titan first stage. please turn off the cell phones

TITAN TITAN First StageFirst Stage

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4

Copyright NoticeCopyright NoticeThis program 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

International. It may not be distributed through the internet or

computer bulletin board systems without prior consent in

writing from Aqua Lung International

©2007 Aqua Lung International, Inc

Titan 1st Stage Service Program

O-ring Removal (Pinch Method)O-ring Removal (Pinch Method)

• Pinch Method: Using fingers, push on opposite sides to create protrusion

• Use only brass or plastic pics to remove o-rings, this will protect delicate seating surfaces

• Never reuse o-rings

P/n 944022

Product FeaturesProduct Features

Go directly to Disassembly

FeaturesFeatures

• A time proven, in-line, balanced, diaphragm mechanism

• 1 HP port, 4 MP ports

– All MP ports are 3/8”

• Turbo assisted

• Available in 232 bar yoke or 300 bar DIN

• Environmental dry kit is available

• MP can be set externally

• Compatible to EAN 40, new out of box

Features (Balanced Diaphragm)Features (Balanced Diaphragm)• Balanced Model

– Seawater enters main spring chamber and acts directly on main diaphragm

– Diaphragm design 1st stages by design are sealed

Features (Balanced Diaphragm)Features (Balanced Diaphragm)

Features (Turbo Assist)Features (Turbo Assist)

Features (Yoke & DIN Available)Features (Yoke & DIN Available)

3365 psi yoke (232 Bar)

4351 psi DIN (300 Bar)

Features (Environmental Dry Kit)Features (Environmental Dry Kit)

• Supreme models come with dry kit

– Allows 1st stage to be used in cold waters <50f (10c)

– Insulates main spring with air

– Prevents ice formation on the spring coils

– Side benefit – keeps contaminants and corrosion out

Features (Nitrox Compatible)Features (Nitrox Compatible)

• The Titan is nitrox (EAN) compatible to 40% out of the box

• Built with a high level of cleanliness

• EAN compatible components and lubricants

• Have passed required adiabatic compression testing to ensure their safety and compatibility

Features (Nitrox Compatible)Features (Nitrox Compatible)

• Responsibility of the owner to maintain the cleanliness of the regulator

• If regulator will be used interchangeably with breathing air, the air should be oxygen-compatible or “hyper-filtered” whereas the condensed hydrocarbons do not exceed 0.1 mg/m3

• Grade E air does not necessarily meet this criterion

• Hydrocarbons found in Grade E air can pose a risk in the presence of elevated oxygen content

Features (Nitrox Compatible)Features (Nitrox Compatible)

• Hydrocarbons build up over time along the passageways of the equipment

• When hydrocarbons come in contact with high-pressure oxygen enriched air, they can pose a very real hazard that can lead to combustion

• If a regulator has had use with Grade E breathing air, it should receive a standard overhaul, including ultrasonic cleaning with a detergent solution, that removes hydrocarbons, prior to being put back into nitrox service

Features (Nitrox Compatible)Features (Nitrox Compatible)

• Although second stage components are not exposed to high pressure EAN, Aqualung 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

DisassemblyDisassembly

Go to DIN

Remove Yoke Screw & Dust CapRemove Yoke Screw & Dust Cap

Install Vise Mounting ToolInstall Vise Mounting Tool• Use a 4mm

hex key

– Install vise mounting tool (p/n 100395) or use empty Co2 cartridge w/HP adapter

– Remove the HP port plug

CAUTION: If using a CO2 cartridge, use an HP adapter so threads don’t break off in 1st stage port!

Remove Yoke RetainerRemove Yoke Retainer• Clamp vise mount

tool in bench vise

– Use a 26mm open end wrench or a large adj. wrench

CAUTION: NEVER mount 1st stage directly in vise!

Remove Yoke From BodyRemove Yoke From Body

Remove Adjustment ScrewRemove Adjustment Screw

• Turn body over

– Use 8mm hex key

Click here for Supreme model

Remove Washer & Main SpringRemove Washer & Main Spring

Remove Spring RetainerRemove Spring Retainer• Use a 30mm

open end wrench for the standard version

• 34mm for the supreme version

Remove Spring PadRemove Spring Pad

Remove Thrust WasherRemove Thrust Washer• Use brass o-ring

removal tool (p/n 944022)

NOTE: Pull thrust washer to one side and rotate

Remove DiaphragmRemove Diaphragm• Insert a LP nozzle into

one of the MP ports

CAUTION: Never remove diaphragm by prying or digging it out around the edges!

– Use a blast of air to lift the diaphragm

– Keep finger over diaphragm to keep from ejecting

Click here for alternate method of diaphragm removal

Remove Pin Pad & PinRemove Pin Pad & Pin

Remove CirclipRemove Circlip• Use circlip pliers

(p/n 111100)

– Keeping finger over work to prevent parts from ejecting, carefully remove circlip

CAUTION: Never remove diaphragm by prying or digging it out around the edges.!

CAUTION: Contents are under spring pressure!

Inspect PartsInspect Parts• Identify and inspect:

– Circlip

– Filter washer *

– Filter

– Spring

– Balance chamber

– HP seat spring

– HP seat

– Pin

*

Click here to learn about filter washer revisions

Remove HP O-ring & Backup RingRemove HP O-ring & Backup Ring

CAUTION: Care must be taken not to scratch the inside wall of the balance chamber or a leak could result!

Click here to learn about back-up ring revisions

Remove DiaphragmRemove Diaphragm• If you have not yet

removed the diaphragm, do so now – Insert extraction tool (p/n 109437)

through the inlet boss

– Engage the pin pad and push out the diaphragm

CAUTION: Never remove diaphragm by prying or digging it out around the edges.!

Remove Crown OrificeRemove Crown Orifice

• Work over a padded surface

Click here to learn about a 1999 body pin pad revision

– Insert the pin or extraction tool at an angle, into the center hole

– Push out crown orifice

Remove Crown O-ringRemove Crown O-ring

Remove Remaining Port PlugsRemove Remaining Port Plugs• Use a 4mm hex key

– Remove port plugs and their associated o-rings

This Concludes DisassemblyThis Concludes Disassembly

Cleaning & LubricationCleaning & Lubrication

Go directly to Reassembly

Cleaning ProceduresCleaning Procedures

• Brass and Stainless Steel Parts

– Pre-clean in warm soapy water; nylon bristle brush

– Ultrasonically clean with soapy water; vinegar OK on tough corrosion

– Rinse in fresh water; use distilled water if tap water is “hard”

– Blow dry with hydrocarbon free gas (for EAN use)

Cleaning ProceduresCleaning Procedures

• Aluminum, Plastic & Rubber Parts

– Soak in warm, soapy water

– Use soft nylon bristle brush to remove deposits

– Rinse with fresh water

– Blow dry with LP hydrocarbon free gas (for EAN use)

CAUTION: DO NOT soak plastic parts in acidic solutions !

Cleaning ProceduresCleaning Procedures

• Regulator Hose

– Hose fittings - Ultrasonically clean with soapy water; vinegar OK on tough corrosion

– Can run soapy water through hose if needed

– Thoroughly rinse with fresh water

– Blow out hose before installing

Lubrication ProceduresLubrication Procedures

• Lubrication

– Christo-lube MCG 111

– Light film only

– Remove visible excess

– If regulator will be used with EAN, you should wear powderless, latex gloves (or equivalent) when lubricating and handling o-rings

ReassemblyReassembly

Install Crown O-ringInstall Crown O-ring

• Critically inspect the crown orifice under magnification

– Confirm it is acceptable for reuse

Sealing area

O-ring groove

Install Crown OrificeInstall Crown Orifice• Use seat

installation tool (p/n 109437)

– Load the crown onto the tool with the raised seating surface facing away from the body

– Lift the crown into the body

Install Crown OrificeInstall Crown Orifice• Turn tool over

and use the dowel side

– Confirm that it is seated evenly with the crown facing up

– Press the crown into place

Place HP Seat In BodyPlace HP Seat In Body

Install HP Seat SpringInstall HP Seat Spring

Install Back-Up RingInstall Back-Up Ring• The concave side

must face up to cradle the o-ring

Install HP O-RingInstall HP O-Ring• Install a well

lubricated o-ring into the balance chamber

Install Balance ChamberInstall Balance Chamber

Install Secondary SpringInstall Secondary Spring

Place The HP Block ToolPlace The HP Block Tool• Set the HP block tool

(p/n 111000) with recessed edge facing down, onto the inlet boss

Install FilterInstall Filter• Lay the filter flat

inside block tool

– The rough side of the filter should face up

Install Filter WasherInstall Filter Washer• Lay the washer

on top of the filter

Install CirclipInstall Circlip• Install circlip

inside the block tool

– The sharp edges should be facing up

Compress The PartsCompress The Parts• Use a ½”

wooden dowel

– Compress the parts until the circlip engages in it’s respective groove

Inspect CirclipInspect Circlip• Inspect the

circlip, it should be seated evenly and fully expanded into it’s designated groove

CAUTION: Failure to fully seat the circlip could result in the ejection of parts from the first stage.

!

Insert Pin In Center BoreInsert Pin In Center Bore• Pin should engage

the central hole of the HP seat on the other side

Install Pin PadInstall Pin Pad

Check The ValveCheck The Valve• By pressing on the pin

pad, you are able to open and close the valve

Install DiaphragmInstall Diaphragm• Work the edges with

your finger to ensure that it is fully seated

Install Thrust WasherInstall Thrust Washer• Make sure it is evenly

seated all the way around

Install Spring PadInstall Spring Pad• Lay the spring pad on

the center of the diaphragm with the raised tab facing up

Add Main SpringAdd Main Spring

Add Spring RetainerAdd Spring Retainer

Apply Proper TorqueApply Proper Torque• Use a ft/lb torque wrench

& spring retainer socket (p/n 111002)

with 3 inch ext.

– Torque to 18 ft/lbs (24.5 Nm)

– 30mm crow foot can also be used on standard Titan

– 34mm crow foot for supreme Titan

Torque: 18 ft/lbs 24.5 Nm

Add Main Spring WasherAdd Main Spring Washer

Add Adjusting ScrewAdd Adjusting Screw• Use a 8mm hex key

– Drive in adj.screw to preliminary setting

• Preliminary settings:

– Flush for standard

– Even with shoulder on supreme

Install YokeInstall Yoke• Turn first stage over

– Place yoke onto inlet boss

Install DIN

Install Yoke NutInstall Yoke Nut• Use a ft/lb torque

wrench & inlet fitting socket (p/n 111001) with 3 inch ext.– Torque to

18 ft/lbs (24.5 Nm)

Torque: 18 ft/lbs 24.5 Nm

Install Yoke Screw & Dust CapInstall Yoke Screw & Dust Cap

Install Port PlugsInstall Port Plugs

• Add a new o-ring to each port plug

• Use a 4mm hex key

– Leave out one MP port plug for testing

TestingTesting

Adjusting Medium Pressure (MP)Adjusting Medium Pressure (MP)

• Install MP gauge (p/n 111610) into 1st stage MP port

– If gauge lacks over-pressure relief valve, attach properly adjusted 2nd stage as relief valve in case of HP leak

Adjusting Medium Pressure (MP)Adjusting Medium Pressure (MP)

• Attach Titan to fully charged cylinder 3000 psi (206 bar)

WARNINGWARNING

If the pressure gauge rapidly exceeds 145 psi (10 bar), there is a HP leak. Quickly close the cylinder valve and purge the regulator. Failure to do so may cause a rupture to the MP hose and/or MP gauge which, in turn, can lead to personal injury

!

Adjusting Medium Pressure (MP)Adjusting Medium Pressure (MP)

• With relief valve open on gauge, slowly open cyl. valve & pressurize the 1st stage

Adjusting Medium Pressure (MP)Adjusting Medium Pressure (MP)

• Close the relief valve

– If MP rapidly exceeds 145 psi (10 bar), close cylinder immediately and purge line

– This means that there is a HP leak

Adjusting Medium Pressure (MP)Adjusting Medium Pressure (MP)

• Use a 8mm hex key

– To increase the MP, turn the adj. screw in 1/8 turn increments clockwise

– Using the relief valve on the gauge, cycle the reg. several times after each adj.

Adjusting Medium Pressure (MP)Adjusting Medium Pressure (MP)

• Use a 8mm hex key

– To decrease the MP, turn the adj. screw in 1/8 turn increments counter-clockwise

– Using the relief valve on the gauge, cycle the reg. several times after each adj.

Adjusting Medium Pressure (MP)Adjusting Medium Pressure (MP)

• Set the MP to:

– 135 psi (9.3 bar) for standard

– 123 psi (8.4 bar) for supreme

– The Titan 1st stage is used with several different 2nd stages, confirm MP settings by checking the appropriate 2nd stage service manual

MP Settings: 135 psi (9.3 bar) std. 123 psi (8.4 bar) supreme

Adjusting Medium Pressure (MP)Adjusting Medium Pressure (MP)

• Let the Titan stand for several minutes

– Check that MP remains stable

– If MP rises more than 5 psi (0.3 bar),

it indicates a leak

– If stable, close valve, purge line & pressurize once again to perform final check

Click here for Dry kit

Immersion TestImmersion Test

– Observe for leaks

– Troubleshoot accordingly

• With the Titan still pressurized, submerge the unit in a tub of water

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 stream.

This Concludes Servicing Of The This Concludes Servicing Of The

TITAN First StageTITAN First Stage

Rev 07/10/07Rev 07/10/07

RevisionsRevisions

Pin Pad Revision - 1999Pin Pad Revision - 1999

– Revision A’s are still acceptable for use and service

• Revision A pin pad and body MUST be used together

• Revision B pin pad and body must be used together

Rev. A Rev. B

Click here to return to disassembly

Filter Washers – Jan. 2005Filter Washers – Jan. 2005• The 845095 nylon washer

was for air use only. It was not nitrox compatible

• The 124627 washer is compatible for nitrox but would not allow for visual inspection of the filter

• 124628 is the current washer

845095 124627 124628

Click here to return to disassembly

Black Back-Up Ring – June 2002 Black Back-Up Ring – June 2002

– The black ring is for nitrox compatibilty

• A black, solid back-up ring replaced the white split ring

Rev. A Rev. B

Click here to return to disassembly

DIN Handwheel Retainer - March 2006DIN Handwheel Retainer - March 2006

– This new steel part can be identified by the satin finish of the part

• The material used in the retainer has been changed to stainless steel

Rev. A Rev. B

Brass Chrome Finish Stainless Steel

Satin Finish

For more information see Technical Bulletin #16 March 27, 2006

Click here to return to disassembly