AUTHORIZED TECHNICIAN TECHNICAL MAINTENANCE MANUAL CALYPSO FIRST STAGE
Contents Copyright notice................................................................................................................................................3 Introduction........................................................................................................................................................3 Warnings, Cautions, & Notes.........................................................................................................................3 Scheduled Service.....
Calypso First Stage Service 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. ©2007 Aqua Lung America, Inc.
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 (pn 944022) when removing o-rings to prevent damage to the sealing surface.
Calypso First Stage Service Manual 9. R emove 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. 10. R emove large piston head o-ring (3). Remove piston shaft o-ring (5). 11. I nsert 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 in accordance with Procedure A : Cleaning and Lubricating, (p.
6. A pply a coat of Christo-Lube® to the outside of the piston head o-ring (3). Insert the piston (4), head first, into the cap (2). 10. Install a new, lubricated o-ring onto the outside of the inlet fitting (16). Using your finger, press fit a new conical filter (14), narrow end first, into the inlet fitting. NOTE: Be careful not to get any lubricant on or near the conical filter. 7. A pply a coat of Christo-Lube® to the outside of the shaft o-ring (5).
Calypso First Stage Service Manual 14. I nstall o-rings (9, 20) onto each port plug (10, 19). Using a 4mm hex key, install each of the port plugs into its respective port. 15. I nstall the MP hose into its respective port. Using an in/lbs torque wrench and a 9/16” crow foot, torque the hose to 40 in/lbs / 4.5 Nm. WARNING: If the pressure gauge rapidly exceeds 145 psi (10 bar), then there is a HP leak. Quickly close the cylinder valve and purge the regulator.
Table 1 - Troubleshooting Guide Symptom Restricted airflow/high inhalation resistance through entire system Possible Cause Treatment 1. Cylinder valve not completely opened. 1. Open valve. Check fill pressure 2. Cylinder valve requires service 2. Connect to a different cylinder 3. Conical filter (14) contaminated 3. Replace filter with new 4. Insufficient medium pressure 4. See below 1. Low inlet pressure 1. Refill test cylinder 2. Main spring (7) weakened 2. Replace main spring 1.
Calypso First Stage Service Manual Table 2 - Recommended Tool List PART # DESCRIPTION APPLICATION MP Gauge 0-400 psi (0-27 bar) 111610 Checking medium pressure O-ring Tool 944022 Removing and installation of o-rings Inlet Fitting Socket 111001 N/A 109437 Apply proper torque to inlet fitting 3" Socket Extension Seat Extraction Tool Use with inlet fitting and spring retainer sockets to apply proper torque Crown (14) assembly/disassembly Vise Mounting Tool 5116230 N/A For holding first stage
Table 3 - Torque Specifications PART # DESCRIPTION / KEY ITEM # TORQUE 125712 Piston Cap / 2 18 ft/lbs / 24.5 Nm 125716 Inlet Fitting / 16 18 ft/lbs / 24.5 Nm 103133 MP Port Plug / 10 40 in/lbs / 4.5 Nm 103137 HP Port Plug / 19 40 in/lbs / 4.5 Nm APF124563 Interstage Hose 40 in/lbs / 4.
Calypso First Stage Service Manual 11 Table 5 - Recommended Lubricants & Cleaners Lubricant / Cleaner Christo-Lube MCG-111 ® Application All O-rings seals Source 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. DO NOT apply grease or spray to silicone rubber parts. Doing so may cause a chemical breakdown and premature deterioration of the material.
Procedure A Cleaning & Lubrication Aqua Lung® and Apeks First Stages and Nitrox 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 exceed 40% (EAN 40).
Calypso First Stage Service Manual 13 NOTES
Calypso First Stage • Exploded Parts Diagram Key # Part # ---------125730 ---------900015 1-------125713 2-------125712 3-------820062 4-------125717 5-------820007 6-------106726 7-------106771 8-------124628 9-------820011 10-------103133 11----- 820007 Description First Stage, Calypso, Yoke Overhaul Parts Kit Decal, Aqua Lung logo Piston cap O-ring Piston O-ring HP seat Spring Body O-ring MP port plug O-ring Key # Part # 12------ 106767 13------ 125710 14------ 129151 15------ 820015 16------ 1
Authorized Technician Technical MAINTENANCE Manual CALYPSO FIRST STAGE Aqua Lung America 2340 Cousteau Court, Vista CA 92081 Tel: 760-597-5000 / Web: www.aqualung.
