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Summary of Contents for Aqua Lung CALYPSO FIRST STAGE
- Page 1 Authorized Technician TECHNICAL MAINTENANCE MANUAL CALYPSO FIRST STAGE...
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Page 2: Table Of Contents
Contents COPYRIGHT NOTICE...............................3 INTRODUCTION ...............................3 WARNINGS, CAUTIONS, & NOTES.........................3 SCHEDULED SERVICE............................3 GENERAL GUIDELINES ............................3 GENERAL CONVENTIONS............................4 DISASSEMBLY PROCEDURES..........................4 REASSEMBLY PROCEDURES..........................6 FINAL TESTING................................8 Checking Medium Pressure ................................8 Immersion Test ..................................... 8 TABLE 1 - FIRST-STAGE TROUBLESHOOTING GUIDE ..................9 TABLE 2 - RECOMMENDED TOOL LIST ......................10 TABLE 3 - RECOMMENDED LUBRICANTS AND CLEANERS................11 PROCEDURE A - CLEANING AND LUBRICATION....................12 TABLE 4 -TORQUE SPECIFICATIONS........................13... -
Page 3: Copyright Notice
Aqua Lung America. It may Checking for smooth operation of the control knob and not be distributed through the internet or computer bulletin board venturi switch. -
Page 4: General Conventions
GENERAL CONVENTIONS Pull back the hose protector to expose wrench flats. Using a ⁹₁₆” wrench, unscrew the hose from the first stage. Unless otherwise instructed, the following terminology and tech- niques are assumed: When instructed to remove, unscrew, or loosen a threaded part, turn the part counterclockwise. - Page 5 Calypso First Stage Service Manual Remove the o-ring (16) from the inlet fitting (17). Insert the Remove the main spring (7) from the piston cap (2). Firmly extraction tool through the center hole of the inlet fitting and grasp the shaft of the piston (4) and directly pull it out of the cap.
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Page 6: Reassembly Procedures
REASSEMBLY PROCEDURES Using your finger, press a new HP (6) seat into the end of the piston (4) until it is seated all the way and is flush with Place a new, lubricated o-ring (11) onto the crown orifice the end of the piston. If you are unable to press the HP seat (12). - Page 7 Calypso First Stage Service Manual Install a new, unlubricated o-ring (15) into the groove inside Thread in the inlet fitting the inlet fitting (17). (17). Using a ft/lbs torque wrench, the 111001 modi- fied 26mm socket and a 3” extension, apply a torque of 18 ft/lbs to the inlet fitting.
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Page 8: Final Testing
CHECKING THE MEDIUM PRESSURE Assuming there are no leaks, close the cylinder valve and depressurize the regulator. Remove the first stage from the valve Attach an MP test gauge (0-400 psig) to a medium pressure and secure the dust cap in place with the yoke screw. hose and thread the hose into the open MP port. - Page 9 1. Replace o-ring NOTE: This is a partial list of possible problems and recommended treatments. For more information, contact Aqua Lung’s Technical Services Department for assis- tance with problems not described here. CAUTION: Recommended treatments which require disassembly of the regu- lator must be performed during a complete overhaul, according to the pre- scribed procedures for scheduled, annual service.
- Page 10 Table 2 - Recommended Tool List PART NO. DESCRIPTION APPLICATION 109437 Installation/extraction tool Seat and filter extraction 5116230 Vise mounting tool Disassembly/reassembly 111610 Test pressure gauge Checking medium pressure 944022 O-ring tool set Removing o-rings 111001 Modified 26mm socket Applying torque to inlet fitting 3”...
- Page 11 Calypso First Stage Service Manual Table 3 - Recommended Lubricants & Cleaners LUBRICANT / CLEANER APPLICATION SOURCE Christo-Lube MCG-111 All O-rings seals Aqua Lung, PN 820466, or ® Lubrication Technologies 310 Morton Street Jackson, OH 45640 (800) 477-8704 CAUTION: Silicone rubber requires no lubrication or preservative treatment.
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Page 12: Procedure A - Cleaning And Lubrication
When it comes to issues of nitrox safety and compatibility, the concerns lie primarily with the first stage as it is subjected to high inlet pressures. High inlet pressures lead to adiabatic compression or heating of the gas. The Calypso first stage, when properly cleaned and assembled, is authorized for use with enriched air nitrox (EAN) that does not exceed 40% (EAN 40). - Page 13 Calypso First Stage Service Manual Table 4 - Torque Specifications PART # DESCRIPTION / KEY ITEM # TORQUE 125712 Piston Cap / 2 18 ft/lbs 125716 Inlet Fitting / 15 18 ft/lbs 103133 MP Port Plug / 10 20 in/lbs...
- Page 14 NOTES...
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Page 15: Exploded Parts Diagram
Calypso First Stage Service Manual Calypso First Stage • Exploded Parts Diagram Key # Part # Description Key # Part # Description 14 ----- 129151 Filter n/a ---- 125730 First Stage, Calypso, Yoke 15 ----- 820011 O-ring n/a ---- 900015... - Page 16 Authorized Technician TECHNICAL MAINTENANCE MANUAL CALYPSO FIRST STAGE Aqua Lung America 2340 Cousteau Court, Vista CA 92081...
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