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Mistral Second Stage Technical Maintenance Manual
Copyright Notice
This manual is copyrighted, all rights reserved. It may not, in whole or in
part, be copied, photocopied, reproduced, translated or reduced to any
electronic medium or machine-readable form without prior consent in
writing from Aqua Lung America. It may not be distributed through the
internet or computer bulletin board systems without prior consent in
writing from Aqua Lung America.
©2006 Aqua Lung America, Inc.
Mistral Second Stage Technical Maintenance Manual
Introduction
This manual provides factory prescribed procedures for the correct
service and repair of the Aqua Lung or Apeks regulator products
described in this manual. It is not intended to be used as an instructional
manual for untrained personnel.
The procedures outlined within this manual are to be performed only by
personnel who have received Factory Authorized training through an
Aqua Lung Service & Repair Seminar. If you do not completely under-
stand all of the procedures outlined in this manual, contact Aqua Lung to
speak directly with a Technical Advisor before proceeding any further.
Warnings, Cautions, & Notes
Pay special attention to information provided in warnings, cautions and
notes that are accompanied by one of these symbols:
WARNINGS
indicate a procedure or
situation that may result in serious
injury or death if instructions are not
followed correctly.
CAUTIONS
indicate any situation or
technique that will result in potential
damage to the product, or render the
product unsafe if instructions are not
followed correctly.
NOTES
are used to emphasize important
points,tips and reminders.
Scheduled Service
If the regulator is subjected to less than 50 dives per year, it is
permissible to overhaul it every other year with an inspection
procedure being performed on the "off" years. For example:
Year #1: Inspection
Year #2: Overhaul
Year #3: Inspection
Year #4: Overhaul, and so on.
Both Inspections and Overhauls need to be documented in the Annual
Service & Inspection Record in the back of the Owner's Manual to keep
the Limited Lifetime Warranty in effect. If a regulator is subjected to more
than 50 dives per year, it should receive the complete overhaul.
An Offi cial Inspection consists of:
1. A pressurized immersion test of the entire unit to check
for air leakage.
2. Checking for stable intermediate pressure that is within
the acceptable range.
3. Checking for opening effort that is within the
acceptable range.
4. Checking for smooth operation of the control knob and
venturi switch.
5. A visual inspection of the fi lter for debris or discoloration.
6. A visual inspection of the exhaust valve to see that it is in
good shape and that it's resting against a clean surface.
7. A visual inspection of the mouthpiece looking for tears
or holes.
8. Pulling back hose protectors and checking that the hoses
are secure in the hose crimps.
If a regulator fails item #1,2,3 or 4, the entire regulator should be
overhauled. If a regulator fails 4,5,6 or 7, it will be up to the technician's
discretion whether or not a full overhaul is required.
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 over the entire manual to become familiar with all procedures
before attempting to disassemble the product in this manual, and to
learn which specialty tools and replacement parts will be required.
Keep the manual open beside you for reference while performing
each procedure. Do not rely on memory.
2. All service and repair should be carried out in a work area
specifi cally set up and equipped for the task. Adequate lighting,
cleanliness, and easy access to all required tools are essential for
an effi cient repair facility.
3. As the regulator is disassembled, reusable components should
be segregated and not allowed to intermix with nonreusable parts
or parts from other units. Delicate parts, including inlet fi ttings and
crowns which contain critical sealing surfaces, must be protected
and isolated from other parts to prevent damage during the cleaning
procedure.
4. Use only genuine Aqua Lung parts provided in the overhaul parts
kit for this product. DO NOT attempt to substitute an Aqua Lung part
with another manufacturer's, regardless of any similarity in shape
or size.
5. Do not attempt to 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 follow every torque
specifi cation prescribed in this manual, using a calibrated torque
wrench. Most parts are made of either marine brass or plastic, and
can be permanently damaged by undue stress.
7. In order to make the regulator compatible with nitrox up to
40%O2 (EAN40), the regulator must be properly cleaned, lubricated
and assembled using genuine Aqua Lung or Apeks replacement
parts. In addition, assembly must be carried out in a clean
environment using powderless, latex gloves or equivalent. For more
detailed information, be sure to read Procedure A: Cleaning and
Lubrication p. 14.
General Conventions
Unless otherwise instructed, the following terminology and techniques
are assumed:
1. When instructed to remove, unscrew, or loosen a threaded
part, turn the part counterclockwise.
2. When instructed to install, screw in, or tighten
turn the part clockwise.
3. When instructed to remove an o-ring, use the pinch method
(see illustration below) if possible, or use a brass or plastic o-ring
removal tool. Avoid using hardened steel picks, as they may damage
the o-ring sealing surface. All o-rings that are removed are discarded
and replaced with brand new o-rings.
4. The following acronyms are used throughout the manual: MP is
Medium Pressure; HP is High Pressure; LP is Low Pressure.
Pinch Method
Press upwards on sides of o-ring to
create a protrusion. Grab o-ring or
insert o-ring tool at protrusion.
5. Numbers in parentheses reference the key numbers on the ex-
ploded parts schematics. For example, in the statement, "...remove
the o-ring (17) from the crown (16)...", the number 17 is the key
number to the crown o-ring.
3
or
or tighten
a threaded part,
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