Aqua Lung SEA MK Operating instructions

MRS III

Mobile Refi ll System for the Aqua Lung SEA

(Survival Egress Air)

Operation and

Maintenance Manual

October, 2011

CHANGE RECORD

Change No.

01-2010

02-2010

03-2010

01-2011

02-2011

03-2011

04-2011

05-2011

Date

5/2010

Title or Description

Add pages 35 & 36, Case dimensions, MRSIII weights, empty & full

5/2010

9/2010

9/2011

9/2011

Page 26, items #7 & #11, part number changed

New page 34, 955SSMM check vakve overhaul

New page 35, PRS6 overhaul

New page 36, Preset Regulator and overhaul kit moved to page 36.

9/2011

9/2011

Inline Bleeder Assembly moved to page 28

Page 28, items #69 & #70 added to list.

10/2011 Page 35, item #347-1 added to picture and table

Change Made By

BAS

BAS

BAS

BAS

BAS

BAS

BAS

BAS

TABLE OF CONTENTS

SECTION 1................................................................................................................................................... 1

DESCRIPTION OF UNIT ............................................................................................................... 1

SECTION 2................................................................................................................................................... 1

FIGURE 1, MRS III UNIT ............................................................................................... 1

SECTION 3 ............................................................................................................................................ 2

PREPARATION FOR USE ............................................................................................................. 2

FIGURE 2, CYLINDER HYDROSTAT STICKER .......................................................... 2

SECTION 4 ............................................................................................................................................ 2

MRS III OPERATING INSTRUCTIONS ........................................................................................ 2

SECTION 5 ............................................................................................................................................ 2

OPERATION .................................................................................................................................. 2

CONNECTING FILL HOSES ......................................................................................................... 2

FIGURE 3, OPENING SUPPLY CYLINDER VALVES .................................................. 2

FIGURE 4, CONNECTING SEA FILL HOSES ............................................................... 3

FIGURE 5, CLOSE BLEEDER VALVE ........................................................................... 3

FIGURE 6. OPEN PANEL-MOUNTED VALVES ........................................................... 3

FIGURE 7, FILL PRESSURE GAUGE ............................................................................ 3

SECTION 6 ............................................................................................................................................ 3

REFILLING SUPPLY CYLINDERS ............................................................................................... 3

CHECK HYDROSTAT DATE ......................................................................................................... 3

FIGURE ............................................................................................. 4

FIGURE 9, REMOVE RUBBER CAP ............................................................................ 4

FIGURE 10, CONNECT TO AIR INLET FITTING ......................................................... 4

FIGURE 11, CHECK SUPPLY AIR PRESSURE ............................................................. 4

SECTION 7 ............................................................................................................................................ 4

AFTER FILLING IS COMPLETED ............................................................................................... 4

FIGURE 12, DRAINING FILL HOSE ............................................................................. 5

FIGURE 13, PUTTING AWAY FILL HOSE .................................................................... 5

SECTION 8 ............................................................................................................................................ 5

MRS III MAINTENANCE

SECTION 9 ............................................................................................................................................ 6

AFTER ONE YEAR, AND EVERY YEAR THEREAFTER .......................................................... 6

OVERHAUL SEA ADAPTERS...................................................................................................... 6

FIGURE 14, REPLACE FILL ADAPTER ASSEMBLY ................................................. 6

FIGURE 15, PRS21-8 ...................................................................................................... 6

INSTALLING ..................................................................................................................... 7

FIGURE 16, USING PRS21-8-1 ...................................................................................... 7

FIGURE 17, USING PRS21-8-2 ....................................................................................... 7

FIGURE 18, USING PRS21-8-3 ...................................................................................... 7

FIGURE 19, FINISHED SPINDLE AND BODY ............................................................ 7

SECTION 10 ............................................................................................................................................ 8

REPLACING BLEEDER VALVE SEAT ......................................................................................... 8

FIGURE 20, BLEEDER VALVE AND SEAT ................................................................... 8

SECTION 11 ............................................................................................................................................ 8

TOP ............................................................................................................... 8

FIGURE 21, REMOVE SCREWS FROM PLATE ........................................................... 8

I

FIGURE 22, REMOVE TOP PLATE ................................................................................ 8

FIGURE 23, INSPECT FOAM PADDING ....................................................................... 8

FIGURE 24, DISCONNECT CYLINDERS ...................................................................... 9

FIGURE 25, REMOVE CYLINDERS ............................................................................. 9

CGA INSPECTION REQUIREMENTS .......................................................................................... 9

REINSTALL SUPPLY CYLINDER ................................................................................................ 9

FIGURE 26, CONNECTING O’ RING ............................................................................ 9

SECTION 12 .......................................................................................................................................... 10

CYLINDER INSPECTION GUIDELINES ................................................................................... 10

SECTION 13 .......................................................................................................................................... 10

REMOVING UNIT FROM CASE ................................................................................................. 10

FIGURE 27, REMOVE SCREWS FROM BACK .......................................................... 11

FIGURE 28, REMOVE UNIT FROM CASE ................................................................. 11

SECTION 14 .......................................................................................................................................... 10

FIGURE 29, REMOVE AND REPLACE GAUGE ....................................................... 11

SECTION 15 .......................................................................................................................................... 12

AFTER FIVE YEARS AND EVERY FIVE YEARS THEREAFTER .......................................... 12

HYDROSTAT OF CYLINDERS ................................................................................................... 12

FILL ......................................................................... 13

FIGURE 31, SUPPLY CYLINDER VALVE ................................................................... 14

REMOVING SUPPLY CYLINDER VALVE ................................................................................ 14

33, ........................................................................................ 14

FIGURE 34, SUPPLY CYLINDER VALVE ASSEMBLY ............................................ 15

FIGURE 35, VAL1-12 VALVE NUT TOOL ................................................................... 15

FIGURE 36, REMOVE BONNET W/VAL1-12 ............................................................. 15

FIGURE 37, REMOVE BONNET W/ WRENCH .......................................................... 15

REPLACING SAFETY DISC ........................................................................................................ 16

FIGURE 38, SAFETY DISC PLACEMENT .................................................................. 16

SUPPLY VALVE GAUGE MAINTENANCE .............................................................................. 16

FIGURE 40, REMOVE GAUGE W/VAL1-11 ................................................................ 16

FIGURE 41, SUPPLY CYLINDER GAUGE ASSEMBLY ............................................ 17

SECTION 16 .......................................................................................................................................... 17

MRS III REGULATOR .................................................................................................................. 17

REMOVING FROM MRS III ........................................................................................................ 17

FIGURE 43, REGULATOR FITTINGS .......................................................................... 18

FIGURE 45, 1120KIT-1 DETAIL .................................................................................... 19

SECTION 17 .......................................................................................................................................... 19

MRS III CASE ............................................................................................................................... 19

FIGURE 46, CASE LATCHES........................................................................................ 20

FIGURE 47, HANDLE LATCH ...................................................................................... 20

FIGURE 48, CARRY HANDLES ................................................................................... 20

II

TROUBLE SHOOTING CHART ........................................................................................................21-23

ILLUSTRATED PARTS BREAKDOWN ................................................................................................ 24

MRS III UNIT COMPLETE ASSEMBLY................................................................................26-28

FILL .................................................................................................................................. 29

CYLINDER ..................................................................................................30-31

ONE-YEAR MAINTENANCE KIT .............................................................................................. 33

FIVE-YEAR MAINTENANCE KIT ............................................................................................. 33

CHECK .......................................................................................................... 34

MRS III FLOW DIAGRAM ......................................................................................................................... 37

PELICAN CASE, DIMENSIONS, TOP ...................................................................................................... 38

PELICAN CASE, DIMENSIONS, BOTTOM ............................................................................................. 39

WARNING:

This unit contains air under high pressure. Serious injury may result from misuse of this

apparatus and the gas it contains.

Avoid blowing compressed gas at yourself or any other person.

Wear hearing protection.

Avoid standing over top of the unit when it is in use.

Have the gauges checked for accuracy every 18 months. They should be plus or minus

100psi.

Do not overpressurize any compressed gas cylinder.

Do not fi ll a damaged cylinder.

Do not use this unit if the hoses are damaged.

Do not fi ll this unit if the supply cylinders have not had the proper hydrostatic testing done

WARNINGS, CAUTIONS, & NOTES

Pay special attention to information provided in warnings, cautions, and notes that are accompanied by one of these symbols: instructions are not followed correctly.

product, or render the product unsafe, if instructions are not followed correctly.

III

MRS III

Mobile Refi ll System

1.0 DESCRIPTION OF UNIT: The MRS III is designed to refi ll the Aqua Lung Survival Egress

Air (SEA) LV, MK1.5, MK2, MK2.5. It has an internal supply of two carbon fi ber composite

4500psi cylinders and has two preset regulated 3000psi fi ll lines. The control panel will allow you to monitor the pressure in the supply cylinders, verify the preset regulated pressure and control the fi lling of one or two SEA units.

2.0 CONFIGURATION: The attached picture shows the COMPLETE MRS III UNIT. The items lettered are listed below.

M

A

D

N

F

R

F

G

B

P

M

H

I

O

J

K

L

O

A

Q E Q

C

fi gure 1 MRS III

A. Supply Cylinder (CYL1)

B. Refi ll Port w/ rubber cap (RCAP)

C. Adapter PRS6 to CGA 347

D. Case (1650)

E. Frame/Control Panel (FRM1)

G. Bleeder valves (712)

H. Fill Hose (HOS1)

I. SEA Fill pressure Gauge (GAG1)

J. Supply Pressure Gauge (GAG1)

K. Preset regulator (1120)

L. Regulated Pressure Gauge (GAG1)

M. Fastener for top cover of the frame

N. Top Cover/ Instruction sheet

O. Fill Valves (YVA3010A)

P. Supply Cylinder Valves (VAL1)

Q. SEA Cylinder Holder/Burst Protector

R. Unit/serial number, Manufacture date

NOTE: These identifi cation letters do not match the I.D. numbers in the PARTS section, page 25 page 1

3.0

PREPARATION FOR USE: First unpack the unit and check for damage caused by shipping.

Next, open the case.. Verify the hydrostatic test date of the supply cylinders, shown on a sticker prominently displayed on the cylinder (fi gure 2) and on the neck of supply cylinders (fi gure 3).

This should also be written on the maintenance log, located on the lower right hand corner of the

3.1 NOTE: THESE CYLINDERS (CYL1)

REQUIRE HYDROSTATIC TESTING

EVERY 5 YEARS, BY A DOT-

APPROVED TEST FACILITY. CHECK

DATE STICKER ON CYLINDER (fi gure 2),

OR ON CYLINDER NECK. (fi gure 3)

3.2. Since the unit is shipped from the factory empty you must fi ll it with air (see Refi lling Supply

Cylinders, Section 6). The MRS III is now ready fi gure 2

4.0 MRS III OPERATING INSTRUCTIONS

4.1. The purpose of this unit is to allow the fi lling either MK or LV series SEA cylinders to

3000psi from an internal source of approved breathing air. You can fi ll either one or two at a time.

4.1.1. WARNING-DO NOT FILL CYLINDERS THAT ARE DAMAGED OR THAT

HAVE LIQUID IN THEM. THEY MUST BE INSPECTED ACCORDING TO

MANUFACTURERS INSTRUCTIONS

5.0 OPERATION:

5.1. Make sure the fi ll valves (YVA3010A) on the panel are closed.

5.2. Open the valves (VAL1) on the supply cylinders

(fi gure 3). Valves lock in place when released. To release, push the knob while turning. Verify that the pressure in the supply cylinders is between 3000 and 4500psi .

5.3. Verify that the Regulated Pressure Gauge on the panel shows 3000psi, +/- 100 psi. If it does not, have a technician that has been trained on the maintenance of the MRS III adjust the regulator, per 16.11.

HYDRO

DA

TE

STICKER

fi gure 3

5.4. Place the SEA in the cylinder holder.

5.5. Connect the SEA to the fi ll hose, by placing the fi ll adapter (PRS21) into the fi ll port and rotating the knob clockwise until the O-ring is fully seated. (fi gure 4) page 2

5.5.1. CAUTION-DO NOT USE A WRENCH OR PLIERS TO TIGHTEN!!!

fi gure 4 fi gure 5

5.6. If the fi tting leaks, remove from the SEA and inspect threads and O-ring for damage. Replace or repair parts as needed.

5.7. Bleeder valve (712) should be closed (fi gure 5).

5.8. Slowly open the panel mounted valve (YVA3010A), counterclockwise, that corresponds to the fi ll hose(s) used (fi gure 6). There is no need to open any valve on the SEA.

5.9. Watch the SEA fi ll pressure gauge (CAG1). Fill the cylinder at a rate not to exceed 500psi per minute

(fi gure 7).

fi gure 6

5.10. After the cylinder reachs 3000psi +/- 100psi, close the fi ll valve (YVA3010A). Open the bleeder valve

(712) on the fi ll hose used to vent the pressure from the fi ll lines.

5.11. Disconnect the fi ll hose from the SEA, by rotating the fi ll adapter (PRS21) counterclockwise.

fi gure 7

6.0 REFILLING SUPPLY CYLINDERS:

6.1. Verify that the cylinders (CYL1) are within 5 years of the last hydrostatic test. Check the dated sticker placed prominently on each cylinder (fi gure 2). There is also a sticker on the cylinder neck, visible without removing MRS top plate (fi gure 3).

6.2. Visually check the observable portion of the outside of the cylinders for damage. If any is found consult manual for acceptable/unacceptable conditions. page 3

6.2.1. NOTE-THIS INSPECTION SHOULD CONFORM TO COMPRESSED

GAS ASSOCIATION PAMPHLET C-6.2 VISUAL INSPECTION OF FIBER

REINFORCED HIGH PRESSURE CYLINDERS (EXTERNAL INSPECTION ).

6.3. This unit may be fi lled from any source of air that meets or exceeds CGA Grade “D” standards at pressures up to and including 4500psi. The standard inlet fi tting is a 4500psi or a 300 BAR DIN (DIN-F) SCUBA fi tting (PRS6). For US users, adapter for CGA 347 fi ll connections are provided.

(fi gure 8)

6.4. Open the valves (VAL1) on both Supply Cylinders.

fi gure 8

REFER TO FIGURE 3 (page 2) FOR

A PICTURE OF THE VALVES

6.5. Remove rubber cap. (RCAP). (fi gure 9) Connect approved source of air to inlet fi tting (DIN-F) (fi gure 10).

fi gure 9 fi gure 10

6.9. Disconnect the approved air source from the fi ll connection (DIN-F). Replace protective rubber dust cap. (RCAP)

6.6. Pressurize the system at a rate not to exceed 500psi per minute until it reaches the maximum pressure of the approved air supply, or 4500 psi, whichever is lower. (fi gure 11).

6.7. Close the supply cylinder valves

(VAL1).

6.8. Close the valve from the approved air source and bleed the air from the fi ll connector.

7.0 AFTER FILLING IS COMPLETED:

7.1. Verify that the supply cylinder valves (VAL1) are closed.

page 4 fi gure 11

7.2. Hold one of the fi ll hoses (HOS1) fi rmly and point the opening away from people (fi gure

12).

7.2.1. WARNING — AIM THE HOSE

AWAY FROM YOURSELF AND

FROM ANY OTHER PERSONNEL.

HIGH PRESSURE AIR COMING

INTO CONTACT WITH THE SKIN IS

DANGEROUS. ALSO, ESCAPING

AIR CAN CAUSE A LOUD NOISE.

7.3. Slowly open the fi ll valve (YVA3010A) that corresponds to the fi ll hose you are holding to release all pressure.

7.4. Close all fi ll hose valves (YVA3010A) and bleeder valves (712).

7.5. Attach the fi ll hoses to the provided mounts (NUT2)

(fi gure 13).

7.6. Close and securely latch the lid.

fi gure 12

8.0 WARNINGS:

8.1. This unit contains air under high pressure. Serious injury may result from misuse of this apparatus and the gas it contains.

8.2. Avoid blowing compressed gas at yourself or any other person.

fi gure 13

8.3. Wear hearing protection.

8.4. Avoid standing over top of the unit when it is in use.

8.5. Have the gauges checked for accuracy every 18 months. They should be plus or minus 100 psi.

8.6. Do not overpressurize any compressed gas cylinder.

8.7. Do not fi ll a damaged cylinder.

8.8. Do not use this unit if the hoses are damaged.

8.9. Do not fi ll this unit if the supply cylinders have not had the proper hydrostatic testing done within FIVE years of today’s date. page 5

MRS III MAINTENANCE

Scheduled Service (1-year and 5-year)

9.0 AFTER 1 YEAR, AND EVERY YEAR THEREAFTER....

9.1. PARTS REQUIRED: 1-year overhaul kit ( Part Number MRSKIT1).

9.2. Open the Supply Cylinder valves (VAL1) and then slowly vent all air from the MRS III thru one of the fi ll hoses (HOS1).

9.2.1. WARNING — AIM THE HOSES AWAY FROM YOURSELF AND FROM ANY

OTHER PERSONNEL. HIGH PRESSURE AIR COMING INTO CONTACT WITH

THE SKIN IS DANGEROUS. ALSO, ESCAPING AIR CAN CAUSE A LOUD NOISE.

9.3. Replace all seals in the SEA fi ll adapter (PRS21). See fi gure 14. This consists of three

O-rings, two (PRS21-3) and one (PRS21-6), and two back-up rings (PRS21-2).

9.3.1. The fi rst O-ring (PRS21-6) is the one that makes the seal to the SEA. This is a normal wear item and can be replaced anytime. The tools required are an O-ring pick and the

PRS21-2

PRS21-1

PRS21-3

PRS21-3

PRS21-5

PRS21-2 fi gure 14

PRS21-4

PRS21-6

9.4. To replace the other parts will require a set of external snap-ring pliers, an O-ring pick, the PRS21-8 , and some non-toxic O-ring lubricant (Christo-lube).

9.5. To start, remove the visible O-ring

(PRS21-6). Then using the snap-ring pliers remove the snap-ring (PRS21-5) and set it aside.

Grasp the hex knob (PRS21-1) in one hand and hold the body (PRS21-4) in the other. Pull apart with a slight rotating motion of the hex knob.

Use the O-ring pick to remove the O-rings and back-up rings.

9.5.1. NOTE THE ORDER THAT THE PARTS

ARE ON THE SHAFT: STARTING

FROM THE HEX KNOB — BACK-UP

RING (PRS21-2); O-RING (PRS21-3);

O-RING(PRS21-3); BACK-UP RING

(PRS21-2); SNAP-RING (PRS21-5);

O-RING (PRS21-6). See fi gure 14.

PRS21-8-2

9.6. Clean the parts with a soft clean cloth to remove all of the old lubricant. Inspect parts for

damage. If any is found replace the assembly.

PRS21-8-1 fi gure 15 PRS21-8-3

NOTE: PRS21-8 (103384) comes as a complete set; not available separately.

page 6

9.7. Lubricate the new seals generously with an approved non-toxic O-ring lubricant

(Christo-lube), and slip the new seal on in the proper order.

9.7.1 It is recommended that you use tool set PRS21-8 (fi gure 15) to install the seals.

9.7.1.1 NOTE; INSTALL THE BACKUP

RINGS (PRS21-2) WITH THE CON-

CAVE SIDE FACING THE O-RINGS

(PRS21-3).

9.7.1.2 Install the seals and backup rings starting from the hex knob. If using the PRS21-8-1, fi rst install backup ring (PRS21-2) and O-ring (PRS21-3)

(fi gure 16).

PRS21-2


PRS21-2 9.7.1.3 Next, using PRS21-8-2, install

O-ring (PRS21-3) and backup ring

(PRS21-2) (fi gure 17).

9.7.1.4 Using PRS21-8-3, install O-ring

(PRS21-6) (fi gure 18).

9.8 If tool set PRS21-8 is not available, install the seals with an O-ring pick, in the same order as 9.7.2, above. Carefully avoid stretching and nicking the seals while

installing them.


PRS21-6

9.8.1. CAUTION: INSTALL THE SEALS

OVER THE THREADED END. DO NOT

ATTEMPT TO STRETCH THEM OVER

THE KNOB, AS DAMAGE TO THE

SEALS WILL RESULT.

9.8.2 When completed, the spindle will look like in fi gure 19.

PRS21-4 9.9. Once the seals are in place, lightly lubricate the inside of the body

(PRS21-4) with Christo-lube, and slide the spindle into the body

(fi gure 19). Once the spindle is in the body install the snap-ring

(PRS21-5), using snap ring pliers.

Wipe off any excess lubricant.


PRS21-1 fi gure 19 page 7

10.0 REPLACING THE SEAT IN THE BLEEDER VALVE (712):

10.1. Unscrew the knob (712KNOB) and turn it over. The knob will pull through the bleeder keeper (59) by using a twisting motion.

Using a sharp instrument get it under the edge of the white tip

(712SSTIP) and lift it out of its hole.

712SSTIP

10.2. If you cannot get out the white seat (712SSTIP) you may attempt to dig it out with an O-ring pick or simply replace the knob assembly (712KNOB). See fi gure 20.

10.3. Push 712SSTIP into hole. Reinstall in bleeder keeper.

712KNOB fi gure 20 fi gure 22

From this point on, it might be easier to perform maintenance with the system removed from the case. See section 13.0.

fi gure 21

11.0 REMOVING THE TOP PLATE:

11.1. There are six (6) screws that hold the top plate to the unit. Unscrew these (fi gure 21) and lift the plate (fi gure 22).

11.1.1. WARNING-VERIFY THAT ALL

PRESSURE HAS BEEN DRAINED

FROM THE PLUMBING BEFORE

PROCEEDING.

11.2. Turn the top plate over, and inspect the foam padding (PAD1and PAD2) for

damage (fi gure 23 ). If foam is worn or damaged, replace.

11.3. Disconnect the cylinders (CYL1) from the fi ll adapters (835) (fi gure 24).

page 8

PAD2

PAD1 fi gure 23

11.3.1. WARNING: IF THESE DO NOT COME LOOSE WITH

FIRM HAND STRENGTH, THERE MAY STILL BE AIR

PRESSURE IN THE SYSTEM. VERIFY THAT ALL

PRESSURE IS REMOVED BEFORE PROCEEDING.

IF YOU CANNOT GET THIS LOOSE BY HAND YOU

CAN USE SLIP JOINT PLIERS. DO NOT USE

EXCESSIVE FORCE AS DAMAGE WILL RESULT.

11.4. Lift the cylinders (CYL1) out of the frame (FRM1) (fi gure 25).

Inspect the padding (TRIM & PRS17) that the cylinders rest on.

If it shows signs of damage or wear, replace with new.

11.4.1 PRS17 replacement requires altering by cutting it into two equal pieces. PRS17 makes the padding for both cylinders.

11.5. Have an authorized / properly trained technician visually inspect the cylinder inside and out to Compressed Gas

Association Pamphlet C-6.2 standards (This is available direct from the CGA by calling 703-788-2700 ext.799 or via email from [email protected])

11.5.1 Basic cylinder inspection criteria are listed in section 12.

11.6. Inspect all other components for obvious damage or excessive wear. If damage or wear is found, replace that component.

fi gure 24

11.7. After the cylinders (CYL1) have been inspected it is time to reassemble the unit. Place a cylinder into the frame and line up the valve (VAL1) with the connection (835).

O-ring (010) fi gure 26 fi gure 25

11.7.1. Before connecting, verify that the O-ring (010) in the connection is in place and not damaged (fi gure 26). If damaged or missing, replace.

11.8. Thread the fi ll adapter (835) onto the cylinder valve (VAL1) by turning it clockwise until it pulls up tight. Snug this fi rmly by hand.

11.8.1. DO NOT USE TOOLS TO TIGHTEN THIS.

11.9. Repeat with the other cylinder.

11.9.1. When both cylinders are in place, reinstall the top plate/instruction sheet. Reinstall in case.

page 9

12.0 CYLINDER INSPECTION GUIDELINES

12.1 Cuts, Scuffs and Scratches

12.1.1 Usually these are confi ned to clear coat and are less than .005” deep. Flaws in clear coat alone are acceptable and repairable.

12.1.2 Flaws in clear coat can be repaired with any 5 minute epoxy, and then hydrostatically tested by a trained and authorized test facility before returning to service.

12.1.3 Rejectable fl aws have visible fi ber damage. If damage extends into the fi bers replace the cylinder and destroy the damaged cylinder.

12.1.4 Heat or fi re damage that causes discoloration or charring is cause for

rejecting cylinder.

12.2 Delamination

12.2.1 Delamination calls for rejecting the cylinder.

12.3 Impact

12.3.1 Look for fi ber delamination; if delaminated, reject cylinder.

12.3.2 fi ber breaks call for rejecting the cylinder.

12.3.3 Small impacts will show white spots without signifi cant delamination. If no fi ber breakage is noted and damage is less than 1/2” diameter and there is no dent, cylinder may be hydrostatically tested and returned to service.

12.4 Internal inspection (to be performed by trained and authorized inspection center only)

12.4.1. Check for cracks in the neck area. If cracks are present reject the cylinder.

12.4.2. Check cylinder walls for corrosion. If corrosion is present have an authorized test facility remove the corrosion and check for cylinder wall pitting damage.

12.4.2.1. If pitting exceeds the allowable limits reject the cylinder. Limits are not printed here as a properly trained inspector will have this data available and it is subject to change .

If there is any question as to the integrity of the cylinder either replace it or return it to

Breathing Air Systems (614-864-1235 or [email protected]) for evaluation.

13.0 WHER FURTHER MAINTENANCE IS SCHEDULED OR REQUIRED, REMOVE

THE UNIT FROM THE CASE.

13.1. With the lid closed and latched, turn the MRS III over. Remove the four screws from the back of the case. (fi gure 27).

13.2. Turn case over, open lid, and lift the unit out of the case (fi gure 28).

13.2.1 Be sure to support the plumbing with your hand as you lift the frame.

verify the accuracy. Gauge calibration in accordance with local instructions. Acceptable variance is

100psi in the center of the range (1500psi to 4500psi), or ±200psi at the bottom or top of range. If not within these limits they will have to be replaced.

14.1. To verify the calibration on these gauges (GAG1), they may be removed from the system, or they can be checked in the system if the calibration technician has the proper connectors.

page 10

14.1.1. CAUTION: DO NOT CONTAMINATE THE MRS III BY USING CALIBRATION

APPARATUS THAT WILL PUT OIL INTO THE SYSTEM.

14.1.2 To calibrate the gauges without removing them from the unit will require you make 3 separate connections. fi gure 28 fi gure 27

14.1.3 To test the supply pressure gauge you will need to connect your master gauge to the refi ll port with a tee. There is a check valve on this port so the air supply must come from the refi ll port and test gauge to the supply pressure gauge. This will allow you to test the supply pressure gauge.

14.1.4 To test the regulated pressure gauges and the fi ll pressure gauges you can connect your test gauge to one of the fi ll lines (removing the PRS-21 for access to a 1/4” NPT). Use air from the supply cylinders or supply air thru the refi ll port to pressurize these gauges. This will allow you to check the fi ll pressure gauge on the side that you are connected on and the regulated pressure gauge. Remove the test gauge; reinstall the PRS21 and repeat on the other side for the other fi ll pressure gauge.

14.2. If the gauges (GAG1) need to be removed simply disconnect the tubing fi tting (PRS10) from the back of the gauge using a 7/16” wrench (fi gure 29). Always use a 3/4” backup wrench. Then loosen the gauge bracket with a small straight screwdriver. Once loose the bracket will slip out of the gauge and the gauge will lift out of the panel. fi gure 29 page 11

14.3. The rear connection on the gauge is ¼” MNPT and will have a standard industrial 1/8” tube highpressure compression fi tting (PRS10). The calibration technician may connect either to the

14.4. If the compression fi tting is removed it must be reinstalled with PTFE (Tefl on) tape. Reinstall the gauge by reversing the removal procedure. The compression fi tting should be tightened by hand and then snugged fi rmly with a 7/16” wrench (see fi gure 29).

14.5. When the inspection and gauge calibration is done, reinstall the frame (FRM1) into the case

(1650). This is easily done by placing the case on a table and lifting the frame into the case.

Close the lid, and turn unit over. Insert the four screws (BLT3), and tighten.

14.5.1 If you have trouble aligning the screw holes, turn the unit right-side up and open the lid.

Then slide the case partway off of the table and reach under the case and start two of the screws

(BLT3). Run these in snug but not tight. Turn the case around so that you can start the other two screws.

14.6. Once all 4 screws are started, tighten all of them securely by hand with #3 Phillips screwdriver.

14.7. Install cylinder per reverse of 11.7 through 11.9.1. Reinstall top plate per reverse of 11.1.

14.8. The MRS III is now ready to pressure test. Close the supply cylinder valves (VAL1). Attach the approved source of CGA grade “D” Breathing Air to the refi ll port (DIN-F) and slowly pressurize to

1000psi. Close the valve on the refi ll source. Allow the unit to stand for 5 minutes. After 5 minutes check for pressure loss. If there was pressure loss repair the leaks and start again.

14.9. If there was no pressure loss, you may pressurize to 4500psi (or to the limit of your supply, whichever is lower). Once the plumbing is at full pressure, hold it there for 5 minutes and check for pressure loss. When the pressure will hold for 5 minutes with no leaks it is time to recharge the supply cylinders, following the procedure from section 6. Return the unit to service.

15.0 AFTER 5 YEARS OF SERVICE AND EVERY 5 YEARS THEREAFTER....

15.1. Perform all of the 1-year maintenance. While unit is removed from case, proceeed with 5-year maintenance.

15.2. While the cylinders are out of the unit they must to be hydrostatically tested according to the DOT standard. This is done by sending them out to an authorized DOT testing facility, or by returning them to Breathing Air Systems (contact Breathing Air Systems at 800-937-2479 or 614-864-1235, or via e-mail at [email protected] ).

15.2.1. NOTE: AS OF OCTOBER 2000 THE CARBON FIBER WRAPPED CYLINDERS (CYL1)

USED IN THE MRS III HAVE A MAXIMUM SERVICE LIFE OF 15 YEARS.

15.2.2. Cylinders (CYL1) are available as replacement parts.

15.3. You will need to rebuild the fi ll valves (YVA3010A), supply cylinder valves (VAL1) and the preset regulator (1120).

page 12

15.4. After the 5-Year Maintenance is completed return the unit to service.

15.5. Fill valve (YVA3010A).

Fill Valve

15.5.1. With valve open, remove the plastic center cap (YVA-

KNOB-2) from the valve knob (YVAKNOB-1). Remove the nut (YVANUT) that holds the knob; using notched screwdriver from your SEA Tool Kit (PN9-47448). See fi gure 30 for parts breakdown.

15.1.1.1. CAUTION: THERE IS LIGHT SPRING

TENSION ON THIS NUT.

15.5.2. Lift off the knob (YVAKNOB-1) and inspect the center hole for damage. The hole should be square; if it shows any rounding you must replace the knob. The knob is a standard replacement item and is included in MRSKIT2.

YVABODY

YVAKIT-5

YVAKIT-1

YVASTEM

15.5.3. This exposes a hex-shaped bonnet nut

(YVA-BONNET). Remove this with a 11/16” wrench or socket. The valve stem (YVASTEM) will likely come out with this. Push the valve stem out and set both parts aside.

YVAKIT-3

15.5.4. The seat (YVAKIT-1) is inside the valve body and can be removed by taking the valve stem and placing over the tang of the seat and using the valve knob (YVAKNOB-1) to turn it counterclockwise, until it is loose from the threads. Lift it out.

YVAKIT-4

YVA-BONNET

15.5.5. Clean the body to remove any dust. The valve overhaul kit (YVAKIT) will contain a new seat, copper gasket, packing washers, and knob. The stem (YVASTEM), spring (YVASPRING), and nut (YVANUT) are also available as replacement parts, but are not normal wear items and typically are only replaced if damaged or lost.

15.5.6. The packing consists of two white plastic washers, one thick (YVAKIT-4) and one thin (YVAKIT-3). Use the

O-ring pick to pull the old ones out of the valve bonnet nut

(YVABONNET). Clean the bonnet with a soft cloth to remove the residue of the worn packing. To install the new packing, place the thick washer into the bonnet followed by the thin washer.

* YVAKNOB consists of YVAKNOB-1 and

YVAKNOB-2. Not available as separate parts.

YVAKNOB-1*

YVASPRING

YVANUT

YVAKNOB-2* fi gure 30 page 13

15.5.7. The only other replaceable part in the valve body is the copper gasket (YVAKIT-5) that seals the bonnet nut to the body. Use the O-ring pick to lift this out. Use caution: a scratch on the body will cause leakage and require body replacement.

15.5.8. To replace the seat (YVAKIT-1) use the stem

(YVASTEM) to screw the new seat assembly into the valve body (YVABODY). Screw this down against the seat but do not use the knob to tighten it. Put the copper gasket (YVAKIT-2) in place at the base of the body threads, and place the stem on the tang of the seat assembly. Slip the bonnet (YVABONNET) down the stem and then screw it into the body. Tighten with the wrench or socket, to 20-30 foot pounds.

15.5.9. Place the knob (1389-2D) on the square of the stem, place the spring (YVASPRING) and then the nut (YVANUT) onto the stem. Use notched screwdriver (9-47448) from SEA toolkit to tighten the nut onto the stem.

Reinstall the plastic center cap. (1389-4) fi gure 31

15.6. SUPPLY CYLINDER VALVES (VAL1).

15.6.1. The supply cylinder valves (fi gure 31) are very similar to the fi ll valves, along with some additional parts.

15.6.2. There are three additional sets of parts. The fi rst is the safety burst disc assembly (6509-72), a normal replacement part. Second are the valve lock parts; these are not normal replacement parts.

The third is the gauge.

VAL1

100785 fi gure 32

15.6.3. Supply Cylinder Valve (VAL1) rebuild procedures.

15.6.3.1. Remove supply cylinder (CYL1) from MRS III.

15.6.3.1.1. WARNING! ASSURE THAT THERE IS

NO PRESSURE INSIDE THE CYLINDER. DO THIS BY

CHECKING THE GAUGE LOCATED ON THE CYLINDER

VALVE AND BY SLOWLY OPENING THE VALVE.

15.6.3.2. The valve (VAL1) can be rebuilt either with it in the cylinder or with it removed from the cylinder. It is preferable to have the valve removed from the cylinder, as this allows easier handling and better cleaning.

page 14 fi gure 33

VAL1-20

VAL1-7

Supply Cylinder Valve Assembly

VAL1-15 VAL1-14

VAL1-19

VAL1-13

VAL1-15

VAL1-16

VAL1-6 VAL1-17

VAL1-8 fi gure 34

15.6.3.2.1. NOTE! DO ALL WORK ON A CLEAN WORK

SURFACE AS IT IS IMPORTANT THAT THIS VALVE

BE KEPT CLEAN.

15.6.3.2.2. NOTE! REMOVING AND

REINSTALLING THE VALVE INTO THE CYLINDER

REQUIRES SPECIAL TOOLS AND TRAINING, SO

THIS SHOULD ONLY BE DONE BY TECHNICIANS

TRAINED IN CYLINDER INSPECTION OR TESTING.

15.6.3.3 When removing the valve, it is recommend that you use valve tool

VAL1-10. (fi gures 32 and 33)

VAL1-18

100786 fi gure 35

15.6.3.4. Using notched screwdriver

#9-47448 from the SEA tool kit, remove the nut (VAL1-18) that holds the knob (VAL1-19) on. Then lift the knob off. Lay aside (fi gure 34).

15.6.3.4.1. CAUTION! THERE IS SLIGHT

SPRING TENSION HOLDING THIS

NUT. USE CAUTION WHEN

REMOVING.

fi gure 36

15.6.3.5. This will expose the bonnet (VAL1-16) nut. Remove the nut using a valve nut tool

VAL1-12 (fi gures 35 and 36) , or if this tool is not available use a 12” adjustable wrench endwise (fi gure 37). Lift the nut off and push the stem out of the nut. Use the stem

(and the knob if needed) to remove valve seat assembly.

fi gure 37

15.6.3.6. Using an O-ring tool remove the packing washers from inside the bonnet nut.

(VAL1-16).

page 15

15.6.3.7. Remove the safety disc plug

(VAL1-9) by using a 3/8” wrench or socket and turning counterclockwise until it is out (fi gure 38).

Reinstallation torque is 70-80 inchpounds (Non-critical, for reference only). If the disc does not come out with the plug, then turn the valve so that the opening is down and then tap it against the palm of your hand.

If this fails to dislodge the disc, use a sharp O-ring tool to push it thru the center of the disc and pull the disc out.

VAL1-9

VAL1-3


15.6.3.7.1. CAUTION! BE CAREFUL NOT TO DAMAGE

THE SEALING SURFACE OF THE VALVE BODY.

DAMAGE MAY REQUIRE THAT THE VALVE BE

REPLACED.

15.6.3.8. Remove the gasket (VAL1-4) from under the disc.

page 16

15.6.4. The gauge requires a special gauge tool VAL1-11 (fi gure 39)

to service. The rubber bumper is removed using a square drive

screwdriver. Under this bumper is a spring washer and the

gauge cover; lift these off and set aside. Using the gauge

tool VAL1-11, remove the gauge by screwing it counter clockwise (fi gure 40).

100787 fi gure 39

15.6.4.1. Once the gauge is out (fi gure 41), remove the

O-ring and back up ring from the stem, and replace with the new parts (VAL1-2 O-ring; VAL1-1 back up ring) and reverse the procedure above to reassemble.

fi gure 40

CAUTION: DO NOT USE POWER TOOLS TO

REMOVE OR INSTALL SQUARE DRIVE SCREWS

(VAL1-26).

15.6.4.2. The valve is now completely disassembled. Clean the valve by one of the following methods: wipe with a clean, lint-free cloth, or use a soft bristle brush and blow with grade D air.

15.6.4.2.1 CAUTION: DO NOT CLEAN THE

GAUGE FACE WITH ANY LIQUID AS THIS WILL

DESTROY THE NUMBERING.. IF THE GAUGE FACE

IS DIRTY, REPLACE THE GAUGE.

Supply Cylinder Gauge Assembly

(VAL1-20)

VAL1-26

VAL1-21

VAL1-25

VAL1-22

VAL1-23

15.6.4.3. If the valve is still in the cylinder the only

method you can use is to wipe with a lint free cloth

(damp or dry either is fi ne), or a soft bristle brush.

Use a source of Grade D breathing air to blow out

all internal passages.

15.6.4.4. Assemble in the reverse order of

disassembly. Use Christo-lube on all O-rings.

15.6.4.5. Replace neck valve O-ring VAL1-8. Lubricate fi rst with Christo-lube.

15.6.4.6. Reinstall the valve into the cylinder if it

was removed, using valve tool VAL1-10 (fi gure 32).

This has a non-critical torque of 45 foot pounds.

15.6.5 If possible, test the valve by pressurizing the

cylinder to 1000psi and checking for air leaks.

After the valve is leak free at 1000psi then

pressurize to 4500psi and check for leaks.

Otherwise, reinstall into system and test. After it

is leak free at 4500psi, reinstall into the MRS III

and return to service.

VAL1-20


16.0 MRS III Regulator (1120)

16.1. In order to rebuild the preset regulator (1120) it fi rst must be removed from the panel. To do this the plumbing must initially be drained of all air, and the unit removed from the case.

1120-1

1120KIT-1*

1120KIT-3*

1120-2

PRS10

1120KIT-2*

Regulator Assembly fi gure 42

* available only as a complete kit

Part # 1120KIT page 17

16.1.1. Place the unit face down on a clean work surface that has been covered with a pad or towel (to protect the unit from scratches on the face). Note the position of the regulator and plumbing.

16.1.2. Disconnect the two compression connections (PRS8 and MRS2) from the regulator’s inlet and outlet fi ttings

(fi gure 43). Use a 7/16” size wrench.

16.1.3. Turn the unit face up on the work surface.

16.1.4. Remove the acorn nut (MRS13) on the adjusting screw with a 9/16” wrench. Using a 3/16” Allen wrench rotate the adjusting screw counterclockwise until all spring pressure is released from it

(fi gure 44). It is possible and acceptable to completely remove this screw from the regulator.

fi gure 43

16.1.5. Using a large adjustable wrench remove the mounting nut (NUT1) by turning counterclockwise.

16.1.6. Lower the regulator out of the hole in the control

panel. Use caution on tubing below.

16.2 Once the regulator has been removed, place the system aside and proceed with the regulator rebuild.

16.2.1. NOTE-THE REGULATOR (1120) MUST

BE KEPT VERY CLEAN INSIDE. IT IS IMPORTANT TO

WORK ONLY IN A CLEAN ENVIRONMENT.

16.3. The regulator can be disassembled using either two wrenches, or one wrench and a vise. Hold the spring cap of the regulator (1120-1). Turn the smaller hex (1120-2)

— the piece with the smaller of the two male threads visible

— counterclockwise until it is separated.

16.4. Take the main body and turn it so that the end you just opened is down. Tap it gently on your hand or the padded bench to get the piston (1120KIT-1) to drop out. Set both aside.

16.5. Take the body (1120KIT2) that you screwed out of fi gure 44 page 18

the spring cap and turn it so that the inside portion is facing up. You will see an O-ring

(1120KIT-3) and a smaller hex opening(1120KIT-2). Using an O-ring tool remove the Oring and set it aside. Use a 5/8 socket wrench to remove the hex valve car-

1120KIT1--1*

1120KIT1--3* tridge (1120KIT-2). Set this aside. (see

PISTON

SEAT fi gure 42).

16.5.1. Part # 1120KIT1 has a seat and

O-ring in its fl at end. These are normally factory installed. If they are loose see fi gure 45 for assembly.

1120KIT1--2*

O-RING

*Not available as separate parts

16.6. Clean all parts with a clean soft lintfree cloth. If there is dirt that does

1120KIT-1 DETAIL fi gure 45 not come off with a cloth, you can wash the parts in a mild detergent (no perfume) and hot water, rinsing with clear hot water, then blow dry or allow to air dry. Ultrasonic cleaning is acceptable using a mild detergent solution and a clear water rinse.

16.7. Once the parts have been cleaned and dried, reassemble in reverse order using the new parts provided in the 5-year maintenance kit for regulator repair. Lubricate all moving parts with an approved O-ring lubricant (Christo-lube).

16.8. Tighten all parts snug with a wrench but avoid using excessive force.

16.9. Reinstall regulator into panel, using the reverse order of 16.1. Do not reinstall acorn nut.

16.10. Reinstall cylinders per 11.6 through 11.9.

16.11. Test plumbing for leaks per 14.8. Fill system to 4500psi, and adjust regulator with the following procedures:

16.11.1. Loosen set screw with a 3/16” Allen wrench.

16.11.2 Open cylinder (CYL1) to pressurize inlet side of regulator, with fi ll valves closed.

Use caution to not overpressurize gauge.

16.11.3 Turn the set screw clockwise until the regulated pressure reads 3000psi. Hold

one fi ll hose, and open and close the fi ll valve.

16.11.4. Verify that the regulated pressure gauge reads 3000psi. If it does not, turn the

set screw clockwise to increase; counterclockwise to decrease.

16.11.5. Open/release the fi ll valve; install the acorn nut, and verify the pressure reading.

16.12. Once plumbing is leak free and regulator is adjusted, reinstall the unit into the case, refi ll with air and return to service.

page 19

17.0 MRS III Case (1650)

17.1 The case for the MRS III is Pelican Products #1650.

17.1.1 This case is covered by “The Pelican Unconditional Lifetime Guarantee of

Excellence”. If the case is damaged or broken contact Pelican Products at 800-473-5422 in the US except California or at 310-326-3311 outside of the US; you can also contact them via fax at 310-326-3311 inside the US, 310-325-5740 outside the US. In Canada you can contact Pelican Products Canada at 780-481-6076 or via fax at 780-481-9586.

You can also contact them at www.pelican.com.

17.1.2 When returning the case for repair or replacement you will need to remove all equipment from the case including the hose mounts and the manual.

17.1.2.1 The case will be returned without any mounting holes, it will be your responsibility to drill the replacement case for the equipment. You may instead return the entire unit to Breathing Air Systems to handle the Pelican Warranty. Please note there will be a charge for labor after the initial 1 year warranty.

fi gure 46 To open and close the MRS III case, note that there are seven latches; three in front, and two on each side.

fi gure 47 Push handle latch

(white arrow) to the right, to raise or lower the case handle.

fi gure 48

Carrying handles on the top and side should be pushed fl at against the case when wheeling or packing.

fi gure 49 Using the handle and wheels to transport the

MRS III.

page 20

TROUBLE SHOOTING CHART

FOR THE MRS III

PROBLEM ACTION

O-ring at fi ll connection is damaged or missing.

Replace O-ring.

Leaks at connection to EBS.

Contaminants on O-ring or sealing surface of fi ll port of EBS. Clean and inspect, repair if damage is present.

Rebuild fi ll connector swivel joint.

Leaks at fi ll connector swivel

Replace fi ll connector.

Tighten valve knob by hand. If valve is tight, replace valve seat.

Leaks at inline bleeder

Leaks at hose

Fill hose shows damage

Replace inline bleeder.

Check fi ttings to make sure they are tight. If the leak is not from the fi tting where it meets another fi tting, replace hose.

Replace fi ll hose.

Rebuild valve.

Fill hose fails to shut-off when valve is closed

Replace valve.

Rebuild valve.

Leak from fi ll valve

Fill valve knob turns but does not operate valve

Replace valve.

Replace valve knob. Rebuild valve.

Verify the accuracy of the gauges.

Fill pressure exceeds 3000 psi Have an authorized and trained technician adjust the regulator. If an adjustment does not correct the problem, rebuild the regulator and adjust.

Verify that it is the regulator that is leaking and not a fi tting. If it is a fi tting see “Leak at Fittings”.

Regulator leaks

Rebuild regulator.

Replace regulator page 21

Inspect fi tting for damage, if damaged replace fi tting.

Leak at fi tting

If fi tting is loose: Pipe Thread fi ttings must be removed, have the Tefl on tape replaced and reinstall with the same orientation as before.

Compression and Flare fi ttings can be tightened without need to remove them. NOTE: Compression and

Flare fi ttings do not use Tefl on tape.

Gauge reading incorrect

Replace fi tting.

Have calibration technician verify accuracy of gauge.

Gauges are not adjustable. Reading should be plus or minus 100psi in the center of the range.

Replace gauge.

Check fi ttings for tightness.

Leak at gauge

MRS leaks out the refi ll port

Replace gauge.

Rebuild inlet check valve.

Check the connection to make sure it is hand tight.

Leak at connection to supply cylinder

Replace O-ring in connector.

Inspect cylinder valve and connector for damage, replace if damaged.

Remove valve replace O-ring and reinstall valve.

Leak at supply cylinder to valve

Inspect cylinder and valve for damage. Replace if damaged.

Leaking supply cylinder valve

Supply cylinder fails hydrostatic test

Rebuild valve.

Verify that both supply cylinder valves are fully opened.

Supply cylinders have air pressure showing on gauge in valve but no pressure showing on supply pressure gauge

Rebuild valves if there is air in the cylinders.

Replace supply cylinder valve gauges if there is no pressure in the cylinders, but the gauge reads pressure.

Replace supply cylinder.

page 22

Supply cylinder is damaged

MRS III case is damaged

Inspect per CGA Pamphlet C-6.2. Replace if damage exceeds allowable limits.

Replace case.

Inspect metal frame:

MRS III metal frame is damaged

If damage is minor then the metal can be straightened using standard shop practices and hand tools.

MRS III exceeds 15 years from manufacture date

If damage is major replace MRS-III.

Contact Breathing Air Systems to see if the supply cylinders life has been extended beyond 15 years. If not, replace the supply cylinders.

page 23

page 24

Illustrated Parts

Breakdown

Mobile Refi ll System III (100701)

FRONT OF

UNIT

page 25

END VIEW

ITEM REQ ’D

01

02

03

04

05

06

07

08

09

10

11

12

13

14

15

16

17

18

19

20

1

1

1

1

1

2

8

1

2

10

6

1

1

2

2

1

4

1

1

2

PART

NO.

1650

FRM1**

FRM1**

PRS17

FRM1**

CYL1

BLT3

MRS22

MRS23

MRS50

WA1

MRS21

FRM1**

FRM1**

FRM1**

FRM1**

GAG1

AQUALUNG

PART NO.

103201

103202

103203

103204

103206

103207

103208

103137

103211

103212

103213

103214

103216

103217

103218

103219

103221

DESCRIPTION

CASE, PELICAN WITH WHEELS

TOP PLATE, 14¼” X 161/4” .125 ALUM.

5052-H32

SUPPORT, 6” X 14 1/8” .125 ALUM. 5052-H32

GROMMET, 1.5”, ALTER

BRACKET 11½” X 28½”.125 ALUM. 5052-H32

CYLINDER, CARBON COMPOSITE, 4500PSI,

87 CU. FT. NO VALVE

SCREW, ¼-20 X 1 SS

BRASS PLUG, 7/16 X 20

BOLT, ¼-20 X 1½ SS

INSERT, ¼ - 20

WASHER, ¼” FLAT, SS

LANYARD

BACK PLATE, 11” X 20 7/8” .125 ALUM.

5052-H32

1/8 WALL X ¾ X ¾ X ¾” SQ ALUM. TUBE

TUBE, 2 7/8” OD. X 2 ¼” ID. X 6 7/8” LG

REST, 5 7/8” X 14 1/8” ” .125 ALUM. 5052-H32

GAUGE, 6000 PSI, SST W/ PANEL MOUNT CLAMP, DRY

GAUGE, 2.5”

TUBING, GAUGE, 1/8” X .028 WALL 304SS MRS5-ASY

MRS13

FRM1**

103222

103223

103224

** FRM1 Items available as assembly only.

NUT, ACORN

BOTTOM, ¾” X 2 5/16”.125 ALUM. 5052-H32 page 26

1

1

1

1

1

1

1

1

1

1

2

1

1

2

1

1

1

1

1

1

1

1

45

46

47

48

49

50

51

52

53

54

41

42

43

44

37

38

39

40

55

56

57

58

30

31

32

33

34

35

36

26

27

28

29

ITEM REQ’D PART NO.

AQUALUNG

PART NO.

21

22

4

2

MRS3-ASY

PRS2

103226

103227

23

24

25

1

4

1

MRS2

PRS8

MRS1

103228

103229

103231

4

3

4

2

2

2

2

2

2

1

1

FESS

STSS

WA3

HOSI

CTXSS

712

PRS21

NUT2

835

SESS

MRS14

103232

103233

103234

103236

103237

103238

103239

103241

103242

103243

103244

955SSMM

DIN-F

347-1

MRS24

MRS12

PAD1

YVA3010A

1120/ASSY

MRS25

MRS11-ASY

MRS17

MRS16

MRS15

MRS18

MRS19

MRS7-ASY

MRS4-ASY

MRS20-ASY

MRS10-ASY

MRS6-ASY

MRS8-ASY

MRS9-ASY

103254

103256

103257

103258

103259

103261

103262

103263

103264

103266

103246

103247

103248

103250

103249

103251

103252

103253

103267

103268

103269

103271

DESCRIPTION

CONNECTOR, 1/8” TUBE X ¼” FNPT, SST

CONNECTOR, ¼” MNPT X 1/8” TUBE, SST

TEE TUBE UNION, 1/8”

ELBOW, ¼” MNPT X 1/8” TUBE

CROSS, 1/8” TUBE SS

ELBOW, SS, FEMALE, ¼” FNPT

TEE, STREET, SST ¼”

WASHER, FENDER ¼” SS

HOSE, FILL MRS III

ELBOW, SS, ¼” FLARE X ¼” MNPT

BLEEDER, INLINE MXF ALUMINUM

FILL ADAPTER, #4 SAE X 14” FNPT

NUT COUPLING, 7/16”—20 SST

ADAPTER, FILL, 4.5 ALUM.

ELBOW, STREET, SS ¼”

TEE, 1/8” TUBE X ¼” MNPT,

SS MALE BRANCH

CHECK VALVE, SS, ¼” MNPT

ADAPTER, DIN WITH 55° THREAD BY ¼” FNPT

CGA 347 TO ¼” FNPT BRASS

MRS III OPERATING INSTRUCTIONS

SCREW SET

PAD, RUBBER, 4” X 21”x.25” ADHESIVE BACK

PANEL FILL VALVE

PRESET REGULATOR, 5000 PSI

BRASS PLUG 7/16”—20

TUBING, CYLINDER 1/8” X .028 WALL, 304SS

LABEL, REGULATOR, 3/8” X 3 ½”

LABEL, SUPPLY PRESSURE, 3/8” X 3½”

LABEL, FILL #1, 3/8” X 3 ½”

LABEL, REGULATED PRESSURE 3/8”X3½”

LABEL, FILL #2, 3/8” X 3 ½”

TUBING, REGULATED, 1/8” X .028 WALL, 304SS

TUBING, FILL #1, 1/8” X .028 WALL, 304SS

TUBING, SUPPLY GAUGE,

1/8” X .028 WALL, 304SS

TUBING, 1/8” X .028 WALL, 304SS

TUBING, #2 SUPPLY, 1/8” X .028 WALL, 304SS

TUBING, #1 JUNCTION, 1/8” X .028 WALL, 304SS

TUBING, #2 JUNCTION, 1/8” X .028 WALL, 304SS page 27

62

63

64

65

66

59

60

61

67

68

69

70

ITEM

2

2

2

2

2

1

1

1

1

2

1

1

NUT1

PRS6

TRIM

VAL1

FRM1

FRM1

MRS26

59

PAD2

RCAP

PRS6-1

PRS6-2

PART NO.

AQUALUNG

PART NO.

103272

103273

103274

103276

103277

103278

103279

103281

103348

100755

820040

820039

DESCRIPTION

NUT, MRSIII, 1.25-12, 1.5 HEX

HANDWHEEL ASSEMBLY, DIN X ¼” MNPT

TRIM, FITS 1/8” MATERIAL

VALVE, SUPPLY CYLINDER, CGA 347

GUSSET, 1½” X 1½” .125 ALUM. 5052-H32

PLATE, ¾” X 1¼” .125 ALUM. 5052-H32

LABEL, .5 X 1.75, AVERY 5267

BLEEDER KEEPER

PAD, RUBBER, 4” X 21” X .375” ADHESIVE BACK

RUBBER COVER FOR MRS INLET

O-RING

O-RING

712 INLINE

BLEEDER

ASSEMBLY

(AQUA LUNG 103238)

1

3

2


AQUALUNG

PART NO.

712 103238

1

2

3

4

1

1

1

1

712BODY

712KNOB

712SSTIP

59

103318

103347

100774

103281

DESCRIPTION

INLINE BLEEDER, COMES

WITH 1, 2, AND 3 BELOW

BLEEDER BODY

KNOB FOR BLEEDER

TIP

BLEEDER KEEPER

4 page 28

FILL VALVE

ASSEMBLY (YVA3010A)

ITEM REQ’D

7

8

9

5

6

10

11

3

4

1

2

1

1

1

1

1

1

1

1

1

1

1

PART NO.

YVABODY

YVAKIT-5 *

YVAKIT-1 *

YVASTEM

YVAKIT-3 *

YVAKIT-4 *

YVABONNET

YVAKNOB-1 **

YVASPRING

YVANUT

YVAKNOB-2 **

AQUALUNG

PART NO.

103282

103283

103284

103286

103287

103288

103289

103291

103292

103293

103294

DESCRIPTION

VALVE BODY

COPPER GASKET

VALVE SEAT

VALVE STEM

THIN PACKING

THICK PACKING

BONNETT NUT

KNOB

SPRING

VALVE NUT

KNOB CAP

4

1

6

Fill Valve

5

3

2

7

* These items are contained in the YVA KIT, and cannot be

purchased separately

** YVA KNOB (100778) consists of YVAKNOB-1 and

YVAKNOB-2, and are only purchased as a unit.

8

FILL VALVE OVERHAUL

KIT (YVAKIT)

2

5 6

3

10

9

11

* YVAKNOB consists of #8 & #11.

page 29

SUPPLY CYLINDER VALVE

(#VAL1 or #103276)

6 1

2

15

10

8

7

19

16

9

4 3 5

14

SUPPLY CYLINDER

VALVE OVERHAUL

KIT (VAL1KIT)

8

1

7

17

22

18

20

21

10

6

12

11

SAFETY DISC

15

13

15

GAUGE

ASSEMBLY

13

12 11 page 30

SUPPLY CYLINDER VALVE

PARTS BREAKDOWN

9

10 +

11 +

12 +

13 +

14

15

1 +

2

3

4

5

6 +

7 +

8 +

16

17

18

19

20 +

21 +

22

23

ITEM

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

2

1

1

REQ’D PART NO.

AQUALUNG

PART NO.

VAL1 103276

VAL1-13

VAL1-15

VAL1-16

VAL1-17

103296

103297

103298

103299

VAL1-18

VAL1-7

VAL1-5

VAL1-6

VAL1-14

VAL1-8

VAL1-4

VAL1-3

VAL1-9

VAL1-19

VAL1-20

103301

103302

103303

103304

103306

103307

103308

103309

103311

103312

103313

VAL1-21

VAL1-22

VAL1-23

VAL1-26

VAL1-1

VAL1-2

VAL1-25

VAL1KIT

103314

103316

103317

103344

103319

103321

103322

103346

DESCRIPTION

SUPPLY CYLINDER VALVE

COPPER GASKET

VALVE STEM

BONNET NUT

LOCK SPRING

VALVE NUT

VALVE SEAT

O-RING

TEFLON WASHER

WEAR WASHER

O-RING

SAFETY DISC GASKET

SAFETY DISC

SAFETY DISC PLUG

KNOB

VALVE BODY.

NOT AVAILABLE SEPARATELY

BUMPER GUARD ASSEMBLY

SPRING, WAVE WASHER

GAUGE ASSEMBLY

SCREW FOR BUMPER

TEFLON BACKUP RING

O-RING

GAUGE COVER

SUPPLY VALVE OVERHAUL KIT

+ Part of valve rebuild kit. Parts cannot be bought separately.

page 31

SEA FILL ADAPTER (PRS-21)

2

3 5

1

4

6

2 3

ADAPTER OVERHAUL

KIT (PRS21KIT)

3

2

5

6

2

3

PRS21KIT


AQUALUNG

PART NO.

PRS21KIT 100782

1**

2

3

4**

5

6

1

2

2

1

1

1

DESCRIPTION

PRS21-1

PRS21-3

PRS21-2

PRS21-4

PRS21-5

PRS21-6

103333

100771

100770

103334

100772

100773

ADAPTER OVERHAUL KIT

ITEMS 2,3,5 & 6 BELOW

SPINDLE

O-RING

BACK-UP RING

BODY

SNAP RING

O-RING

**Items 1 & 4 cannot be purchased seperately.

page 32

3

4

1

2

5

6

7

ONE-YEAR MAINTENANCE KIT MRSKIT1

(AQUA LUNG 100703)

ITEM REQ’D

2

2

4

4

2

2

2

PART NO

PRS21-2

PRS21-3

PRS21-5

PRS21-6

712SSTIP

010

VAL1-8

AQUALUNG

PART NO.

100770

100771

100772

100773

100774

100775

103307

DESCRIPTION

BACKUP RING

O-RING

SNAP RING

O-RING

TIP

O-RING - CYL FILL ADAPTER

O-RING FITS VAL1 NECK

10

11

12

13

14

15

4

5

6

7

8

9

1

2

3

16

17

18

19

20

21

22

FIVE-YEAR MAINTENANCE KIT MRSKIT2

(AQUA LUNG 100704)

ITEM REQ’D

2

2

1

1

2

2

2

2

2

2

2

2

2

1

2

2

1

2

4

4

4

2

PART NO

PRS21-2

PRS21-3

PRS21-5

PRS21-6

712SSTIP

010

VAL1-8

YVAKIT

YVAKNOB

1120KIT

955KIT

VAL1-1

VAL1-2

VAL1-3

VAL1-4

VAL1-5

VAL1-6

VAL1-7

VAL1-9

VAL1-13

PRS6-1

PRS6-2

AQUALUNG

PART NO.

100770

100771

100772

100773

100774

100775

103307

100777

100778

100776

100781

103319

103321

103309

103308

103303

103304

103302

103311

103296

820040

820039

DESCRIPTION

BACKUP RING

O-RING

SNAP RING

STAINLESS

O-RING

TIP

O-RING

O-RING FITS VAL1 NECK

REPAIR KIT YVA VALVE

KNOB

KIT FOR 1120 REGULATOR

REBUILD KIT, 955SSMM

TEFLON B/U RING FOR VAL1

O-RING, FITS VAL1

BURST DISC FOR VAL1 SAFETY

NYLON WASHER FOR

VAL1 SAFETY

O-RING, FITS VAL1

TEFLON WASHER FOR

VAL1 STEM

PLUG SEAT ASSEMBLT FOR VAL1

SAFETY DISC PLUG

COPPER GASKET FITS VAL1

O-RING FOR PRS6 FOR SEAL

O-RING FOR PRS6 INTERNAL page 33

CHECK VALVE OVERHAUL

(#955SSMM or #100781)

1

2 3 4

ITEM REQ’D

3

4

1

2

1

1

PART NO.

955KIT-1**

955KIT-2**

DESCRIPTION

SPRING (Cannot be purchased separately.)

GASKET (Cannot be purchased separately.)

1 955KIT-3** BALL (Cannot be purchased separately.)

1 955KIT-4** O-RING (Cannot be purchased separately.)

1 955KIT Items 1, 2, 3, and 4 above.

+** Part of valve rebuild kit. Parts cannot be bought separately.

Parts needed: 955KIT and Christo-Lube

1. Using an 11/16” and a 3/4” wrench, separate the halves of the check valve.

2. Remove the spring (1) ball (3) gasket (2) and the o-ring (4). Discard.

3. Using a soft cloth or papertowel clean the internal surfaces of the body. Open 955KIT.

Lubricate the o-ring (4) with a small amount of non-toxic lubricant (Christo-lube). NOTE:

Do not leave heavy concentrations

4. Place the new o-ring (4) into the body, pushing into the groove.

5. Place a thin fi lm of lube on the ball (3), place the ball into the body on the o-ring.

6. Place the gasket (2) into place in the body.

7. Place the spring (1) in the opposite half of the body

8. Reassemble the 2 halves.

page 34

1

2

PRS6 OVERHAUL

4

5

3

6


AQUALUNG

PART NO.

3

4

1

2

5

6

1

1

1

1

1

1

PRS6

PRS6-1

PRS6-3

PRS6-2

PRS6-4

PRS6-5

347-1

820040

106058

820039

108657

054159

103248

DESCRIPTION

O-RING

STEM (Cannot be purchased separately.)

O-RING

HANDWHEEL (Cannot be purchased separately.)

1/4”NPT FITTING (Cannot be purchased separately.)

CGA 347 TO 1/4” FNPT BRASS

1. To disassemble, hold 1/4” NPT fi tting (5) using 11/16” socket. Using a 6mm Allen

2.

3. wrench, unscrew stem (2) with a counter-clockwise motion.

Remove O-rings from stem, using O-ring pick. Discard.

The 820039 O-ring (3) on the PRS/MRS DIN connector must have a light coat of nontoxic lubricant (Christo-Lube) applied prior to being installed on the assembly. NOTE:

4.

Do not apply any lubricant to the 820040 O-ring (1).

Install lubricated O-ring (3) over the threads of the stem (2) taking care to not damage the

5.

6.

O-ring.

Install O-ring (1) all the way back into the O-ring groove of stem (2).

Place the handwheel (4) over the 1/4” NPT fi tting (5) with the threads pointed upward.

7. Thread stem (2) into 1/4” NPT fi tting (5) using a 6mm Allen wrench. Use 11/16” socket

8. to hold 1/4” NPT fi tting.

Torque stem (2) to 1/4” NPT fi tting (5) -- 40.0 +/- 5.0 inch pounds.

page 35

PRESET REGULATOR (1120)

5

1

2

3

4

6

**Items 2, 3, and 4 are not available separately. They are included in overhaul kit 1120KIT, shown below.

PRESET REGULATOR OVERHAUL KIT

(1120KIT)

2

3

3 4

1120KIT1--1**

PISTON

1120KIT-1

BREAKDOWN

1120KIT1--2**

7 O-RING

1120KIT1--3**

SEAT 8

** 1120KIT-1 comes assembled in

1120KIT. Breakdown at left is shown for information only, in case parts become seperated. Parts cannot be bought seperately.

6

7

8

4

5

1

2

3

ITEM REQ’D

1

1

1

1

1

1

1

1

PART NO.

1120KIT

1120-1

1120KIT-1

1120KIT-2

1120KIT-3

1120-2

PRS10

1120KIT-1-2

1120KIT-1-3

AQUALUNG

PART NO.

100776

103336

103337

103338

103339

103341

103342

DESCRIPTION

KIT FOR 1120 REGULATOR, all items below

SPRING CAP

PISTON

CARTRIDGE

O-RING

BODY

FITTING

O-RING **

SEAT **

**1120KIT-1-2 and 1120KIT-1-3 are part of 1120KIT-1. Cannot be purchased seperately.

page 36

page 37

page 38

page 39

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