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

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 1st stages by design are sealed

8. Features (Balanced Diaphragm)

9. Features (Turbo Assist)

10. Features (Yoke & DIN Available)
4351 psi DIN (300 Bar)
3365 psi yoke (232 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
Remove the HP port plug
Install vise mounting tool (p/n ) or use empty Co2 cartridge w/HP adapter
CAUTION: If using a CO2 cartridge, use an HP adapter so threads don’t break off in 1st 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 1st 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
Remove the HP port plug
Install vise mounting tool (p/n ) or use empty Co2 cartridge w/adapter
CAUTION: If using a CO2 cartridge, use an HP adapter so threads don’t break off in 1st stage port !

23. Remove DIN Connector ! Clamp vise mounting tool in bench vise
Use 6mm hex key
Remove the handwheel retainer
CAUTION: NEVER mount 1st 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 ) 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
Use a blast of air to lift the diaphragm
Keep finger over diaphragm to keep from ejecting
CAUTION: Never remove diaphragm by prying or digging it out around the edges !
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)
CAUTION: Contents are under spring pressure
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. !

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 ) 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
Insert the pin or extraction tool at an angle, into the center hole
Push out crown orifice
Click here to learn about a 1999 body pin pad revision

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
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
Sealing area
Confirm it is acceptable for reuse
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
Press the crown into place
Confirm that it is seated evenly with the crown facing up

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 ) 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 it’s respective groove

67. Inspect 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. !

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 ) 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: ft/lbs Nm

77. Add Main Spring Washer

78. Add Adjusting Screw Use a 8mm hex key Preliminary settings:
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 ) with inch ext.
Torque to ft/lbs (24.5 Nm)
Torque: ft/lbs Nm

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

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

83. Add DIN Handwheel

84. Add O-rings To Retainer
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 !
Click here to learn about handwheel retainer revisions

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

90. Adjusting Medium Pressure (MP)
Attach Titan to fully charged cylinder 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 1st stage is used with several different 2nd stages, confirm MP settings by checking the appropriate 2nd stage service manual
MP Settings: psi (9.3 bar) std psi (8.4 bar) supreme

97. Adjusting Medium Pressure (MP)
Let the Titan stand for several minutes
Click here
for Dry kit
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

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

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
With the Titan still pressurized, submerge the unit in a tub of water
Observe for leaks
Troubleshoot accordingly
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
Revision A pin pad and body MUST be used together
Revision B pin pad and body must be used together
Revision A’s are still acceptable for use and service
Rev. A
Rev. B
Click here to return to disassembly

104. Filter Washers – Jan. 2005
The nylon washer was for air use only. It was not nitrox compatible
The washer is compatible for nitrox but would not allow for visual inspection of the filter
is the current washer
845095
124627
124628
Click here to return to disassembly

105. Black Back-Up Ring – June 2002
A black, solid back-up ring replaced the white split ring
The black ring is for nitrox compatibilty
Rev. A
Rev. B
Click here to return to disassembly

106. DIN Handwheel Retainer - March 2006
The material used in the retainer has been changed to stainless steel
Brass Chrome Finish
Stainless Steel Satin Finish
This new steel part can be identified by the satin finish of the part
For more information see Technical Bulletin #16 March 27, 2006
Rev. A
Rev. B
Click here to return to disassembly