 15 pressure creep seconds after cycling regulator purge Opening effort Inlet 2 500 3 000 100 psi 1 6 to 2 2 inch H2O intermediate pressure 140 5 psi Flow effort Intermediate pressure 140 5 psi at 45 5 inches H20 maximum 8 SCFM Purge flow Intermediate pressure 140 5 psi 4 0 SCFM flow rate minimum AQUA JLuNG Procedure A Cleaning amp Lubrication H A B D 1 Acid Bath Aqua Lung strongly recommends Oakite Cleaner for cleaning all reusable brass and stain less steel parts Oakite 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 dam age to sealing surfaces A CAUTION Harsh acids such as muriatic acid may cause damage to parts and must be strictly avoided White vinega
40. ise to ensure that it is open Inspect the nozzle of the SCUBA fill adapter PN 100655 to ensure the O ring is present and seated evenly at the base of the threads and mate the nozzle into the open HP port Turn clockwise by hand until snug DO NOT apply a wrench or otherwise overtighten the fill adapter into the first stage Loosen the fill adapter yoke screw as needed to remove the dust cap from the inlet fitting While supporting the H A B D with one hand place the yoke onto the valve of a supply cylinder that is filled with exactly 500 psi Align the inlet fitting flush against the valve O ring and tighten the fill adapter yoke screw clockwise into the small dim ple on the backside of the cylinder valve until finger snug see Figure 50 Figure 50 SCUBA fill adapter connection with supply cylinder 23 ho bo 1 10 o 4 Check to ensure that the first stage adjustment screw 1 is preset flush with the top of the spring retainer 2 see Figure 51 Push Figure 51 Adjustment screw preliminary setting P NOTE Do not open the H A B D valve at this time This will cause the cylinder to fill with air and will require that the cylinder is emptied in the event that any problems are detected which require the disas sembly of the first stage Check to ensure that the H A B D valve is turned to the OFF position While supporting the H A B D cylinder proceed to slowly open the valve of the
41. limi stage nate leakage CE NOTE If air flow is detected it will be necessary 9 Turn the air supply valve completely shut and check to repeat steps 13 amp 14 of the second stage reas to ensure that the H A B D valve remains shut to the OFF position Purge the second stage to depressurize the system and remove the in line adjustment tool and second stage from the IP hose sembly procedure in order to correctly pre set the crown and adjustment screw 5 Place the notched side of the lever height gauge PN 102868 directly over the rim of the box bottom and ad just the orifice crown as needed to set the lever height so that the top of the lever is flush with the bottom of the gauge see Figure 53 C NOTE Correct intermediate pressure for the H A B D is 140 5 psi with an inlet pressure of 3 000 psi 25 AQUA JLuNG FINAL ASSEMBLY SECOND STAGE Right Hand amp Left Hand Models 1 2a 2b Disconnect the in line adjustment tool from the second stage and the IP hose LH Model Install the O ring 10 securely into the groove of the cap plug 9 Thread the cap plug clock wise into the female threaded end of the valve body 23 Apply a torque wrench with 5 32 hex key to tight en the cap plug to a torque measurement of 30 3 inch Ibs RH Model Install the O ring 10 securely inside the groove between the female threaded end of the valve body and the box bottom Thread
42. ment parts under any circumstances regardless of the amount of use the product has received since it was manufactured or last serviced When reassembling it is important to follow every torque specification prescribed in this manual using a calibrat ed torque wrench Most parts are made of either marine brass or plastic and can be permanently damaged by undue stress H A B D Service amp Repair Manual Initial Inspection Procedure EXTERNAL INSPECTION 1 4 5 When possible inspect the filter of the fill adapter which has been used to fill the H A B D to check for any signs that contaminants such as moisture or particulate mat ter may have entered the system from the charging sys tem Visually inspect the condition of the IP hose along its length to check for any signs of deterioration or damage such as blistering and abrasion and corrosion of the fit tings Closely examine the chrome finish of the first stage to check for any flaking chipping or other damage to the chrome CAUTION Ultrasonic cleaning may cause further chrome loss for parts which show damage to their chrome finish This loss DOES NOT render the part unusable While holding the first stage secure slowly turn the H A B D cylinder counterclockwise only until the indica tor pin can be sighted through the small aperture marked ON see Figure 1 While the valve is in the ON position examine the pres sure gauge to de
43. oceeding Cg NOTE If the lever has been properly installed it will rise slightly as the adjustment screw is turned in 9 While holding the lever securely in place and standing straight up insert the retaining pin 6 into the recessed hole of the valve body past the notched section of the lever and through the poppet inside Gently wiggle the lever back and forth if necessary to cause the pin to seat completely until the head rests flush inside the recess of the valve body see Figure 38 to its preliminary setting If the lever does not rise check to determine if it is properly installed into the valve body H A B D Service amp Repair Manual 14 Apply the large blade of the Micra pre adjustment tool to turn the crown clockwise as far the engagement of the tool will allow see Figure 40 Or if the Micra pre adjustment tool is not available apply a medium blade screwdriver to turn the crown clockwise exactly six 360 full turns 15 Press the square end of the valve body into the box bot tom so that the inlet end exits the opposite side While maintaining pressure against the square end install the O ring 24 into the groove that is exposed outside the box bottom see Figure 41 Figure 41 Installation of valve body O ring Cg NOTE It is important to install the O ring after the valve body has been installed into the box bottom in order to avoid cutting or damaging the O ring while sliding the valv
44. ody and into the center of the spring and turn it clockwise by hand to engage the threads until it is perfectly flush with the end of the valve body Figure 37 Valve body amp box bottom index 13 Apply the small blade of the Micra pre adjustment tool i CAUTION Proper alignment is critical to avoid to turn the adjustment screw clockwise as far as the en damage to the box bottom 7 Continue to hold the valve body secure standing vertical gagement of the tool will allow see Figure 39 Or if the Guide the round inlet opening of the box bottom down pre adjustment tool is not available apply a 1 8 blade over the valve body until the indexed features of both screwdriver to turn the adjustment screw clockwise ex parts can be visually aligned with each other Press the actly 360 full turns box bottom completely down over the valve body until the squared end of the valve body is protruding out of the opening 8 Insert the notched end of the lever 5 into the elliptical hole of the valve body that is Just below the recessed pin hole Stand the lever up vertically straight out of the box bottom and hold it securely in place to prevent it from falling out Cg NOTE If the lever cannot be easily inserted into the valve body the poppet is not correctly aligned inside Remove the valve body to disassemble and repeat steps 10 12 to realign the poppet as needed Figure 39 Adjustment screw pre set adjustment before pr
45. op posite corner and check to ensure that all three tabs are securely locked into their slots Install the mouthpiece 19 onto the box bottom and lightly fasten a mouthpiece clamp 17 onto the groove of the mouthpiece Turn the clamp so that the locking tab is aligned with the air inlet of the box bottom and pull the clamp sufficiently snug Snip the extra length with a small pair of wire cutters Cg NOTE The cap plug 9 O ring 10 diaphragm 4 purge cover 3 and retaining ring 2 should not be installed until after the final adjustments and testing procedures have been completed This concludes the reassembly of all H A B D components Refer directly to the section titled Final Adjustment 4 Testing on page 22 22 Final Adjustment amp Testing Procedures FIRST STAGE ADJUSTMENT 1 CAUTION Do not proceed unless step 21 of the first stage reassembly procedure has been completed The spring retainer 2 and safety plug 11c may otherwise not remain torqued to their correct values which could lead to a pos sible airleak situation NOTE The following procedure is for SCUBA bot tle HABD charging Follow instructions on the MRS Ill or local instructions for alternate charging meth ods Connect the intermediate pressure test gauge to the female fitting of the IP hose and tighten the hose fitting onto the gauge by hand until finger snug Turn the bleed valve knob of the gauge counterclockw
46. ounterclockwise to loosen and remove the hose from the second stage Remove the O ring 28 from the hose and discard Remove the mouthpiece cover 18 if present and care fully snip the plastic mouthpiece clamp 17 to remove the mouthpiece 19 from the box bottom 22 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 discomfort Discard the mouthpiece or set it aside to be reused depending on its condition Turn the purge guard 1 counterclockwise by hand to loosen and remove from the second stage box bottom 22 10 Mate both pins of the Micra retaining ring tool PN 100188 securely into two opposite slots of the retaining ring 2 Turn the tool counterclockwise to loosen and remove the retaining ring together with the purge cover 3 and demand diaphragm 4 See Figure 12 Figure 12 Remove retaining ring Separate the retaining ring purge cover and diaphragm and inspect each of these items closely to ensure that they are perfectly round and free of any tears corrosion or other damage If damage or deterioration is found discard the item s and do not reuse C NOTE Newer versions of the purge cover do not feature the word Micra If no damage is found the old purge covers may still be used Apply a 13 16 open end wrench to the hex nut and turn it counterclockwise to loosen and remove Apply a 5 32
47. oves on opposite sides of the orifice of the port swivel 22 Resecure the first stage horizontally inside the vise with the IP port facing up Mate the port swivel into the IP port and turn clockwise to engage the threads Apply a torque wrench with 5 32 hex key socket to tighten to a torque measurement of 60 3 inch Ibs Cg NOTE If the port swivel was identified as a Revi sion A part during disassembly it is important to replace it with the Revision B port swivel that is pro vided in the SRU 40A P retrofit kit 23 Loosen the vise to remove the first stage and remove the vise mounting tool from the high pressure port 24 Mate the stem of the valve assembly through the flat side of the indicator ring 15 so that the indicator ring is flush against the first stage body and the OFF aperture is facing down 25 While holding the first stage and indicator ring together mate the first stage valve assembly into the cylinder adapter Be careful to avoid contact with the anti sieze lubricant While holding the cylinder secure turn the first stage clockwise by hand and stop when resistance is felt 26 Turn the indicator ring clockwise to align the set screw hole with the female threaded hole of the valve assem bly which is to the immediate right of the indicator pin See Figure 32 Figure 32 Indicator ring alignment AQUA LUNG 27 Mate the male end of the set screw 12 through the indicator ring ag
48. r although less effective is one suitable substitute for Oakite f 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 Cg NOTE Although Oakite contains a degreasing agent cleaning heavily greased parts in Oakite 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 tooth brush 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 Oakite cleaner as needed and not allow any solution to ent
49. rst disc assembly 11 See Figure 4 Remove the shop rag to allow the safety disc and gasket to fall out of the first stage body Discard these items and do not reuse 3a Alternate method Pierce the safety disc with the point 4 ed o ring tool Remove disc and discard gasket Use caution not to damage the seating surface Fig 4 Burst disc removal Apply external circlip pliers PN 111100 to the retaining ring 20 which holds the IP hose 19 in place Spread the retaining ring and remove from the IP port swivel 17 Discard the retaining ring and do not attempt to reuse Firmly grasp the banjo fitting of the IP hose and pull it straight off the port swivel Set the hose and second stage aside H A B D Service amp Repair Manual 6 r 10 AN bo Apply either a 5 16 blade screwdriver Revision A or a 5 32 hex key Revision B to the port swivel and turn counterclockwise to loosen and remove Remove and discard all three O rings 16 8 18 NOTE If the port swivel is a Rev A part PN 100612 it is important to discard it and install the SRU40A P retrofit kit PN 100699 which includes a Rev B port swivel PN 102812 See Figure 5 Rev A Figure 5 Rev A amp Rev B identification Apply a 1 16 hex key to the set screw 12 which holds the indicator ring 15 in place Turn the screw counter clockwise to loosen until the indicator ring can turn freely see Figure 6
50. s 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 A that may result in serious injury or death if in structions are not followed correctly that will result in potential damage to the product or render the product unsafe if instructions are not followed correctly A CAUTION indicates any situation or technique sg A NOTE is used to emphasize important points tips and reminders Scheduled Service The H A B D should be given the same care and mainte nance as life support equipment It is therefore important to perform scheduled overhaul service for the complete unit according to the procedures outlined in this manual on a regularly scheduled basis at least once a year with normal use Ce NOTE H A B D units manufactured prior to Sep tember 1 1999 may require the installation of the SRU40A P Extreme Weather Retrofit Kit PN 1006 99 in addition to the mandatory replacement parts provided in the H A B D overhaul parts kits This manual contains important information regarding the proper identification of certain components to help determine whether this retrofit may be need ed 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
51. sassembly Procedures Cg NOTE Before performing any disassembly refer to the schematic drawing which references all man datory replacement parts These parts should 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 AQUA LUNG CAUTION Use only a plastic or brass O ring re moval tool PN 944022 when removing O rings to prevent damage to the sealing surface Even a small scratch across an O ring sealing surface could result in leakage Once an O ring sealing surface has been damaged the part must be re placed with new DO NOT use a dental pick or any other steel instrument FIRST STAGE DISASSEMBLY 1 Apply an 11 16 open end wrench to the flats of the pres sure gauge assembly 14 and turn the gauge counter clockwise to loosen and remove from the first stage Re move and discard the O ring 13 and set the pressure gauge assembly aside Apply a 1 2 open end wrench to the safety plug 11c and turn counterclockwise to loosen and remove Dis card the safety plug and do not attempt to reuse Check to ensure that the H A B D valve is closed to the OFF position While holding a shop rag over the first stage to cover the open HP port of the safety plug direct low pressure air 120 140 psi through the open HP port to dislodge the safety disc 11b and gasket 11a of the safety bu
52. sc Assy 3000 psi Set Screw O ring 10 pk Pressure Gauge Assy Ring Indicator O ring 10 pk LP Port Swivel w Hex Slot O ring 10 pk AQUA LUNG H A B D First Stage with Cylinder Assembly Key Part Description 19 102835 Hose Assy 20 20 860065 Hose Retaining Ring 21 105321 HP Seat Black Rubber 22 101504 Spring 23 820306 O ring 24 828005 Back up Ring 25 105324 HP Spring Block 26 104613 Spring 27 820314 O ring 28 102822 Valve Assy 29 828510 Backup Ring 30 820310P O ring 10 pk 31 100609 Indicator Pin 32 100605 Cylinder Adapter 33 820316P O ring 10 pk 34 079105 1 5 cf Cylinder Black N S 100699 Retrofit Kit Extreme Weather SRU 40A P Part numbers in BOLD ITALICS indicate standard overhaul replacement parts H A B D Service amp Repair Manual 36 es H A B D Second Stage LH Version Key Part 102882 102872 100699 1 100652 2 100119 3 100104 4 100181 5 100257 6 100132 7 100122 8 100109 9 100262 10 820017P 11 100223 12 100173 13 100134 14 100127 106738 Description Service Kit HABD 2nd Stage SRU 40B P 2nd Stage Assy HABD SRU 40B P SPARE Retrofit Kit Extreme Weather SRU 40A P Cover Hard Purge Guard Ring Retainer Cover Front Demand Diaphragm Lever Coated Left Pin Valv
53. sely to check for any bubble streams to locate the source of any leakage Note the source of any leakage found and refer to Table 1 Troubleshooting to determine its possible cause Turn the valve to the OFF position and depress the sec ond stage purge to completely depressurize the system see Figure 3 Wait at least five minutes and depress the second stage purge to determine whether any sig nificant air pressure has built up inside the IP hose and second stage valve Figure 3 OFF position f CAUTION Do not turn the first stage any further than is necessary to shut the valve Doing so may cause premature wear or damage to the main valve and indicator pin Cg NOTE Ifa buildup of air pressure occurs inside the IP hose and second stage valve after the H A B D valve has been turned to the OFF position and the system has been depressurized the valve body 28 must be replaced with new INTERMEDIATE OVER BOTTOM PRESSURE TEST 1 Depress the second stage purge to determine once again that the system is not pressurized While holding the hex nut 27 of the second stage secure with a 13 16 open end wrench apply an 11 16 open end wrench to the female fitting of the IP hose Turn the fitting coun terclockwise to loosen and remove the hose from the second stage 2 Connect the intermediate pressure test gauge to the fe male fitting of the IP hose and tighten the hose fitting by hand un
54. slightly down ward to hold the poppet in place rotate the valve body 180 degrees so that the recessed hole for the lever re taining pin is visible and facing up While holding the valve body in this position insert the threaded inlet end into the circular opening of the box bottom Pass the valve body through until only 2 3 threads protrude out side the opposite side of the box bottom and the re cessed pinhole remains visible 21 8 Insert the notched end of the lever 5 into the elliptical hole of the valve body that is just below the recessed pin hole Stand the lever up vertically straight out of the box bottom and hold it securely in place to prevent it from falling out C NOTE If the lever cannot be easily inserted into the valve body the poppet is not correctly aligned inside Remove the valve body to disassemble and repeat steps 11 13 to realign the poppet as needed before proceeding 9 While holding the lever securely in place and standing straight up insert the retaining pin 6 into the recessed hole of the valve body past the notched section of the lever and through the poppet inside Gently wiggle the lever back and forth if necessary to cause the pin to seat completely until the head rests flush inside the recess of the valve body see Figure 46 saute amp ing Figure 46 Installation of lever NOTE The valve body and box bottom are both indexed with four flat surfaces where their inlet
55. squarely against the ends of the circlip see Figure 23 Gently press the circlip off the anti venturi vane and set it aside Figure 25 Removal of exhaust cover Step 2 22 Remove and discard the two exhaust valve diaphragms 7 23 Closely examine the exhaust valves inside the box bot tom and count the number of spokes in each valve to identify whether the box bottom is a Revision A part three spokes or Revision B six spokes See Figure 26 Figure 23 Removal of anti venturi vane KG F hi i FN bog 19 Pull the anti venturi vane straight up and out of the An res z Pa mouthpiece boss of the box bottom Remove and dis HA RES RE F Ke l il Pn card the O ring 21 and set it aside Ce LAT ic I IE 2 NM Min 20 Place a medium blade screwdriver approximately 1 2 Res FwB inside the top corner of the exhaust corner 8 and press Figure 26 Rev A amp Rev B Identification the exhaust cover between thumb and screwdriver see Figure 24 While holding the box bottom horizontal and CE NOTE If the box bottom is a Revision A part PN secure sharply pull the exhaust cover out and away 100644 it is important to discard it and install the from the box bottom only until that corner of the exhaust SRU40A P retrofit kit PN 100699 which includes cover is disengaged a Revision B box bottom PN 102844 This concludes the disassembly of all H A B D components Refer directly
56. supply cylinder while closely monitoring the IP test gauge to ensure that the intermediate pressure does not rise above 150 psi WARNING If the intermediate pressure rises above 150 psi shut the cylinder valve immedi ately Refer to Table 1 Troubleshooting and remedy as needed before proceeding any fur ther Failure to shut the cylinder valve before the intermediate pressure exceeds 400 psi will result in damage to the test gauge and may cause serious personal injury Proceed to slowly turn the knob of the bleed valve clock wise until it is completely shut while continuosly monitor ing the test gauge to ensure that the intermediate pres sure does not rise above 150 psi cg NOTE If the intermediate pressure continues to rise above 150 psi immediately reopen the bleed valve of the test gauge and shut the valve of the supply cylinder Refer directly to Table 1 Trouble shooting and remedy as needed before proceed ing any further T AQUA GS LUNG o Il PT kaaa When the intermediate pressure has stabilized before 150 psi apply a 5 16 blade screwdriver to turn the first stage adjustment screw in small increments of adjust ment Turn the adjustment screw clockwise to raise the intermediate pressure or counterclockwise to lower it While turning the adjustment screw it is important at the same time to also turn the bleed valve of the test gauge briefly open and shut to maintain an accurate reading
57. t corrosion is found dis AN card the spring and replace with new DO NOT at tempt to reuse 14 Apply a 1 open end wrench to the spring retainer and turn the spring retainer counterclockwise to loosen and remove from the first stage body 10 Inspect the spring retainer to check for any signs of oxidation or corrosion such as pitting or thread damage If any corrosion or damage is found replace with new and do not reuse Lift the spring pad 5 out of the first stage and set it aside Remove the thrust washer 6 and discard Direct a short burst of low pressure 50 psi air through the open IP port to dislodge the diaphragm 7 from the first stage body see Figure 8 Lift out the diaphragm and discard If LP air is not available DO NOT attempt to pry out the diaphragm Please use the alternate method described after Step 22 Figure 8 Removal of diaphragm CAUTION DO NOT attempt to pry the diaphragm out of the first stage with a metal instrument Doing so will permanently damage the seating shoulder in the first stage requiring replacement of the body If using the alternate method please proceed to Step 18 17 Loosen the vise to remove the vise mounting tool and first stage Turn the first stage over to allow the pin sup port 8 and pin 9 to drop out and set the pin support aside 17a Closely examine the head of the pin to identify whether it is a Revision A or Revision B part see Figure 9
58. termine whether the needle is within the green zone indicating that the H A B D cylinder is full see Figure 2 p e P M TG Figure 1 ON position Figure 2 Full indication cg NOTE If the pressure gauge does not indicate that the cylinder is completely full it will be nec essary to perform the filling procedure outlined in the H A B D Owner s Manual before proceeding further WARNING The H A B D is designated compat ible for use only with normal atmospheric com pressed air 21 oxygen and 79 nitrogen by volume DO NOT attempt to fill with pure oxy gen or enriched air which contains more than 23 5 oxygen Failure to observe this warning may result in serious injury or death due to fire and explosion or the serious deterioration and failure of the equipment IMMERSION LEAK TEST After ensuring that the system is pressurized and the cyl inder is full listen for any obvious signs of leakage from the system including freeflow from the second stage CAUTION If leakage from the second stage is de tected it should be presumed that the first stage intermediate pressure exceeds 160 psi In this event DO NOT attempt to perform the intermediate pressure test Doing so may cause damage to the test gauge and possibly result in serious personal injury If leakage cannot be heard or if the source of leak age detected audibly is not obvious immerse the entire system in fresh water Examine clo
59. the open end of the spring block 25 into the center of the high pressure seat spring and then place the smaller spring 26 directly over the large end of the spring block 6 Install the backup ring 29 onto the stem of the valve body with the concave surface facing up followed by the O ring 30 which should fit flush against the concave surface see Figure 28 Then install the O ring 27 onto the opposite side of the valve body at the base of the threads O CAUTION It is important to ensure that the backup ring is installed with the concave surface facing to ward the O ring The O ring may otherwise extrude and become damaged 7 Lightly lubricate the male threaded end of the valve body with Christo Lube and carefully mate it into the inlet boss of the first stage body Press the valve body down ward while turning clockwise to engage the threads and tighten it until finger snug H A B D Service amp Repair Manual 8 While holding the first stage with the low pressure side facing up carefully insert the small end of the pin 9 into the center hole of the body until only the larger end is protruding Cg NOTE If the pin was identified as a Revision A part during disassembly it is important to replace it 11 12 13 14 15 with the Revision B pin that is provided in the SRU 40A P retrofit kit Install the pin support 8 over the large end of the pin Lay the diaphragm
60. the small blade of the Micra pre adjustment tool to turn the adjustment screw clockwise as far as the en gagement of the tool will allow see Figure 48 Or if the pre adjustment tool is not available apply a 1 8 blade screwdriver to turn the adjustment screw clockwise ex actly eight 360 full turns Figure 48 Adjustment screw pre set adjustment Cg NOTE If the lever has been properly installed it will rise slightly as the adjustment screw is turned in to its preliminary setting If the lever does not rise check to determine if it is properly installed into the valve body H A B D Service amp Repair Manual 14 Apply the large blade of the Micra pre adjustment tool 15 16 17 to turn the crown clockwise as far as the engagement of the tool will allow see Figure 49 Or if the Micra pre adjustment tool is not available apply a medium blade screwdriver to turn the crown clockwise exactly six 360 full turns Figure 49 Crown pre set adjustment Thread the hex nut 27 clockwise onto the inlet end of the valve body with the shoulder facing inward Turn it by hand until it is finger snug and seated flush against the box bottom Examine the exhaust cover 8 and the box bottom to identify the locking tabs and slots of each respective part Press one corner of the exhaust cover onto the box bottom until the mating tab audibly snaps into place Press the center tab next followed by the tab of the
61. til finger tight 3 While holding the IP test gauge positioned facing away from you pressurize the system by slowing turning the H A B D valve to the ON position Check the H A B D pressure gauge assembly once again to ensure that it indicates the cylinder is filled with at least 2 500 psi 4 Note the intermediate over bottom pressure indicated by the test gauge and briefly open and shut the bleed valve of the test gauge to ensure that lockup is achieved without creeping or fluctuating back and forth 5 Ifthe intermediate pressure creeps up or otherwise fluc tuates after cycling the regulator wait for it to stabilize if possible before noting the final intermediate pressure C NOTE Correct intermediate pressure for the H A B D is 140 5 psi with an inlet pressure be tween 2 500 3 000 psi 6 Partially open the bleed valve of the test gauge to empty the H A B D cylinder very slowly DO NOT fully open the test gauge bleed valve to empty the cylinder as this may cause condensation of moisture to form inside the first stage and hose as well as the cylinder itself If the cylin der of valve becomes cold to the touch while preforming this step the air has been relieved too rapidly WARNING Failure to completely empty the H A B D of air prior to performing any disas sembly may cause the sudden separation of components or ejection of parts and may re sult in serious personal injury Di
62. tion tool PN 109436 through the squared end of the valve body and through the opening in the center of the crown Gently press the crown out see Figure 14 Remove and discard the O ring 26 Figure 14 Removal of crown Closely examine the crown with the use of a magnifier checking for any scoring nicks or other damage to the 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 sealing surface Stand the box bottom upside down with the mouthpiece boss facing forward so that the circlip 16 which holds the anti venturi vane 20 secure is clearly visible If necessary gently turn the circlip with a small probe until both ends are facing toward the open side of the box bottom cg NOTE To prevent the circlip from becoming lost in the process of removal place a shop rag over the 18 mouthpiece boss of the box bottom before perform ing the following step While holding the box bottom secure place the tines of the Micra pre adjustment tool PN 100168 or two medium blade screwdrivers if this specialty tool is not available squarely against the ends of the circlip see Figure 15 Gently press the circlip off the anti venturi vane and set it aside Figure 15 Removal of anti venturi vane 19 Pull the anti venturi vane straight up and out of the mouthpiece boss of the box bottom
63. to Procedure A Cleaning amp Lubrication and Table A Recommended Lubricants amp Cleaners be fore proceeding to the Reassembly Procedures Figure 24 Removal of exhaust cover Step 1 21 Turn the box bottom vertical and press the disengaged side of the exhaust cover up from below rotating it over the box bottom until the opposite side disengages see Figure 25 15 Reassembly Procedures Cg NOTE Before reassembling it is important to in spect all parts both new and those that are be ing reused to ensure that every part is perfectly clean and free of any dust corrosion or blemishes Check all O rings to ensure they are clean and sup ple before dressing with Christo Lube WARNING Use only genuine Aqua Lung parts provided in the HABD overhaul parts kits DO NOT attempt to substitute an Aqua Lung part with another manufacturer s regardless of any similarity in shape or size Doing so may render the product unsafe and could result in serious injury or death CYLINDER ADAPTER REASSEMBLY CAUTION Before proceeding it is necessary to perform a visual inspection of the cylinder accord ing to Compressed Gas Association CGA stan dards with the use of a visual inspection light If the condition of the cylinder does not meet the required standards it must either be serviced or replaced with new before it can be assembled and filled 1 Lightly lubricate the O ring 33 and place onto the threade
64. ug Slight rotation of the purge cover is not critical Figure 54 Installation of retaining ring 8 Thread the purge guard 1 onto the box bottom and turn clockwise by hand until snug Final Testing Procedures Second Stage Air Flow Test With the H A B D still connected to the test bench pressurize the system to 3 000 100 psi Place the second stage mouthpiece over the mouthpiece adapter Slowly turn the flow meter control knob until the flow reaches a minimum of 8 SCFM 425 liters per minute The reading on the Magnahelic gauge inhalation exhalation effort gauge should indicate no more than 5 5 H 0 If the reading exceeds 45 5 H 0 refer to Table 1 Troubleshooting for corrective guidelines and specific procedures Second Stage Opening Effort Test Turn the flowmeter control knob shut and then slowly reopen while watch ing both the Magnahelic gauge and the intermediate pressure gauge When the intermediate pressure gauge begins to drop below the intermediate pressure lockup the magnahelic gauge should indicate an opening effort of 1 6 of H2O to 2 2 of H2O If the opening effort is not within this range refer to Table 1 Troubleshooting Second Stage Purge Flow Test Turn off the flow meter control knob Next while the second stage is still mounted on the mouthpiece adapter watch the flowme ter gauge and fully depress the purge cover The flow meter gauge must indicate a minimum of
65. ur face that are caused by slight corrosion or normal wear may be removed with the use of the Crown Polishing Tool PN 105997 Scratches nicks or severe corrosion cannot be removed however and will require the replacement of the first stage body H A B D Service amp Repair Manual CYLINDER ADAPTER DISASSEMBLY 1 Inspect the indicator pin 31 to ensure that it is per fectly straight and is securely seated inside the cylinder adapter If the pin is found to be bent or otherwise dam aged remove it with a pair of pliers by twisting slightly and replace with a new pin Tap the new pin in with a plastic face hammer until it bottoms out D a Figure 11 Removal of cylinder adapter Place the bottle in a bottle vise PN 100397 vise insert 100398 or place a cloth or rubber strap wrench onto the cylinder 34 to hold it secure see Figure 11 While holding the cylinder secure with the strap wrench apply a 1 1 8 open end wrench to the adapter 32 and turn counterclockwise to loosen and remove the adapter from the cylinder Remove and discard the O ring 33 SECOND STAGE DISASSEMBLY Left Hand Model Cg NOTE If the second stage is a right hand model 1 please refer to the disassembly procedure on page 19 While holding the hex nut 27 ofthe second stage secure with a 13 16 open end wrench apply an 11 16 open end wrench to the female fitting of the IP hose Turn the fitting c

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