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Aqua Lung EA-3000 LW, Technical Manual

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SEA-3000 LW & 4500 Technical Manual

PART #

DESCRIPTION

APPLICATION

108509

Tool Kit

SEA Tool Kit

820466

Christo-Lube 
MCG III

Parts lubrication

9-43001

103006

9-43226

Socket (3/8”)
Socket (9/16”)
Socket (3/4")

Removal / Installation of Safety Plug (35)
Removal / Installation of Fill Port Adapter (32)
Installation of Bonnet (23)

9-46661

8367A23

103637

Hex Bit Tool (3/16”)
Hex Bit Tool (5mm)
Hex Bit Tool (10mm)

Removal / Installation of Swivel Port Plug (41)
Removal / Installation of Valve Seat (56)
Removal / Installation of Spring Adjuster (2)

108512

5 in 1 Tool

Removal / Installation of the following parts:
Handwheel Retainer (29)
Retainer Ring (45)
Bonnet (23)

103636

Pliers, Tapered 
3/8” Auto Return

Installation of Safety Wire (36)

AT71

Diaphragm
Clamp
Tool

Removal / Installation of Diaphragm Clamp (3)

944022

O-ring Tool
Kit

Removal / Installation of o-rings

10-102-400

O-ring Tool

Removal of MP hose O-ring (21)

103638

Hose Assy
Yellow 6” 

Testing medium pressure (MP)

TABLE 3: LIST OF TOOLS AND SERVICE KITS

Summary of Contents for EA-3000 LW

Page 1: ...TECHNICAL MANUAL SEA 3000 LW 4500 Survival Egress Air Rev 4 17 Tertiary Branding...

Page 2: ...You can contact a Technical Adviser via e mail at sreilly aqualung com jbutner aqualung com grubin aqualung com Warnings Cautions Notes Pay special attention to information provided in warnings cautio...

Page 3: ...embly 16 Final Testing 19 Table 1 Troubleshooting Guide First Stage 20 Table 2 Troubleshooting Guide Second Stage 21 Table 3 List of Tools and Service Kits 22 Table 4 Torque Specifications 25 Table 5...

Page 4: ...reuse mandatory replacement parts under any circumstances regardless of the amount of use the product has received since it was manufactured or last serviced 6 When reassembling it is important to fo...

Page 5: ...ing the notched end of the 5 in 1 tool Remove the handwheel washer 28 spring 27 handwheel 26 nylon washer 25 from the stem 17 Remove the indicator ring 24 from the bonnet 23 4 Unscrew the safety plug...

Page 6: ...e HP module body during removal 12 Remove o ring 15 from the fill port 32 and o ring 33 from the fill port pin 34 14 Using a 10mm hex bit socket and flex wrench unscrew the spring adjuster 2 from the...

Page 7: ...ring tool to remove o ring 11 from the balance chamber inside the HP module body 13 21 Insert cylinder into the vise jaw inserts and tighten until snug Unscrew the HP module body 13 from the cylinder...

Page 8: ...ocking slide ring out far enough to clear the box bottom and remain on the inlet fitting 55 7 Using a 5mm hex bit socket and flex wrench turn the valve seat 56 clockwise and remove it from the smaller...

Page 9: ...Grasp both sides of the exhaust valve 63 and pull straight out to remove it from the box bottom NOTE Before beginning reassembly perform parts cleaning and lubrication in accordance with Procedure A C...

Page 10: ...g 30 onto the bottom threads of the HP module body 13 Lubricate the first 4 to 5 threads on the HP module body 2 Install o ring 15 over the threads of the fill port cap 31 Set the fill port cap to the...

Page 11: ...13 until hand tight 8 Attach a 3 4 socket to a inch pound torque wrench and torque the bonnet to a value of 90 in lb 10 2 Nm 9 Place the nylon washer 25 over the stem 17 so it sits on top of the bonne...

Page 12: ...inside the HP module body 13 17 Install o ring 12 into the groove below the threads on the HP module body 13 CAUTION Do not over torque the fill port into the HP module body 18 Install spring 10 into...

Page 13: ...when installing the diaphragm clamp Connection Points 24 Lubricate the threads of the HP module body 13 Screw the LP module body 8 all the way down onto the HP module body 13 until it stops Loosen th...

Page 14: ...bodily injury due to sharp edges 29 Grasp the twisted end of the safety wire 36 with the tapered pliers and bend the safety wire 180 degrees to the opposite side Using the end of the flat brass o rin...

Page 15: ...e 3 Slowly fill the cylinder to 3000 PSI 207 BAR Secure the end of the 6 yellow MP hose when filling the cylinder 4 During the fill process check for any air leaking from the open end of the MP hose I...

Page 16: ...e exhaust valve 63 into the box bottom 59 by inserting the stem through the center hole of the exhaust port Pull the stem through until the barb is on the opposite side of the hole in the exhaust port...

Page 17: ...Use the palm of your hand to carefully push the locking slide ring all the way into place until it clicks 11 Insert the 5mm hex bit socket and flex wrench into the open end of the inlet fitting 55 Hol...

Page 18: ...ser preferred positions Reference the User s Manual for more information 13 Install the retainer ring 45 into the box bottom 59 Insert the pin spanner on the 5 in 1 tool into the slots of the retainer...

Page 19: ...is in the open position and the system is pressurized Check the dial indicator gauge 14 reads 3000 PSI 207 BAR Immersion Test NOTE Do not confuse bubbles from trapped air with a true leak If a true l...

Page 20: ...n HP module body 13 is worn or damaged 5 Replace HP module body 13 Low MP 1 The MP spring 4 is weakened damaged or first stage is improperly adjusted 1 Replace MP spring 4 or check MP adjustment using...

Page 21: ...e MP hose 38 5 The spring 52 is worn or damaged 5 Replace the spring 52 External Air Leak Immersion Test 1 The MP hose 38 is loose or damaged 1 Re tighten MP hose 38 at second stage fitting or replace...

Page 22: ...10mm Removal Installation of Swivel Port Plug 41 Removal Installation of Valve Seat 56 Removal Installation of Spring Adjuster 2 108512 5 in 1 Tool Removal Installation of the following parts Handwhe...

Page 23: ...val Installation of parts 103560 Spanner 1st Stage Removal Installation of HP Module Body 13 103013 Cylinder Light Inspection of Cylinder 42 43 100398 Vise Jaw Inserts Tool Removal Installation of HP...

Page 24: ...nch in lb Apply torque to parts listed in Table 4 Torque Specifications Not included in Tool Kit N A Torque Wrench ft lb Apply torque to parts listed in Table 4 Torque Specifications Not included in T...

Page 25: ...iquid dish washing detergent diluted with warm water Degreaser for brass and stainless steel parts general cleaning solution for plastic and rubber Household grade CAUTION Silicone rubber requires no...

Page 26: ...ylon toothbrush to scrub away any deposits Rinse in fresh water and thoroughly blow dry using low pressure filtered air Cleaning Hoses 1 Hose fittings Ultrasonically clean with soapy water vinegar OK...

Page 27: ...licone Key Part Description 21 820010P O ring 25 pk 55 AP7586 Inlet Fitting 19 820015P O ring 10 pk 56 AP7563 Egress Valve Seat 57 103559P O ring 10 pk 58 AP7595 Locking Slide Ring 59 103564 Box Botto...

Page 28: ...10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 15 32 33 34 15 35 37 38 39 41 42 40 36 15 ft lb 20 Nm 45 in lb 5 Nm 90 in lb 10 2 Nm 25 ft lb 33 9 Nm 90 in lb 10 2 Nm 60 in lb 6 8 Nm 9...

Page 29: ...er Stem Top Brass 21 820010P O ring 25 pk 22 828009 Ring Back up 23 108318 Bonnet Complete 24 108317 Ring On Off Indicator 25 108326 Washer Stem Top Nylon 26 108313 Handwheel On Off 27 108316 Spring O...

Page 30: ...30 SEA 3000 LW 4500 Technical Manual MAINTENANCE NOTES...

Page 31: ...31 MAINTENANCE NOTES...

Page 32: ...LW 4500 Survival Egress Air Technical Manual 2340 Cousteau Court Vista CA 92081 Phone 760 597 5000 Fax 760 597 4900 www aqualung com militaryandprofessional Blue Pantone 2728C Primary Preferred Brandi...

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