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Impulse Second Stage Service & Repair Manual

7

© 1997 U.S. Divers Co., Inc.

CAUTION:  

Do not use a tool to install the exhaust tee.

Doing so may cause serious damage to the seating flange,
requiring replacement of the box bottom.

7.

Lay the valve body(23) lengthwise with the positioning mark
facing up as shown in Figure 11.  Gently flex the arms of the
lever(26) evenly apart while fitting them over the positioning
mark and onto the valve body, until they are seated inside their
respective square holes.  Closely examine the shape of the
lever to ensure that it has not become bent during installation.

8.

Install the O-ring(20) onto the crown(21), and carefully insert
the threaded end of the crown into the inlet end of the valve
body.  Gently press it in further with the blunt end of the seat
extraction Tool (P/N 1094-36) until it stops (see Fig. 12).

9.

Apply a medium blade screwdriver to the slotted head of the
adjustable crown, and turn the crown clockwise to engage the
threads.  Continue turning the crown clockwise to the full
extent of its thread engagement, and stop turning when resis-
tance is felt.  Then turn the crown out counterclockwise
exactly 

2 1/2

 turns to arrive at its correct preliminary setting.

10. Closely inspect the poppet/ LP seat assembly(27) to ensure

that the low pressure seat is seated securely inside the head of
the poppet, and that no foreign matter, indentations, or scars
are visible.  Fit the spring(28) over 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-
rectly to the left, resting perpendicular to the valve body.
While holding the poppet assembly by the spring, align the
poppet above the top of the valve body so that the two retain-
ing ears which engage the arms of the lever are facing directly
to the right; opposite of the lever (see Fig. 13).

12. Lower the poppet assembly and spring straight down inside

the barrel of the valve body without disturbing this alignment,
so that the poppet assembly is resting directly over the arms of
the lever.  Gently spread both arms of the lever evenly outward
to allow the poppet assembly to drop into place, and relax the
lever arms  (see Fig. 14).

WARNING:  

DO NOT attempt to press the poppet forcefully

into the barrel of the valve body, past the arms of the lever.
Doing so may damage the poppet and impair its correct
engagement with the lever.  If left undetected, this damage
could lead to serious injury or death.

13. Turn the valve body over to ensure that the poppet does not

fall out, and test the movement of the lever to the ensure that it
swings freely as the valve body is turned over in each direc-
tion, without any interference.  If the poppet assembly falls
out of the valve body, or if the lever does not swing freely
back and forth, remove the poppet and closely inspect the
retaining ears for any signs of damage, such as cracking or

Fig. 12 - Crown Installation

Fig. 14 - Poppet & Lever Engagement

Fig. 13 - Poppet & Lever Alignment

"Ears"

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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