Cousteau DIN Installation Instructions
Removal of the Yoke Assembly
Cousteau/ Spectrum/ SEA DIN Adapter
Authorized Dealer Installation Procedures
1. Install a vise mounting tool (P/N 1003-95) or a discharged CO2 cartridge
with 3/8” female to 7/16” male adapter (P/N 1020-85) into the high pressure
(HP) port of the first stage main body(3). (To discharge a CO2 cartridge,
install first into a CO2 firing mechanism and discharge the gas into a B.C..
DO NOT attempt to pierce the cartridge outside of such a mechanism.)
WARNING: DO NOT use a CO2 cartridge which has not been
discharged. Doing so may cause the cartridge to rupture, which could
result in severe personal injury.
2. Secure the vice mounting tool in a bench vise, with the first stage positioned vertically so the yoke(2) faces up. (See Fig. 1.)
Figure 1
CAUTION: DO NOT mount the first stage directly in a vise. Doing so
may result in permanent damage which could render the first stage
inoperable or unsafe for use.
Maintenance, operating procedures, and techniques that may
result in personal injury or death if not carefully followed.
Maintenance techniques that will result in damage to parts if
not carefully followed.
Service procedures and maintenance techniques that are
considered important enough to emphasize.
WARNING: Installation of an Aqua Lung DIN adapter must only be
performed by an Authorized Aqua Lung Dealer, and must not be
attempted by unauthorized individuals. Failure to obtain this service
through an Authorized Aqua Lung Dealer may result in faulty
installation, which could lead to severe injury or death.
WARNING: DO NOT exceed the torque values prescribed in these
installation instructions. Excessive torque can overstress parts, which
could cause them to weaken or break. Weak parts cannot always be
detected, and may fail unexpectedly while in use, possibly resulting in
serious injury or death.
NOTE: The DIN Adapter package may be used to store the yoke and
inlet fitting for future use.
WARNINGS, CAUTIONS, and NOTES used in this manual
have the following significance:
3. Loosen the yoke screw to remove the dust cap, and apply a modified 26mm
open end wrench to the inlet fitting(1). Using firm, steady force, turn the
inlet fitting counter-clockwise to loosen and remove from the first stage
body. Lift the inlet fitting and yoke (with screw and dust cap) off the body,
and set these items aside.
Precautions & Warnings
Installation of the DIN Adapter
1. Disassemble the filter retainer(10) from the DIN inlet fitting(6), if necessary,
to lubricate all O-rings with either Christo Lube® or Dow 111 silicone
grease. Reinstall all O-rings(9&5&8) onto the inlet fitting and the filter
2. Check to ensure that the filter(7) lays flat inside the top of the inlet fitting,
with the coarse surface facing up. Mate the filter retainer into the top of the
inlet fitting, and tighten clockwise by hand until snug.
3. Mate the inlet fitting through the handwheel(4), and thread clockwise into
the inlet orifice of the first stage body(3).
4. Apply a torque wrench with 19mm hex socket to the inlet fitting and tighten
clockwise to a torque value of 22 foot-pounds (±2).
5. Apply a torque wrench with 4mm hex key to the filter retainer and tighten
clockwise as needed to ensure that it is tightened to a torque value of 15
foot-pounds (±2).
Final Inspection Procedure
To test the installation of the adapter, mount the regulator, fully assembled with
second stage attached, onto a HP 3.5 cylinder with DIN valve as follows:
1. Thread the adapter handwheel clockwise by hand onto the DIN valve until it
is lightly snug. (See Fig. 2.)
2. Open the cylinder valve slowly to pressurize the regulator and check for any
possible leaks.
3. If leakage is detected, immerse the valve and first stage in fresh water while
pressurized to determine the source. Disassemble and correct as needed.
Repeat the installation and final inspection procedure.
Figure 2
Preventative Maintenance for DIN Adapters & Valves
Because moisture may enter DIN valves and adapters more easily than yoke
regulators and valves, it is especially important to advise the customer of the
following maintenance procedures:
• Before attaching the regulator to a cylinder, open the cylinder valve slightly
to blow out any moisture which may be inside the mouth of the valve.
• After each dive, it is important to use care when removing the regulator
from the cylinder valve in order to prevent moisture from entering the
regulator inlet fitting or the cylinder valve.
• Prior to storage, soak and rinse the complete regulator system while
pressurized and mounted onto a cylinder.
• Ensure that the first stage and cylinder valve protector caps are completely
dry before installing them.
WARNING: When filling the HP 3.5 cylinder, DO NOT exceed the
3500 PSI maximum pressure. Unlike conventional steel cylinders, the
HP 3.5 does not allow for 10% overfills. Disregard of this specification
may cause damage to the cylinder which could result in serious injury or
© 1999 Aqua Lung International, Inc.
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