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Calypso First Stage Service Manual

COPYRIGHT NOTICE

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.

Calypso First Stage Repair Manual

INTRODUCTION

This manual provides factory prescribed procedures for the

correct service and repair of the Aqua Lung Calypso first-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 Official Inspection consists of:

A pressurized immersion test of the entire unit to check for

air leakage.

Checking for stable intermediate pressure that is within the

acceptable range.

Checking for opening effort that is within the acceptable

range.

Checking for smooth operation of the control knob and

venturi switch.

A visual inspection of the filter for debris or discoloration.

A visual inspection of the exhaust valve to see that it is in

good shape and that it's resting against a clean surface.

A visual inspection of the mouthpiece looking for tears or

holes.

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

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

first-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.

All service and repair should be carried out in a work area

specifically set up and equipped for the task. Adequate

lighting, cleanliness, and easy access to all required tools

are essential for an efficient repair facility.

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 fittings and crowns which contain critical

sealing surfaces, must be protected and isolated from other

parts to prevent damage during the cleaning procedure.

Use only genuine Aqua Lung parts provided in the Calypso

first-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.

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.

When reassembling, it is important to follow every torque

specification 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.

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.