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TITAN First Stage. Please Turn Off The Cell Phones.

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Presentation on theme: "TITAN First Stage. Please Turn Off The Cell Phones."— Presentation transcript:

1 TITAN First Stage

2 Please Turn Off The Cell Phones

3 Copyright Notice This 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

4 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

5 Product Features Go directly to Disassembly

6 Features 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

7 Features (Balanced Diaphragm) Balanced Model –Seawater enters main spring chamber and acts directly on main diaphragm –Diaphragm design 1 st stages by design are sealed

8 Features (Balanced Diaphragm)

9 Features (Turbo Assist)

10 Features (Yoke & DIN Available) 3365 psi yoke (232 Bar) 4351 psi DIN (300 Bar)

11 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

12 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

13 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

14 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

15 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

16 Disassembly Go to DIN

17 Remove Yoke Screw & Dust Cap

18 Install 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 dont break off in 1 st stage port !

19 Remove Yoke Retainer Clamp vise mount tool in bench vise –Use a 26mm open end wrench or a large adj. wrench CAUTION: NEVER mount 1 st stage directly in vise !

20 Remove Yoke From Body

21 Remove Protective Cap Return to yoke

22 Install Vise Mounting Tool Use a 4mm hex key –Install vise mounting tool (p/n 100395) or use empty Co2 cartridge w/adapter –Remove the HP port plug CAUTION: If using a CO2 cartridge, use an HP adapter so threads dont break off in 1 st stage port !

23 Remove DIN Connector Clamp vise mounting tool in bench vise –Use 6mm hex key –Remove the handwheel retainer CAUTION: NEVER mount 1 st stage directly in vise !

24 Remove Retainer O-rings

25 Remove Handwheel

26 Remove DIN Adapter Use a 26mm open end wrench

27 Remove O-ring From Inlet Boss

28 Remove Enviromental Dry Kit Turn the body over –Use retainer wrench (p/n 081247) to remove diaphragm retainer

29 Remove External Diaphragm

30 Remove Load Transmitter

31 Remove Adjustment Screw Turn body over –Use 8mm hex key Click here for Supreme model

32 Remove Washer & Main Spring

33 Remove Spring Retainer Use a 30mm open end wrench for the standard version 34mm for the supreme version

34 Remove Spring Pad

35 Remove Thrust Washer Use brass o-ring removal tool (p/n 944022) NOTE: Pull thrust washer to one side and rotate

36 Remove 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

37 Remove Pin Pad & Pin

38 Remove Diaphragm (Alt. Method) If a LP nozzle is not available, you may leave the diaphragm in place for the time being –After disassembling the HP side of the first stage, you can reach through the body to push out the diaphragm CAUTION: Never remove diaphragm by prying or digging it out around the edges !

39 Remove 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 !

40 Inspect 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

41 Remove 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

42 Remove 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. !

43 Remove 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

44 Remove Crown O-ring

45 Remove Remaining Port Plugs Use a 4mm hex key –Remove port plugs and their associated o-rings

46 This Concludes Disassembly

47 Cleaning & Lubrication Go directly to Reassembly

48 Cleaning 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)

49 Cleaning 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 !

50 Cleaning 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

51 Lubrication 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

52 Reassembly

53 Install Crown O-ring Critically inspect the crown orifice under magnification –Confirm it is acceptable for reuse Sealing area O-ring groove

54 Install 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

55 Install 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

56 Place HP Seat In Body

57 Install HP Seat Spring

58 Install Back-Up Ring The concave side must face up to cradle the o-ring

59 Install HP O-Ring Install a well lubricated o-ring into the balance chamber

60 Install Balance Chamber

61 Install Secondary Spring

62 Place The HP Block Tool Set the HP block tool (p/n 111000) with recessed edge facing down, onto the inlet boss

63 Install Filter Lay the filter flat inside block tool –The rough side of the filter should face up

64 Install Filter Washer Lay the washer on top of the filter

65 Install Circlip Install circlip inside the block tool –The sharp edges should be facing up

66 Compress The Parts Use a ½ wooden dowel –Compress the parts until the circlip engages in its respective groove

67 Inspect Circlip Inspect the circlip, it should be seated evenly and fully expanded into its designated groove CAUTION: Failure to fully seat the circlip could result in the ejection of parts from the first stage. !

68 Insert Pin In Center Bore Pin should engage the central hole of the HP seat on the other side

69 Install Pin Pad

70 Check The Valve By pressing on the pin pad, you are able to open and close the valve

71 Install Diaphragm Work the edges with your finger to ensure that it is fully seated

72 Install Thrust Washer Make sure it is evenly seated all the way around

73 Install Spring Pad Lay the spring pad on the center of the diaphragm with the raised tab facing up

74 Add Main Spring

75 Add Spring Retainer

76 Apply 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

77 Add Main Spring Washer

78 Add Adjusting Screw Use a 8mm hex key –Drive in adj.screw to preliminary setting Preliminary settings: –Flush for standard –Even with shoulder on supreme

79 Install Yoke Turn first stage over –Place yoke onto inlet boss Install DIN

80 Install 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

81 DIN Assembly Turn 1 st stage over –Add o-ring to the base of the inlet boss

82 Install DIN Adapter Use a ft/lb torque wrench and 26mm crow foot Torque to 18 ft/lbs (24.5 Nm) Torque: 18 ft/lbs 24.5 Nm

83 Add DIN Handwheel

84 Add O-rings To Retainer Click here to learn about handwheel retainer revisions Install o-ring to the base of the retainer Install an unlubricated o-ring to the retainer face CAUTION: Inspect the retainer and replace old version with new revision !

85 Torque Handwheel Retainer Use an in/lb torque wrench and a 6mm hex key adapter –Torque to 85 in/lbs (9.6 Nm) Torque: 85 in/lbs 9.6 Nm

86 Install Yoke Screw & Dust Cap

87 Install Port Plugs Add a new o-ring to each port plug Use a 4mm hex key –Leave out one MP port plug for testing

88 Testing

89 Adjusting Medium Pressure (MP) Install MP gauge (p/n 111610) into 1 st stage MP port –If gauge lacks over-pressure relief valve, attach properly adjusted 2 nd stage as relief valve in case of HP leak

90 Adjusting Medium Pressure (MP) Attach Titan to fully charged cylinder 3000 psi (206 bar)

91 WARNING 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 !

92 Adjusting Medium Pressure (MP) With relief valve open on gauge, slowly open cyl. valve & pressurize the 1st stage

93 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

94 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.

95 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.

96 Adjusting Medium Pressure (MP) Set the MP to: –135 psi (9.3 bar ) for standard –123 psi (8.4 bar) for supreme –The Titan 1 st stage is used with several different 2 nd stages, confirm MP settings by checking the appropriate 2 nd stage service manual MP Settings: 135 psi (9.3 bar) std. 123 psi (8.4 bar) supreme

97 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

98 Dry Kit Installation Keep Titan pressurized Install a new external diaphragm into the retainer –Drop in load transmitter, replace decal if necessary

99 Tighten Retainer Use retainer wrench (p/n 081247) –Tighten retainer until metal meets metal –NOTE: The MP should not change during this procedure

100 Immersion 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.

101 This Concludes Servicing Of The TITAN First Stage Rev 07/10/07

102 Revisions

103 Pin Pad Revision - 1999 –Revision As 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. ARev. B Click here to return to disassembly

104 Filter 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 845095124627124628 Click here to return to disassembly

105 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. ARev. B Click here to return to disassembly

106 DIN 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. ARev. B Brass Chrome Finish Stainless Steel Satin Finish For more information see Technical Bulletin #16 March 27, 2006 Click here to return to disassembly


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