Cousteau-SEA 1st Stage Service Manual1508 KBytes
Contents
1. 14 Closely inspect both springs to check for any signs of corro sion that may have resulted from moisture entering the first stage If corrosion is found on either spring discard and do not reuse 2000 Aqua Lung America Inc 6 Cousteau SEA First Stage Service amp Repair Manual 16 Carefully remove the O ring 15 and backup ring 16 from inside the balancing chamber of the spring block using a brass or plastic O ring removal tool to prevent any damage to the internal sealing surface of the spring block 17 With the use of a magnifier closely examine the sealing surface inside the balancing chamber of the spring block to check for any signs of permanent corrosion scoring or other damage If found discard the spring block and do not reuse CAUTION The slightest scratch or scar across the sealing surface inside the spring block may cause leakage and could prevent the regulator from achieving a stable lock up of intermediate pressure 18 Using the seat extraction tool P N 1094 36 press the crown 11 out of the first stage body by inserting the pin through the low pressure side see Fig 3 Carefully pull the crown out of the body being careful to prevent damage to the sealing surfaces inside the body and on the raised edge of the crown Remove and discard the O ring 12 19 Closely inspect the sealing surface inside the bore of the first stage body to ensure that is perfectly smooth and free of any Fig 32. AQUALUNG Authorized Dealer SERVICE amp REPAIR MANUAL Cousteau SEA First Stage Regulator Contents Introduction Warnings Cautions amp Notes Scheduled Service General Guidelines Initial Inspection Procedure External Inspection Immersion Leak Test Intermediate Pressure Test Disassembly Procedures Disassembly of Yoke Connection Disassembly of DIN Connection Reassembly Procedures Reassembly of Yoke Connection Reassembly of DIN Connection Final Adjustment and Testing Procedures Table 1 Troubleshooting Guide Table 2 Recommended Tool List Table 3 Standard Parts Replacement Schedule Table 4 Torque Specifications Table 5 Test Bench Specifications Procedure A Cleaning amp Lubrication Table A Recommended Lubricants amp Cleaners Schematic Cousteau SEA First Stage Schematic EAN Configuration Copyright 92000 Aqua Lung America Inc Service amp Re AQUA LUNG air Manual Cousteau SEA First Sta Introduction This manual provides factory prescribed proce dures for the service and repair of the Cousteau SEA first stage regulator It is not intended to be used as an instructional manual for untrained person nel The procedures outlined within this manual are to be performed only by personnel who have re ceived factory authorized training through an Aqua Lung Service amp Repair Seminar If you do not completely un
3. and turn the retainer counter clockwise to loosen and remove from the first stage body 8 Lift the spring pad 27 and thrust washer 26b out of the first stage body Discard the thrust washer and do not reuse 9 Using a 4mm hex key install spare LP port plugs 23 into three of the four LP ports leaving one LP port open while the other ports are sealed 10 Direct a short burst of low pressure 50 psi air through the primary LP port to partially dislodge the diaphragm 26a from the first stage body see Fig 2 Lift out the diaphragm and discard Remove the port plugs that were installed in the previous step CAUTION DO NOT attempt to pry the diaphragm out of the first stage with a metal instrument Doing so will perma nently damage the seating shoulder in the first stage requir ing replacement of the body 11 Loosen the vise to remove the first stage and turn it over to allow the pin support 25 and pin 24 to drop onto the bench 12 Resecure the first stage in the vise with the high pressure side facing straight up Apply a 8mm hex key to the end plug 19 and turn the plug counter clockwise to loosen and remove from the body Remove and discard the O ring 18 and set the end plug aside 13 Loosen the vise to remove the first stage and carefully turn the body over to allow the springs 14b amp 14a spring block 17 and high pressure seat 13 to drop out onto the bench Discard the seat and do not attempt to reuse
4. N 9440 22 when removing O rings Once an O ring sealing surface has been damaged the part must be replaced with new in order to prevent the possibility of leakage DO NOT use a dental pick or any other type of steel instrument 1 Before disassembling the first stage remove the low pressure second stage hoses with a 6 open end wrench and the low pressure inflator hose with a 6 or 1 2 open end wrench Remove the high pressure hose with a open end wrench or the high pressure port plug with a 4mm hex key Remove and discard the O rings from the male fittings of each hose 2 Install a vise mounting tool P N 1003 95 or a discharged CO cartridge P N 7039 09 connected to a HP port adapter P N 1020 85 into the HP port of the first stage body 10 WARNING DO NOT use a CO cartridge which has not been discharged Doing so may cause the cartridge to rupture possibly resulting in serious personal injury 3 Secure the vise mounting tool inside a bench vise so that the first stage is positioned standing vertical outside the vice with the spring retainer and adjustment screw facing straight up See Fig 1 NOTE If a DRY Environmental Protection Kit has not been installed on the first stage proceed directly to step 5 If an Environmental Protection Kit has been installed disas semble according to steps 4a 4c outlined below 4a Mate an environmental diaphragm retainer wrench P N 0812 47 into the slots on both
5. Replace diaphragm Replace first stage body NOTE This is a partial list of possible problems and recommended treatments For more information refer to the second stage troubleshooting guide or contact the Technical Services Department for assistance with problems not described here CAUTION Recommended treatments which require disassembly of the regulator must be performed during a complete overhaul according to the prescribed proce dures for scheduled annual service Do not attempt to perform partial service 2000 Aqua Lung America Inc Cousteau SEA First Stage Service amp Repair Manual PART NO 1116 10 Table 2 Recommentied Tool List DESCRIPTION I P test gauge APPLICATION Intermediate pressure testing 15 9440 22 O ring tools O ring removal amp installation N A Magnifier w illumination Sealing surface and spring inspection N A Ultrasonic cleaner Brass amp stainless steel parts cleaning N A 0 120 inch lbs torque wrench Small fittings N A 10 50 foot lbs torque wrench Large fittings N A Bench vise First stage disassembly reassembly 1003 95 Vise mounting tool First stage disassembly reassembly N A 4mm or 2 hex key Port plugs and DIN filter retainer N A 19mm open end wrench amp hex socket DIN inlet fitting N A 8mm hex key Adjustment screw amp end plug N A 26mm open end wr
6. of the crown when installing the pin and high pressure seat Excessive force or carelessness may other wise scratch or nick the crown and require it to be replaced 13 Insert the backup ring 16 into the high pressure spring block 17 and gently tamp it into place with a non metallic probe so that it is seated evenly and flat inside Then gener ously lubricate and install the O ring 15 into the spring block directly over the backup ring 2000 Aqua Lung America Inc 10 14 15 16 17 18 19 Cousteau SEA First Stage Service amp Repair Manual NOTE If the backup ring is an earlier version that is black with a concave surface on one side it is important to install it into the spring block with the concave side facing up towards the O ring Insert the seat spring 14a and open end of the spring block assembly into the body over the stem of the high pressure seat Then place the shorter seat spring 14b directly over the top of the spring block assembly Install the O ring 18 onto the end plug 19 and mate the end plug into the body directly over the spring and spring block assembly Turn the end plug clockwise by hand until snug Resecure the vise mounting tool in the vise so the first stage stands vertical with the end plug facing up Apply a torque wrench with 8mm hex key socket and tighten the end plug to a torque measurement of 45 2 inch lbs Loosen the vise to remove the first stage
7. sides of the external dia phragm retainer 36 While holding the tool securely in place turn the diaphragm retainer counter clockwise to loosen and remove 4b Remove the external diaphragm 35 from either the dia phragm retainer or the spring retainer 32 Discard the diaphragm and do not attempt to reuse 4c Remove the environmental piston 33 and inspect it closely to check for any signs of stress or other damage Discard the piston if it is found to be damaged or set it aside if it is in reusable condition Replace the decal 34 as needed 2000 Aqua Lung America Inc Cousteau SEA First Stage Service amp Repair Manual Fig 2 5 Apply a 8mm hex key to the adjustment screw 31 and turn the screw counter clockwise to loosen and remove from the spring retainer 6 Lift out the washer 30 and spring 29 Examine the spring with the use of a magnifier checking closely for any signs of pitting rusting or other corrosion which permeates the surface of the metal Set the spring and washer aside if they are in reusable condition or replace with new as needed CAUTION If permanent corrosion is found discard the spring and DO NOT attempt to reuse A damaged or badly corroded spring may seriously impair first stage performance by failing to provide stable intermediate pressure 7 Apply a 30mm open end wrench to the spring retainer 28 or use a 34mm open end wrench for the DRY version spring retainer 32
8. 4 Port Plug LP 24 1063 23 Pin 25 1060 22 Pin Support 26 1034 25 Diaphragm w Thrust Washer 27 1017 29 Spring Pad 28 1063 24 Spring Retainer 29 1063 56 Spring 30 8450 97 Washer 31 1060 26 Adjustment Screw Used with Dry Environmental Kit Ferse 1005 25 Dry Environmental Kit Complete 32 1063 17 Spring Retainer Dry 33 1063 19 Piston 34 1063 38 Decal 35 1063 37 External Diaphragm 36 1063 18 Diaphragm Retainer Part numbers in BOLD ITALICS indicate standard overhaul replacement part 2000 Aqua Lung America Inc Cousteau SEA First Stage Service amp Repair Manual 21 Cousteau SEA EAN Configuration TE t TD BANN NOTE Parts purchased individually for use in any Aqua Lung EAN product must be cleaned and inspected according to the procedures outlined in the Enriched Air Cleaning amp Service Manual Doc 9002 08 O rings are included with the Overhaul Parts Kit and may not be ordered individually Key Part 4 Description Key Part Description 1041 71 1041 51 9002 06 1 1063 94 2 1075 06 3 1073 28 4 n a 5 8630 51 6 1068 29 7 n a 8 1063 39 9 1073 11 10 n a 11 1073 24 12 1063 22 13 1060 27 14 n a 15 1059 40 16 1015 09 17 n a 18 8280 05 19 1015 65 20 n a 21 1063 27 First St
9. age Cousteau EAN First Stage Cousteau Dry EAN Overhaul Parts Kit pre cleaned amp sealed Decal EAN Yoke Screw Dust Cap Green O ring EAN Circlip Filter Conical O ring EAN Inlet Fitting Yoke O ring EAN Color Ring EAN Body Crown O ring EAN HP Seat Spring Kit includes 16a amp 16b O ring EAN Back up Ring Spring Block O ring EAN Plug 22 n a O ring EAN 23 1063 03 Port Plug High Pressure 24 n a O ring EAN 25 1063 04 Port Plug Low Pressure 26 1063 23 Pin 27 1060 22 Pin Support 28 1034 25 Diaphragm w Thrust Washer 29 1017 28 Spring Pad 30 1063 24 Spring Retainer 31 1063 56 Main Spring 32 8450 97 Washer Main Spring 33 1060 26 Adjustment Screw Used with Dry Environmental Kit ae 1005 25 Dry Environmental Kit Complete 34 1063 17 Spring Retainer 35 1063 19 Piston 36 1063 38 Decal 37 1063 37 External Diaphragm 38 1063 18 Diaphragm Retainer Part numbers in BOLD ITALICS indicate standard overhaul replacement part 2000 Aqua Lung America Inc AOWA LUNG Be 2340 Cousteau Court Vista California 92083 Phone 760 597 5000 Fax 760 597 4900 www aqualung com
10. al it is important to follow each step exactly in the order given Read over the entire manual to become familiar with all procedures before attempting to disassemble or service the Cousteau SEA first stage and to learn which specialty tools and replacement 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 specifically set up and equipped for the task Adequate lighting cleanliness and easy access to all required tools are essential for maintaining a professional repair facility 3 Before beginning any disassembly it is impor tant to first perform the Initial Inspection proce dure and refer to Table 1 Troubleshooting to determine the possible cause of any symptoms which may be present 4 As each individual regulator is disassembled reusable components should be segregated to prevent them from mixing with non reusable parts or parts from other regulators Delicate parts and those which contain critical sealing surfaces must be protected and isolated from other parts to prevent damage during the clean ing procedure 5 Use only genuine Aqua Lung parts purchased directly from Aqua Lung when servicing any Aqua Lung product Substitution with another manufacturer s parts constitutes an after market modification of the product and renders the original warranty null and void 6 Do no
11. alation resistance through entire system Cousteau SEA First Stage Service amp Repair Manual Table 1 Troubleshooting Guide POSSIBLE CAUSE Cylinder valve not completely opened Cylinder valve requires service Filter 8d is installed upside down or 5 or 8d is contaminated Insufficient intermediate pressure TREATMENT Open valve check fill pressure Connect to a different cylinder Reinstall or replace filter with new as needed See below High or unstable intermediate pressure First stage improperly adjusted HP seat 13 damaged or worn Spring block O ring 15 damaged or worn Spring block 17 damaged Crown O ring 12 damaged or worn Sealing surface of HP crown 11 damaged Springblock springs 14a amp 1 4b weakened or damaged Readjust adjustment screw 31 Replace HP seat Replace spring block O ring Replace spring block Replace crown O ring Replace HP crown Replace springblock springs Low intermediate pressure First stage improperly adjusted Main spring 29 damaged Spring retainer 28 or 32 loose Readjust adjustment screw 31 Replace main spring Tighten to 20 2 foot Ibs External air leakage Immersion Test Spring retainer 28 or 32 loose Diaphragm 26a worn or damaged Diaphragm seating surface inside first stage body 10 damaged Tighten to 20 2 foot Ibs
12. and refer to the procedures below for assembling the yoke or DIN connection REASSEMBLY OF YOKE CONNECTION A Install the O ring 6 into the recessed groove inside the inlet fitting 7 B Install a new filter 5 into the yoke retainer with the conical portion facing downward and press it firmly into place so that it seats inside the O ring Using internal circlip pliers install a circlip 4 to secure the filter NOTE Install the circlip with the flat side facing up to ensure greater holding strength C Mate the inlet fitting through the yoke 8 and into the inlet of the first stage body Tighten clockwise by hand until snug D Secure the vise mounting tool in a vise so that the first stage is horizontal and the yoke faces up see Fig 7 Apply a torque wrench with 26mm crow foot to tighten the yoke retainer to a torque measurement of 20 2 foot lbs Loosen the vise to remove the first stage and remove the vise mounting tool E Install the O ring 3 into the dust cap 2 Wrap the cord that is tied to the dust cap around one leg of the yoke and pass the cap through the loop to form a loose knot F Mate the yoke screw into the top of the yoke and turn it clockwise to fasten the dust cap snugly in place over the Fig 7 inlet boss REASSEMBLY OF DIN CONNECTION A Install the O ring 8f onto the inlet fitting and mate the inlet fitting through the handwheel 8g and into the inlet of the first stage body T
13. d result in serious personal injury This concludes the reassembly of the Cousteau SEA first stage regulator Refer directly to the following section titled Final Adjustment amp Testing 2000 Aqua Lung America Inc 12 Cousteau SEA First Stage Service amp Repair Manual Final Adjustment and Testing Procedures 1 Connect the intermediate pressure test gauge either to a quick disconnect inflator hose or to the female fitting of a second stage LP hose depending on the connection of the test gauge Check to ensure there are no open ports CAUTION Before testing intermediate pressure it is impor tant to connect the first stage to a fully assembled and properly adjusted second stage This will provide a safety relief valve if the intermediate pressure exceeds 155 170 psi If a properly adjusted second stage is not available be sure to open the bleed valve of the test gauge before pressurizing Failure to relieve intermediate pressure in excess of 400 psi may result in damage to the test gauge or LP hose 2 Check to ensure that the first stage adjustment screw 31 is correctly set to its preliminary adjustment flush with the top of the standard spring retainer 28 or flush with the shoulder inside the environmental spring retainer 32 3 Connect the first stage to a filtered air source of 500 psi and slowly pressurize the first stage While closely monitoring the IP test gauge to ensure that the intermediate pressur
14. derstand all of the procedures outlined in this manual contact Aqua Lung to speak directly with a Technical Advisor before proceeding any further Warnings Cautions amp Notes Pay special attention to information provided in warnings cautions and notes that are accompanied by one of these symbols A WARNING indicates a procedure or situation that may result in serious injury or death if instructions are not followed correctly A CAUTION indicates any situation or tech A nique that will result in potential damage to the product or render the product unsafe if in structions are not followed correctly A NOTE is used to emphasize important points tips and reminders Scheduled Service Regulators should be given the same care and maintenance as life support equipment It is there fore important to perform scheduled overhaul service for the Cousteau SEA complete with second stages according to the procedures outlined in this manual at least once a year with normal or infrequent use NOTE A unit that receives heavy or frequent use such as in rental instruction or commer cial applications should be serviced at least twice each year or more often depending on the conditions of use and the manner in which itis maintained Refer to the care and mainte nance procedures outlined in the Regulator Owner s Manual GENERAL GUIDELINES 1 In order to correctly perform the procedures outlined in this manu
15. e does not rise above 120 psi slowly turn the knob of the bleed valve clockwise until it is completely shut CAUTION If a second stage is not connected to the first stage and the intermediate pressure rises above 200 psi immediately reopen the bleed valve of the test gauge and shut off the air supply Refer directly to Table 1 Trouble shooting and remedy as needed before proceeding further 4 When the intermediate pressure has stabilized below 120 psi apply a 8mm hex key to turn the adjustment screw clockwise in small increments of adjustment While turning the adjust ment screw it is important to simultaneously purge the sec ond stage or briefly turn the test gauge bleed valve open and shut Monitor the test gauge while adjusting in this manner until the intermediate pressure locks up between 115 120 psi CAUTION Failure to cycle the regulator during adjustment can result in a false reading of the intermediate pressure 5 When the intermediate pressure has been determined to be stable at 120 psi or less increase the inlet pressure to between 2 500 3 000 psi while checking the IP test gauge once again to ensure that the intermediate pressure does not rise above 135 psi If the intermediate pressure rises above 135 psi immediately purge the second stage or re open the bleed valve of the test gauge and shut off the air supply Refer directly to Table 1 Troubleshooting and remedy as needed 2000 Aqua Lung Am
16. e regulator before performing the next procedure 2000 Aqua Lung America Inc Cousteau SEA First Stage Service amp Repair Manual 3 INTERMEDIATE OVER BOTTOM PRESSURE TEST 1 Depress the second stage purge button once again to ensure that the system is not pressurized Connect the intermediate pressure test gauge either to a quick disconnect inflator hose or to the female fitting of a second stage IP hose depending on the connector of the test gauge NOTE Whenever possible Aqua Lung strongly recom mends that a fully assembled and properly adjusted second stage should be connected to the first stage before pressur izing to test intermediate pressure This will provide a safety relief valve in the event that the intermediate pressure ex ceeds 155 170 psi CAUTION If a second stage is not connected to the first A stage turn the bleed valve knob of the test gauge counter clockwise to ensure that it is open before pressurizing Failure to relieve intermediate pressure in excess of 400 psi may result in damage to the test gauge or rupture of the IP hose 2 Slowly open the valve of the supply cylinder only as far as necessary to pressurize the first stage While closely monitor ing the IP test gauge to ensure that the intermediate pressure does not rise above 200 psi slowly turn the knob of the bleed valve clockwise until it is completely shut CAUTION If a second stage is not connected to the first stage and the i
17. egulator to a cylinder which contains 2 500 3 000 psi and open the cylinder valve to pressurize the system Submerge the cylinder and regulator in a test tank of fresh water and observe closely for up to one minute to check for the formation of bubbles If a steady stream of bubbles is present the system must be disassembled at the source to check sealing surfaces assembly sequence and component positioning in order to correct the problem s NOTE Extremely small leaks may be better detected by A applying a soap solution or Snoop to the leak area Bubble streams will indicate the source of the leak Before disassembling to correct any leaks rinse the entire regulator thoroughly with fresh water and blow out all residual mois ture with filtered low pressure 30 psi air Disassemble and remedy the problem referring to Table 1 Troubleshooting 10 Subjective Breathing Test Depress the second stage purge to ensure that the volume of airflow is adequate to clear the second stage Then breathe deeply from the mouthpiece A properly serviced and adjusted regulator should deliver a smooth uninterrupted airflow upon deep inhalation without excessive effort hesitation or freeflow If any abnormalities or problems occur refer to Table 1 Troubleshooting This concludes the annual service procedures for the Cousteau SEA First Stage 2000 Aqua Lung America Inc 14 SYMPTOM Restricted airflow high in h
18. ench crow foot Yoke inlet fitting N A 30mm open end wrench crow foot Spring retainer N A 34mm open end wrench crow foot DRY spring retainer N A s open end wrench crow foot Low pressure hose fitting N A open end wrench crow foot High pressure hose fitting 1111 00 Snap ring pliers Removal and installation of filter circlip 1094 36 Extraction tool Crown removal amp installation 0812 47 DRY retainer wrench DRY diaphragm retainer 2000 Aqua Lung America Inc 16 Cousteau SEA First Stage Service amp Repair Manual Table 3 Standard Parts Replacement Schedule PART NUMBER DESCRIPTION KEY NUMBER 8200 94 O ring 8630 51 Circlip 1068 29 Filter 8200 14 O ring 8244 08 O ring 8200 38 O ring 1059 40 High Pressure Seat 8200 80 O ring 8280 05 Backup Ring 8244 07 O ring 9570 04 O ring 8200 11 O ring 1034 25 Diaphragm w Washer 1063 37 Environmental Diaphragm 2000 Aqua Lung America Inc Cousteau SEA First Stage Service amp Repair Manual 17 Table 4 Torque Specifications PART NUMBER DESCRIPTION KEY NUMBER TORQUE 1063 39 Inlet Fitting 7 20 2 ft lbs 1063 32 DIN Filter Retainer 8a 15 2 ft lbs 1063 33 DIN Inlet Fitting 5f 22 2 ft lbs 1063 24 Spring Retainer 32 20 2 ft lbs 1063 17 DRY Spring Retainer 36 20 2 ft
19. er valve threads Lubrication Technologies preferred for high pressure DIN systems 310 Morton Street Jackson OH 45640 614 286 2644 Dow Corning 111 All O ring seals Dow Corning Corp pure silicone grease P O Box 1767 T Midland MI 48640 800 248 2481 CAUTION Silicone rubber requires no lubrication or preservative treatment DO NOT apply silicone grease or spray to silicone rubber parts Doing so will cause a chemical breakdown and premature deterioration of the material Silicone Pump General preservative conditioner for McNett Corp non aerosol silicone milk spray hoses instrument console boots etc P O Box 996 Bellingham WA 98227 800 221 7325 CAUTION Aerosol spray silicone should be avoided because 1 common aerosol propellants may attack plastic and rubber parts and 2 because only a slight amount of silicone remains after the solvent evaporates and provides no lasting benefit Anti Seize Lubricant 80208 M A S cylinder adapter female threads Permatex Industrial Corp Micra ADJ adjustment screw 705 N Mountain Rd Newington CT 06111 860 520 5000 ChromeSafe Degreaser and acid bath for reusable Aqua Lung P N 0201 05 ultrasonic cleaning solution stainless steel and brass parts 1 quart Oakite 31 Acid bath for reusable stainless Oakite Products Inc steel and brass parts 50 Valley Road Berkeley Heights NJ 07922 White distilled vinegar Acid bath for reusable stainless Household grade 100 g
20. erica Inc Cousteau SEA First Stage Service amp Repair Manual 13 6 Repeat the adjustment procedure in step 4 to adjust the Cousteau SEA first stage intermediate pressure to exactly 135 psi Repeatedly purge the second stage or open and shut the test gauge bleed valve at least 15 times to ensure that the intermediate pressure locks up consistently and remains stable at 135 5 psi with no signs of creeping or fluctuation 7 Final Assembly DRY Environmental Kit a While the regulator is still pressurized with 2 500 3 000 psi insert the stem of the piston 33 into the hex opening of the adjustment screw Lay the external diaphragm 36 inside the external dia phragm retainer 36 and tamp it down past the threads to ensure that it seats evenly against the sealing surface Mate the external diaphragm retainer onto the spring retainer and apply the retainer wrench P N 0812 47 to tighten it clockwise until completely snug Cycle the regulator to ensure that the intermediate pres sure has not dropped below 135 psi If necessary depres surize the regulator and disassemble the environmental kit to reset the intermediate pressure and repeat steps 6 7 8 After performing the overhaul and adjustment procedures outlined in the Aqua Lung Service amp Repair Manual provided for the second stage connect the first and second stage regu lators to perform the following tests 9 External Leak Test Connect the r
21. inish CAUTION Do not clean any parts which show damage to their plated finish inside an ultrasonic cleaner Ultrasonic vibration may cause further damage to the finish 4 Closely examine all other parts of the first stage for any other signs of external damage or corrosion 5 If present examine the external diaphragm of the DRY environmental protection kit to determine whether moisture has entered the sealed chamber above the main diaphramg IMMERSION LEAK TEST 1 While the regulator is fully assembled and connected to a second stage connect the first stage to a cylinder that is filled with 3 000 psi Check to ensure there are no open ports or hoses and slowly open the cylinder valve to pressurize the regulator If obvious leakage occurs including freeflow from the second stage shut off the air supply and proceed directly to the section titled Disassembly Procedures 2 If leakage cannot be heard or if the source of leakage de tected audibly is not obvious immerse the entire system in fresh water and observe closely for up to one minute to check for the formation of bubbles Pay particularily close attention to the area of the spring retainer and to all hoses along their length and at their fittings on both ends 4 Locate the source of any leakage found and refer to Table 1 Troubleshooting to determine its possible cause 5 Turn the cylinder valve shut and depress the second stage purge button to depressurize th
22. ishes Before dress ing each O ring with Christo Lube check to ensure it is clean supple and free of any blemish WARNING Use only genuine Aqua Lung parts subassem blies and components whenever assembling any Aqua Lung product DO NOT attempt to substitute an Aqua Lung part with another manufacturer s regardless of any similarity in shape size or appearance Doing so may render the prod uct unsafe and could result in serious injury or death Install the O ring 12 onto the crown 11 and place the crown over the pin of the extractor tool P N 1094 36 with the orifice sealing surface facing up 2 While holding the first stage body 10 vertical with the high pressure side facing straight up insert the handle of the extractor tool into the body Pass the tool through the low pressure side so that the crown remains inside resting above its seating shoulder see Fig 4 3 Insert the handle of the extractor tool into the high pressure side of the body once again and press the crown into place so that it fits snugly over the seating shoulder 4 Turn the body over and stand it on a padded surface with the high pressure side facing down Place the small end of the pin support 25 inside the opening in the center of the body Fig 4 5 Lay the diaphragm 26a inside the body and gently tamp it down below the threads until it is seated evenly on all sides 6 Lay the thrust washer 26b inside the body and ta
23. lbs 1063 27 End Plug 19 45 2 ft lbs 1063 03 Port Plug 21 or HP Hose 20 2 inch Ibs 1063 04 Port Plug 23 or LP Hose 20 2 inch Ibs Table 5 Test Bench Specifications CONDITION ACCEPTABLE RANGE Leak test Inlet 2 500 3 000 psi None Intermediate pressure Inlet 2 500 3 000 psi 135 5 psi Intermediate pressure creep Inlet 2 500 3 000 psi 5 psi max between 5 to 15 seconds after cycling regulator purge Opening effort Inlet 2 500 3 000 psi 0 8 to 1 4 inch H 0 intermediate pressure 135 5 psi Flow effort Intermediate pressure 135 5 psi 6 inches H 0 maximum at 10 SCFM Purge flow Intermediate pressure 135 5 psi 5 0 SCFM flow rate minimum 2000 Aqua Lung America Inc 18 Cousteau SEA First Stage Service amp Repair Manual Procedure A Cleaning amp Lubrication All Aqua Lung Regulators Acid Bath Aqua Lung strongly recommends ChromeSafe regulator cleaner P N 0201 05 for clean ing all reusable brass and stainless steel parts ChromeSafe is a specially formulated cleaner that does not harm rubber or Teflon parts yet effectively removes silicone grease corrosion and grime from metal parts leaving only a brilliant shine For best results soak parts in an ultrasonic cleaner for 5 to 15 minutes unless the chrome finish is chipped or flaking Parts with damage to their chrome finish should be cleaned separately outside the ultrasonic cleaner to av
24. mp it down below the threads until it is evenly seated over the diaphragm 7 Lay the spring pad 27 in the center of the diaphragm with the mating tab facing up and thread the spring retainer 28 or 32 clockwise into the body by hand until snug 8 Install a vise mounting tool P N 1003 95 or a discharged CO cartridge P N 7039 09 connected to a HP port adapter P N 1020 85 into the HP port of the first stage body WARNING DO NOT use a CO cartridge which has not been discharged Doing so may cause the cartridge to rupture resulting in serious personal injury 9 Secure the vise mounting tool in a vise so the first stage stands vertical with the spring retainer facing up Apply a torque wrench with 30mm crow foot or use a 34mm crow foot for the D environmental version spring retainer and 2000 Aqua Lung America Inc Cousteau SEA First Stage Service amp Repair Manual Fig 6b tighten the spring retainer to a torque measurement of 20 2 foot lbs 10 Check to ensure that the spring pad is positioned over the center of the diaphragm and place the main spring 29 over the spring pad inside the spring retainer Then lay the washer 30 on top of the spring 11 Mate the adjustment screw 31 over the spring and washer and turn it clockwise to engage the threads of the spring retainer Apply a 8mm hex key to turn the adjustment screw to its appropriate preliminary setting depending on whether it will as
25. ntermediate pressure continues to rise above 200 psi immediately reopen the bleed valve of the test gauge and shut the valve of the supply cylinder Proceed directly to perform the Disassembly Procedures outlined in the next section 3 Note the intermediate over bottom pressure indicated by the test gauge and briefly purge the second stage or open and shut the bleed valve of the test gauge to ensure that lockup is achieved without creeping or fluctuating back and forth 4 If the intermediate pressure creeps up or otherwise fluctu ates after cycling the regulator wait for it to stabilize if possible before making a final note of the intermediate pressure NOTE Correct intermediate pressure for the Cousteau SEA first stage is 135 5 psi with an inlet pressure of 3 000 psi 5 Turn the cylinder valve shut and depress the second stage purge button to depressurize the system before attempting to perform any disassembly 2000 Aqua Lung America Inc 4 Cousteau SEA First Stage Service amp Repair Manual Disassembly Procedures NOTE Before performing any disassembly refer to Table 3 which references all mandatory replacement parts These parts must be replaced with new and must never be reused regardless of the age of the regulator or how much use it has received since it was last serviced CAUTION To prevent damage to critical sealing surfaces A use only a plastic or brass O ring removal tool P
26. oid agitation Be certain to isolate more delicate parts such as orifice cones to prevent damage to sealing surfaces CAUTION Harsh acids such as muriatic acid may cause damage to parts and must be strictly avoided White vinegar although less effective is one suitable substitute for ChromeSafe CAUTION Ultrasonic cleaning times in excess of 15 minutes may damage the chrome finish of certain parts Be certain to use a timer and do not leave parts unattended while cleaning NOTE Although ChromeSafe contains a degreasing agent cleaning heavily greased parts in ChromeSafe will shorten the effective life of the solution and require it to be replaced on a more frequent basis Heavily greased parts may be degreased in a solution of warm water and mild dish detergent prior to being placed in the acid bath Fresh Water Rinse If tap water is extremely hard distilled water may be used to prevent any mineral residue Remove parts from the acid bath and place directly into this rinse Agitate lightly and allow to soak for 5 10 minutes Remove and blow dry with low pressure 25 psi filtered air and inspect closely to ensure proper cleaning and like new condition ANODIZED ALUMINUM PLASTIC amp RUBBER PARTS Anodized aluminum parts and parts made of plastic or rubber such as box bottoms box tops dust caps etc may be soaked and cleaned in a solution of warm water mixed with mild dish soap Use only a soft nylon toothbru
27. r steel and brass parts CAUTION DO NOT use muriatic acid for the cleaning of any parts Muriatic acid even when strongly diluted can harm chrome plating and may leave a residue that is harmful to O ring seals and other parts Liquid dishwashing detergent Degreaser for brass and stainless steel parts Household grade diluted with warm water general cleaning solution for plastic rubber and anodized aluminum parts Snoop Leak testing Nupro Company 400 E 345th St Willoughby OH 44094 440 951 7100 19 2000 Aqua Lung America Inc 20 Cousteau SEA First Stage Service amp Repair Manual Cousteau SEA First Stage N a Key Part Description Key Part Description ann 1005 11 ann 1005 21 Fana 9000 00 1 1075 07 2 1031 14 3 8200 94 4 mu 8630 51 1068 29 6 8200 14 7 1063 39 8 1068 42 9 8244 08 10 1063 22 11 1060 27 12 8200 38 13 1059 40 14 1015 09 15 8200 80 16 8280 05 17 1015 65 18 8244 07 19 1063 27 20 9570 04 First Stage Cousteau Yoke First Stage Cousteau Dry Yoke Overhaul Parts Kit Yoke Screw Dust Cap O ring Circlip Filter O ring Inlet Fitting Yoke O ring Body Crown O ring HP Seat Spring Kit includes 14a amp 14b O ring Backup Ring Spring Block O ring End Plug O ring 21 1063 03 Port Plug HP 22 8200 11 O ring 23 1063 0
28. scratches or other blemishes If the body shows these signs of damage or serious corrosion it must be replaced with new and cannot be reused 20 Using a magnifier closely examine the crown seating surface to check for any signs of scratches nicks or other blemishes If found discard the crown and do not attempt to reuse 21 Resecure the vise mounting tool in the vise so that the first stage is positioned standing outside the vice with either the yoke or DIN connector facing straight up NOTE Before proceeding determine whether the first stage is configured with a DIN or yoke connection and refer to the appropriate disassembly procedure provided below 22 Disassembly of Yoke Connection A Remove the yoke screw 1 and untie the dust cap 2 from the yoke 8 Remove and discard the dust cap O ring 3 B Apply a 26mm open end wrench to the inlet fitting 7 Using firm steady force turn the inlet fitting counter clockwise to loosen and remove from the first stage body Lift the inlet fitting and yoke straight off the inlet boss and set the yoke aside CAUTION It is important that the wrench is securely seated over the entire hex surface of the inlet fitting to prevent any damage to the part Do not use impact to loosen 2000 Aqua Lung America Inc Cousteau SEA First Stage Service amp Repair Manual 7 C While holding the inlet fitting secure apply a pair of circlip pliers P N 1111 00 to the circlip 4 and sq
29. sembled in the standard configuration or with the D environmental protection kit a Standard Spring Retainer Turn the adjustment screw clock wise until it is exactly flush with the top of the spring retainer see Fig 5a b D Environmental Spring Retainer Turn the adjustment screw clockwise until it is exactly flush with the internal shoulder above the female threads see Fig 5b When the adjustment screw has been set at its preliminary adjustment loosen the vise to remove the first stage NOTE Do not proceed further with the assembly of the D A environmental protection kit at this time Instructions for final assembly follow the section titled Final Adjustment amp Testing Procedures 12 While holding the high pressure seat 13 by its stem insert the pin 24 into the center opening Hold the first stage above the pin with the high pressure side facing down and carefully align the end of the pin with the opening of the crown inside see Fig 6a Gently guide the pin and seat into the first stage body so that the pin passes through the crown and into the bottom of the pin support which can be sighted through one of the low pressure ports see Fig 6b When the pin is securely seated between the pin support and high pressure seat turn the fist stage over and stand it on a padded surface with the high pressure side facing up CAUTION Be careful to avoid damaging the polished A sealing surface
30. sh to scrub away any deposits Thoroughly blow dry using low pressure filtered air HOSES If buildup of corrosion is severe it is permissible to soak only the hose fittings in ChromeSafe cleaner as needed and not allow any solution to enter the hose Rinse in fresh water and allow to dry with the cleaned ends hanging down Blow filtered air through them prior to installing onto the regulator LUBRICATION AND DRESSING All O rings should be lubricated with either Christo Lube preferred for high pressure systems or Dow Corning 111 food grade silicone grease Dress the O rings with a very light film of grease and remove any visible excess by running the O ring between thumb and forefinger Avoid applying excessive amounts of silicone grease as this will attract particulate matter that may cause damage to the O ring Hoses and other black rubber parts may be dressed and preserved using a clean cloth impregnated with a pump silicone milk CAUTION Aerosol spray silicone must be strictly avoided Do not attempt to use as a substitute for silicone grease CAUTION Do not apply any form of silicone lubricant to silicone rubber parts as this will cause them to deteriorate prematurely 2000 Aqua Lung America Inc Cousteau SEA First Stage Service amp Repair Manual Table A Recommended Lubricants amp Cleaners All Aqua Lung Regulators LUBRICANT CLEANER APPLICATION SOURCE Christo Lube All O rings seals cylind
31. t 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 7 When reassembling it is important to follow every torque specification prescribed in this manual using a quality torque wrench Most parts are made of either marine brass or plastic and can be permanently damaged by undue stress caused by overtightening 2 Cousteau SEA First Stage Service amp Repair Manual Initial Inspection Procedure EXTERNAL INSPECTION 1 Visually inspect the sintered filter to check for any signs that contaminants may have entered the system such as moisture rust aluminum oxide or charcoal NOTE A green discoloration positively indicates that mois ture has entered the regulator and internal corrosion is therefore likely to be found in the first stage A white or rust colored residue usually indicates that the regulator has been used with a corroded aluminum or steel cylinder Advise the customer of the proper methods for maintaining the regula tor and the possible need to obtain service for their cylinder 2 Slide back the hose protector s to inspect the condition of the LP hose at its fittings and along its length Check closely for any signs of blistering or abrasion or corrosion of the fittings 3 Closely examine the finish of the first stage to check for any scratches dents or other signs of damage to the plated f
32. ueeze the circlip until it has disengaged from the yoke retainer Remove the circlip from the inlet fitting along with the filter 5 and both O rings 6 amp 9 Discard the filter and O rings and do not reuse Disassembly of DIN Connection A Unscrew the thread protector cap and remove it from the first stage B Apply a4mm hex key to the filter retainer 8a and turn it counter clockwise to loosen and remove from the inlet fitting 8e Remove and discard both O rings 8b amp 8c C Apply a 19mm open end wrench to the hex feature of the inlet fitting and turn the inlet fitting counter clockwise to loosen and remove from the first stage body Remove and discard the O ring 8f and the filter disc 8d D Closely inspect the threaded portion of the handwheel to ensure it is free of any burrs or other damage that could prevent proper threading Replace the handwheel if damage is found or set it aside to be reused This concludes the disassembly of the Cousteau SEA First Stage Refer directly to Procedure A and Table A titled Cleaning amp Lubrication before proceeding to the Reassembly Procedures 2000 Aqua Lung America Inc 8 Cousteau SEA First Stage Service amp Repair Manual Reassembly Procedures NOTE Before performing any reassembly it is important to inspect all parts both new and those that are being reused to ensure that every part and component is perfectly clean and free of any dust corrosion or blem
33. urn the inlet fitting clockwise by hand until snug 2000 Aqua Lung America Inc Cousteau SEA First Stage Service amp Repair Manual 11 B C Lay the filter disc 8d flat inside the top of the inlet fitting with the coarser surface facing up Install the O ring 8c onto the filter retainer 8a and mate the filter retainer into the top of the inlet fitting Tighten clockwise until finger snug Secure the vise mounting tool in a vise so that the first stage is horizontal and the yoke faces up Apply a torque wrench with 19mm hex socket to the inlet fitting and tighten clockwise to a torque value of 22 foot lbs 2 Apply a torque wrench with 4mm hex key socket to the filter retainer and tighten clockwise to a torque measure ment of 15 foot lbs 2 Loosen the vise to remove the first stage and remove the vise mounting tool Install the O ring 8b into the groove at the top of the inlet fitting and fasten the DIN protective cap over the DIN connection 20 Install all O rings 20 amp 22 onto all hoses and port plugs 21 amp 23 Install all LP and HP hoses and port plugs into the body and tighten the port plugs clockwise until snug Apply a torque wrench with respective crow foot to tighten each hose to a torque measurement of 40 5 inch pounds WARNING Be certain not to install a low pressure hose into the high pressure port via an adapter Doing so may cause the hose to rupture when pressurized and coul
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