Aqua Lung CORE User manual

Service Manual Core 1st stage 1Rev. 05/2015
SERVICE MANUAL
CORE
FIRST STAGE
Copyright © 2015 Aqua Lung France

Service Manual Core 1st stage
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Rev. 05/2015 2
Date
Revision description
02/2015
Document creation

Service Manual Core 1st stage
Service Manual Core 1st stage
Rev. 05/2015 3
CONTENT
COPYRIGHT......................................................................................................................................................................4
INTRODUCTION ...............................................................................................................................................................4
WARNINGS, ATTENTION, NOTES..................................................................................................................................4
MAINTENANCE ................................................................................................................................................................4
GENERAL INSTRUCTIONS.............................................................................................................................................5
GENERAL CONVENTIONS..............................................................................................................................................5
DISASSEMBLY PROCEDURE.........................................................................................................................................6
YOKE CONNECTION...............................................................................................................................................6
DIN CONNECTION...................................................................................................................................................7
WET CHAMBER .......................................................................................................................................................7
DRY CHAMBER........................................................................................................................................................8
COMMOM TO ALL MODELS ...................................................................................................................................8
REASSEMBLY PROCEDURE........................................................................................................................................10
COMMOM TO ALL MODELS .................................................................................................................................10
YOKE CONNECTION.............................................................................................................................................11
DIN CONNECTION.................................................................................................................................................12
WET CHAMBER .....................................................................................................................................................13
DRY CHAMBER......................................................................................................................................................14
COMMOM TO ALL MODELS .................................................................................................................................14
FIRST STAGE ADJUSTING ...........................................................................................................................................15
FINAL REASSEMBLY FOR SUPREME VERSION .......................................................................................................15
TEST IN WATER.............................................................................................................................................................16
APPENDIX.......................................................................................................................................................................17
TABLE 1. TROUBLESHOOTING GUIDE ..............................................................................................................................17
TABLE 2. TOOLS AND SERVICE KITS LIST..........................................................................................................................18
TABLE 3. RECOMMENDED CLEANERS AND LUBRICANTS....................................................................................................19
TABLE 4. TORQUE VALUES .............................................................................................................................................20
TABLE 5. CHECKING SPECIFICATIONS..............................................................................................................................20
PROCEDURE A–CLEANING AND LUBRICATING................................................................................................................21
MAINTENANCE NOTES....................................................................................................................................................22

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COPYRIGHT
This manual is the property of Aqua Lung France. Any copying, photocopying, reproduction, translation, electronic distribution (email,
Internet...), even partial, and in whatever format, is expressly forbidden without the written consent of Aqua Lung France.
©2015 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 Aqua Lung 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 Aqua Lung equipment
during a specialised course.
If you do not understand certain procedures in this manual you should contact an Aqua Lung 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:
.
MAINTENANCE
In order to conform with the Aqua Lung Regulator Lifetime Guarantee, all servicing (inspection, servicing and repairs)
should be recorded in the Service Record incorporated in the regulator User Manual.
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.
ATTENTION: According to Aqua Lung
specifications, any regulator should undergo
servicing at least once every two years and visual
inspection at least once per year. These two
checks must be performed by an authorized Aqua
Lung dealer. Depending on the conditions and the
number of dives, the regulator may need to be
serviced more often.
hatever 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.

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GENERAL INSTRUCTIONS
1. In order 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 (116230) into a HP or
MP 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 Aqua Lung service kits. Never replace an Aqua Lung 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 values, Torque. Some parts can
be irretrievably 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 (506001) 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.
4. The acronyms used:
LP: Low Pressure
MP: Medium Pressure (or IP: Intermediate Pressure)
HP: High Pressure
5. Bracket numbers indicate components references from exploded views.
Press simultaneously on the two sides
of the O-ring in order to form an ‘eye’.
Insert the special tool (506001) into this
eye to remove the O-ring.

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DISASSEMBLY PROCEDURE
1. Unscrew the hose from the first stage using a 9/16”
spanner.
Unscrew MP plugs (122233) and HP plugs (122237)
with a 4mm Allen key. Remove the O-rings (124701
and 124703) with the tool (506001).
Screw the holding tool
(116320) into a free MP port.
YOKE CONNECTION
Start after point 1
2. Remove the yoke screw
(128631) and the dust cap
(124555).
Securely clamp holding tool
(116230) into vice with yoke
connection facing up. Place the
socket (A11001) on the yoke
retainer (129242) and unscrew
it. Remove the yoke retainer and
the yoke (124611) from the
body.
Remove the regulator from the
vice.
3. Remove the filter (129209) and the O-ring (124703)
from the body (129254).
4. Take the assembly yoke retainer (129242) & yoke
(124611). Put back in place the dust cap (124555)
and the yoke screw (128631) into the yoke. Screw
the yoke screw and compress the dust cap between
the yoke retainer and the yoke screw, to open the
ACD connection (see pictures below).
Yoke screw not screwed Yoke screw enough
enough screwed
Securely clamp the assembly into
vice by gripping the yoke retainer
hexagon part with yoke connection
facing down. With a 3mm Allen key,
turn clockwise to unscrew the yoke
shutter valve (129207).
Remove the assembly from the
vice.
5. Remove the yoke screw (128631)
and the dust cap (124555) to
disassemble the system.
Using the tool (506001), remove the
O-ring (473056) of the yoke shutter
valve (129207).
Separate the yoke shutter valve from the yoke shutter
crown (129205).
Extract the O-ring (124703) from
the inside groove of the yoke
shutter crown with the tool
(506001).
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.
ATTENTION: Use only the special tool (506001)
when removing O-rings in order to avoid damaging
the 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.

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DIN CONNECTION
Start after point 1
6. Take a DIN/Yoke adapter (125237) and thread it onto
the DIN hand wheel (129929) in order to compress
the spring. Securely clamp holding tool (116230) into
vice with DIN connection facing up.
7. Using a 4mm Allen key, unscrew the DIN shutter
valve (129202). Remove it from the connection.
8. Unscrew the adapter DIN/Yoke (125237), then
remove the DIN shutter crown (129243) and the
spring (129204).
9. Using the tool (506001),
remove the O-rings
(124709) and (473057) from
the DIN shutter crown
(129243).
10. Using a 7/16 socket, remove the
DIN screw (129213).
11. Using the tool (506001), remove
the O-ring (444243) from the
DIN screw.
12. Remove the DIN hand wheel (129929), then unscrew
the DIN union (129241) with a key of 17.
13. Remove the regulator from the vice. Extract the filter
(129209) and the O-ring (124703) from the body
(129254).
WET CHAMBER
Start after points 5 (if yoke) or 13 (if DIN)
14. Securely clamp holding tool (116230) into vice with
wet chamber facing up.
With an 8mm Allen key, unscrew the MP adjusting
screw (128117).
Remove the washer (127568) and the MP spring
(127567).
15. Using the socket (122152),
unscrew the wet chamber body
(129904).
16. Remove by hand the diaphragm (119159) and the
spring pad (127565) from the wet chamber body
(129904). Remove the pin support (127563) and the
pin (127564) from the body (129254).
Remove the regulator from the vice.

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17. Place the wet chamber body (129904) on a table,
plastic washer (129958) down. Push the washer
down.
Entirely remove the washer from the wet chamber
body.
DRY CHAMBER
Start after points 5 (if yoke) or 13 (if DIN)
18. Securely clamp holding tool (116230) into vice with
dry chamber facing up.
Using a lug spanner (129198) unscrew the dry
chamber plug (129902). Remove the diaphragm
(127579) and the piston (127581).
19. Using an 8mm Allen key, unscrew the MP adjusting
screw (127566).
Remove the washer (127568) and the MP spring
(127567).
20. Using the socket (122152),
unscrew the dry chamber body
(129903).
21. Remove by hand the diaphragm (119159) and the
spring pad (127565) from the dry chamber body
(129903). Remove the pin support (127563) and the
pin (127564) from the body (129254).
Remove the regulator from the vice.
22. Place the dry chamber body (129903) on a table,
plastic washer (129959) down. Push the washer
down.
Entirely remove the washer from the dry chamber
body.
COMMOM TO ALL MODELS
Start after points 17 (if wet chamber) or 22 (if dry chamber)
23. Using an 8mm Allen key, unscrewthe plug (129120).
Turn over the body in order to recover the spring
(122244) and the HP seat (124624). Separate the
spring from the HP seat.
24. Using the tool (506001), remove the exterior O-ring
(213714) from the plug (129120), then the O-ring
(124612) and the anti-extrusion washer (119129)
inside the plug.

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25. Insert the plastic side of the
extraction tool (116236) into the
body’s central hole, wet / dry
chamber side. Make sure that the
tool is in contact with the crown
(127585). Press down to remove
the seat.
Remove the O-ring (124704) from
the seat, using the tool (506001).
26. While holding the holding tool (116230), remove the
body protector (128124) at the opposite side of the
tool. Then, unscrew the holding tool.
DISASSEMBLY END
Before starting to re-assemble the regulator,
make sure that all replacement parts have been
cleaned and lubricated in accordance with
Procedure A –Cleaning and Lubricating, page
21.
ATTENTION: Before continuing, make sure that
you are working on a soft surface in order to
avoid damaging the crown (127585) during
disassembly.

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REASSEMBLY PROCEDURE
COMMOM TO ALL MODELS
1. Screw the wet chamber body
(129904) or the dry chamber body
(129903) onto the body (129254)
WITHOUT ITS DIAPHRAGM, then
place it standing on a table, the
chamber down.
2. Place the body protector (128124) on the body
(129254) and then engage the polyurethane collar
over the two HP ports.
3. Completely engage the body protector by pressing
the top of it.
4. Unscrew the wet chamber body (129904) or the dry
chamber body (129903).
Finish positioning the body protector collar.
5. Fit a new lubricated O-ring (124704) on the crown
(127585).
Slide the seat onto the tool (116236), positioning the
seat lip against the tool plastic part. Move the system
into the body (129254), plug side, and position the
seat by pushing with the tool.
6. Screw the holding tool (116320) into a free MP port.
Securely clamp holding tool into vice with plug facing
up.
Lubricate the new HP seat tail (124624). Insert it in
the body (129254), blue face facing the body interior.
Check that the seat stay upright inside the body.
Place the spring (122244) around the seat.
7. Fit a new anti-extrusion washer
(119129) then a new lubricated O-
ring (124612) in the plug (129120).
Using a 4mm Allen key, press the
anti-extrusion washer and the O-ring
against the plug bottom.
8. Fit a new lubricated O-ring (213714) onto the plug
(129120).
NOTE: Before continuing, closely examine the anti-
extrusion washer (119129). You will note that it has
a flat side and a concave side. For correct
assembly the concave side should be against the
O-ring, as shown in the picture below.
O-ring
Anti extrusion washer

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9. With the thumb, engage the plug
(129120) into the body (129254).
Push on the plug to compress the
spring, at the same time screwing
the plug into the body until it blocks.
Using a torque wrench (122154),
tighten the plug to 0.5 m.kg (3.62
ft.lb).
Remove the regulator from thevice.
YOKE CONNECTION
Start after point 9
10. Fit a new lubricated O-ring (124703) into the yoke
shutter crown groove (129205), using the tool
(506001).
11. Install the yoke shutter valve (129207) inside the
yoke shutter crown (129205), and then fit in a new
lubricated O-ring (473056) in the shutter valve
groove.
12. Install the spring (129204) into the
yoke retainer (129212).
13. Place the yoke shutter crown (129205) onto the
spring (129204), put the sub-assembly into the yoke
(124611).
14. Install the dust cap (124555) between the yoke
(124611) and the yoke shutter crown (129205).
Tighten the yoke screw (128631) so that the spring
(129204) is compressed.
15. Stop tightening when the
yoke shutter crown
(129205) is set in this
position, the yoke screw
(128631) becomes hard
to turn.
16. Position the yoke retainer with
threads facing upward, using a
3mm Allen key, turn counter-
clockwise 3 full turns.
17. Tighten the yoke screw
(128631) again, so that
dust cap (124555) is snug
against the yoke retainer
(129242).
Securely clamp the assembly into
vice by gripping the yoke retainer
(129212) hexagon part with yoke
connection facing down.
18. Using a torque screwdriver
(122152) and a 3mm Allen key
adapter, turn counter-clockwise
and torque the yoke shutter
valve (129207) to 0.3 m.kg
(2.17 ft.lb).
19. Remove the assembly from the vice, entirely
unscrew the yoke screw (128631). Remove the dust
cap (124555) and the sub-assembly shutter/retainer
from the yoke (124611).

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20. Check that the yoke shutter crown (129205) shoulder
is about 1.5mm (0.4 inches) above the yoke retainer
(129242). Push down with your finger against the
crown shutter to confirm the ACD system works.
21. Using a 1/4’’ socket wrench
(116239), fit a new O-ring not
lubricated (124703) in the body
counterbore (129254) DIN
connection side.
22. Insert a new filter (129209) in the socket wrench
(116239) and then turn over the body (129254) and
put the filter inside the O-ring (124703) thanks to the
socket wrench.
23. Place the sub-assembly shutter/retainer in the yoke
(124611). Screw it manually into the body (129254)
until it blocks.
Securely clamp holding tool (116230) into vice with
yoke connection facing up.
Using a torque wrench (122154) with the socket
(A11001), tighten the yoke retainer to 2.5 m.kg
(18.08 ft.lb). Remove the regulator from the vice.
24. Thread the dust cap (124555) into the yoke screw
(128631), with the Aqua Lung logo outside. Screw
the yoke screw into the yoke (124611).
DIN CONNECTION
Start after point 9
25. Using a 1/4’’ socket wrench
(116239), fit a new O-ring not
lubricated (124703) in the body
counterbore (129254) DIN
connection side.
26. Insert a new filter (129209) in the socket wrench
(116239) and then turn over the body (129254) and
put the filter inside the O-ring (124703) thanks to the
socket wrench.
27. Fit in a new and lubricated O-
ring (444243) on the DIN screw
(129213).
28. Take the DIN union (129241), install the
DIN hand wheel (129929) on it, and
place on top the DIN screw (129213).
Screw by hand the DIN screw into the
DIN union.
29. Using a 7/16'' socket, screw the sub-assembly into
the body (129254).
Securely clamp holding tool (116230) into vice with
DIN connection facing up.
Using a socket and a torque wrench (122154),
tighten the DIN screw to 2.5 m.kg (18.08 ft.lb).

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30. Fit a new lubricated O-ring (473057) into the DIN
shutter crown interior groove (129243),using the tool
(506001).
Fit a new lubricated O-ring (124709) into the shutter
crown exterior groove.
31. Place the spring (129204) into the DIN screw
(129213). Set the DIN shutter crown (129243) with its
associated O-ring onto the spring.
32. Thread a DIN/Yoke adapter (125237)
onto the DIN screw (129213) so that
the spring gets compressed.
33. Install the DIN shutter valve
(129202). Using a torque
screwdriver (122152), tighten it
to 0.3 m.kg (2.17 ft.lb).
Remove the regulator from thevice.
Unscrew the DIN/Yoke adapter
(125237).
WET CHAMBER
Start after points 24 (if yoke) or 33 (if DIN)
34. Insert the pin (127564) into the central hole, wet
chamber side. Place the pin support (127563) over
the pin.
35. Fit a new diaphragm (119159) into
the wet chamber body (129904).
Make sure that the diaphragm is
correctly positioned by pressing all
around its edge with your finger.
36. Insert the plastic washer (129958) onto the wet
chamber body (129904). Watch out of the text
orientation, the biggest ring should be at the exterior
side of the wet chamber body.
Press the plastic washer up against the wet chamber
body shoulder.
37. Securely clamp holding tool (116230) into vice with
wet chamber facing up.
Screw by hand the wet chamber body (129904) onto
the body (129254).
Using a socket (122152) and a torque wrench
(122154), tighten the wet chamber body to 2.5 m.kg
(18.08 ft.lb).
38. Fit the spring pad (127565), the MP spring (127567)
and the washer (127568) on the diaphragm.
39. Grease the thread of the MP adjusting screw
(128117) with a brush. Using an 8mm Allen key,
screw the MP adjusting screw until coming to the
same level than the wet chamber body (129904).
NOTE: the tightening of the wet chamber on
the body SHOULD NOT be done with the MP
spring assembled in the wet chamber. The
previous steps must be respected.
NOTE: Press several times on the pin
support. It should feel like a push-button.

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DRY CHAMBER
Start after points 24 (if yoke) or 33 (if DIN)
40. Insert the pin (127564) into the central hole, wet
chamber side. Place the pin support (127563) over
the pin.
41. Fit a new diaphragm (119159) into
the dry chamber body (129903).
Make sure that the diaphragm is
correctly positioned by pressing all
around its edge with your finger.
42. Insert the plastic washer (129959) onto the dry
chamber body (129903). Watch out of the text
orientation, the biggest ring should be at the exterior
side of the wet chamber body.
Press the plastic washer up against the dry chamber
body shoulder.
43. Securely clamp holding tool (116230) into vice with
dry chamber facing up.
Screw by hand the dry chamber body (129903) onto
the body (129254).
Using a socket (122152) and a torque wrench
(122154), tighten the wet chamber body to 2.5 m.kg
(18.08 ft.lb).
44. Fit the spring pad (127565), the MP spring (127567)
and the washer (127568) on the diaphragm.
45. Grease the thread of the MP adjusting screw
(127566) with a brush. Using an 8mm Allen key,
screw the MP adjusting screw until coming to the
same level than the first thread of the dry chamber
body (129904).
COMMOM TO ALL MODELS
Start after points 39 (if wet chamber) or 45 (if dry chamber)
46. Remove the regulator from the vice and unscrew the
holding tool (116230).
47. Fit new lubricated O-rings (124701) on both HP plugs
(122237).
Fit new lubricated O-rings (124703) on the three MP
plugs (122233).
Using a 4 mm Allen key, screw two HP plugs and two
MP plugs on the outlets indicated herein below.
REASSEMBLY END
NOTE: the tightening of the wet chamber on
the body SHOULD NOT be done with the MP
spring assembled in the wet chamber. The
previous steps must be respected.
MP plug
MP
HP plug
Free ports
NOTE: Press several times on the pin
support. It should feel like a push-button.

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FIRST STAGE ADJUSTING
1. Connect the first stage to a MP gauge 0-16 bar. If the
gauge is not fitted with an over-pressure valve, then
it is vital that the second stage is fitted so that it can
act as an over-pressure valve in the event of an HP
leak.
2. Connect the first stage to a cylinder charged to 200
bars. Slowly open the cylinder valve to put the
regulator under pressure.
3. Check that there is no leak.
4. Using an 8mm Allen key, turn the MP adjusting screw
(128117 or 127566) by increments of 1/8 of a turn
and purge the regulator several times, using the
second stage, after each increment.
Screwing the MP adjusting screw, increase the MP
value, unscrewing it, decrease the MP value.
To know which MP value is required, refer to Table
5. Checking specifications.
5. Leave the regulator under pressure for several
minutes and check that the MP remains stable. If the
MP rises more than 0.3 bar this indicates that there
is a leak. Refer to Table 1. Troubleshooting Guide.
6. Close the cylinder valve and completely purge the
regulator. Put the regulator under pressure once
more and check that the MP is stable. If the MP is
different, repeat steps 4 and 5 until a stable pressure
is obtained.
7. For wet chamber version, disconnect the regulator
from the pressure gauge and screw the MP plug
(122233) equipped with its O-ring (124703).
FINAL REASSEMBLY FOR
SUPREME VERSION
1. With the regulator under pressure, insert the piston
(127581) into the dry chamber. Place the diaphragm
(127579) right to the bottom of the dry chamber plug
(129902). Screw it fully home on the body using a lug
spanner (129198).
2. Check that the MP is still stable (see Table 5. Checking
specifications).
3. Close the cylinder valve and purge the regulator.
Disconnect the regulator from the pressure gauge and
screw the MP plug (122233) equipped with its O-ring
(124703).
FINAL REASSEMBLY END
ATTENTION: if the MP indicated by the gauge
rapidly exceeds 9.5 bar for standard version and
8.5 bar for supreme version, then this indicates a
HP leak. Close the cylinder valve immediately and
purge the regulator. Refer to Table 1.
Troubleshooting Guide.
NOTE: The following step should be carried
out with the regulator under pressure.

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TEST IN WATER
1. Check that all the MP and HP plugs are in place and
that a correctly adjusted second stage is connected
to the first stage. Slowly open the cylinder valve to
put the regulator under pressure.
2. Immerse the first stage completely in water to check
that there is no leak.
3. When you are sure that there is no leak, close the
cylinder valve and purge the regulator. Remove the
first stage from the cylinder and refit the dust cap.
4. If a leak has been detected then note its source and
refer to Table 1. Troubleshooting Guide.
NOTE: Do not mistake any bubbles that are
trapped in the regulator with a leak. If there
is a leak there will be a constant stream of
bubbles.

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APPENDIX
Table 1. Troubleshooting Guide
SYMPTOM
POSSIBLE CAUSE
TREATMENT
1. The HP seat (124624) is worn or damaged
1. Replace the HP seat
2. The crown (127585) is damaged
2. Replace the crown
Increase in MP
3. The O-ring (124704) is worn or damaged
3. Replace the O-ring
(likely to cause a second
stage leak)
4. Groove on the plug (129120) damaged
4. Replace the plug
5. O-ring (124612) is worn or damaged
5. Replace the O-ring
6. O-ring crown groove on the body (129254) is
damaged
6. Replace the body
1. O-rings on the MP and HP plugs are worn,
extruded or damaged
1. Replace the O-rings
2. The diaphragm (119159) is worn or damaged
2. Replace the diaphragm
3.The diaphragm (127579) is worn or damaged
3. Replace the diaphragm
External leak
4. The diaphragm (127579) sealing face on the body
(129254) is damaged
4. Replace the body
5. Wet or dry chamber screw (128113 or 128115)
loose
5. Tighten the chamber
6. Din shutter crown O-ring (124709) damaged
6. Replace the O-ring
7. Filter O-ring (124703) damaged
7. Replace the O-ring
8. Plug O-ring (213714) damaged
8. Replace the O-ring
9. Yoke shutter valve O-Ring (473056) damaged
9. Replace the O-ring
10. Yoke shutter crown O-ring (124703) damaged
10. Replace the O-ring
11. DIN shutter crown O-ring (473057) damaged
11. Replace the O-ring
1. Cylinder valve not completely open
1. Open the valve, check the cylinder
pressure
2. Cylinder valve requires servicing
2. Try another cylinder
Reduced airflow or significant
breathing resistance on
complete regulator
3. Filter (129209) blocked
3. Replace the filter
4. The cylinder is empty
4. Charge the cylinder
5. The hose is closed
5. Change the hose

Service Manual Core 1st stage
Service Manual Core 1st stage
Rev. 05/2015 18
Table 2. Tools and service kits list
REF
DESCRIPTION
PICTURES
APPLICATION
US PART NO.
506001
O-ring tool
Fitting and removing O-rings
944022
116236
Disassemble tool
HP club
Seat assembly / disassembly
109437
129198
Hook wrench
Dry chamber plug screwing /
unscrewing
129198
116230
HP disassembly
tool
1st stage holding in vice
100395
116239
1/4’’ box wrench
Filter and O-ring installation
n/a
122154
Torque wrench
SAM
Yoke retainer, wet and dry
chamber body, DIN screw, plug
screwing / unscrewing
n/a
122155
Facom screw
driver A404 2-10
NM
Yoke and DIN shutter valve
screwing / unscrewing
n/a
125237
DIN/yoke adaptor
300B
DIN shutter valve assembly /
disassembly
n/a
122152
Socket dry ch
Legend/Mistral
Wet and dry chamber body
screwing / unscrewing
122152
A11001
Socket inlet fitting
26mm
Yoke retainer screwing /
unscrewing
111001
n/a
7/16 ‘’ socket
DIN screw screwing / unscrewing
n/a
n/a
17mm key
ACD DIN union screwing /
unscrewing
n/a
n/a
9/16’’ key
Hose HP side screwing /
unscrewing
n/a
n/a
3mm Allen key
Yoke shutter valve screwing /
unscrewing
n/a
n/a
4mm Allen key
HP and MP plugs, Din shutter
valve screwing / unscrewing
Pressing of anti-extrusion washer
and O-ring against plug bottom
n/a
n/a
8mm Allen key
MP adjusting screw, plug, yoke
retainer screwing / unscrewing
n/a
128016
Service kit first stage balanced diaphragm
HP Core yoke, HP Core DIN, HP Core supreme
yoke, HP Core supreme DIN
n/a

Service Manual Core 1st stage
Service Manual Core 1st stage
Rev. 05/2015 19
Table 3. Recommended cleaners and lubricants
LUBRICIANT / CLEANER
APPLICATION
SOURCE
Christo-Lube MCG 111
All O-rings
Aqua Lung, ref. 480025
Oakite #31
Acid bath for cleaning brass and stainless
steel parts
Oakite Products, Inc.
NETALU
Acid bath for cleaning brass and stainless
steel parts
Aqua Lung, ref. 455001
Diluted white vinegar
Acid bath for cleaning brass and stainless
steel parts
Household stores
Washing-up liquid (diluted with hot water)
Degreases brass and stainless steel parts;
general cleaning of plastic and rubber
parts
Household stores
Disinfectant STERANIOS 2%
Disinfectant for all plastic and metal parts
Aqua Lung, ref : 382062
ATTENTION: Silicone parts do not require lubrication. Do not grease them. Greasing
silicone parts can change their molecular construction and cause premature
degradation of the material.
ATTENTION: Do not use hydrochloric acid for cleaning parts. Hydrochloric acid, even
when well diluted, attacks the coating of metal parts and leaves a corrosive deposit that
damages plastic parts and O-rings.

Service Manual Core 1st stage
Service Manual Core 1st stage
Rev. 05/2015 20
Table 4. Torque values
N° REFERENCE
DESCRIPTION
COUPLE
129904
Wet chamber body
2.5 m.kg (18.08 ft.lb)
129903
Dry chamber body
2.5 m.kg (18.08 ft.lb)
129242
Yoke retainer
2.5 m.kg (18.08 ft.lb)
129207
Yoke shutter valve
0.3 m.kg (2.17 ft.lb)
129213
DIN screw
2.5 m.kg (18.08 ft.lb)
129202
DIN shutter valve
0.3 m.kg (2.17 ft.lb)
129120
Plug
0.5 m.kg (3.62 ft.lb)
129241
DIN union
2.5 m.kg (18.08 ft.lb)
Table 5. Checking specifications
TEST
INSTRUCTIONS
SPECIFICATIONS
Leak Test
160 bar < Working pressure < 200 bar
No leak
Medium Pressure
160 bar < Working pressure < 200 bar
MP at 9.5 bar ± 0.5 bar : Core
MP at 8.5 bar ± 0.5 bar : Core supreme
MP Variation
160 bar < Working pressure < 200 bar
After purging the regulator several times, the MP should not
increase by more than 0.3 bar in 5-15 seconds