
Calypso First Stage Service Manual
7
14. Install o-rings (9, 20) onto each port plug (10, 19). Us-
ing a 4mm hex key, install each of the port plugs into
its respective port.
15. Install the MP hose into its respective port. Using an
in/lbs torque wrench and a 9/16” crow foot, torque the
hose to 40 in/lbs / 4.5 Nm.
This Concludes Reassembly
16. Slide hose protector back into position.
CHECKING THE MEDIUM PRESSURE
1. Attach an MP test gauge (0-400 psig or 0-27 bar) to a
MP hose and thread the hose into the open MP port. If
your test gauge does not have an over-pressure relief
valve, you must also attach a properly adjusted second
stage to the rst stage to act as the relief valve in case
of a HP leak.
2. Attach the rst stage to a cylinder charged to 3000 psi
(206 bar). Slowly open the cylinder valve to pressurize
the regulator.
FINAL TESTING
3. With the regulator under pressure, cycle the over-pres-
sure relief valve or the second stage purge button to
produce an airow.
4. Check the MP reading, which should be between 130
and 145 psi (9-10 bar).
5. Leave the regulator under pressure for about 10 sec
-
onds - the MP should remain stable and should not rise
by more than 5 psi (.35 bar). If the MP rises more than
5 psi (.35 bar), this indicates that there is a leak. Refer
to Table 1, Troubleshooting Guide.
IMMERSION TEST
With the port plugs and at least one properly adjusted
second stage installed, slowly open the cylinder valve and
pressurize the rst stage. Completely submerge the rst
stage in fresh water and check for leaks.
WARNING: If the pressure gauge rapidly ex-
ceeds 145 psi (10 bar), then 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 the MP gauge which in
turn, can lead to personal injury. Refer to Table
1, Troubleshooting Guide, for the causes of HP
leaks.
Assuming there are no leaks, close the cylinder valve and
depressurize the regulator. Remove the rst stage from the
valve and secure the dust cap in place with the yoke screw.
If a leak is detected, note the source of the leak and refer to
Table 1, Troubleshooting Guide for possible causes and
corrective actions.
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.
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