Aqua Lung MISTRAL SECOND STAGE Technical Maintenance Manual Download Page 7

Mistral Second Stage Technical Maintenance Manual

  7

4.  Using the crown adjusting tool (p/n 125727), engage the  

slotted head of the crown (16) and drive it in clockwise as

far as the tool will allow. If the tool is not available, use a

medium blade screwdriver to drive the crown in as far as it 

will go and then back it out 3 revolutions.

CAUTION : 

If resistance is felt, immediately 

stop and unscrew the valve body from the 
inlet fi tting. To check the alignment of the 
poppet shaft and poppet bearing.  Excessive 
force and misalignment will otherwise result 
in damage to the poppet bearing, requiring 
its replacement.

5.  Press a new LP seat (15) into the cavity in the head of the 

poppet (14), with the smooth side facing out.

NOTE:

  

It is essential to use a spare LP seat 

in order to prevent damage to the new seat 

while performing the following steps of the 

reassembly procedure.

6.  Stand the inlet fi tting (19) vertical on a fl at surface with the 

sealing edge of the crown (16) facing up inside. Lay the 

previously used LP seat (15) inside the inlet fi tting over the 

sealing edge of the crown.

7.  Place the poppet bearing (12) over the pin of the 

extraction tool with the square feature facing up. Guide the 

pin of the tool into the open end of the valve body (11) and 

out through the square hole in it’s center. While sighting 

through the top of the valve body, rotate the tool as needed to 

align the square feature of the poppet bearing with the square 

hole, and press the tool upward to seat the bearing securely 

in place. When fi nished, check to ensure that the top of the 

poppet bearing is fl ush with the top of the valve body.

8.  Stand the poppet (14) on its head inside the top of the inlet 

fi tting (19) and on top of the old LP seat. Place the spring (13) 

over the poppet shaft (14).

9.  Hold the inlet fi tting (19) secure and mate the valve body 

(11) with poppet, bearing down over the poppet shaft (14). 

Press the valve body downward to compress the spring while 

turning it clockwise to engage the threads of the inlet fi tting. 

Continue turning it slowly until the threaded portion of the 

poppet shaft stands outside the poppet bearing (12).  

10.  Lay the arms of the lever (10) inside the groove of the 

valve body (11), straddling the poppet shaft (14), so that the 

curved portion of the lever faces away from the air outlet hole.

Summary of Contents for MISTRAL SECOND STAGE

Page 1: ...Authorized Technician TECHNICAL MAINTENANCE MANUAL MISTRAL SECOND STAGE...

Page 2: ...Y PROCEDURE 6 FINAL TESTING PROCEDURES 10 Second Stage Opening Effort Test 10 Table 1 Troubleshooting Guide 11 Table 2 List of Tools and Service Kits 12 Table 3 Recommended Cleaners and Lubricants 13...

Page 3: ...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 overha...

Page 4: ...the surface is clean and unscratched It should be exible and have a clean edge If it is in good condition it is not necessary to replace it If there are any signs of deterioration it should be replac...

Page 5: ...condition of the lever 10 and the spring 13 to ensure it is not bent corroded or other wise damaged If any signs of damage are found discard the part and do not reuse 12 Place the handle of the seat e...

Page 6: ...amage to the sealing edge 17 Remove the o rings from the crown and the inlet tting THIS ENDS DISASSEMBLY Before starting reassembly perform parts cleaning and lubrication in accordance with Procedure...

Page 7: ...er the sealing edge of the crown 7 Place the poppet bearing 12 over the pin of the extraction tool with the square feature facing up Guide the pin of the tool into the open end of the valve body 11 an...

Page 8: ...ew in the inlet tting snug by hand while pressing the lever down 14 Using a torque wrench and a 3 4 19mm crows foot torque the inlet tting 19 to 85 in lbs 15 Fit new lubricated o rings to the MP hose...

Page 9: ...ever touching the tool there should be no leaks Once the adjustment is completed turn off the air supply and purge the regulator 19 Install the sealing ring 4 onto the diaphragm 5 and place the assemb...

Page 10: ...b shut and then slowly reopen while watching both the magnahelic gauge and the medium pressure gauge a If the opening effort is too low disassemble the second stage to give access to the lever disasse...

Page 11: ...pring 12 is damaged 7 Replace the spring Breathing effort is too high 1 MP is too high 1 Readjust the lever and the crown 2 The lever 9 is adjusted too low 2 Readjust the lever and the crown 3 The MP...

Page 12: ...ing bands 944022 O ring removal and installation N A 3mm Allen Keys Assemble disassemble casing N A Cleaning inside of corrugated hoses N A Removing panduit clamps 900016 Service Kit MISTRAL Crown and...

Page 13: ...r reusable stainless steel and brass parts Household grade Liquid dishwashing detergent diluted with warm water Degreaser for brass and stainless steel parts general cleaning solution for plastic and...

Page 14: ...e 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...

Page 15: ...CRIPTION KEY ITEM TORQUE 104106 Inlet tting 19 85 in lbs Table 5 Checking Speci cations TEST CONDITION SPECIFICATIONS Leak Test Inlet 2500 3000 100 psig No leaks allowed Opening Effort Inlet 2500 3000...

Page 16: ...16 Maintenance Notes...

Page 17: ...900016 Overhaul Parts Kit Entire Mistral 1 125929 Screw caphead 2 125935 Exhalation box 3 129174 Exhaust valve 4 124509 Sealing ring 5 125705 Diaphragm 6 125937 Inhalation box 7 7 7 125928 Locknut 8 8...

Page 18: ...Authorized Technician TECHNICAL MAINTENANCE MANUAL MISTRAL SECOND STAGE Aqua Lung America 2340 Cousteau Court Vista CA 92081 760 597 5000 www aqualung com Rev 2 2006 Aqua Lung USA Aqua Lung USA...

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