Aqua Lung CALYPSO Technical Maintenance Manual
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Also See for CALYPSO:
- Owner's manual (25 pages) ,
- User manual (20 pages) ,
- Maintenance manual (20 pages)
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Summary of Contents for Aqua Lung CALYPSO
- Page 1 TECHNICAL MAINTENANCE MANUAL CALYPSO/TITAN SECOND STAgE...
- Page 2 CHANgE RECORD Page # Rev. Date Title and/or brief description Change made by February 25, Update format Aqua Lung America 2009...
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Page 3: Table Of Contents
Calypso/Titan Second Stage Technical Maintenance Manual Contents COPYRIgHT NOTICE ...............................4 INTRODUCTION ...............................4 WARNINgS, CAUTIONS, & NOTES ........................4 SCHEDULED SERvICE ............................4 gENERAL gUIDELINES ............................4 gENERAL CONvENTIONS ............................4 DISASSEMbLY PROCEDURES..........................5 REASSEMbLY PROCEDURES..........................7 FINAL TESTINg ..............................11 Second Stage Airflow Test ................................Second Stage Opening Effort Test .............................. -
Page 4: Copyright Notice
Lung Service & Repair Seminar. If you do not completely understand all 4. Use only genuine Aqua Lung parts provided in the overhaul parts kit of the procedures outlined in this manual, contact Aqua Lung to speak for this product. -
Page 5: Disassembly Procedures
Calypso/Titan Second Stage Technical Maintenance Manual begin Disassembly Lift out the sealing ring (2) and diaphragm (3) from the box bottom (4), and closely in- spect the diaphragm to ensure While holding the inlet fitting (13) of the second stage secure with that it is perfectly round and a ¾”... - Page 6 Remove and discard Closely examine the the O-ring (8) from the crown (14) with the use of magnifier to check for any venturi switch (9), and closely examine the O-ring groove of scoring, nicks, or other damage the venturi switch to check for to the polished sealing surface.
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Page 7: Reassembly Procedures
Calypso/Titan Second Stage Technical Maintenance Manual Using a needle or sharp REASSEMbLY PROCEDURES pick, stick the center of the MP seat (23) inside the head of the poppet (22) and lift the seat NOTE: Before performing any reassembly, it is important... - Page 8 Using tool p/n 125727, engage the slotted head of the crown Stand the poppet (22) on (14) and drive it in clockwise as far as the tool will allow. If the its head inside the top of tool is not available, use a medium flathead screwdriver to drive the inlet fitting (13) and on top the crown in as far as it will go and then back it out 3 revolutions.
- Page 9 Calypso/Titan Second Stage Technical Maintenance Manual Place the locknut (16), with the flat side facing down. CAUTION: Prior to adjusting and testing the Ca- Being careful to avoid disturbing the lever (18), turn the lypso/Titan second stage regulator, the accom-...
- Page 10 Fit the washer (2) on to the front of the diaphragm (3) and to the second stage. place the assembly into the box bottom (4). ” Using an 11/16 crow-foot, ap- ply a torque of 40 inch- pounds (4.5 Nm). This ends reassembly of the Calypso/Titan Second Stage...
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Page 11: Final Testing
External Leak Test NOTE: Before performing the following procedure, refer to Table 4, titled Test Bench Specifications – Calypso Second Stage. After disconnecting the regulator from the flow bench, connect If an accurately calibrated airflow test bench is not NOTE: it to a scuba cylinder filled to approximately 3,000 psi (206 available, proceed to the Subjective Breathing Test. - Page 12 6. Replace the 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 assistance 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 13 Calypso/Titan Second Stage Technical Maintenance Manual Table 2 - Recommended Tool List PART # DESCRIPTION APPLICATION 944022 O-ring Tool Set Removing and installation of o-rings 103102 O-ring Tool (Plastic) Seat Extraction 109437 Final adjustment and tuning Tool 125727 Crown/Lever Adjusting crown (14) and lever (18)
- Page 14 ACCEPTAbLE RANgE Leak Test Inlet 3,000 psig (206 bar) No leaks allowed Inlet 3,000 psig (206 bar) Calypso/Titan: +1.0 - 1.6 inch-H 0 (2.5-4.0 mbar) Opening Effort Medium pressure 130-145 psi (9-10 bar) Octopus: +1.1 - 1.7 inch-H 0 (2.8-4.3 mbar)
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Page 15: 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 Aqua Lung or Apeks regulator product described in this manual, when properly cleaned and assembled, is authorized for use with enriched air nitrox (EAN) that does not ex- ceed 40% (EAN 40). -
Page 16: Maintenance Notes
MAINTENANCE NOTES... -
Page 17: Exploded Parts Diagram
Calypso/Titan Second Stage Technical Maintenance Manual Titan • Calypso • Calypso O2 • Octopus (2004 - present) Key # Part # Description Key # Part # Description 12 ----- 820015P O-ring (10 pk) -------- 125740 Calypso 2nd Stage only 13 ----- 124506... - Page 18 Authorized Technician TECHNICAL MAINTENANCE MANUAL CALYPSO/TITAN SECOND STAgE Aqua Lung America 2340 Cousteau Court, Vista CA 92081 Tel: 760-597-5000 / Web: www.aqualung.com Rev 2/09...
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