® Authorized Dealer SERVICE & REPAIR MANUAL Titan First Stage Regulator Copyright ©1999 Aqua Lung America, Inc. Doc. No.
Table of Contents Introduction .................................................................................................... 3 Warnings, Cautions, & Notes ........................................................................................... 3 Scheduled Service ........................................................................................................... 3 General Guidelines ...........................................................................................................
Doc. #7803-01 Service & Repair Manual - Titan First Stage Regulator Introduction GENERAL GUIDELINES This manual provides factory prescribed procedures for the service and repair of the Titan first 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.
Titan First Stage Service & Repair Manual 4 Initial Inspection Procedure EXTERNAL INSPECTION 1. Visually inspect the sintered filter to check for any signs that contaminants may have entered the system, such as moisture, rust, aluminum oxide, or charcoal. NOTE: A green discoloration positively indicates that moisture has entered the regulator, and internal corrosion is therefore likely to be found in the first stage.
Titan First Stage Service & Repair Manual 5 INTERMEDIATE (OVER-BOTTOM) PRESSURE TEST 1. Depress the second stage purge button once again to ensure that the system is not pressurized. Connect the intermediate pressure test gauge either to a quick-disconnect inflator hose, or to the female fitting of a second stage IP hose, depending on the connector of the test gauge.
Titan First Stage Service & Repair Manual 6 Disassembly Procedures NOTE: Before performing any disassembly, refer to Table 3, which references all mandatory replacement parts. These parts must be replaced with new, and must never be reused regardless of the age of the regulator or how much use it has received since it was last serviced. CAUTION: To prevent damage to critical sealing surfaces, use only a plastic or brass O-ring removal tool (P/N 9440-22) when removing O-rings.
Titan First Stage Service & Repair Manual 7 Fig. 2 5. Fig. 3 Fig. 4 Disassembly of DIN Connector A. Unscrew the thread protector cap(5a) and remove it from the first stage. B. Apply a 6mm hex key to the hand wheel retainer(5c), and turn it counter-clockwise to loosen and remove (see Fig. 2). Remove and discard both O-rings(5b&5d). C.
Titan First Stage Service & Repair Manual 8 CAUTION: If permanent corrosion is found, discard the spring and DO NOT attempt to reuse. A damaged or badly corroded spring may seriously impair first stage performance by failing to provide stable intermediate pressure. 9. Apply a 30mm open end wrench to the spring retainer(26), or use a 34mm open end wrench for the “DRY” version spring retainer(30), and turn the retainer counter-clockwise to loosen and remove from the first stage body. 10.
Titan First Stage Service & Repair Manual Brass pin support Smaller bore diameter 9 17. With the use of a magnifier, closely examine the sealing surface inside the balancing chamber of the spring block to check for any signs of permanent corrosion, scoring, or other damage. If found, discard the spring block and do not reuse.
Titan First Stage Service & Repair Manual 10 Reassembly Procedures NOTE: Before performing any reassembly, it is important to inspect all parts, both new and those that are being reused, to ensure that every part and component is perfectly clean and free of any dust, corrosion, or blemishes. Before dressing each O-ring with Christo-Lube®, check to ensure it is clean, supple, and free of any blemish.
Titan First Stage Service & Repair Manual 11 8. Fig. 11 Fig. 12a Secure the vise mounting tool in a vise so the first stage stands vertical with the spring retainer facing up. Apply a torque wrench with 30mm crow-foot, or use a 34mm crow foot for the “D” environmental version spring retainer(30), and tighten the spring retainer to a torque measurement of 20 (±2) foot-lbs (see Fig. 11). 9.
Titan First Stage Service & Repair Manual 12 12. Insert the backup ring(11) into the high pressure spring block(10), and gently tamp it into place with a non-metallic probe so that it is seated evenly and flat inside. Then, generously lubricate and install the O-ring(12) into the spring block, directly over the backup ring.
Titan First Stage Service & Repair Manual 13 D. Mate the yoke screw into the top of the yoke, and turn it clockwise to fasten the dust cap snugly in place over the inlet boss. Reassembly of DIN Adapter A. Install the O-ring(5g) onto the groove at the base of the first stage body inlet boss, just below the threads. B. Mate the large female threads of the DIN adapter(5f) onto the inlet boss, and tighten it clockwise by hand until snug. C.
Titan First Stage Service & Repair Manual 14 Final Adjustment and Testing Procedures 1. Connect the intermediate pressure test gauge either to a quick-disconnect inflator hose, or to the female fitting of a second stage LP hose, depending on the connection of the test gauge. Check to ensure there are no open ports. CAUTION: Before testing intermediate pressure, it is important to connect the first stage to a fully assembled and properly adjusted second stage.
Titan First Stage Service & Repair Manual 15 6. 7. 8. 9. Repeat the adjustment procedure in step 4 to adjust the Titan first stage intermediate pressure to exactly 135 psi. Repeatedly purge the second stage or open and shut the test gauge bleed valve at least 15 times to ensure that the intermediate pressure locks up consistently and remains stable at 135 (±5) psi, with no signs of creeping or fluctuation. Final Assembly – “DRY” Environmental Kit a.
Titan First Stage Service & Repair Manual 16 Table 1 Troubleshooting Guide – Titan First Stage SYMPTOM Restricted airflow/ high inhalation resistance through entire system. High or unstable intermediate pressure Low intermediate pressure External air leakage (Immersion Test) POSSIBLE CAUSE TREATMENT 1. Cylinder valve not completely opened. 1. Open valve, check fill pressure. 2. Cylinder valve requires service. 2. Connect to a different cylinder. 3.
Titan First Stage Service & Repair Manual 17 Table 2 Recommended Tool List PART NO. DESCRIPTION APPLICATION 1116-10 I.P.
Titan First Stage Service & Repair Manual 18 Table 3 Standard Parts Replacement Schedule – Titan First Stage PART NUMBER DESCRIPTION KEY NUMBER QTY 8200-94 O-ring 3 1 8630-51 Circlip 6 1 8450-95 Washer 7 1 1051-06 Filter 8 1 8280-05 Backup Ring 11 1 8240-06 (or) 8200-80 O-ring 12a (or) 12b 1 1059-40 High Pressure Seat 13 1 8200-38 O-ring 14 1 9570-04 O-ring 20 1 8200-11 O-ring 22 4 1034-25 Diaphragm w/ Washer 24 1 1063-37 Environmental Diaphragm 33 1 Tab
Titan First Stage Service & Repair Manual 19 Table 5 Test Bench Specifications Titan First Stage TEST CONDITION ACCEPTABLE RANGE Leak test Inlet 2,500-3,000 psi None Intermediate pressure Inlet 2,500-3,000 psi 135 (±5) psi Intermediate pressure creep Inlet 2,500-3,000 psi 5 psi max between 5 to 15 seconds after cycling regulator (purge) Opening effort Inlet 2,500-3,000 psi, intermediate pressure 135 (±5) psi +0.8 to +1.
Titan First Stage Service & Repair Manual 20 Procedure A Cleaning & Lubrication (All Aqua Lung Regulators) 1. Acid Bath - Aqua Lung strongly recommends ChromeSafe™ regulator cleaner (P/N 0201-05) for cleaning all reusable brass and stainless steel parts. ChromeSafe™ is a specially formulated cleaner that does not harm rubber or Teflon parts, yet effectively removes silicone grease, corrosion, and grime from metal parts, leaving only a brilliant shine.
Titan First Stage Service & Repair Manual 21 Table A Recommended Lubricants & Cleaners (All Aqua Lung Regulators) LUBRICANT / CLEANER APPLICATION SOURCE Christo-Lube® All O-rings seals; cylinder valve threads (preferred for high pressure DIN systems) Lubrication Technologies 310 Morton Street Jackson, OH 45640 (614) 286-2644 Dow Corning® 111 (pure silicone grease) All O-ring seals Dow Corning Corp. P.O.
Titan First Stage Service & Repair Manual 22 Titan First Stage 2 1 24a 6 7 3 24b 8 4 9a 25 10 11 12 9b 26 5 30 13 14 27 15 5a 27 16* 28 28 5b 29 22 29 23 5c 17 5d 31 5e 18 20 32 19b 19a 21 33 5f 34 5g Key # Part # ----- 9000-01 1 ----- 1075-07 2 ----- 1031-14 3 ----- 8200-94 4 ----- 1031-62 5 ----- 1068-43 5a ---- 1074-42 5b ---- 8200-94 5c ---- 1060-56 5d ---- 8200-72 5e ---- 1031-76 5f ---- 1031-74 5g ---- 8200-77 6 ----- 8630-51 7 ----- 8450-95 8 ----- 1051-06 9 ----- 1015-0
Titan First Stage Service & Repair Manual 23 TECHNICIAN'S NOTES © 1999 Aqua Lung America, Inc.
2340 Cousteau Court Vista, California 92083 Phone (760) 597-5000 Fax (760) 597-4900 www.aqualung.
