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U.S. Divers Impulse, Service & Repair Manual

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U.S. Divers Impulse Service & Repair Manual Download Page 17

Impulse Second Stage Service & Repair Manual

15

© 1997 U.S. Divers Co., Inc.

PART NO.

DESCRIPTION

APPLICATION

7803-00

Aqua-Lung Service Manual

All Aqua-Lung regulators

1116-00

I.P. test gauge

Intermediate pressure testing

N/A

0-120 inch-lbs torque wrench

Small fittings

9440-22

O-ring tools

O-ring removal & installation

N/A

Magnifier w/ illumination

Sealing surface inspection

N/A

Ultrasonic cleaner

Brass & stainless steel parts cleaning

N/A

Medium blade screwdriver

Crown removal/ installation

N/A

22mm wrench & crow foot

Hex nut removal/ installation

N/A

                  11/16" 

wrench & crow fo

ot          I

P hose fitting

1078-46

Circlip & Retaining Ring Tool

C-clip & retaining ring removal/ installation

1094-36

Seat extraction/installation tool

Crown removal & installation

1001-95

In-line adjustment tool

Final adjustment & tuning

Table 2

Recommended Tool List

Table 3

Standard Parts Replacement Schedule

PART NUMBER

DESCRIPTION

KEY NUMBER

QTY

9570-25

O-ring

7

1

8200-10

O-ring

9, 13, 20

3

1078-22

Exhaust Valve

19

1

1078-06

O-ring

22

1

1078-12

Poppet/ LP Seat Assy

27

1

1078-13

Washer

29

1

1078-14

O-ring

30

1

1078-16

O-ring

31

1

Summary of Contents for Impulse

Page 1: ...Impulse SecondStageRegulator P O Box 25018 3323 W Warner Ave Santa Ana CA 92799 5018 Copyright 1997 U S Divers Co Inc Doc No 1078 56 Authorized Aqua Lung Dealer SERVICE REPAIR MANUAL...

Page 2: ...Testing Procedures 10 Second Stage Air Flow Test 12 Second Stage Opening Effort Test 12 Second Stage Purge Flow Test 12 External Leak Test 12 Subjective Breathing Test 13 Table 1 Troubleshooting Guide...

Page 3: ...es outlined in the Impulse Owner s Manual 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...

Page 4: ...tage with a stable intermediate pressure of 140 psi 5 with no open ports or hoses 2 Connect the first stage to a cylinder that is filled with 3 000 psi and open the cylinder valve to pressurize the re...

Page 5: ...mouthpiece 15 from the box bottom Inspect the mouth piece to ensure it is free of any tears or cuts that may cause leakage of water into the second stage or other discomfort Discard or set the mouthp...

Page 6: ...the washer 29 for any signs of wear or damage and discard if found 14 Remove and discard both O rings 30 31 and set the adjust ment knob aside to be cleaned separately in a mild acid bath white vineg...

Page 7: ...the polished sealing surface If damage is found discard the crown and do not attempt to reuse If it is in reusable condition set it aside on a soft surface to prevent damage to the sealing edge 25 Us...

Page 8: ...place while it is being positioned inside the box bottom 4 While holding the vane switch in place set the box bottom on a flat surface with the open side facing down and the switch at 12 o clock Guide...

Page 9: ...er the stem of the poppet assembly so that it is seated securely at the base 11 Stand the valve body vertically with the male threaded inlet end facing down and positioned so that the lever faces di r...

Page 10: ...til it stops This will hold the pin securely in place to prevent it from falling out while installing the valve module into the box bottom 19 Lay the valve module assembly horizontally so that the adj...

Page 11: ...ment knob can be completely unscrewed and removed from the valve body do not attempt to assemble any further Disassemble as needed to cor rectly install the retaining pin Severe injury or death may ot...

Page 12: ...Thread the male fitting of the IP hose into the preferred low pressure port of the first stage and apply a torque wrench with 11 16 crow foot to tighten to 40 inch pounds 2 2 Connect an intermediate...

Page 13: ...low has stopped Release the knob of the adjustment tool to ensure that it no longer makes contact with the crown CAUTION Over adjustment of the crown will cause exces sive spring load in the second st...

Page 14: ...e intermediate pressure gauge 2 When the intermediate pressure gauge begins to drop below the intermediate pressure lockup the magnahelic gauge should indicate an opening effort of 6 of H2O to 1 0 of...

Page 15: ...ECTIVE BREATHING TEST 1 While the regulator is connected to a cylinder containing 3 000 psi and pressurized turn the second stage adjustment knob completely out counterclockwise to the full positive p...

Page 16: ...erly engaged with 2 Disassemble and inspect condi Poppet LP Seat Assy 27 tion of Poppet LP Seat Assy 3 Crown 21 incorrectly adjusted 3 Reset crown and perform Final lever 26 set too low Tuning Testing...

Page 17: ...blade screwdriver Crown removal installation N A 22mm wrench crow foot Hex nut removal installation N A 11 16 wrench crow foot IP hose fitting 1078 46 Circlip Retaining Ring Tool C clip retaining ring...

Page 18: ...Slight leak Knob turned in CW 1 2 3 4 turn None Intermediate pressure Inlet 2 500 3 000 100 psi 140 5 psi Intermediate pressure creep Inlet 2 500 3 000 100 psi 5 psi max between 5 to 15 seconds after...

Page 19: ...esh Water Rinse If tap water is extremely hard distilled water may be used to prevent any mineral residue Remove parts from the neutralizing bath and place directly into this rinse Agitate lightly and...

Page 20: ...7922 White distilled vinegar Acid bath for reuseable stainless Household grade 100 gr steel and brass parts Liquid dishwashing detergent Degreaser for brass and stainless steel parts Household grade d...

Page 21: ...Impulse Second Stage Service Repair Manual 19 1997 U S Divers Co Inc TECHNICIAN S NOTES...

Page 22: ...e Adjustment Switch 15 1094 38 Mouthpiece Comfo Bite Black 16 1049 13 Clamp Black 17 1078 11 Exhaust Tee Key Part Description Key Part Description 18 8601 37 C clip 19 1078 22 Exhaust Valve 20 8200 10...

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