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Related Manuals for Aqua Lung Cousteau/ SEA
Summary of Contents for Aqua Lung Cousteau/ SEA
- Page 1 ® Authorized Dealer SERVICE & REPAIR MANUAL Cousteau/ SEA First Stage Regulator Copyright © 2000 Aqua Lung America, Inc.
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Page 2: Table Of Contents
Table 4 – Torque Specifications ..............17 Table 5 – Test Bench Specifications ............17 Procedure A – Cleaning & Lubrication............18 Table A – Recommended Lubricants & Cleaners ........19 Schematic – Cousteau/ SEA First Stage ............ 20 Schematic – EAN Configuration ..............21... -
Page 3: Introduction
Copyright ©2000 Aqua Lung America, Inc. Service & Repair Manual - Cousteau/ SEA First Stage Regulator GENERAL GUIDELINES Introduction In order to correctly perform the procedures This manual provides factory prescribed proce- outlined in this manual, it is important to follow dures for the service and repair of the Cousteau/ each step exactly in the order given. -
Page 4: Initial Inspection Procedure
Cousteau/ SEA First Stage Service & Repair Manual Initial Inspection Procedure EXTERNAL INSPECTION Visually inspect the sintered filter to check for any signs that contaminants may have entered the system, such as moisture, rust, aluminum oxide, or charcoal. NOTE: A green discoloration positively indicates that mois- ture has entered the regulator, and internal corrosion is therefore likely to be found in the first stage. -
Page 5: Intermediate Pressure Test
Cousteau/ SEA First Stage Service & Repair Manual INTERMEDIATE (OVER-BOTTOM) PRESSURE TEST Depress the second stage purge button once again to ensure that the system is not pressurized. Connect the intermediate pressure test gauge either to a quick-disconnect inflator hose, or to the female fitting of a second stage IP hose, depending on the connector of the test gauge. -
Page 6: Disassembly Procedures
Cousteau/ SEA First Stage Service & Repair Manual Disassembly Procedures NOTE: Before performing any disassembly, refer to Table 3, which references all mandatory replacement parts. These parts must be replaced with new, and must never be reused - regardless of the age of the regulator or how much use it has received since it was last serviced. - Page 7 Cousteau/ SEA First Stage Service & Repair Manual Apply a 8mm hex key to the adjustment screw(31), and turn the screw counter-clockwise to loosen and remove from the spring retainer. Lift out the washer(30) and spring(29). Examine the spring with the use of a magnifier, checking closely for any signs of pitting, rusting, or other corrosion which permeates the surface of the metal.
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Page 8: Disassembly Of Yoke Connection
Cousteau/ SEA First Stage Service & Repair Manual 16. Carefully remove the O-ring(15) and backup ring(16) from inside the balancing chamber of the spring block, using a brass or plastic O-ring removal tool to prevent any damage to the internal sealing surface of the spring block. -
Page 9: Disassembly Of Din Connection
Cousteau/ SEA First Stage Service & Repair Manual C. While holding the inlet fitting secure, apply a pair of circlip pliers (P/N 1111-00) to the circlip(4) and squeeze the circlip until it has disengaged from the yoke retainer. Remove the circlip from the inlet fitting, along with the filter(5) and both O-rings(6&9). -
Page 10: Reassembly Procedures
WARNING: Use only genuine Aqua Lung parts, subassem- blies, 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 prod- uct unsafe, and could result in serious injury or death. - Page 11 Cousteau/ SEA First Stage Service & Repair Manual tighten the spring retainer to a torque measurement of 20 (±2) foot-lbs. 10. Check to ensure that the spring pad is positioned over the center of the diaphragm, and place the main spring(29) over the spring pad inside the spring retainer.
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Page 12: Reassembly Of Yoke Connection
Cousteau/ SEA First Stage Service & Repair Manual NOTE: If the backup ring is an earlier version that is black with a concave surface on one side, it is important to install it into the spring block with the concave side facing up, towards the O-ring. - Page 13 Cousteau/ SEA First Stage Service & Repair Manual B. Lay the filter disc(8d) flat inside the top of the inlet fitting, with the coarser surface facing up. C. Install the O-ring(8c) onto the filter retainer(8a), and mate the filter retainer into the top of the inlet fitting. Tighten clockwise until finger snug.
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Page 14: Final Adjustment And Testing Procedures
Cousteau/ SEA First Stage Service & Repair Manual Final Adjustment and Testing Procedures Connect the intermediate pressure test gauge either to a quick-disconnect inflator hose, or to the female fitting of a second stage LP hose, depending on the connection of the test gauge. - Page 15 6-7. After performing the overhaul and adjustment procedures outlined in the Aqua Lung Service & Repair Manual provided for the second stage, connect the first and second stage regu- lators to perform the following tests: External Leak Test –...
- Page 16 Cousteau/ SEA First Stage Service & Repair Manual Table 1 Troubleshooting Guide SYMPTOM POSSIBLE CAUSE TREATMENT Restricted airflow/ high in- 1. Cylinder valve not completely opened. 1. Open valve, check fill pressure. halation resistance through entire system. 2. Cylinder valve requires service.
- Page 17 Cousteau/ SEA First Stage Service & Repair Manual Table 2 Recommended Tool List PART NO. DESCRIPTION APPLICATION 1116-10 I.P. test gauge Intermediate pressure testing 9440-22 O-ring tools O-ring removal & installation Magnifier w/ illumination Sealing surface and spring inspection Ultrasonic cleaner Brass &...
- Page 18 Cousteau/ SEA First Stage Service & Repair Manual Table 3 Standard Parts Replacement Schedule PART NUMBER DESCRIPTION KEY NUMBER 8200-94 O-ring 8630-51 Circlip 1068-29 Filter 8200-14 O-ring 8244-08 O-ring 8200-38 O-ring 1059-40 High Pressure Seat 8200-80 O-ring 8280-05 Backup Ring...
- Page 19 Cousteau/ SEA First Stage Service & Repair Manual Table 4 Torque Specifications PART NUMBER DESCRIPTION / KEY NUMBER TORQUE 1063-39 Inlet Fitting/ (7) 20 (±2) ft-lbs 1063-32 DIN Filter Retainer/ (8a) 15 (±2) ft-lbs 22 ±2 ft-lbs 1063-33 DIN Inlet Fitting/ (5f) 20 ±2 ft-lbs...
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Page 20: Procedure A - Cleaning & Lubrication
Cousteau/ SEA First Stage Service & Repair Manual Procedure A Cleaning & Lubrication (All Aqua Lung Regulators) ™ 1. Acid Bath - Aqua Lung strongly recommends ChromeSafe regulator cleaner (P/N 0201-05) for clean- ™ ing all reusable brass and stainless steel parts. ChromeSafe... - Page 21 Cousteau/ SEA First Stage Service & Repair Manual Table A Recommended Lubricants & Cleaners (All Aqua Lung Regulators) LUBRICANT / CLEANER APPLICATION SOURCE ® Christo-Lube All O-rings seals; cylinder valve threads Lubrication Technologies (preferred for high pressure DIN systems) 310 Morton Street...
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Page 22: Schematic - Cousteau/ Sea First Stage
Cousteau/ SEA First Stage Service & Repair Manual Cousteau/ SEA First Stage Key # Part # Description Key # Part # Description 21 ---- 1063-03 Port Plug, HP ----- 1005-11 First Stage, Cousteau, Yoke 22 ---- 8200-11 O-ring ----- 1005-21... -
Page 23: Schematic - Ean Configuration
Cousteau/ SEA First Stage Service & Repair Manual Cousteau/ SEA (EAN Configuration) NOTE: Parts purchased individually for use in any Aqua Lung EAN product must be cleaned and inspected according to the procedures outlined in the Enriched Air Cleaning & Service Manual, Doc. #9002-08. O-rings are included with the Overhaul Parts Kit, and may not be ordered individually. - Page 24 2340 Cousteau Court Vista, California 92083 Phone (760) 597-5000 Fax (760) 597-4900 www.aqualung.com...
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