Octopus ABS - scubaspares
Contents
1. t Lt 2 13 aman IDHYH O12 70 5190420 Sgv uou duse 89 ShdO 2O 1 a 91 sU D Bungenbiy jo juesuoo ues eig Oya pesaprap JO pu joys si sug p yuo uzqotuogno sues gsnj p vieni Burqonby p or pre uord 92 LLL SOW asbab ZO esf LLLOOW ZO 9551216 __ zk anbioyabeues ejdno y FOOSE pod S98 YA BAAS au ui 210 Jaquunu apod senbi pjr 5016 us moo i 87967 ee sndojoo 4 869621 ajqejsnipy 09 1 65221 12 uO ____________ 02 xog saog 726911 61 Jaysem ayjapuoy 2 euexjueurnor3 i 26911 91 nossnod 6269LL SI euuoJno L PL dijo 019 CL ebers euod 9061 cL BF emori 902002 wi amu 926911101 aren sme US edednos z 021001 6 emo pue jedem spod2. RE ASSEMBLY PROCEDURE NOTE Before starting reassembly it is important to check all the parts All old and new parts should be perfectly clean and free of any dust or rust 1 Fit the two exhalation valves 9 pass the valve tail through the hole in the casing from the outside and pull gently until the notch is inside the casing If itis a new valve cut off any excess tail leaving about 5mm Repeat for the second valve Engage the two upper grid clips 10 in the two upper slits in the casing Engage the two lower clips and press on the bottom of the grid next to the two clips the crown holder threaded part first from the hose connection side Push the seat home using the handle of tool 116236 Fig 4 Crown Installation 3 Use a screwdriver to screw the seat 21 into the crown holder Screw it in completely and then unscrew it two and a half turns 4 Place the crown holder upright on a flat surface the seat s sealing surface uppermost Fit the O ring 11 in the groove at the base of the threaded part 5 Place the old seat removed during disassembly onto the sealing surface 6 Fit the square poppet holder 5 onto the rod of the tool 116236 square side upwards Engage the tool into the insert 4 and across the centre square Align the square section of the holder with the square recess in the insert and push with the tool to engage the holder into the insert After assembly the square holder sho
3. AQUAG gt LUNG FIRST TO DIVE SERVICE MANUAL opyright 11 Rev 1 2004 Service manual Octopus ABS Index 3 3 WARNINGS ATTENTION NO TE toro boit a bo au reete opos 3 MSAN Ve zc 3 GENERALE WN dme A aren 3 GENERAL CONVENTION Petits udo tente eda tss 4 DISASSEMBLEY PISOGEDUISE triente uana mated sido _ 4 PROCEDURE 6 FINALASSEMBEY ERN 7 Table T Troubleshooting guide eoe no Ex pe ceo St tere E En uen Ce cute eoo o Ever acu odas 9 Table 22500116015 T S Table Recommended cleaners and 5 11 Procedure A Cleaning and 12 Talie 4 Torge Em 13 5 Checking S 2 DAP 13 ere a AQuAG gt LUNG FIRST TO DIVE COPYRIGHT This manual is the property of Aqualung France Any copying photocopying reproduction translation electronic distribution email Internet even partial and in whatever format is expressly forbidden without the written consent of Aqualung France 2004 Aqua Lung France INTRODUCTION This manual gives the instructions and the recommendations for the disassembly the cleaning the checking the reassembly and the adjustment of an
4. Z sas wes i p usse 9 2592 S We i 08 jewel 826911 3605 sa 907 i orszow NOLLVNOIS30 31O0 33H 16 Service manual Octopus ABS AQUAG gt LUNG FIRST TO DIVE Avenue 14 rue BP 148 06513 CARROS cedex France 2 00 33 0 4 92 08 28 88 FAX 00 33 0 4 92 08 28 99 Rev 11 2003
5. 10 minutes Dry with filtered low pressure air and then check that their condition is now suitable for re use Cleaning plastic rubber and anodised aluminium parts For anodised aluminium parts soak in a NETALU diluted to 2590 Rinse in fresh water and dry with low pressure filtered air For plastic parts casings plugs clean in an ultrasonic bath containing a mixture of washing up liquid and hot water Use only a toothbrush with nylon bristles to remove any deposits Rinse in fresh water and dry with low pressure filtered air Attention D not place plastic and rubber parts in contact with acid solutions This could alter their physical properties and cause degradation and premature breakdown Cleaning parts for Nitrox O2 use Metal parts Pre clean by soaking in NETALU diluted to 25 Ultrasonic cleaning in Promoclean TP108 diluted at 5 Rinse in demineralised water Soak for 10 min Dry in the open air in a clean and dust free atmosphere Place the parts on a white cloth allow to dry and check after drying that the cloth shows no grease deposits and that the condition of the parts is appropriate for re use with Nitrox O2 PON gt Cleaning hoses If there is significant corrosion then it is permissible to soak only the ends in an ultrasonic bath avoiding any possibility of the solution entering the hose Rinse in fresh water and allow to dry with the connections hanging down Dry the inside with filtered compresse
6. damaged if the acceptable torque is exceeded GENERAL CONVENTIONS The conventions described below define the actions to be carried out when an instruction is given 1 Unscrew to unscrew a threaded part turn it anti clockwise 2 Screw to screw a threaded part turn it clockwise 3 Remove the O ring To remove an O ring follow the method below using the special tool provided for this purpose Any tool that could damage the O ring should be avoided In every case replace the O ring removed with a new one Press simultaneously on the two sides of the O ring in order to form an eye Insert the special tool into this eye to remove the O ring 4 The acronyms used LP Low Pressure MP Medium Pressure HP High Pressure 5 Numbers in brackets indicate the part number of the component shown on the exploded view attached DISASSEMBLY PROCEDURE Note Before commencing disassembly consult the exploded view to check the reference numbers of all parts requiring replacement These parts should all be replaced by new parts and should not be re used on the pretext that the regulator has seen little use since its manufacture or since its last service seal recess The slightest scratch on a sealing surface could cause a leak If a surface should be damaged then this part should be replaced with a new one Do not use any pointed instrument or metal tool to remove O rings Attention Use only specia
7. Aqualung regulator This manual is not an instruction manual for unqualified personnel The procedures described in this manual are intended only for qualified personnel who have been trained in the servicing of Aqualung equipment during a specialised course If you do not understand certain procedures in this manual you should contact an Aqualung service consultant before undertaking any operation WARNINGS ATTENTION NOTES Certain icons have been used to facilitate the reading and understanding of this manual They have the following meanings WARNING Indicates situations that could result in serious or fatal accidents if the advice given is not followed correctly ATTENTION Indicates a situation or action that could cause serious damage to the product making it dangerous if the advice given is not followed correctly NOTE Notes are used to emphasize important points as well as information which needs to be remembered MAINTENANCE Attention Whatever the number of dives carried out during a year the regulator should receive a complete service each year If the regulator is used in a chlorinated or aggressive environment the service period should be reduced to six months gt In order to conform with the Aqualung Regulator Lifetime Guarantee all servicing inspection servicing and repairs should be recorded in the Service Record incorporated in the regulator User Manual GENERAL INSTRUCTIONS 1 In orde
8. CKS 1 Connect the Octopus ABS to a first stage adjusted to 9 5 0 5 2 Put the regulator under pressure with 200 bar 10 bar supply Note Tests 2 3 and 4 require the use of a Regulator Test bench 3 Opening effort check Apply an increasing inhalation flow When the MP starts to fall note the effort reading and compare it with the limits shown on Table 5 Checking specifications the opening effort is outside the limits then check Table 1 Troubleshooting Guide 4 Flow effort test an inhalation flow of 400 l min and check that the effort does not exceed 15 mbar the effort exceeds this then check Table 1 Troubleshooting Guide 5 Purge flow test Connect the second stage to a flow meter and press on the purge button The measured flow should be above or equal to 300 L min If it is below then check Table 1 Troubleshooting Guide 6 Leak test Connect the first stage to a cylinder charged to 200 bar open the cylinder valve and immerse the set in a fresh water bath for one minute Check that there are no leaks If a leak is detected disassemble the entire 29 stage check all sealing surfaces and the correct positioning of all parts 7 Breathing test Press several times on the purge button Put the regulator in your mouth and breathe deeply and slowly several times A regulator in good condition should deliver air without excess effort throughout the inhalation and without vibration of the
9. NER APPLICATION SOURCE Christolube MCG 111 All O rings Aqualung ref 480025 silicone parts can change their molecular construction and cause premature Attention Silicone parts do not require lubrication Do not grease them Greasing degradation of the material Oakite 31 Acid bath for cleaning brass and stainless Oakite Products Inc steel parts NETALU Acid bath for cleaning brass and stainless Aqualung ref 455001 steel parts Diluted white vinegar Acid bath for cleaning brass and stainless Household stores steel parts when well diluted attacks the coating of metal parts and leaves a corrosive deposit that Attention Do not use hydrochloric acid for cleaning parts Hydrochloric acid even damages plastic parts and O rings Washing up liquid diluted with hot water Degreases brass and stainless steel parts Household stores general cleaning of plastic and rubber parts 12 Service manual Octopus ABS Procedure A Cleaning and Lubricating All Aqualung Regulators Cleaning brass and stainless steel parts 1 Pre clean by soaking in NETALU diluted to 2596 2 Cleaning in an ultra sonic bath filled with a mixture of washing up liquid hot water If some resistant deposits remain then fill the ultrasonic bath with white vinegar and repeat DO NOT put plastic rubber silicone or anodised aluminium parts in contact with vinegar 3 Rinse in demineralised or fresh water to avoid calcium deposits Soak for
10. d air before reconnecting the hose to the regulator Wiping To wipe parts use a white filter paper a pure cotton cloth or any other material that does not produce fluff Inspection Visually check under a white light day light or artificial light The parts are completely free of any traces of organic materials oil grease paint rust cleaning agents dust humidity gt Lubrication When handling O rings wear unpowdered latex gloves It is important not to allow contact between the internal components and the skin or any other source of contamination when the regulator is being prepared for Nitrox use All seals should be lubricated with Cristolube MCG111 Cover the seals with a light film of grease and remove any excess by rolling the seal between finger and thumb Do not use an excess of grease this can have the effect of accumulating particles which could damage the O rings Table 4 Torque values REFERENCE DESCRIPTION COUPLE Table 5 Checking specifications TEST INSTRUCTIONS SPECIFICATIONS Medium Pressure 160 bar lt Working pressure lt 200 bar MP at 9 5 bar 0 5 Opening effort 160 bar Working pressure 200 bar between 2 mbar and 5 mbar Effort Flow MP at 9 5 bar 0 5 bar 15 mbar maxi at 400 L min 4 Service manual Octopus ABS Maintenance Notes Exploded view of octopus ABS second stage 0269 0 40 80 eng vn v mn
11. diaphragm During exhalation the exhaust valves should not stick or vibrate If any of these faults occur then check Table 1 Troubleshooting Guide END OF REASSEMBLY Service manual Octopus ABS Table 1 Troubleshooting Guide SYMPTOM POSSIBLE CAUSE TREATMENT 1 MP too high 1 Refer to First stage Troubleshooting Guide 2 The valve 8 is worn or damaged 2 Replace the valve s 3 The seat 21 is not correctly adjusted 3 Readjust the seat Leak or free flow at 2 stage 4 The lever 3 is bent 4 Replace the lever 5 The sealing face of the seat 21 is damaged 6 The spring 6 is damaged 6 Replace the spring 5 Replace the seat anesthe seca 17 refit the assembly correctly 8 The insert O ring 11 is damaged Reduced air flow or high breathing resistance from complete regulator 10 Service manual Octopus ABS Table 2 List of Tools US REF DESCRIPTION APPLICATION PART NO 116222 MP pressure gauge complete 0 16B Checking medium pressure 111610 N C O ring tool Fit remove O rings 944022 116236 Seat fitting tool Seat assembly disassembly 109436 128004 Second stage service kit Tools from service kit 116245 UTIL DE MONTAGE 116256 CLE PIPE 1 4 116239 CLE ERGOTS 129195 MODIFICATION OUTIL BP LX 12300 CLE PIPE 5 5 122046 OUTIL HP TITAN COMSHELF 511000 Table 3 Recommended cleaners and lubricants LUBRICANT CLEA
12. l tool when AN removing O rings in order to avoid damaging the Service manual Octopus ABS 1 Block the crown holder 12 using a 19mm spanner and unscrew the hose with a 11 16 spanner Remove the hose and then remove its O rings 2 Cut the collar 23 using wire snips and remove the mouthpiece 22 from the casing 19 Check that the mouthpiece has no holes or defects A 3 Hold the casing 19 firmly and unscrew the ring cover 14 using tool 129198 4 Remove the purge button 15 check that it has no cuts or defects 4 7 d P E LL t 5 Use tool 129198 or A00188 to unscrew the diaphragm screw 15 LUNG FIRST TO DIVE 6 Hold the casing 19 down firmly and unscrew the crown holder 12 with a 19mm spanner Remove the O ring 11 from the crown holder 12 7 Using a screwdriver unscrew the seat 21 6 or 7 turns Note As the crown is fitted with an O ring it may not fall out of the crown holder It can be extracted using the tool 116236 to avoid damaging the sealing surface 8 Insert tool 116236 into the insert on the side opposite the hose push the crown out Remove the O ring 20 Fig 1 Crown Removal 9 Examine the crown with a magnifying glass to check that its sealing surfaces are all in good condition 10 Push the insert assembly 4 into the casing inserting the index into the bump on the casing Remove the insert assembly 4 b
13. r to carry out the procedures described in this manual correctly it is important that you follow the steps in the exact order indicated Read the manual through completely so that you become familiar with all the procedures the special tools and the replacement parts before starting to disassemble the product Keep this manual open near to you so that you can refer to it step by step Do not rely on your memory 2 All servicing and repair procedures should be carried out in a workshop that is clean well lit easy to access and specially fitted for the purpose 3 The regulator body should never be directly held in the jaws of a vice To hold the body screw the tool 006230 into the HP port and then grip the tool with the vice 4 Once the regulator has been disassembled the re usable components should be separated from the components that need to be replaced Fragile items with seats or crowns with critical sealing surfaces should be separated and protected during servicing in order to prevent any damage 5 Use only spare parts from Aqualung service kits Never replace an Aqualung part with one from another manufacturer even if it appears similar 6 Never re use regulator parts which should be replaced on the pretext that the regulator has seen little use since its manufacture or since its last service 7 When reassembling check that the torque used conforms with that shown in Table 4 Torque Some parts can be irretrievably
14. rew can overload the screw in the Octopus which could degrade performance 1 Screw in the Nylstop using a 6 35mm hex spanner until a slight leak is heard 2 Press lightly on the lever several times to induce airflow Unscrew the Nylstop 74 turn 4 Press lightly on the lever several times to induce airflow to check that there are no leaks Attention Overtightening the Nylstop can cause a slight withdrawal of the poppet from the seat Do not correct this defect by screwing in the seat T Turn off the air supply to the regulator purge the circuit by pushing gently on the lever Remove the adjustment tool 8 Unscrew the seat from the insert while pressing on the lever Final Assembly 1 Place the insert assembly into the casing with the lever pointing upwards Introduce the insert assembly into its position in the casing until the threaded female part of the insert is just visible outside the casing 2 While holding the lever down manually screw the seat into the casing While holding the lever down use a 19mm torque wrench to screw in the seat at 1m Kg 3 Fit the diaphragm and the washer into casing 4 Screw in the diaphragm retainer 15 using the spanner 129198 or A00188 5 Fit the purge button into the casing and screw on the outer ring by hand or using tool 129198 6 Refit the mouthpiece on the casing Fit the collar strap into the groove on the mouthpiece FINAL CHE
15. uld be at the same level as the insert AQUALUNG FIRST TO DIVE T Fit seat 8 into the seat holder 7 8 Fit the spring 6 onto the tail of the seat holder 7 9 Insert the poppet and its spring into the seat holder and screw in the insert 4 to compress the spring Continue to screw in until the threaded part of the poppet emerges from the insert Attention If resistance is felt while screwing N in step and unscrew a little to ensure that the square sections of the crown holder and the poppet holder are aligned 10 Position the insert assembly and turn it so that the injection hole is at 8 o clock Put the lever into the groove on the insert with the rounded part of the lever uppermost 11 Place the washer 2 onto the tail of the poppet then the Nylstop screw with its flat side downwards Screw the Nylstop in by hand to engage the thread then continue using 6 35mm spanner until the first thread appears 12 Hold the insert and the lever and unscrew the crown holder 12 Check that the lever feet have not come out of the groove Remove the old seat 8 13 After removing the old seat 8 screw the crown holder 12 back in to the insert 4 Tighten the crown holder by hand NOTE The preliminary reassembly of the Octopus ABS is now complete Do not continue reassembly until you have adjusted the insert assembly using the following procedure Attention Bad adjustment of the Nylstop sc
16. y holding the lever 3 11 To separate this assembly screw the crown holder 12 into the insert 4 Using a 6 35 mm spanner unscrew the Nylstop screw 1 Remove the washer 2 and the lever 3 from the insert Unscrew the crown holder 12 to allow the poppet 7 and the spring 6 to be removed 12 Check the condition of the lever 3 it should not be deformed or corroded 13 Check the condition of the spring 6 it should not be deformed or corroded 14 Using the O ring tool prick the centre of the seat 8 and extract the seat from the poppet 7 Keep the seat as it can be useful during reassembly NOTE The old HP seat can be useful during the reassembly of the Octopus Put it aside for this purpose 15 Place the handle of tool 116236 directly against the square poppet holder 5 and press until the poppet holder falls out 16 To remove the two exhaust valves you should first remove the grid 10 Insert the blade of a small screwdriver into one of the two slits in the casing 19 and push the screwdriver in until the grid clip is released Repeat the operation for the second clip Service manual Octopus ABS 2 Fit the O ring 20 onto the seat 21 Insert the crown into END OF DISASSEMBLY Before starting to re assemble the Octopus make sure that all replacement parts have been cleaned lubricated accordance with Procedure A Cleaning and Lubricating page 13
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