Aqua Lung CALYPSO FIRST STAGE User manual

Authorized Technician
TECHNICAL MAINTENANCE MANUAL
CALYPSO FIRST STAGE

2 Calypso First Stage Service Manual 3
Contents
COPYRIGHT NOTICE...............................................................................................................................................3
INTRODUCTION .......................................................................................................................................................3
WARNINGS, CAUTIONS, & NOTES.........................................................................................................................3
SCHEDULED SERVICE............................................................................................................................................3
GENERAL GUIDELINES..........................................................................................................................................3
GENERAL CONVENTIONS......................................................................................................................................4
DISASSEMBLY PROCEDURES...............................................................................................................................4
REASSEMBLY PROCEDURES................................................................................................................................6
FINAL TESTING........................................................................................................................................................8
Checking Medium Pressure ................................................................................................................................................................ 8
Immersion Test ..................................................................................................................................................................................... 8
TABLE 1 - FIRST-STAGE TROUBLESHOOTING GUIDE ........................................................................................9
TABLE 2 - RECOMMENDED TOOL LIST ..............................................................................................................10
TABLE 3 - RECOMMENDED LUBRICANTS AND CLEANERS...........................................................................11
PROCEDURE A - CLEANING AND LUBRICATION..............................................................................................12
TABLE 4 -TORQUE SPECIFICATIONS..................................................................................................................13
TABLE 5 - TEST BENCH SPECIFICATIONS .........................................................................................................13
EXPLODED PARTS DIAGRAM ..............................................................................................................................15

2 Calypso First Stage Service Manual 3
COPYRIGHT NOTICE
This manual is copyrighted, all rights reserved. It may not, in
whole or in part, be copied, photocopied, reproduced, translated,
or reduced to any electronic medium or machine readable form
without prior consent in writing from Aqua Lung America. It may
not be distributed through the internet or computer bulletin board
systems without prior consent in writing from Aqua Lung America.
©2004 Aqua Lung America, Inc.
Calypso First Stage Repair Manual
INTRODUCTION
This manual provides factory prescribed procedures for the
correct service and repair of the Aqua Lung Calypso rst-stage
regulator. It is not intended to be used as an instructional manual
for untrained personnel. The procedures outlined within this
manual are to be performed only by personnel who have received
factory authorized training through an Aqua Lung Service &
Repair Seminar. If you do not completely understand all of the
procedures outlined in this manual, contact Aqua Lung to speak
directly with a Technical Advisor before proceeding any further.
WARNINGS, CAUTIONS, & NOTES
Pay special attention to information provided in warnings, cau-
tions, and notes that are accompanied by one of these symbols:
WARNINGS indicate a procedure or situation that
may result in serious injury or death if instructions
are not followed correctly.
CAUTIONS indicate any situation or technique
that will result in potential damage to the prod-
uct, or render the product unsafe if instructions
are not followed correctly.
NOTES are used to emphasize important points, tips, and
reminders.
SCHEDULED SERVICE
If the regulator is subjected to less than 50 dives per year, it is
permissible to overhaul it every other year with an inspection
procedure being performed on the “off” years. For example:
Year #1: Inspection
Year #2: Overhaul
Year #3: Inspection
Year #4: Overhaul
and so on.
Both Inspections and Overhauls need to be documented in the
Annual Service & Inspection Record in the back of the Owner’s
Manual to keep the Limited Lifetime Warranty in effect.
If a regulator is subjected to more than 50 dives per year, it
should receive the complete overhaul.
An Ofcial Inspection consists of:
1. A pressurized immersion test of the entire unit to check for
air leakage.
2. Checking for stable intermediate pressure that is within the
acceptable range.
3. Checking for opening effort that is within the acceptable
range.
4. Checking for smooth operation of the control knob and
venturi switch.
5. A visual inspection of the lter for debris or discoloration.
6. A visual inspection of the exhaust valve to see that it is in
good shape and that it’s resting against a clean surface.
7. A visual inspection of the mouthpiece looking for tears or
holes.
8. Pulling back hose protectors and checking that the hoses
are secure in the hose crimps.
If a regulator fails item #1,2,3 or 4 the entire regulator should
be overhauled. If a regulator fails 4,5,6 or 7 it will be up to the
technician’s discretion whether or not a full overhaul is required.
GENERAL GUIDELINES
1. In order to correctly perform the procedures outlined in this
manual, it is important to follow each step exactly in the or-
der given. Read over the entire manual to become familiar
with all procedures before attempting to disassemble the
rst-stage, and to learn which specialty tools and replace-
ment parts will be required. Keep the manual open beside
you for reference while performing each procedure. Do not
rely on memory.
2. All service and repair should be carried out in a work area
specically set up and equipped for the task. Adequate
lighting, cleanliness, and easy access to all required tools
are essential for an efcient repair facility.
3. As the regulator is disassembled, reusable components
should be segregated and not allowed to intermix with
nonreusable parts or parts from other units. Delicate parts,
including inlet ttings and crowns which contain critical
sealing surfaces, must be protected and isolated from other
parts to prevent damage during the cleaning procedure.
4. Use only genuine Aqua Lung parts provided in the Calypso
rst-stage overhaul parts kit (p/n 900015). DO NOT attempt
to substitute an Aqua Lung part with another manufactur-
er’s, regardless of any similarity in shape or size.
5. Do not attempt to reuse mandatory replacement parts
under any circumstances, regardless of the amount of use
the product has received since it was manufactured or last
serviced.
6. When reassembling, it is important to follow every torque
specication prescribed in this manual, using a calibrated
torque wrench. Most parts are made of either marine brass
or plastic, and can be permanently damaged by undue
stress.
7. In order to make the regulator compatible with nitrox up to
40%O2 (EAN40), the regulator must be properly cleaned,
lubricated and assembled using genuine Aqua Lung or
Apeks replacement parts. In addition, assembly must be
carried out in a clean environment using powderless, latex
gloves or equivalent. For more detailed information, be sure
to read Procedure A, Cleaning and Lubrication.

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Calypso First Stage Service Manual 5
GENERAL CONVENTIONS
Unless otherwise instructed, the following terminology and tech-
niques are assumed:
1. When instructed to remove, unscrew, or loosen a threaded
part, turn the part counterclockwise.
2. When instructed to install, screw in, or tighten a threaded
part, turn the part clockwise.
3. When instructed to remove an o-ring, use the pinch method
(see gure) if possible, or use a brass or plastic o-ring
removal tool. Avoid using hardened steel picks, as they may
damage the o-ring sealing surface. All o-rings that are re-
moved are discarded and replaced with brand new o-rings.
1. Pull back the hose protector to expose wrench ats. Using a
⁹₁₆” wrench, unscrew the hose from the rst stage.
2. Using a 4mm Allen wrench, unscrew the HP (20) and MP
(10) port plugs. Remove the o-rings (9,21) from the port
plugs.
3. Remove yoke screw (22) and dust cap (19). Thread a rst
stage vise mounting tool into the HP port.
4. Secure mounting tool in a vise. Using a large crescent
wrench, remove the inlet tting (17) and the yoke (18).
Remove the yoke washer (13).
4. The following acronyms are used throughout the manual:
MP is Medium Pressure; HP is High Pressure; LP is Low
Pressure.
5. Numbers in parentheses reference the key numbers on the
exploded parts schematics. For example, in the statement,
“...remove the o-ring (3) from the piston (4)...”, the number 3
is the key number to the piston o-ring.
DISASSEMBLY PROCEDURES
NOTE: Before performing any disassembly, refer to the
exploded parts drawing, which references all mandatory
replacement parts. These parts should be replaced with
new, and must not be reused under any circumstances
- regardless of the age of the regulator or how much use it
has received since it was last serviced.
CAUTION: Use only a plastic or brass o-ring
removal tool (p/n 944022) when removing o-rings
to prevent damage to the sealing surface. Even
a small scratch across an o-ring sealing surface
could result in leakage. Once an o-ring sealing
surface has been damaged, the part must be
replaced with new. DO NOT use a dental pick, or
any other steel instrument.
Pinch Method
Press upwards on sides
of o-ring to create a
protrusion. Grab o-ring
or insert o-ring tool at
protrusion.

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Calypso First Stage Service Manual 5
5. Remove the o-ring (16) from the inlet tting (17). Insert the
extraction tool through the center hole of the inlet tting and
push out the conical lter (14).
9. Remove the main spring (7) from the piston cap (2). Firmly
grasp the shaft of the piston (4) and directly pull it out of the
cap.
6. Remove the recessed
o-ring (15) from the inside
of the inlet tting (17).
7. Turn the regulator in the vise so that the end cap (2) faces
up. Using a large crescent wrench, remove the end cap.
Remove the vise mounting tool.
8. Insert the handle end of the extraction tool into the threaded
end of the body (8) and push out the crown orice (12).
Remove the o-ring (11) from the crown orice.
10. Remove large piston head o-ring (3). Remove piston shaft
o-ring (5).
11. Insert the extraction tool
through the head of the
piston (4) and push out
the piston HP seat (6).
This Ends Disassembly
Before starting reassembly, perform parts
cleaning and lubrication according to the
procedures outlined in Procedure A, titled
Cleaning & Lubrication, on page 12.

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Calypso First Stage Service Manual 7
3. Install a new, lubricated o-ring (5) into its groove on the
piston (4) shaft.
4. Install a new, lubricated o-ring (3) onto the head of the
piston (4).
REASSEMBLY PROCEDURES
1. Place a new, lubricated o-ring (11) onto the crown orice
(12). Load the crown orice onto the installation / extraction
tool at end rst.
2. Insert the crown orice (12) into the inlet side (non-threaded
side) of the body (8). Turn the tool over and press on the
head of the crown orice to conrm that it is seated all the
way in the body.
5. Using your nger, press a new HP (6) seat into the end of
the piston (4) until it is seated all the way and is ush with
the end of the piston. If you are unable to press the HP seat
into the piston all the way with your nger, as an option, you
can place the HP seat on a clean surface and press the
piston shaft over it.
6. Apply a coat of Christo-Lube to the outside of the piston
head o-ring (3). Insert the piston (4), head rst, into the cap
(2).
7. Apply a coat of Christo-Lube to the outside of the shaft
o-ring (5). Lower main spring (7) over the shaft of the piston
(4).
8. Apply a light coat of Christo-Lube to the threads on the
main body (8). Mate the cap assembly (2) to the main body.
Thread until hand-tight.

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Calypso First Stage Service Manual 7
14. Install o-rings (9,21) on to each port plug (10,20). Using a
4mm allen key, install each of the port plugs into its respec-
tive port.
15. Install the interstage hose into its respective port. Using
an in/lbs torque wrench and a 9/16” crows foot, torque the
hose to 40 in/lbs.
16. Slide hose protector back
into position.
10. Install a new, lubricated o-ring (16) onto the outside of the
inlet tting (17). Using your nger, press t a new conical
lter (14), narrow end rst, into the inlet tting.
NOTE: Be carefull not to get any lubricant on or near the
conical lter.
11. Load the body (8) into a
vise using the vise-mount-
ing tool. Using a large
crescent wrench, snug the
cap (2) onto the body mak-
ing sure that metal meets
metal.
12. Invert the body (8) in vise. Install the cosmetic black washer
(13), smooth side up, onto the body. Set the yoke (18) on
top of the washer.
9. Install a new, unlubricated o-ring (15) into the groove inside
the inlet tting (17).
13. Thread in the inlet tting
(17). Using a ft/lbs torque
wrench, the 111001 modi-
ed 26mm socket and a 3”
extension, apply a torque of
18 ft/lbs to the inlet tting.
Install dust cap (19) and
yoke screw (22).

8 Calypso First Stage Service Manual 9
CHECKING THE MEDIUM PRESSURE
1. Attach an MP test gauge (0-400 psig) to a medium pressure
hose and thread the hose into the open MP port. If your
test gauge does not have an over-pressure relief valve, you
must also attach a properly adjusted second stage to the
rst stage to act as the relief valve in case of a HP leak.
2. Attach the rst stage to
a cylinder charged to
2900-3000 psi. Slowly
open the cylinder valve
to pressurize the regula-
tor.
WARNING: If the pressure gauge rapidly exceeds
145 psi, then there is a HP leak. Quickly close
the cylinder valve and purge the regulator. Fail-
ure to do so may cause a rupture to the MP hose
and/or the MP gauge which, in turn, can lead to
personal injury. Refer to Table 1. Troubleshooting
Guide for the causes of HP leaks.
3. With the regulator under pressure, cycle the over-pressure
relief valve or the second stage purge button to produce an
airow.
4. Check the MP reading, which should be between 130 and
145 psi.
5. Leave the regulator under pressure for about 10 seconds–
the MP should remain stable and should not rise by more
than 5 psi. If the MP rises more than 5psi, this indicates that
there is a leak. Refer to Table 1. Troubleshooting Guide.
IMMERSION TEST
With the port plugs and
at least one properly
adjusted second stage
installed, slowly open
the cylinder valve and
pressurize the rst
stage. Completely sub-
merge the rst stage in
fresh water and check
for leaks.
NOTE: Do not confuse bubbles from trapped air with a
true leak. If there is an air leak, bubbles will come out in a
constant sream.
Assuming there are no leaks, close the cylinder valve and
depressurize the regulator. Remove the rst stage from the valve
and secure the dust cap in place with the yoke screw.
If a leak is detected, note the source of the leak and refer to
Table 1. Troubleshooting Guide for possible causes and
corrective actions.

8 Calypso First Stage Service Manual 9
Table 1 - Troubleshooting Guide
SYMPTOM POSSIBLE CAUSE TREATMENT
Restricted air ow/high inhalation
resistance through entire system
1. Cylinder valve not completely
opened. 1. Open valve. check  ll pressure
2. Cylinder valve requires service 2. Connect to a different cylinder
3. Conical  lter (13) contaminated 3. Replace  lter with new
4. Insuf cient medium pressure 4. See below
Insuf cient medium pressure
1. Low inlet pressure 1. Re ll test cylinder
2. Main spring (7) weakened 2. Replace main spring
High intermediate pressure (leakage
or free ow through second stage)
1. HP seat (6) damaged or worn 1. Replace HP seat
2. Piston o-rings (3,5) damaged and
worn 2. Replace o-rings
3. Crown o-ring (5) damaged 3. Replace o-ring
4. Crown ori ce (11) sealing surface
damaged 4. Replace crown
5. Damaged piston (4) 5. Replace piston
Leakage of air from ambient ports of
piston cap
1. Piston shaft o-ring (5) damaged or
worn 1. Replace o-ring
2. Piston head o-ring (3) damaged or
worn 2. Replace o-ring
Leakage of air from inlet  tting 1. Inlet  tting o-ring (14) damaged 1. Replace o-ring
CAUTION: Recommended treatments which require disassembly of the regu-
lator must be performed during a complete overhaul, according to the pre-
scribed procedures for scheduled, annual service. Do not attempt to perform
partial service.
NOTE: This is a partial list of possible problems and recommended treatments. For
more information, contact Aqua Lung’s Technical Services Department for assis-
tance with problems not described here.

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Calypso First Stage Service Manual 11
Table 2 - Recommended Tool List
PART NO. DESCRIPTION APPLICATION
109437 Installation/extraction tool Seat and lter extraction
5116230 Vise mounting tool Disassembly/reassembly
111610 Test pressure gauge Checking medium pressure
944022 O-ring tool set Removing o-rings
111001 Modied 26mm socket Applying torque to inlet tting
n/a 3” socket extension, 3/8” drive Attach torque wrench through yoke
n/a Torque wrench, foot-pound Inlet tting
n/a Torque wrench, inch-pound Hose installation
n/a Large crescent wrench Inlet tting/cap removal
n/a 9/16” open end wrench MP hose tting
n/a 5/8” open end wrench HP hose tting
n/a 4mm alen key Port plug removal/installation
n/a Bench vise Disassembly/reassembly
n/a Magnier w/ illumination Inspection of seating surfaces
n/a Ultrasonic cleaner Metallic parts cleaning
n/a Powderless latex gloves or nger cots Keep nger oils off of parts

10
Calypso First Stage Service Manual 11
Table 3 - Recommended Lubricants & Cleaners
LUBRICANT / CLEANER APPLICATION SOURCE
Christo-Lube® MCG-111 All O-rings seals Aqua Lung, PN 820466, or
Lubrication Technologies
310 Morton Street
Jackson, OH 45640
[phone]
Oakite #31 Acid bath for reusable stainless
steel and brass parts.
Oakite Products, Inc.
50 Valley Road
Berkeley Heights, NJ 07922
White distilled vinegar Acid bath for reusable stainless
steel and brass parts.
“Household” grade
Liquid dishwashing detergent
(diluted with warm water)
Degreaser for brass and stainless
steel parts; general cleaning solu-
tion for plastic and rubber
“Household” grade
CAUTION: Silicone rubber requires no lubrication or preservative treatment.
DO NOT apply grease or spray to silicone rubber parts. Doing so may cause a
chemical breakdown and premature deterioration of the material.
CAUTION: Do not use muriatic acid for the cleaning of any parts. Even if
strongly diluted, muriatic acid can harm chrome plating and may leave a resi-
due that is harmful to O-ring seals and other parts.

12
Calypso First Stage Service Manual 13
Procedure A
Cleaning & Lubrication
Aqua Lung and Apeks First Stages and Nitrox
When it comes to issues of nitrox safety and compatibility, the concerns lie primarily with the rst stage as it is subjected to high inlet
pressures. High inlet pressures lead to adiabatic compression or heating of the gas. The Calypso rst stage, when properly cleaned
and assembled, is authorized for use with enriched air nitrox (EAN) that does not exceed 40% (EAN 40). It is authorized because it has
undergone adiabatic compression testing and the authorized service kit components and lubricants are compatible in elevated oxygen
environments. During cleaning, a mild detergent must be used to remove condensed hydrocarbons (compressor oils) from the inside
passageways of the rst stage. For the rst stage to remain EAN40 compatible, only use hyperltered compressed gas (hydrocarbons <
0.1 mg/m3). Ordinary compressed breathing air (Grade E) usually does not meet this criterion. Once ordinary breathing air is used, the
rst stage is no longer EAN40 compatible until it is cleaned and serviced again.
Although regulator second stage components are not exposed to high pressure EAN, Aqua Lung recommends that the same cleaning
procedures be followed for the complete regulator. This prevents the possibility of cross contamination and guarantees the cleanliness
of the entire regulator.
Cleaning Brass and Stainless Steel Parts
1. Preclean in warm, soapy water* using a nylon bristle tooth brush.
2. Thoroughly clean parts in an ultrasonic cleaner lled with soapy water. If there are stubborn deposits, household white distilled
vinegar (acetic acid) in an ultrasonic cleaner will work well. DO NOT place plastic, rubber, silicone or anodized aluminum parts in
vinegar.
3. Remove parts from the ultrasonic cleaner and rinse with fresh water. If tap water is extremely “hard,” place the parts in a bath of
distilled water to prevent any mineral residue. Agitate lightly, and allow to soak for 5-10 minutes. Remove and blow dry with low
pressure (25 psi) ltered air, and inspect closely to ensure proper cleaning and like-new condition.
Cleaning Anodized Aluminum, Plastic & 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 toothbrush to scrub away any deposits. Rinse in
fresh water and thoroughly blow dry, using low pressure ltered air.
CAUTION: Do not place plastic and rubber parts in acid solutions. Doing so my alter the physical properties
of the component, causing it to prematurely degrade and/or break.
Cleaning Hoses
1. Hose ttings: Ultrasonically clean with soapy water; vinegar OK on tough corrosion
2. Run soapy water through hose if need
3. Thoroughly rinse with fresh water
4. Blow out hose before installing
Lubrication and Dressing
Wear powderless, latex gloves when handling and lubricating o-rings. Keeping internal parts free from skin oils and other contaminates
is important when running enriched air nitrox through a rst stage. All o-rings should be lubricated with Christo-Lube® MCG-111. Dress
the o-rings with a very light lm of grease, and remove any visible excess by running the o-ring between thumb and forenger. Avoid
applying excessive amounts of Christo-Lube grease, as this will attract particulate matter that may cause damage to the o-ring.
*Soapy water is dened as “household” grade liquid dishwashing detergent diluted in warm water.

12
Calypso First Stage Service Manual 13
Table 5 - Test Bench Specications
TEST CONDITION SPECIFICATIONS
Immersion Test Supply Pressure 2900 - 3000 psi No leaks
Medium Pressure Supply Pressure 2900 - 3000 psi MP at 130 - 145 psi
MP Variation Supply Pressure 2900 - 3000 psi
After cycling the regulator several times,
the MP should not increase by more than
5 psi in 5 - 15 seconds.
Table 4 - Torque Specications
PART # DESCRIPTION / KEY ITEM # TORQUE
125712 Piston Cap / 2 18 ft/lbs
125716 Inlet Fitting / 15 18 ft/lbs
103133 MP Port Plug / 10 20 in/lbs
103137 HP Port Plug / 18 20 in/lbs
APF124563 Interstage Hose 40 in/lbs

14
Calypso First Stage Service Manual 15
NOTES

14
Calypso First Stage Service Manual 15
Calypso First Stage • Exploded Parts Diagram
Key # Part # Description
n/a ---- 125730 First Stage, Calypso, Yoke
n/a ---- 900015 Service Kit
1------- 125713 Decal, Aqua Lung logo
2------- 125712 Piston cap
3------- 820062 O-ring
4------- 125717 Piston
5------- 820007 O-ring
6------- 106726 HP seat
7------- 106771 Spring
8------- 125718 Body
9------- 820011 O-ring
10 ----- 103133 MP port plug
11 ----- 820007 O-ring
12 ----- 106767 Crown orice
13 ----- 125710 Yoke washer
14 ----- 129151 Filter
15 ----- 820011 O-ring
16 ----- 820015 O-ring
17 ----- 125716 Inlet tting
18 ----- 106843 Yoke
19 ----- 124555 Dust cap
20 ----- 103137 HP port plug
21 ----- 957004 O-ring
22 ----- 107507 Yoke screw
Part numbers in BOLD ITALICS are included in the service kit.
Key # Part # Description

Authorized Technician
TECHNICAL MAINTENANCE MANUAL
CALYPSO FIRST STAGE
Aqua Lung America
2340 Cousteau Court, Vista CA 92081