Aqua Lung Mistral Mouthpiece User manual

SERVICE MANUAL
MISTRAL
MOUTHPIECE
Copyright ©2005 Aqualung France
2005

2 Mistral Mouthpiece Service Manual
CONTENTS
COPYRIGHT...............................................................................................................................3
INTRODUCTION........................................................................................................................ 3
WARNINGS, ATTENTION, NOTE.........................................................................………………3
MAINTENANCE..........................................................................................................................3
GENERAL INSTRUCTIONS................................................................................................…….3
GENERAL CONVENTIONS.................................................................................................…….3
DISASSEMBLY PROCEDURE............................................................................................…....4
REASSEMBLY PROCEDURE.........................................................…….....................................5
TEST IN WATER …………...............................................................………................................7
Table 1. Troubleshooting guide …………………………………….………………………………….8
Table 2. List of tools and service kits...............................………..............................................…9
Table 3. Recommended cleaners and lubricants................................................................... 10
Procedure A Cleaning and Lubricating......................………….....………......……………............11
Maintenance Notes …………………………………………………….……………………...……….12
Exploded views of Mistral mouthpiece ...........……......................…..............…..........................13

FIRST TO DIVE 3
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.
©2005 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 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:
.
MAINTENANCE
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 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 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 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.
4. The acronyms used:
LP: Low Pressure
MP: Medium Pressure
HP: High Pressure
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 that
needs to be remembered.
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.
A
ttention: 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 o
r
aggressive environment the service period
should be reduced to six months.

4 Mistral Mouthpiece Service Manual
5. Numbers in brackets indicate the part number of the
component shown on the exploded view attached.
DISASSEMBLY PROCEDURE
1. Cut the two tightening collars at the mouthpiece level
and remove the corrugated hoses from the connectors.
2. Unscrew the screw connectors by hand.
3. Remove the two connectors from the mouthpiece body.
4. Remove the O-rings from the connectors.
5. Remove the lip guard.
6. Remove the mouthpiece clip (8) by lifting the cam with
your thumb, then remove the mouthpiece.
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.
A
ttention: Use only the special tool 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.

FIRST TO DIVE 5
7. Using the tool (ref: 116236), extract the exhalation valve
holder (side with the arrow pointing outwards) by
pushing with the tool from the inhalation valve holder
side, then extract the O-ring.
8. Using the tool (ref: 116236), extract the inhalation valve
holder taking care not to press on the valve, then
remove the valve holder O-ring.
9. Remove the inhalation and exhalation valves (5) and
check their surface is clean and free from any scratches.
They should be flexible and have a clean edge.
If they are in good condition it is not necessary to
discard them and they can be reused. If they show any
signs of deterioration they should be replaced.
END OF DISASSEMBLY
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
on page 14.
RE-ASSEMBLY PROCEDURE
1. If the valves have been extracted, pass the tail through
the hole in the valve holder and pull gently on it until the
shoulder passes through to the inside of the valve
holder. If the valve is new then cut the excess length
leaving a tail of about 15mm.
2. Fit the O-ring (6) onto the valve holder.
3. Insert the valve holder into the body on the side with the
outward-facing arrow (start by fitting the valve holder into
the orifice then position it correctly by pushing it with
your finger.
4. Insert the valve holder into the body on the side with the
inward-facing arrow.
A
ttention: The valve holders should be
fitted so that the gas can circulate in the
direction indicated by the arrows engraved
on the mouthpiece body.

6 Mistral Mouthpiece Service Manual
5. Insert the O-ring (6) into the mouthpiece body to the left
of the sticker.
6. Fit the O-rings (6) to the two connectors (3).
7. Lubricate the two O-rings and the surface in contact
with the mouthpiece body using a brush.
8. Fit the connectors into the mouthpiece body
9. Screw the two screws completely home by hand.
10. Fit the moulded mouthpiece (9) then the mouthpiece
clip (8).
11. Fit the lip guard
12. Check the condition of the two corrugated hoses, they
should not show any cuts or any other signs of
deterioration.
If they are in good condition, it is not necessary to replace
them and they can be reused. If they show any signs of
deterioration they should be replaced and refitted following
the procedure described in the Mistral Second Stage Service
Manual.
13. Place the corrugated hoses onto the connectors and
proceed as follows:
a. Fit the corrugated hoses to the connectors.
Note: Check that the connectors are correctly
fitted.
A
ttention: The corrugated hoses should be
fitted to the connectors so that the gas can
circulate in the direction indicated by the arrow
s
engraved on the mouthpiece body.
A
ttention: The valve holders should be
fitted so that the gas can circulate in the
direction indicated by the arrows engrave
d
on the mouthpiece body.

FIRST TO DIVE 7
b. Check that the corrugated hose mould line is
identical with that shown below when the regulator
is laid flat with the mouthpiece pointing upwards.
14. Fit the tightening collars (11) and tighten them with
PANDUIT GS4H pliers following the adjustment
information supplied:
END OF REASSEMBLY
TEST IN WATER
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.
Immerse the first and second stages and the hoses
completely in water to check that there are no leaks.
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.
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.
WARNING: Only pliers and tightening collars
following the references given by Aqualung
should be used.
PANDUIT GS4H :
- Tension = 8
- Locker = HVY
A
ttention: The lug of the tightening collar
s
should be aligned with the mould line of the
hoses (white line on the photos of 13.b.)
when the collar is tightened.
- Lug
- Mould line

8 Mistral Mouthpiece Service Manual
Table 1. Troubleshooting Guide
SYMPTOM POSSIBLE CAUSE TREATMENT
1.The connector or valve support O-rings
are extruded, worn or damaged. 1. Replace the O-ring(s)
2. The mouthpiece body is cracked 2. Replace the mouthpiece body
3. The corrugated hoses are worn or
damaged 3. Replace the corrugated hoses
External leak
4. The corrugated hose tightening collars
are damaged or badly tightened 4. Replace the collar(s)
1. The cylinder valve is not completely open 1. Open the valve and check the
cylinder pressure
2. The valve needs servicing 2. Try another cylinder
3. The first stage filter (10) is blocked 3. See the Mistral First Stage Trouble
Shooting Guide
Reduced air flow or a significant
general increase in breathing
resistance in the complete regulator
4. The cylinder is empty 4. Charge the cylinder
1. The valve holders have been fitted the
wrong way round in the mouthpiece 1. Disassemble and refit following the correct procedure
2. The mouthpiece has been fitted
backwards to the corrugated hoses 2. Disassemble and refit following the correct procedure
3. The cylinder valve is not open 3. Open the valve
Impossible to inhale or exhale from the
complete regulator
4. The cylinder is empty 4. Charge the cylinder
1. Mouthpiece pierced or broken (1) 1. Replace the mouthpiece
2. Diaphragm damaged 2. See the Mistral Second Stage
Trouble Shooting Guide
3. The connector or valve support O-rings
are extruded, worn or damaged. 3. Replace the O-ring(s)
4. The corrugated hose tightening collars
are damaged or badly tightened 4. Replace the collar(s)
Water enters the mouthpiece during
inhalation
5. The corrugated hoses are worn or
damaged 5. Replace the corrugated hoses

FIRST TO DIVE 9
Table 2. List of tools and service kits
REF DESCRIPTION APPLICATION US PART NO.
116236 Valve support disassembly 109436
N/C O-ring tool Fit and remove O-rings 944022
N/C
Tightening collar tool
PANDUIT GS4H
Tightening collars PLT4H N/a
N/C Collar cutting pliers Removing tightening collars N/a
125905 Service Kit MISTRAL All versions except Nitrox N/a
125936 Service Kit MISTRAL Nitrox/O2 Nitrox Version N/a

10 Mistral Mouthpiece Service Manual
Table 3. Recommended cleaners and lubricants
LUBRICANT / CLEANER APPLICATION SOURCE
Cristo-Lube MCG 111 All O-rings Aqualung, 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.
Aqualung, 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
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.

FIRST TO DIVE 11
Procedure A
Cleaning and Lubricating
(All Aqualung Regulators)
Cleaning brass and stainless steel parts.
1. Pre-clean by soaking in NETALU diluted to 25%.
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 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 25% ». 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
Cleaning parts for Nitrox/O2 use.
1. Metal parts: Pre-clean by soaking in NETALU diluted to 25%.
2. Ultrasonic cleaning in Promoclean TP108 diluted at 5%.
3. Rinse in demineralised water. Soak for 10 min.
4. 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.
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
compressed 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:
1. organic materials (oil, grease, paint, rust…)
2. cleaning agents
3. dust
4. humidity
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 that could damage the O-rings.
A
ttention: Do not place plastic and rubber parts in contact with acid solutions. This could alter their physical
p
roperties and cause degradation and premature breakdown.

12 Mistral Mouthpiece Service Manual
Maintenance Notes.

FIRST TO DIVE 13
Exploded view of Mistral mouthpiece - 125910.

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