Reassembly Procedure; First Stage Reassembly - Aqua Lung EA-4500 LW Technical Manual

10

REASSEMBLY PROCEDURE

NOTE: Before performing any reassembly, it is important to
inspect all parts, both new and those that are being reused,
to ensure that every part and component is perfectly clean
and free of any dust, corrosion or blemishes. Before dressing
each o-ring with Christo-Lube
supple and free of any blemish.
WARNING: Use only genuine Aqua Lung
semblies and components whenever assembling any
Aqua Lung product. DO NOT attempt to substitute an
®
Aqua Lung part with another manufacturer's, regardless
®
of any similarity in shape, size or appearance. Doing so
may render the product unsafe and could result in serious
injury or death.

First Stage Reassembly

CAUTION: Before proceeding, visually inspect the COPV
cylinder according to Worthington Industries publication
(A GUIDE TO THE BASIC USE & CARE OF SCI TYPE
3 COMPOSITE PRESSURE VESSELS USER GUIDE).
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.
CAUTION: Before proceeding, visually inspect the aluminum
cylinder according to Compressed Gas Association (CGA)
standards pamphlet (CGA C-6.1--2013, "STANDARDS FOR
VISUAL INSPECTION OF HIGH PRESSURE 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.
NOTE: Aluminum cylinders require visual inspection only
during service, hydrostatic re-testing is optional.
COPV cylinders require visual inspection during service,
hydrostatic re-testing is required every 5 years.
For more information reference Aqua Lung Technical
Bulletin: Hydro Testing #09-001. This information can be
found on the Aqua Lung Military and Professional website at
www.aqualung.com/militaryandprofessional
1. Install o-ring (30) onto the bottom threads of the HP
module body (13). Lubricate the first 4 to 5 threads on the
HP module body.
, check to ensure it is clean,
®
parts, sub-as-
®
SEA-3000 LW & SEA-4500 Technical Manual
2. Install o-ring (15) over
the threads of the fill port
cap (31). Set the fill port
cap to the side, it will be
installed after final testing
is completed.
CAUTION: Improper alignment of the first stage
spanner to the HP module body will cause permanent
damage to the body.
3. Thread the HP module
body (13) into the cylinder
(42 or 43) until hand-tight.
Secure vise jaw inserts into
shop vise. Place the cylinder
into the vise jaw inserts and
tighten until snug. Attach the
first stage spanner to a foot
pound torque wrench. While
holding the cylinder firmly,
torque the HP module body
into the cylinder to a value of
25 ft lb (33.9 Nm).
NOTE: To avoid over-torquing of the safety plug assembly
during installation, do not apply any type of lubricant to the
safety plug threads.
WARNING: Ensure the proper safety disc is being
installed into HP module body. (i.e. 3000 PSI / 207
BAR for aluminum cylinders and 4500 PSI / 310 BAR
for COPV cylinders). Failure to do so could result in
damage to the product and serious injury or death.
4. Inser t the safety plug
assembly (35) into the port
directly below the safety
wire holes on the HP module
body (13). Screw the safety
plug assembly in by hand
until it bottoms out. Attach a
3/8" socket to an inch pound
torque wrench and torque to
a value of 90 in lb (10.2 Nm).