S.E.A.

(Survival Egress Air)

MK

TECHNICAL MANUAL

REV 01/10

2

SEA MK Technical Maintenance Manual

CopyRIgHT NoTICE

This 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 format without prior consent in writing from Aqua Lung America International, Inc.

©2010 AqUA LUNg AMERICA

S.E.A. / MK TECHNICAL MANUAL, p/N 108348

You can contact a Technical Adviser via e-mail at: [email protected]

[email protected]

[email protected]

[email protected]

[email protected]

[email protected]

Trademark Notice

Aqua Lung ® , is a registered trademark of Aqua Lung America, Inc.

Warnings, Cautions, & Notes

Pay special attention to information provided in warnings, cautions and notes that are accompanied by one of these symbols:

A WARNINg indicates a procedure or situation that, if not avoided, could result in serious injury or death to the user.

A CAUTIoN indicates any situation or technique that could cause damage to the product, and could subsequently result in injury to the user.

A Note is used to emphasize important points, tips and reminders.

3

CoNTENTS

Change Record ....................................................................................................................................4

Copyright Notice ...................................................................................................................................5

General Guidelines ...............................................................................................................................5

General Conventions ............................................................................................................................5

Initial Inspection Procedure ..................................................................................................................6

External Inspection ..........................................................................................................................6

Immersion/Leak Test ......................................................................................................................6

Medium Pressure (Over-Bottom) Test .............................................................................................6

DISASSEMBLY PROCEDURE .............................................................................................................7

First Stage Disassembly ..................................................................................................................7

Second Stage Disassembly .............................................................................................................9

REASSEMBLY PROCEDURE ............................................................................................................ 11

First Stage Reassembly .................................................................................................................11

First Stage Testing .........................................................................................................................14

Second Stage Reassembly ...........................................................................................................14

Adjusting the Second Stage ..........................................................................................................15

FINAL TESTING .................................................................................................................................16

Subjective Test ..............................................................................................................................16

Immersion Test .............................................................................................................................16

Table 1: Troubleshooting Guide for First Stage/Valve Assembly .........................................................18

Table 2: Troubleshooting Guide for Second Stage..............................................................................18

Table 3: List of Tools and Service Kits ................................................................................................20

Table 4: Torque Specifications ............................................................................................................24

Table 5: Test Bench Specifications ....................................................................................................24

Table 6: Recommended Cleaners and Lubricants ..............................................................................24

Procedure A: Cleaning and Lubricating ..............................................................................................25

S.E.A. First Stage with Cylinder Assembly, Exploded View ...............................................................26

MK Second Stage, Exploded View .....................................................................................................27

Maintenance Notes .............................................................................................................................28

4

SEA MK Technical Maintenance Manual

CHANgE RECoRD

Change No.

001-11

Date

10/6/11

Title or Description p. 20-23 Table 3: List of Tools and Service

Kits Updated

Change made by

AqA

5

Introduction

This manual provides factory prescribed procedures for the correct service and repair of the Aqua Lung SEA MK. It is not intended to be used as an instructional manual for untrained personnel.

The procedures outlined within this manual are to be performed only by personnel who have received Factory Authorized training through an

Aqua Lung Service & 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. MK has black external parts, however, chrome parts are used in this manual for clarification.

Scheduled Service

The SEA MK should be given the same care and maintenance 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; once every two years with normal use.

general Conventions

Unless otherwise instructed, the following terminology and techniques are assumed:

1. When instructed to remove, unscrew, or loosen a threaded part, turn the part counterclockwise.

2. When instructed to install, screw in, or tighten a threaded part, turn the part clockwise.

3. When instructed to remove an o-ring, use the pinch method

(see illustration below) if possible, or use a brass or plastic o-ring removal tool. Avoid using hardened steel picks (unless directed), as they may damage the o-ring sealing surface. All o-rings that are removed are discarded and replaced with brand new o-rings.

4. The following acronyms are used throughout the manual: Lp is Low Pressure; Mp is Medium Pressure; and Hp is High

Pressure.

5. Numbers in parentheses reference the key numbers on the exploded parts schematics on pages 26 and 27. For example, in the statement, “...remove the o-ring (31) from the...”, number 31 is the key number to the piston head o-ring.

general guidelines

1. In order to correctly perform the procedures outlined in this manual, it is important to follow each step exactly in the order given. Read over the entire manual to become familiar with all procedures before attempting to disassemble the product in this manual, and to learn which specialty tools and replacement parts will be required. Keep the manual open beside you for reference while performing each procedure. Do not rely on memory.

2. All service and repair should be carried out in a work area specifically set up and equipped for the task. Adequate lighting, cleanliness, and easy access to all required tools are essential for an efficient repair facility.

3. Before beginning any disassembly, it is important to first perform the Initial Inspection procedure. Refer to Tables 1 & 2:

Troubleshooting, p. 18 & 19, to determine the possible cause of any symptoms which may be present.

4. As each unit is disassembled, reusable components should be segregated and not allowed to intermix with nonreusable 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.

5. Use only genuine Aqua Lung ® parts provided in the overhaul parts kit for this product. DO NOT attempt to substitute an Aqua

Lung ® part with another manufacturer’s, regardless of any similarity in shape or size.

6. Do not attempt to reuse mandatory replacement parts under any circumstances, regardless of the amount of use the product has received since it was manufactured or last serviced.

7. When reassembling, it is important to follow every torque specification prescribed in this manual, using a calibrated torque wrench. Most parts are made of either marine brass or plastic, and can be permanently damaged by excessive stress.

Pinch Method

Press upwards on sides of o-ring to create a protrusion. Grab o-ring or insert o-ring tool at protrusion.

6

SEA MK Technical Maintenance Manual

Initial Inspection procedure

External Inspection

1. When possible, inspect the filter of the fill adapter for

any signs that contaminants, such as moisture or

particulate matter, may have entered the system.

2. Visually inspect the MP hose along its length for any

signs of deterioration or damage, such as blistering,

abrasion, or corrosion of the fittings.

3. Slowly pressurize the system by turning the on-off

handwheel counterclockwise

4. Examine the pressure indicator (pin or dial) to deter-

mine whether the pin is within the full range or dial is

in the green, indicating that the SEA MK cylinder is

full.

NoTE : If the pin indicator or dial indicator does not indicate that the cylinder is completely full, it will be necessary to perform the filling procedure outlined in the SEA MK Owner’s

Manual before proceeding further.

WARNINg: only use the SEA MK with normal, atmospheric, compressed air (21% oxygen and 79% nitrogen by volume).

DO NOT attempt to fill with pure oxygen, 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

1. After ensuring that the system is pressurized and the cyl-

inder is full, listen for any obvious signs of leakage from

the system, including free flow from the second stage.

CAUTIoN: If a second stage leak is detected, carefully perform the medium pressure test. Use caution and avoid over pressurizing the Mp test gauge. performing this test may cause damage to the test gauge, and possibly result in serious personal injury.

2. If there are no detectable leaks, immerse the entire sys-

tem in fresh water. Check for any bubble streams to

locate the source of any leakage.

3. Note the source of any leakage found and refer to Table

2: Troubleshooting, p. 18 & 19 to determine its possible

cause.

4. Close the valve and depress the second stage purge

to completely depressurize the system. Wait at least five

minutes, and depress the second stage purge to deter-

mine whether any air pressure has built up inside the

MP hose and second stage valve.

NoTE : A buildup of pressure is caused by either a bad valve seat (20) or damaged sealing surface inside the body (36). If a buildup of air pressure occurs, check both items. Replace the valve seat first. If the problem still occurs, replace the body.

Medium (over-Bottom) pressure Test

1. With the valve closed, purge the second stage to depres-

surize the system. While securely holding the second

stage inlet fitting (51) with a thin 3/4" open-end wrench,

apply an 11/16" open-end wrench to the female fitting

of the MP hose. Turn the hose fitting counterclockwise to

loosen and remove the hose from the second stage.

2. Connect the medium pressure test gauge (PN

111610) to the female fitting of the MP hose, and tighten

the hose fitting by hand until finger tight.

3. While holding the MP test gauge positioned so that it is

facing away from you, pressurize the system by slowly

turning the SEA MK valve handle counterclockwise.

Check the SEA MK pin indicator or dial gauge to ensure

that it indicates the cylinder is filled with at least 2,700

psi.

4. Note the medium (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. If the medium pressure “creeps” up or otherwise

fluctuates after cycling the regulator, wait for it to stabilize

(if possible) before noting the final medium pressure.

NoTE : Correct medium pressure for the SEA MK is 135

(±20) psi, with an inlet pressure between 2,500 - 3,000 psi.

6. Partially open the bleed valve of the MP test gauge to

empty the SEA MK 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 cylinder or valve becomes cold to the touch while

performing this step, the air has been relieved too rapidly.

WARNINg: Failure to completely empty the SEA MK of air prior to performing any disassembly may cause the sudden separation of components or ejection of parts, and may result in serious personal injury.

DISASSEMBLy pRoCEDURE

NOTE:

Before performing any disassembly, refer to the exploded parts drawing, which references all mandatory 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.

CAUTION: Use only a plastic or brass o-ring removal 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 replaced with new. Do

NoT use a dental pick or any other steel instrument.

First Stage Disassembly

1. Completely open the on-off handwheel (10). Make sure all the air is completely drained from the cylinder (see p.6, step 6).

7

5. Unscrew and discard the burst plug (6) from the first stage

(36) using a 3/8" socket.

6. Unscrew the valve handwheel retaining nut (7) using a medium flat blade modified screwdriver (pn 9-47448). Remove the washer (8), spring (9), handwheel (10), washer (11) and indicator ring (12) from the stem (19).

12

11 10

9

8

7

7. Using a 3/4" wrench, unscrew the bonnet (13) from the first stage body. Pull the valve stem (19) out of the bonnet.

2. While holding the second stage inlet fitting (52) with a thin

3/4" wrench (not wider than the nut), use an 11/16" wrench to unscrew the hose from the second stage.

hold

3. Remove and discard the o-ring (16) located inside the hoseend swivel fitting, using o-ring removal tool (pn 10-102-400). DO

NOT use this tool on any other parts or damage may result.

8. Remove the backup ring (15), o-ring (16), spacer (17) and washer (18) from the stem. (Note: It is possible that some or

all of these parts are in the bonnet.) Discard backup ring, oring and washer.

check bonnet

18

17

16

15

4. Using a 3/16" hex key, unscrew the swivel port plug (1) from the first stage body. Separate the hose (4) and spacer (5) from the fitting. Remove the o-rings (2 & 3) from the swivel port plug.

9. Remove the o-ring (14) from the bonnet.

8

10. Insert the squared end of the stem into the valve seat

(20) and unscrew and discard the valve seat from the first stage body.

11. Using a magnifier, inspect the condition of the crown.

There should be no scratches, nicks or dents on the crown sealing surface.

SEA MK Technical Maintenance Manual

b. Using a 1/8" hex key unscrew the retaining screw (27g) from the pin indicator body (27b). Remove the spring (27e) and pin (27f).

27b

27b

27e

27f

27g

27g

c. Turn the indicator body upside down to remove the washer (27d) and o-ring (27c). If they do not exit the body freely, use an o-ring removal tool to extract these parts.

12. If the SEA MK is equipped with a dial-type pressure indicator (27), remove the gauge using a 7/8" wrench.

27c

27d

15. Using your fingers, unscrew the fill port plug (21) from the end of the fill adapter port (23). Remove the o-ring (22) from the fill port plug.

13. If equipped with a pin-type pressure indicator (27a), remove the gauge with valve handling retainer tool (pn 053035). For either gauge, remove and discard the o-ring (22).

NoTE: There is a small pin inside the adapter port.

Take care not to lose the pin when the adapter port is removed.

16. Using a 9/16" wrench, unscrew the fill adapter port (23) from the first stage body. Remove and discard the o-ring

(22). Remove the check valve (26) and the o-ring (25) from the check valve.

14. Disassembly of pin-type pressure indicator

CAUTION: The pin indicator parts are under spring pressure. Be sure to apply pressure against the retaining screw (27g) while unscrewing it from the indicator body (27b).

a. If the o-ring (22) has not been removed yet, do so now.

NoTE: The check valve may be in either the first stage or the fill port plug.

17. Remove and discard the fill adapter port o-ring (22).

9

22. Using the bottle vice (pn 100397), vice insert (pn 100398) or strap wrench (pn 54325A22), hold the cylinder secure. While holding the cylinder secure, unscrew the first stage body (36) from the cylinder using a 1 3/16" crowfoot & flex handle drive.

18. Using your fingers, peel the cap protector (29) off the first stage.

23. Remove and discard the o-ring (37) from the cylinder threads.

19. Insert the pins of an adjustable spanner wrench into corresponding holes in the top of the piston cap (30).

Second Stage Disassembly

1. Using small wire cutters, carefully snip the plastic mouthpiece clamp (55) and remove the mouthpiece (58) from the box bottom (54). 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.

20. Unscrew the piston cap from the first stage body. Separate the piston (32) from the cap. Remove the spring (35) from the first stage.

2. Using your fingers, unscrew the front cover assembly (40

& 41) from the box bottom (54).

21. Remove and discard the o-rings (31 & 33) from the piston.

Insert the pin of the seat extraction tool (pn 109437) down the bore of the piston and press out and discard the HP seat (34).

31

33 34

10

3. Lift out the Ring Cover Support (42) and diaphragm (43).

Inspect the diaphragm for any tears or pin holes by holding it up to a light and gently stretching around the perimeter. Discard the diaphragm or set it aside to be reused, depending on its condition.

SEA MK Technical Maintenance Manual

7. Remove and discard the exhaust valve (56) by grasping the flap of each valve and pulling straight outward.

4. While depressing the lever (45), unscrew the inlet fitting (52) using a 3/4" wrench. Remove and discard the inlet fitting o-ring (14).

inlet fitting

5. Gently grasp the lever and remove the entire valve assembly (44-51) from the box bottom. It may be necessary to push in on the valve assembly through the inlet hole.

CAUTION: Valve assembly parts are under spring pressure. When removing the locknut (44), be sure to keep the poppet side of the valve assembly against the work surface or place a finger over the poppet to prevent the parts from ejecting from the valve body.

8. Hold the valve assembly, poppet side facing down, firmly against the work surface. Using a 1/4" nutdriver, remove and discard the locknut (44). Separate the locknut (44), washer (46), lever (45), poppet (50), and spring (49) from the valve body (47).

Using the threaded end of the poppet, press the poppet bearing

(48) out of the valve body from the outside to the inside.

50

49

47

45

46

44

6. The exhaust cover (57) is held in place by four tabs: One side has two short tabs (usually on top), and the other side has two longer tabs (usually on bottom). The two longer tabs come all the way through until flush with the box bottom; the shorter tabs are recessed. The exhaust cover is removed by popping out the short tabs. To do this, use your index and middle fingers to press downward on the center rib, toward the long tabs, while simultaneously pulling out on the exhaust cover.

9. Using the tip of the o-ring removal tool, or any type of pointed tip type tool, pierce the center of the low pressure seat (51) and remove it from the poppet. DO NOT discard the seat, as it will be used later to aid in reassembly.

THIS ENDS DISASSEMBLy

Before starting reassembly, perform parts cleaning and lubrication in accordance with

Procedure A: Cleaning and Lubricating

(p. 25).

REASSEMBLy pRoCEDURE

First Stage Reassembly

CAUTION: Before proceeding, visually inspect the cylinder according to Compressed gas Association

(CgA) standards (pamphlet CgA C-6.1--1984, "STAN-

DARDS FoR VISUAL INSpECTIoN oF HIgH pRES-

SURE ALUMINUM CoMpRESSED gAS CyLINDERS".

This inspection requires a visual inspection light.

If the cylinder does not pass the visual inspection, it must be serviced or replaced with a new cylinder before it can be assembled and filled.

*Lubricate all O-rings with Christo-Lube ® before assembly.

1. Install a new, lightly lubricated o-ring (37) over the cylinder threads so that it is seated against the first stage body. Lubricate the first 4 to 5 threads on the first stage body with Christo-

Lube ® . Do not use an excessive amount.

37

11

4. Place the spring (35) into the body. Press the piston into the cap (30) so that the piston head is seated flat against the cap. Verify there is no dirt or damage to the smooth inner sides of the cap.

35

30

5. Lightly lubricate the first stage body threads. Pass the piston shaft through the spring. While pressing down on the cap, handtighten the cap onto the first stage by turning clockwise.

Tighten the cap with an adjustable spanner wrench until the cap stops against the first stage body.

29

2. Place the cylinder in the Bottle Vice or Vice Insert. Attach a 1 3/16" crow foot adapter to a torque wrench. Tighten the regulator body to 25 ± 2 ft/lbs OR:

2a. Thread the first stage into the cylinder until handtight. Attach a 1 3/16" crowfoot adapter to a torque wrench. Apply a strap wrench to the cylinder. While holding the cylinder firmly, tighten the first stage body to a torque value of 25 ± 2 ft/lbs.

6. Install a new lubricated o-ring (25) onto the shaft of the check valve (26). Install a new lubricated o-ring (22) onto the fill port plug (21).

3. Install a new lubricated piston shaft o-ring (33) and piston head lubricated o-ring (31) onto the piston (32). Closely inspect the edges of new HP seat (34). One edge is sharp and one edge has a chamfer. With the chamfered edge facing outward, press the HP seat into the small, recessed hole in the end of the piston. The easiest method is to place the chamfered edge down on a flat surface and simply press the piston down over it.

23

7. Insert the check valve (26), o-ring side first, into the malethreaded end of the fill adapter port (23). Install a new lubricated o-ring (22) onto the fill adapter port. Lubricate the threads, then thread the fill adapter port into the lower of the two high pressure ports.

26

34

8. Attach a 9/16" socket adapter to a torque wrench and tighten the fill adapter port (23) to 90±3 in/lbs. Do not overtighten - damage to the fill port adapter will result.

32

33

12

9. SEA MK with a pin-type pressure indicator (27a):

a. Drop a new lubricated o-ring (27c) into the pin indicator body (27b), making sure it is properly seated in the small recess inside the body. Drop the washer (27d) over the oring, making sure it is laying flat atop the o-ring.

SEA MK Technical Maintenance Manual

10. SEA MK with a dial-type pressure indicator (27):

a. Install a new o-ring (22) onto the dial pressure indicator

(27). Thread the pressure indicator into the upper HP port and torque to 45±3 in/lbs using a 7/8" crowfoot wrench.

27b

b. Insert the spring (27e) into the indicator body and insert the pin (27f) into the spring. Place the retaining screw

(27g) on the pin and press the retaining screw against the indicator body. While keeping the retaining screw pressed against the indicator body, turn the indicator body counterclockwise to engage the screw threads.

27e

27f

Press retaining screw against body and hold

27g

Turn body to engage threads

11. Thread a new burst plug (6) into the lower port on the first stage body (the side opposite of the fill adapter). Attach a 3/8" socket to a torque wrench and tighten the burst plug to 90±3 in/lbs.

12. Install new lubricated o-rings (2) into the grooves located on either side of the center hole of the swivel port plug (1). Install a new o-ring (3) on the threaded end of the swivel port plug.

c. Using a 1/8" hex key, tighten the retaining screw by turning it clockwise until it stops. Install a new o-ring

(22) onto the threaded end of the indicator body. Thread the pressure indicator into the upper HP port until firmly fingertight. Use the T-handle tool (pn 053035) to tighten.

Maintain firm pressure to avoid damage to the pin gauge.

22 13. Pass the threaded end of the swivel port plug through the hose swivel, then through the spacer (5). Make sure that both o-rings (2) are covered by the hose swivel. Thread the swivel adapter into the first-stage body. Attach a 3/16" hex key to a torque wrench and tighten the swivel port plug to 60±3 in/lbs.

5 2

14. Place a new, lubricated white washer (18) onto the valve stem (19), followed by the metal spacer (17) and lubricated o-ring (16).

13

17. Attach a 3/4" crowfoot or medium deep-well socket to a torque wrench and tighten the bonnet to 90±3 in/lbs.

CAUTION: Do NoT over-torque. Damage to the bonnet will occur.

Note : Before continuing, closely examine the back up ring (15). You will note that it has a flat side and a concave side. For correct assembly the concave side should be against the o-ring

(16), as shown in the picture below.

Backup ring

O-ring

15. Lubricate the threads of the new high pressure seat. Then, using the squared end of the stem (19), screw a new high pressure seat (20) into the first stage body until fingertight. Leave the stem in the high pressure seat. Place the handwheel over the stem and tighten the valve seat. Remove the handwheel.

CAUTION: Failure to fully seat the Hp seat will damage the bonnet.

18. Place the washer (11) over the stem, against the bonnet.

With the rounded edge of the indicator ring (12) facing outward, lightly thread the indicator ring onto the bonnet. When the indicator ring bottoms out, turn it slightly counterclockwise so the corners of the square shaft of the stem point towards the centers of the square cut outs of the indicator ring. Turn the indicator ring an additional 90º, aligning the corners of the stem to the next square cut outs.

19. Place the handwheel (10) over the indicator ring. Place the spring (9) into the valve handle, followed by the washer (8).

CAUTION: Start the retaining nut by hand. If any resistance is felt, stop and remove, then start again to avoid cross threading.

Using the medium flat bladed screwdriver (pn 9-47488), screw the retaining nut (7) onto the end of the stem until the retaining nut will not turn any further.

16. Install a new lubricated o-ring (14) onto the bonnet (13) so that the o-ring fits into the groove located above the longer threads. Pass the bonnet over the stem and thread it into the body.

9

14

8

7

SEA MK Technical Maintenance Manual

Second Stage Reassembly

1. Install a new exhaust valves (56) by inserting the stem of the exhaust valve through the center hole of the exhaust port.

Pull the stem all the way through until the mushroom plug pops through the hole and keeps the valve securely in place. Examine the flap of each exhaust valve to make sure it is laying flat and is not distorted or folded under. Using a pair of small wire cutters (pn 9-45171), snip the stem of the exhaust valve so it is only about a 1/4" long.

20. Install a new lubricated o-ring (16) into the swivel end

(second stage end) of the hose. NOTE: This o-ring is in the second stage rebuild kit (pn 108344).

2. Insert the two long tabs on the exhaust cover (57) into the corresponding bottom two slots on the box bottom (54). Using your index and middle fingers, press down on the center rib and simultaneously press in on the two short tabs until they pop into place.

First Stage Testing

Note: Initial first stage testing is done WITHOUT anything attached to the end of the hose. For proper filling instructions, refer to the operator's manual of the fill equipment, e.g., MRSIII portable refill station, cylinder fill adapter to fill from a larger cylinder, or yoke fill adapter to fill from a compressor.

1. Cycle the handwheel on and off several times to ensure the proper function of the indicator ring and valve seat. Close the on-off valve by turning the handwheel (10) clockwise until it stops.

2. Remove the fill port plug (21) and attach the fill adapter.

Attach a 3000 psi supply to the fill adapter. Secure the end of the hose prior to pressurizing.

3. Slowly begin to fill the cylinder with 3000 psi of air.

During the fill process, check any air leaking from the open end of the hose. If an air leak is detected, immediately stop the filling process consult the Table 1: Troubleshooting guide

p. 18. If a leak is not detected, finish filling the cylinder to 3000 psig. Turn off the supply line valve and bleed the line pressure.

Remove the supply line from the fill adapter and unscrew the fill adapter from the fill port. Reinstall the fill port plug.

4. Thread a medium pressure (MP) gauge to the hose until fingertight. Slowly turn the handwheel (10) and open the valve.

Check the MP to make sure it "locks up" at 135±20 psig. Closely monitor the MP gauge for a few minutes to make sure the MP does not begin to creep upward. Any MP creep indicates a small high pressure leak somewhere in the system. Cycle the bleed valve open and closed on the IP gauge a minimum of two times to insure the HP seat is seated and the regulator stays locked up. If a MP creep is detected, consult Table 1:

Troubleshooting guide p. 18.

5. Assuming the medium pressure is properly set, close the

SEA valve and open the bleeder valve on the MP gauge to relieve the air from the system. Remove the MP gauge from the end of the hose.

6. Since there is nothing attached to the end of the hose and the cylinder is fully charged, set the system in a secure place so that the valve cannot be accidentally opened.

long tabs

3. Press a new low pressure seat (51) into the end of the poppet (50) until it is flush and seated evenly. Ensure the dimpled side is toward the poppet.

51

50

4. Place the poppet bearing (48), rounded side first, onto the stem of the poppet (50). Using the poppet as an installation tool, insert the bearing into the barrel of the valve body (47).

Align the squared side of the poppet bearing with the square hole in the valve body and press it into place. Remove the poppet. If the poppet bearing does not stay in place, put a small amount of Christo-lube and re-insert.

® on the square sides of the bearing

48 47

5. Install a new inlet fitting o-ring (14) in the groove located between the wrench flats and shorter threads.

15

9. Place the washer (46) over the threads of the stem. Thread a new locknut (44) onto the stem. Using a 1/4" nutdriver, tighten the locknut until about two threads show past the locknut. two threads

46

44

6. Take the used low pressure (LP) seat that was removed during disassembly and place it on top of the crown sealing surface inside the inlet fitting (52). Place the spring (49) over the stem of the poppet (50) and set this assembly into the inlet fitting, on top of the used LP seat.

50

52 51 49

10. Unscrew the inlet fitting from the valve body. Discard the used LP seat. While depressing the lever with your finger, thread the inlet fitting (52) back into the valve body.

Note: The used LP seat is only used to aid in reassembly. It will be removed and discarded later in the reassembly procedure.

7. Place the barrel of the valve body (47) over the top of the poppet. While pressing down on the valve body to compress the spring, screw the valve body onto the inlet fitting. This will fully expose the threads of the poppet.

Adjusting the Second Stage

11. Attach the valve assembly to the end of the hose until fingertight. Slowly turn the SEA on/off valve (10) counterclockwise to open the valve. If a leak is detected while opening the valve, immediately close the valve. Loosen the locknut a 1/2 turn and slowly open the valve again. Repeat this step until the unit does not leak.

If air leaks when pressurized, loosen locknut until leak stops

8. Place the "feet" of the lever (45) into the groove on the face of the valve body (47) such that the lever is pointing away from the air outlet hole.

45 feet air outlet hole

12. Using a 1/4" nutdriver, tighten the locknut until air starts to leak. As soon as a leak is detected, loosen the locknut until the leak stops, then continue to loosen for another 1/4 to 1/2 turn.

Tighten until air leaks.

Lo o sen unt il air leaks stops, then loosen 1/4 to 1/2 turn more.

16

13. Close the SEA on/off valve by turning the handwheel clockwise. Purge the air from the system by pressing down on the lever. Remove the valve/inlet assembly from the hose.

While depressing the lever with your finger, unscrew the inlet fitting from the valve body.

Press lever to relieve pressure.

SEA MK Technical Maintenance Manual

18. Install the mouthpiece (58) onto the box bottom. Loosely fasten a tie-strap clamp (55) over the slots at the base of the mouthpiece. Orient the clamp buckle to the side of the mouthpiece with the hose. Pull the clamp tight and snip the excess strap flush with the buckle using a small pair of wire cutters.

Red indicates "off".

14. With the lever facing upward, reinsert the valve body back into the box bottom. Make sure the flat sides of the valve body

(47) are within the plastic slot. This will prevent the valve body from rotating when installing the inlet fitting.

19. Thread the hose onto the inlet fitting. Attach an 11/16" crowfoot to a torque wrench. While holding the inlet fitting with a 3/4" thin wrench, tighten the hose to 45±3 in/lbs.

15. While depressing the lever, thread the inlet fitting into the valve body. It may be necessary to press inward on the valve body to prevent it from rotating. Attach a 3/4" crowfoot to a torque wrench and tighten the inlet fitting to 50±3 in/lbs.

16. Place the diaphragm (43) over the lever, making sure the perimeter of the diaphragm is seated below the threads and against the box bottom (54). Place the wider side of the Ring,

Cover Support (42) on top of the diaphragm.

17. Screw the front cover assembly (40 & 41) onto the box bottom until fingertight.

FINAL TESTINg

Subjective Test

1. Slowly open the SEA MK First Stage valve to pressurize the system.

2. Press the purge cover a few times to ensure there is a strong purge.

3. Perform a subjective breathing test to ensure that the second stage is operating properly.

Note: Regulator must be cleaned and sanitized per local instruction before issue.

Immersion Test

1. Refill the SEA to 3000 psi. Turn the SEA MK valve to the

"ON" position to repressurize, and check the pressure gauge to ensure that the SEA cylinder is completely filled to 3,000 psi.

If the SEA has a pin gauge, ensure that the gauge indicates correct pressure.

2. Remove the fill cap and protective rubber cover. Submerge the entire system in a test tank of clean water with the valve turned all the way open. Observe any bubbles arising from the submerged system over a 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).

Note: Do not confuse bubbles from trapped air with a true leak. If there is an air leak, bubbles will come out in a constant stream.

WARNING: The SEA MK is designed to assist helicopter crew members and passengers in emergency egress situations from submerged aircraft. It is very critical to ensure that no leakage is present, and that the unit has met all requirements in the Final Testing procedures outlined above. Do NoT issue to a crew member or passenger any SEA MK which exhibits any signs of leakage or unsatisfactory performance until the problem has been thoroughly diagnosed and repairs have been made as needed, including the possible replacement of a damaged component or subassembly.

3. As a final test, leave the unit pressurized with the valve completely open at a stable temperature for a period of at least twelve hours, and check the pressure gauge to determine whether any air loss occurs. If air loss occurs, repeat Immersion

Test (p. 16) for a longer period of time until leak is discovered.

Repair as required.

4. Upon completion of test, ensure no water remains in the cap.

Shake or blow out with clean air. Ensure unit is dry. Reinstall fill port cap (21) and rubber protective cover (29).

21

23

THIS ENDS REASSEMBLy

This concludes the service procedures for the SEA MK First and Second Stages.

17

18

SEA MK Technical Maintenance Manual

Table 1: Troubleshooting guide

First Stage/Valve Assembly

SyMpToM poSSIBLE CAUSE TREATMENT

Lp system will not remain depressurized after valve is shut and second stage is purged.

1. The valve seat (20) is worn or damaged.

1. Replace valve seat.

2. The valve seating surface is damaged.

2. Replace body (36).

1. The valve seat (20) is worn or damaged.

1. Replace valve seat .

High or Unstable Mp

Low Mp

External Air Leak

SyMpToM

Leakage or freeflow from the second stage

2. The valve seating surface is damaged.

3. The main spring (35) is defective.

2. Replace body (36).

3. Replace main spring.

4. The HP seat (34) is worn or damaged.

4. Replace HP seat.

5. The HP crown sealing surface is

damaged.

1. Main spring (35) is weakened or

damaged.

1. The piston head o-ring (31) or shaft o-ring

(33) is worn or damaged.

2. The o-ring grooves on the piston (32)

are damaged.

3. The piston head o-ring sealing surface in

the piston cap (30) is damaged.

5. Replace o-ring.

1. Replace spring (35).

1. Replace o-ring(s).

2. Replace piston.

3. Replace piston cap.

4. The piston shaft o-ring sealing surface in

the body is damaged.

4. Replace body.

5. Blow out plug not seated correctly.

5. Retorque or replace.

6. Check seating surface for nicks or debris.

Table 2: Troubleshooting guide

Second Stage

poSSIBLE CAUSE

1. High first stage MP (should be 135±20

psi).

TREATMENT

1. Refer to first stage Troubleshooting

Guide above.

2. The LP seat (51) is worn or damaged.

2. Replace LP seat.

3. The lever (45) is set too high.

4. The lever (45) is damaged.

5. The crown sealing surface on the inlet

fitting (52) is worn or damaged.

6. The poppet (50) is worn or damaged.

7. The poppet spring (49) is damaged.

3. Readjust locknut.

4. Disassemble second stage and replace lever.

5. Replace inlet fitting.

6. Replace poppet and LP seat.

7. Replace poppet spring.

SyMpToM

Low purge or breathing effort is too high (full cylinder)

External Air Leak

(Immersion Test)

Table 2: Troubleshooting guide

Second Stage (continued)

poSSIBLE CAUSE

1. Low MP (should be 135±20 psi).

TREATMENT

1. Refer to Table 1: Troubleshooting

Guide First Stage, p. 18.

2. The lever (45) is set too low.

3. The lever (45) is bent.

4. The poppet spring (49) is incorrectly

installed.

5. The MP hose is clogged or obstructed.

1.The MP hose is loose.

2. The MP hose o-ring is damaged.

2. Readjust locknut.

3. Disassemble second stage and

replace lever.

4. Disassemble second stage and

reinstall poppet spring.

5. Clean or replace hose.

1. Tighten hose to 45 in/lbs at second

stage fitting.

2. Disassemble and replace o-ring.

19

Water entering second stage

1. The mouthpiece (58) has a hole.

1. Replace mouthpiece.

2. The demand diaphragm (43) is damaged. 2. Replace demand diaphragm.

3. The exhaust valve (56) is damaged.

4. The diaphragm is improperly seated

between the box bottom (54) and purge

cover ring (41).

5. The box bottom (54) is damaged.

6. The valve body o-ring (53) is damaged.

3. Replace exhaust valve.

4. Disassemble and properly

reassemble (check for distortion).

5. Check exhaust valve sealing

surface replace box bottom.

6. Disassemble and replace o-ring.

Note: This is a partial list of possible problems and recommended treatments.

For more information, contact Aqua Lung Technical Service Department for assistance with problems not described here.

CAUTION: Recommended treatments which require disassembly of the regulator must be performed during a complete overhaul, according to the prescribed procedures for scheduled, annual service. Do not attempt to perform partial service.

20

SEA MK Technical Maintenance Manual

Table 3: List of Tools and Service Kits

pART # DESCRIpTIoN AppLICATIoN

108361

Tool Pouch

SEA MK / LV2

Tool holder

111610

Test Gauge

0-400 psi

108362

Soft Case,

IP Test Gauge

108325

SCUBA Fill

Adapter

944022

O-ring Tool

Kit

Checking medium pressure

IP test gauge

IP testing and filling

Removing and installation of o-rings

Internal hose o-ring (16) 10-102-400 O-ring Tool

100188

Micra Retaining

Ring Wrench

107394

Adjustable

Spanner

Wrench

109437

Seat

Extraction

Tool

108357

Repair Mat with Windows

Retaining ring removal and installation

Piston cap (30) removal and installation

HP seat (34) removal

Service and maintenance

pART #

820466

Table 3: List of Tools and Service Kits (continued)

DESCRIpTIoN AppLICATIoN

Christo-Lube MCG III

2 oz. tube

Lubrication

9-AM11708

9-46661

Hex Bit Tool (1/8”)

Hex Bit Tool (3/16”)

Pin-type pressure indicator (27a) and LP swivel port plug (1)

9-45171

Diagonal Pliers

(small)

9-47709

Cylinder

Light

Mouthpiece clamp (55)

Cylinder (38) visual inspection

9-BA819008

Magnifier w/Illumination

9-43001

9-43004

9-43226

3/8” Socket

9/16” Socket

3/4” Socket

9-43625

9-43628

9-43626

11/16” Crowfoot

7/8” Crowfoot

3/4” Crowfoot

Sealing surface spring inspection

Burst plug (6) (3/8”), Fill adapter port (23) (9/16”) , Bonnet (13) and 2nd stage inlet fitting (52) (3/4”)

Hose fitting (11/16”) , Dial pressure indicator (27) (7/8”),

Bonnet (13) (3/4”)

21

FC38A 1 3/16” Crowfoot 1st stage body (36)

9-44388

LTA2428

Tappet

Wrench

(7/8” & 3/4”)

9-44584

Wrench

(11/16”)

Wrench

(7/8” & 3/4”)

Hose fitting (11/16”)

Inlet fitting (52)

Pressure indicator, bonnet (13)

22

SEA MK Technical Maintenance Manual

Table 3: List of Tools and Service Kits (continued)

pART # DESCRIpTIoN AppLICATIoN

9-44572

9-44385

9-44592

3/8” & 7/16” Wrench

1/2” Wrench

5/8” & 9/16” Wrench

MRS III

9-44605

12’ Adjustable

Wrench

MRS III

947448

Medium Blade

Modified

Screwdriver

Handwheel retainer nut (7)

9-41971

1/4” Nut

Driver

5682A28

#2 Phillips

Screwdriver

Lock nut (44)

MRS III

111100 Circlip Pliers MRS III

9-44363

3/8” Drive,

Flex Handle

053035

Valve Handle

Retainer Tool

54325A22

Strap

Wrench

Removal of parts

Pin Type Pressure Indicator (27a) / MRS III

Cylinder removal (52)

108342

Tool Kit (includes all items listed above for SEA LV-2, SEA-MK and MRS III)

SEA LV-2 / SEA-MK / MRS III Maintenance

pART #

820467

Table 3: List of Tools and Service Kits (continued)

DESCRIpTIoN AppLICATIoN

Christo-Lube MCG III

16 oz. tube

Lubrication

100398

HABD/SEA

Vise Jaw Inserts

100397

N/A

HABD/SEA

Table Mount

Bottle Vise

Torque

Wrench ft/lbs / in/lbs

SEA cylinder removal and installation for use w/ existing vice

SEA cylinder removal & installation

Apply torque to parts listed in

Table 4: Torque Specifications, p. 24

23

Note: Photos of tools contained in the SEA tool kit are representative. Tool manufacturers and part numbers are subject to change without notice.

24 pART #

108312

102812

054201

108318

108308

742537

108346

1006-25

108338

SEA MK Technical Maintenance Manual

Table 4: Torque Specifications

DESCRIpTIoN / KEy ITEM #

1st stage body (item 36/1st stage)

ToRqUE

25±2 ft/lbs / 33.9±3 Nm

Swivel port plug (item 1/1st stage)

Burst plug (item 6/1st stage)

Bonnet (item 13/1st stage)

Fill adapter port (item 23/1st Stage)

Pressure gauge blk (item 27/1st stage)

Pin type pressure indicator (item 27a/

1st stage)

MP hose assembly (item 4/1st stage)

Inlet fitting (item 52/2nd stage)

60±3 in/lbs / 6.8±.3 Nm

90±3 in/lbs / 10.2±.3 Nm

90±3 in/lbs / 10.2±.3 Nm

90±3 in/lbs / 10.2±.3 Nm

45±3 in/lbs / 5.0±.3 Nm

20±2 in/lbs / 2.3±.2 Nm

(or wrench tight)

45±3 in/lbs / 5.0±.3 Nm

50±3 in/lbs / 5.6±.3 Nm

TEST

Leak Test

MP

MP Creep

Opening Effort

Flow Effort

Purge Flow

Table 5: Test Bench Specifications

CoNDITIoN SpECIFICATIoN

Inlet 2,500-3,000 (±100) psi

Inlet 2,500-3,000 (±100) psi

Inlet 2,500-3,000 (±100) psi

No leaks allowed

135±20 psi

5 psi max between 5 to 15 seconds after cycling regulator (purge)

Inlet 2,500-3,000 (±100) psi

MP 135±20 psi

MP 135±20 psi at 5 SCFM

MP 135±20 psi

+1.4 to +3.0 inch H

2

0

+5 inches H

2

0 (maximum)

5.0 SCFM flow rate (minimum)

Table 6: Recommended Cleaners and Lubricants

LUBRICANT/CLEANER AppLICATIoN SoURCE

Christo-Lube MCg 111

All o-rings

Aqua Lung, PN 820466, or

Lubrication Technologies

310 Morton Street

Jackson, OH 45640

(800) 477-8704 oakite #31

White distilled vinegar

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 breakdown and premature deterioration of the material.

Acid bath for reusable stainless steel and brass parts.

Oakite Products, Inc.

50 Valley Road

Berkeley Heights, NJ 07922

CAUTION: Do not use muriatic acid for the cleaning of any parts. Even if strongly diluted, muriatic acid can harm chrome plating and may leave a residue that is harmful to o-ring seals and other parts.

Acid bath for reusable stainless steel and brass parts.

“Household” grade

Liquid dishwashing detergent

(diluted with warm water)

Degreaser for brass and stainless steel parts; general cleaning solution for plastic and rubber

“Household” grade

25

procedure A: Cleaning and Lubricating

Cleaning Brass and Stainless Steel parts

1. Preclean in warm, soapy water* using a nylon bristle tooth brush.

2. Thoroughly clean parts in an ultrasonic cleaner filled with soapy water. If there are stubborn deposits, household white distilled

vinegar (acetic acid) in an ultrasonic cleaner will work well. DO NOT place plastic, rubber or silicone parts in vinegar.

3. Remove parts from the ultrasonic cleaner and rinse with fresh water. If tap water is extremely “hard,” place the parts in a bath

of distilled water to prevent any mineral residue. 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.

Cleaning plastic & Rubber parts

Parts made of plastic or rubber, such as box bottoms, box tops, dust caps, etc., may be soaked and cleaned in a solution of warm water mixed with mild dish soap. Use only a soft nylon toothbrush to scrub away any deposits. Rinse in fresh water and thoroughly blow dry, using low pressure filtered air.

CAUTION: Do not place plastic and rubber parts in acid solutions.

Doing so may alter the physical properties of the component, causing it to prematurely degrade and/or break.

Cleaning Hoses

1. Hose fittings: Ultrasonically clean with soapy water*; vinegar OK on tough corrosion

2. Run soapy water through hose if needed

3. Thoroughly rinse with fresh water

4. Blow out hose before installing

Lubrication and Dressing

Wear powderless, latex gloves when handling and lubricating o-rings. Keeping internal parts free from skin oils and other contaminates is important when running enriched air nitrox through a first stage. All o-rings should be lubricated with Christo-Lube ® MCG-111. Dress the o-rings with a very light film of grease, and remove any visible excess by running the o-ring between thumb and forefinger. Avoid applying excessive amounts of Christo-Lube grease, as this will attract particulate matter that may cause damage to the o-ring.

*Soapy water is defined as “household” grade liquid dishwashing detergent diluted in warm water.

CAUTION: Silicone grease and sprays must be strictly avoided for the

SEA MK, since silicone does not provide adequate lubricity in extreme weather conditions.

26

SEA MK Technical Maintenance Manual

S.E.A. First Stage with Cylinder Assembly

29

30

38a, 38b, 38c

31

32

4

27g

27b

25

27d

27e

27f

22

Wrench

Tight

45 ± 2 in. lbs.

(5.0 ± .5 Nm)

27a

27

25

26

22

21

NLA - No Longer Available

22

23

90 ± 3 in. lbs.

(10.2 ± .3 Nm)

Key # part # Description

.......108343 overhaul Service Kit

.......108311 First Stage, Spare

.......108469 First Stage, Spare, USCG/CBP

1 .......108305 Port Plug, Swivel, Black

.......108333 Port Plug, Swivel, Chrome

2 .......820312p o-ring (10 pk)

3 .......820311p o-ring (10 pk)

4 .......100625 Hose Assy. MK, 27" Black

.......102835 Hose Assy. MK, 20" Black

.......108392 Hose Assy. LV2, 27” Black

.......108391 Hose Assy. LV2, 20” Black

5 .......108306 Spacer, Black

.......108334 Spacer, Chrome

6 .......054201 Burst plug

7 .......108304 Retaining Nut, Handwheel, Black

.......108314 Retaining Nut, Handwheel, Silver (NLA)

8 .......108329 Washer, Handwheel

9 .......108316 Spring, Handwheel

10 .......108313 Handwheel

11 .......108326 Washer

12 .......108317 On-off indicator ring

13 .......108318 Bonnet

14 .......820015 o-ring (10 pk)

15 .......828009 Backup ring

16 .......820010 o-ring (25 pk)

17 .......108328 Spacer, metal

18 .......108327 Washer, white Teflon ®

19 .......108319 Stem

20 .......108322 Valve seat

21 .......108307 Fill port plug

22 .......820319 o-ring (10 pk)

37

33

34

35

5

3

2

1

60 ± 5 in. lbs.

(6.8 ± .5 Nm)

20

6 90 ± 3 in. lbs.

(10.2 ± .3 Nm)

18

19

36

17

25 ± 2 ft. lbs.

(33.9 ±2.7 Nm)

16

15

14

90 ± 3 in. lbs.

(10.2 ± .3 Nm)

13

12

On-off valve assembly may be replaced with optional "no onoff" plug, part number 108367

(see key # 39 below) & part number 820015 ( see key # 14 below).

14 11

39

Key # part # Description

90 ± 3 in. lbs.

(10.2 ± .3 Nm)

23 .......108308 Fill adapter port

25 .......820304 o-ring (10pk)

26 .......108309 Check valve

27 .......742537 Pressure indicator, Dial, Black

27a .......108346 Pressure indicator, Pin

27b .......108347 Body, Pin indicator

25 .......820304 o-ring (10 pK)

27d .......845034 Washer

27e .......100688 Spring

27f .......100613 Pin

27g .......100607 Retaining screw

29 .......108302 Cap protector

30 .......108303 Piston cap

31 .......820062 o-ring (10 pk)

32 .......106769 Piston

33 .......820007 o-ring (20 pk)

34 .......106726 Hp Seat

35 .......106771 Spring

36 .......108312 First stage body

37 .......820316 o-ring (10 pk)

38a .......079105 Cylinder, 1.5 cu.ft.

38b .......079120 Cylinder, 2.0 cu.ft.

38c .......079125 Cylinder, 2.5 cu.ft.

39 .......108367 Plug, Blank, 5/8, Black

10

9

On/Off Valve

Conversion Kit

PN 108441

7

8

MK Second Stage Exploded parts

40

41

44

46

45

42

47

48

49

50

43

51

54

57

56

55

58

16

14

52

45 ± 3 in.lbs.

5.0 ± .3 Nm

50 ± 3 in.lbs.

5.6 ± .3 Nm

16

Key # part # Description

.......

108344 overhaul parts Kit

.......108315 MK Second Stage Assy., Spare

.......108468 Mk Second Stage Assy., Spare USCG/CBP

14 .......820015 o-ring (10 pk)

16 .......820010 o-ring (25 pk)

40 .......100904 Purge cover

41 .......100906 Ring, Reetaining Threaded

42 .......100909 Ring Cover Support

43 .......100181 Diaphragm

44 .......102510 Locknut

45 .......100923 Lever

46 .......104129 Washer

47 .......100945 Valve body

Part numbers in BoLD ItALICS indicate standard overhaul replacement part.

Key # part # Description

48 .......104134 Poppet bearing

49 .......104127 Spring

50 .......104122 Poppet

51 .......106738 LP seat

52 .......108438 Inlet fitting, Black

54 .......100905 Box bottom, Black

55 .......104913 Clamp

56 .......100922 exhaust valve

57 .......100907 Exhaust cover

58 .......105831 Mouthpiece

Parts Not Shown

n/s ..... 100653 Mouthpiece Cover

n/s ..... 102835 Hose Assy MK, 20” Black

n/s ..... 100625 Hose Assy MK, 27” Black

n/s ..... 108414 USCG Hard Cover (replaces key #’s 40 & 41)

27

28

SEA MK Technical Maintenance Manual

Maintenance Notes

Maintenance Notes

29

S.E.A. MK

2340 Cousteau Court • Vista, CA 92081

Phone (760) 597-5000 • Fax (760) 597-4900 www.aqualung.com/militaryandprofessional

©2010 Aqua Lung International PN 108348 Rev. 01/10