Aqua Lung CALYPSO FIRST STAGE Manual de usuario
Authorized Technician
TECHNICAL MAINTENANCE MANUAL
CALYPSO FIRST STAGE
2 Calypso First Stage Service Manual 3
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
TABLE 5 - TEST BENCH SPECIFICATIONS .........................................................................................................13
EXPLODED PARTS DIAGRAM ..............................................................................................................................15
2 Calypso First Stage Service Manual 3
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.
©2004 Aqua Lung America, Inc.
Calypso First Stage Repair Manual
INTRODUCTION
This manual provides factory prescribed procedures for the
correct service and repair of the Aqua Lung Calypso rst-stage
regulator. 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 understand 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, cau-
tions, 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 prod-
uct, 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 Ofcial 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 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 or-
der given. Read over the entire manual to become familiar
with all procedures before attempting to disassemble the
rst-stage, and to learn which specialty tools and replace-
ment 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
specically set up and equipped for the task. Adequate
lighting, cleanliness, and easy access to all required tools
are essential for an efcient 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 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 Calypso
rst-stage overhaul parts kit (p/n 900015). DO NOT attempt
to substitute an Aqua Lung part with another manufactur-
er’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
specication 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.
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Calypso First Stage Service Manual 5
GENERAL CONVENTIONS
Unless otherwise instructed, the following terminology and tech-
niques 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 a threaded
part, turn the part clockwise.
3. When instructed to remove an o-ring, use the pinch method
(see gure) 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 re-
moved are discarded and replaced with brand new o-rings.
1. Pull back the hose protector to expose wrench ats. Using a
⁹₁₆” wrench, unscrew the hose from the rst stage.
2. Using a 4mm Allen wrench, unscrew the HP (20) and MP
(10) port plugs. Remove the o-rings (9,21) from the port
plugs.
3. Remove yoke screw (22) and dust cap (19). Thread a rst
stage vise mounting tool into the HP port.
4. Secure mounting tool in a vise. Using a large crescent
wrench, remove the inlet tting (17) and the yoke (18).
Remove the yoke washer (13).
4. The following acronyms are used throughout the manual:
MP is Medium Pressure; HP is High Pressure; LP is Low
Pressure.
5. Numbers in parentheses reference the key numbers on the
exploded parts schematics. For example, in the statement,
“...remove the o-ring (3) from the piston (4)...”, the number 3
is the key number to the piston o-ring.
DISASSEMBLY PROCEDURES
NOTE: Before performing any disassembly, refer to the
exploded parts drawing, which references all mandatory
replacement parts. These parts should be replaced with
new, and must not be reused under any circumstances
- regardless of the age of the regulator or how much use it
has received since it was last serviced.
CAUTION: Use only a plastic or brass o-ring
removal tool (p/n 944022) when removing o-rings
to prevent damage to the sealing surface. Even
a small scratch across an o-ring sealing surface
could result in leakage. Once an o-ring sealing
surface has been damaged, the part must be
replaced with new. DO NOT use a dental pick, or
any other steel instrument.
Pinch Method
Press upwards on sides
of o-ring to create a
protrusion. Grab o-ring
or insert o-ring tool at
protrusion.
4
Calypso First Stage Service Manual 5
5. Remove the o-ring (16) from the inlet tting (17). Insert the
extraction tool through the center hole of the inlet tting and
push out the conical lter (14).
9. Remove the main spring (7) from the piston cap (2). Firmly
grasp the shaft of the piston (4) and directly pull it out of the
cap.
6. Remove the recessed
o-ring (15) from the inside
of the inlet tting (17).
7. Turn the regulator in the vise so that the end cap (2) faces
up. Using a large crescent wrench, remove the end cap.
Remove the vise mounting tool.
8. Insert the handle end of the extraction tool into the threaded
end of the body (8) and push out the crown orice (12).
Remove the o-ring (11) from the crown orice.
10. Remove large piston head o-ring (3). Remove piston shaft
o-ring (5).
11. Insert the extraction tool
through the head of the
piston (4) and push out
the piston HP seat (6).
This Ends Disassembly
Before starting reassembly, perform parts
cleaning and lubrication according to the
procedures outlined in Procedure A, titled
Cleaning & Lubrication, on page 12.
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Calypso First Stage Service Manual 7
3. Install a new, lubricated o-ring (5) into its groove on the
piston (4) shaft.
4. Install a new, lubricated o-ring (3) onto the head of the
piston (4).
REASSEMBLY PROCEDURES
1. Place a new, lubricated o-ring (11) onto the crown orice
(12). Load the crown orice onto the installation / extraction
tool at end rst.
2. Insert the crown orice (12) into the inlet side (non-threaded
side) of the body (8). Turn the tool over and press on the
head of the crown orice to conrm that it is seated all the
way in the body.
5. Using your nger, press a new HP (6) seat into the end of
the piston (4) until it is seated all the way and is ush with
the end of the piston. If you are unable to press the HP seat
into the piston all the way with your nger, as an option, you
can place the HP seat on a clean surface and press the
piston shaft over it.
6. Apply a coat of Christo-Lube to the outside of the piston
head o-ring (3). Insert the piston (4), head rst, into the cap
(2).
7. Apply a coat of Christo-Lube to the outside of the shaft
o-ring (5). Lower main spring (7) over the shaft of the piston
(4).
8. Apply a light coat of Christo-Lube to the threads on the
main body (8). Mate the cap assembly (2) to the main body.
Thread until hand-tight.
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Calypso First Stage Service Manual 7
14. Install o-rings (9,21) on to each port plug (10,20). Using a
4mm allen key, install each of the port plugs into its respec-
tive port.
15. Install the interstage hose into its respective port. Using
an in/lbs torque wrench and a 9/16” crows foot, torque the
hose to 40 in/lbs.
16. Slide hose protector back
into position.
10. Install a new, lubricated o-ring (16) onto the outside of the
inlet tting (17). Using your nger, press t a new conical
lter (14), narrow end rst, into the inlet tting.
NOTE: Be carefull not to get any lubricant on or near the
conical lter.
11. Load the body (8) into a
vise using the vise-mount-
ing tool. Using a large
crescent wrench, snug the
cap (2) onto the body mak-
ing sure that metal meets
metal.
12. Invert the body (8) in vise. Install the cosmetic black washer
(13), smooth side up, onto the body. Set the yoke (18) on
top of the washer.
9. Install a new, unlubricated o-ring (15) into the groove inside
the inlet tting (17).
13. Thread in the inlet tting
(17). Using a ft/lbs torque
wrench, the 111001 modi-
ed 26mm socket and a 3”
extension, apply a torque of
18 ft/lbs to the inlet tting.
Install dust cap (19) and
yoke screw (22).
8 Calypso First Stage Service Manual 9
CHECKING THE MEDIUM PRESSURE
1. Attach an MP test gauge (0-400 psig) to a medium pressure
hose and thread the hose into the open MP port. If your
test gauge does not have an over-pressure relief valve, you
must also attach a properly adjusted second stage to the
rst stage to act as the relief valve in case of a HP leak.
2. Attach the rst stage to
a cylinder charged to
2900-3000 psi. Slowly
open the cylinder valve
to pressurize the regula-
tor.
WARNING: If the pressure gauge rapidly exceeds
145 psi, then there is a HP leak. Quickly close
the cylinder valve and purge the regulator. Fail-
ure to do so may cause a rupture to the MP hose
and/or the MP gauge which, in turn, can lead to
personal injury. Refer to Table 1. Troubleshooting
Guide for the causes of HP leaks.
3. With the regulator under pressure, cycle the over-pressure
relief valve or the second stage purge button to produce an
airow.
4. Check the MP reading, which should be between 130 and
145 psi.
5. Leave the regulator under pressure for about 10 seconds–
the MP should remain stable and should not rise by more
than 5 psi. If the MP rises more than 5psi, this indicates that
there is a leak. Refer to Table 1. Troubleshooting Guide.
IMMERSION TEST
With the port plugs and
at least one properly
adjusted second stage
installed, slowly open
the cylinder valve and
pressurize the rst
stage. Completely sub-
merge the rst stage in
fresh water and check
for leaks.
NOTE: Do not confuse bubbles from trapped air with a
true leak. If there is an air leak, bubbles will come out in a
constant sream.
Assuming there are no leaks, close the cylinder valve and
depressurize the regulator. Remove the rst stage from the valve
and secure the dust cap in place with the yoke screw.
If a leak is detected, note the source of the leak and refer to
Table 1. Troubleshooting Guide for possible causes and
corrective actions.
8 Calypso First Stage Service Manual 9
Table 1 - Troubleshooting Guide
SYMPTOM POSSIBLE CAUSE TREATMENT
Restricted air ow/high inhalation
resistance through entire system
1. Cylinder valve not completely
opened. 1. Open valve. check ll pressure
2. Cylinder valve requires service 2. Connect to a different cylinder
3. Conical lter (13) contaminated 3. Replace lter with new
4. Insuf cient medium pressure 4. See below
Insuf cient medium pressure
1. Low inlet pressure 1. Re ll test cylinder
2. Main spring (7) weakened 2. Replace main spring
High intermediate pressure (leakage
or free ow through second stage)
1. HP seat (6) damaged or worn 1. Replace HP seat
2. Piston o-rings (3,5) damaged and
worn 2. Replace o-rings
3. Crown o-ring (5) damaged 3. Replace o-ring
4. Crown ori ce (11) sealing surface
damaged 4. Replace crown
5. Damaged piston (4) 5. Replace piston
Leakage of air from ambient ports of
piston cap
1. Piston shaft o-ring (5) damaged or
worn 1. Replace o-ring
2. Piston head o-ring (3) damaged or
worn 2. Replace o-ring
Leakage of air from inlet tting 1. Inlet tting o-ring (14) damaged 1. Replace o-ring
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. Do not attempt to perform
partial service.
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.
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Calypso First Stage Service Manual 11
Table 2 - Recommended Tool List
PART NO. DESCRIPTION APPLICATION
109437 Installation/extraction tool Seat and lter extraction
5116230 Vise mounting tool Disassembly/reassembly
111610 Test pressure gauge Checking medium pressure
944022 O-ring tool set Removing o-rings
111001 Modied 26mm socket Applying torque to inlet tting
n/a 3” socket extension, 3/8” drive Attach torque wrench through yoke
n/a Torque wrench, foot-pound Inlet tting
n/a Torque wrench, inch-pound Hose installation
n/a Large crescent wrench Inlet tting/cap removal
n/a 9/16” open end wrench MP hose tting
n/a 5/8” open end wrench HP hose tting
n/a 4mm alen key Port plug removal/installation
n/a Bench vise Disassembly/reassembly
n/a Magnier w/ illumination Inspection of seating surfaces
n/a Ultrasonic cleaner Metallic parts cleaning
n/a Powderless latex gloves or nger cots Keep nger oils off of parts
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