J, K, Z AND TWIN MANIFOLD VALVES
Contents
1. nnns co P EXPLODED DRAWING s k u u Eas Ras elk roa RUE Rad COR XU ER KEV AER sapa Do DIR TABLE 1 RECOMMENDED TOOL cain pao uu n TABLE 2 RECOMMENDED LUBRICANTS AND TABLE 3 TORQUE SPECIFICATIONS uu REO UR OQ E Ded TABLE 4 TEST BENCH SPECIFICATIONS u u nnns TABLE 5 TROUBLESHOOTING GUIBDE u anco coe PROCEDURE A CLEANING AND APPENDIX A REPLACEMENT OF NYLON DIP TUBES VALVE ADAPTER ILLUSTRATION uu u 0 WWW eco cC O kp AQUALUNG COPYRIGHT NOTICE This manual 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 written consent from Aqua Lung America It may not be distributed through the internet or computer bulletin board systems without prior written consent from Aqua Lung America 2007 Aqua Lung America Inc J K Z amp Twin Manifold Service Manual INTRODUCTION This manual provides factory prescribed procedures for the correct service and repair of the Aqua Lung J Valve K Valve Z2. Military amp Professional Operations AQuA Lunc AUTHORIZED TECHNICIAN TECHNICAL MAINTENANCE MANUAL d 29 T 7 QE J K Z AND TWIN MANIFOLD VALVES J K Twin Manifold Valve Service Manual Contents COPYRIGHT NOTICE LIIW C eon E ERR KR EVI VR MN CER INTRODUCTION UU ao POBRE RD ERG Gn B cd FG ERG XR EX PR RUD NA EE awa WARNINGS CAUTIONS AND NOTES u uu SCHEDULED SERVICE u ass haasi bn ou Foo GENERAL PREVENTATIVE GENERAL GUIDELINES aiebant ER ERI RR ERA oea X ER ERU EC ER ERR ECCE A REED A RR GENERAL CONVENTIONS anao ha arra rnb nap arr 1a re nan sas ks eu ER FER Eo XXE SEE J VALVE AND TWIN MANIFOLD VALVE DISASSEMBLY PROCEDURE J UI III s BREASSEMBLY uuu luu benc dos kir au bebo devoret cba ATTACHING VALVE ASSEMBLY TO THE TESTING c EXPLODED PARTS DRAWINGS U U xi Hi RE EK U u U U u innana anai K VALVE AND Z VALVE DISASSEMBLY PROCEDURE UU a REASSEMBLY ATTACHING VALVE ASSEMBLY TO THE
3. 050241 Safety Disc Assembly 3000 psi 3 052541 Handwheel ei 050242 Safety Disc Assembly 2250 psi 4 845058 Washer 2 req on J Valve 16 052508 Reserve Assembly 5 050233 Bonnet Left Handed Thread wren 052548 Reserve Assembly Red See NOTE 050216 Bonnet Right Handed Thread 17 845021 Washer 6 957007 O ring 18 052514 Stem J Valve 7 828510 Back up ring 19 821014 Gasket 8 820010 O ring 20 820015 O ring 9 921019 Thrust Washer 21 828515 Back up Ring 10 052521 Stem K Valve 22 214204 Bonnet 11 052519 Seat J Valve 23 052540 Handwheel Reserve 050109 Seat K Valve n s 074305 Reserve Pull Rod J Valve Part numbers in BOLD ITALICS indicate standard overhaul replacement part AQUALUNG TWIN TANK MANIFOLD WITH RESERVE 44 009 90 inch Ibs 15 90 inch Ibs T ga Sii 2 Su he numbers in BOLD ITALICS indicate standard overhaul replacement part 90 inch Ibs s 15 gt 16 4 80 inch Ibs 1 Key Part Description Key Part Description 280000 Twin Manifold 3000 psi J valve 14 820214 O ring 280020 Twin Manifold 3000 psi Canada 15 050241 Safety Disc Assembly 3000 psi 1 052518 Nut Handle Retaining _ 050242 Safety Disc Assembly 2250 psi 2 050107 Spring 16 052508 Reserve Assembly 3 052541 Handwh
4. izing a cylinder To install the valve onto a cylinder see Attaching Valve Assembly to Cylinder found on the previous page WARNING Pressurize the valve assembly only up to the working pressure designated for the valve and safety disc system This manual has been written for 3 000 psig valves LEAKAGE TEST This test determines if there is external leakage in either the AFC or reserve valve To do the test slowly pressurize the valve assembly When pressurizing the J valve or Manifold reserve valve always make sure the reserve lever is set to the on or down position 1 Test Bench With the AFC handwheel in the fully OPEN position slowly pressurize the valve in four separate stages first to 500 psig then to 1 000 psig then to 2 000 psig and finally to 3 000 psig 100 psig air pressure At each level of test pressure soap test the unit and observe it for 30 sec onds see note below or apply a soapy water solution The persistence of bubbles indicates leakage If leakage does exist refer to the Troubleshooting Guide in Table 5 Vent the system and completely retest going through the entire procedure a second time Gg 2 Turn the handwheel 3 to the off position and remove the charging system Soap test the unit or apply a soapy water solution to the outlet and wait 30 seconds If bubbles appear from the outlet there is leakage in and around the seat Item 8 Vent the system and repeat this procedure to
5. removing or replacing this bonnet Turn clockwise flat bladed screwdriver may be helpful in remov to loosen and counterclockwise to tighten ing the reserve assembly 16 from the valve body 16 Tilt the valve body downward until washer 17 and reserve assembly 16 fall out of the body CAUTION If after inspection replacement of the re serve assembly is called for be sure the new assem bly fits the body On valve bodies which have Japan stamped on the base use only reserve assemblies Figure 1 with part number 052548 This part will have a red dye m marking to make identification easier Bodies without 9 Remove the bonnet 5 by unscrewing it CLOCKWISE with Japan markings call for reserve assemblies num a 3 4 inch wrench Then remove the external O ring 6 and bered 052508 These are dyed black on the end discard 10 Next remove the stem 10 With a blunt non metallic or brass instrument remove the O ring 7 and back up ring 8 WARNING Failure to install the correct reserve from inside the bonnet Discard the O ring and back up ring assembly could cause a malfunction resulting in loss of air supply to the diver LEFT NOTE Item 9 is a blue colored thrust washer and must be replaced during service If a white thrust This concludes the disassembly of the J Valve and Twin Manifold Before beginning reassembly perform all the cleaning and lubrication procedures outlined in Procedure A on page 21
6. With the AFC handwheel in the fully OPEN position slowly pressurize the valve in four separate stages first to 500 psig then to 1 000 psig then to 2 000 psig and finally to 3 000 psig 100 psig air pressure At each level of test pressure soap test the unit and observe it for 30 seconds see note below or apply a soapy water solution The persistence of bubbles indicates leakage If leakage does exist refer to the Troubleshooting Guide in Table 5 Vent the system and completely retest going through the entire procedure a second time NOTE It is important to retest at each pressure level even if no leakage was found the first time through 2 Turn the handwheel 3 to the off position and remove the charging system Soap test the unit or apply a soapy water solution to the outlet and wait 30 seconds If bubbles appear from the outlet there is leakage in and around the seat 8 Vent the system and repeat this procedure to check a sec ond time Valve Inlet Flow Test The purpose of this test is to verify a measured controlled flow of air through the valve inlet Begin the test by applying 100 10 psig to the valve inlet The flow from the valve outlet should be 300 SCFM minimum This concludes the testing for the Z valve 5 AQUALUNG K VALVE DIN VALVE Z VALVE AIR Z VALVE EAN Discontinued sss eei O D qu 5 6 0 11a 7 8 ie 9 90 10 in Ibs 15
7. all new O rings with Christo Lube MCG 111 AUTHORIZED REASSEMBLY 1 With the valve in a valve adapter PN 280036 or screwed into a cylinder to hold it thread the burst plug 15a clockwise into the valve until finger tight DO NOT lubricate Attach a 3 8 inch socket to a torque wrench and tighten the plug to 90 10 inch pounds 2 Using the slotted end of the stem 8 or screwdriver thread the seat assembly 9 clockwise into the valve until finger tight Failure to seat the seat assembly all the way will cause damage to the bonnet 3 Inserta new brass gasket 10 into the valve with the round side of the gasket facing down 4 a Place a new O ring 7 onto the stem 8 b Place a new teflon washer 6 onto the stem 8 5 a Position the slotted end of the stem onto the seat assembly b Slide the bonnet 5 over the stem and thread into the valve body by turning the bonnet clockwise Tighten the bonnet until hand tight 6 Putthe valve body into a mounted valve adapter or threaded into a cylinder Using an 11 16 inch crow foot or socket at tached to a torque wrench tighten the bonnet clockwise to 35 40 foot pounds 7 Install the large teflon washer 4 over the stem b Install the valve handwheel 3 8 a Insert the spring 2 into the handwheel b Using the valve handle tool or modified screwdriver thread the handwheel nut 1 clockwise onto the end of the stem Turn clockwise until the nut is flus
8. check a second time INSPECT SCUBA RESERVE J VALVE ACTUATION PRESSURE NOTE It is important to retest at each pressure level even if no leakage was found the first time through 1 Tools test equipment required Single hose 2 stage balanced or unbalanced diaphragm SCUBA regulator and a SCUBA cylinder pressure gauge submersible or non submersible PROCEDURE NOTE All inspecting is to be conducted under conditions of standard temperature and pressure 68 72 F and 14 7 ambient pressure Acceptable reserve actuation pressure ranges single cylin der minimum of 450 psig double cylinder 225 psig N 10 NOTE A balanced or unbalanced diaphragm first stage regulator must be used to perform this maintenance Piston type first stage regulators wil not be used to perform this maintenance Place reserve handwheel in on reserve down position Charge cylinder s or reduce cylinder pressure to approxi mately 750 800 psig Remove filler hose if applicable Attach standard single hose 2 stage SCUBA regulator to valve outlet Return reserve handwheel to start dive up position Fully open cylinder valve Gradually reduce cylinder pressure using one of the following methods a Using second stage regulator breathe system down until there is a noticeable restriction or increase in inhalation resistance or b Fully depress purge button second stage as follows 5 sec
9. not to damage the disc sealing surface of the valve body with this tool If this should occur the entire valve body will have to be replaced 13 Place the valve in an adapter PN 280036 or an EMPTY cylinder Unscrew the valve handle retainer 1 with the modified screwdriver Then remove the spring 2 lever 23 and washer 4 6b Safety disc removal alternate method With the O ring tool puncture the center of the disc 15a and remove it then CAUTION The reserve valve bonnet 22 has stan using the same tool lift out the gasket 15b Discard the AN dard right handed threads plug disc and gasket 7 Ifyou are disassembling a manifold use a 3 4 inch wrench or deep socket to unscrew the plug 24 Lift off the gasket 14 Using a 5 8 inch wrench remove the bonnet 22 Remove 25 Discard the gasket o ring 20 and back up ring 21 Discard o ring and back 8 Remove the valve handle retainer 1 from the assembly up ring with the modified screwdriver Then remove the spring 2 15 Next remove the stem 18 small O ring 8 gasket 19 handwheel 3 and washer 4 Discard the O ring and gasket Remove the valve body from the adapter PN 280036 or cylinder CAUTION If the bonnet 5 has notches on the corners of the wrench flats see Figure 1 itis a light tap on the reserve mechanism or left hand thread Special care must be taken when rotation of the reserve cam mechanism with a
10. test for leaks use a soapy water solution in a spray bottle 1 Test Bench Slowly pressurize the valve assembly With the on off handwheel 3 in the full open position cap the valve outlet using a regulator and slowly pressurize the valve in four separate stages first to 500 psig then to 1000 psig then to 2000 psig and finally to 3000 or 3500 psig At each level of test pressure soap test the unit and observe it for 30 seconds If continuous bubblng is detected there is a leak Refer to the Troubleshooting Guide in Table 5 for solutions to this problem Vent the system and completely retest going through the entire procedure a second time NOTE It is important to retest at each pressure level even if no leakage was found the first time through J K Twin Manifold Valve Service Manual 14 A A SOUS A _ A 2 Turn the handwheel to the off position but do NOT cap the valve outlet Pressurize the inlet to 3000 or 3500 100 psig air pressure Soap test the unit for 30 seconds If bubbles appear from the outlet there is a leak in and around the seat 9 Vent the system and repeat this procedure to check a second time LEAKAGE TEST This test determines if there is external leakage in either the AFC or reserve valve To do the test slowly pressurize the valve assembly When pressurizing the J valve or Manifold reserve valve always make sure the reserve lever is set to the on or down position 1
11. tighten it 11 Tighten the left hand bonnet 5 counterclockwise into the valve body by hand Using a in Ibs torque wrench and a 3 4 inch socket tighten the bonnet to 90 in lIbs NOTE When installing the spring 2 and retainer 1 use the handwheel 3 to fully open the valve turned all the way counterclockwise This will allow the stem to be fully extended past the handwheel to make the installation easier Remove the handwheel 12 Next position washer 4 on the top of the bonnet and place the handwheel 13 over this assembly Set the spring 2 into the handwheel and add the handwheel retainer 1 Finally use the modified screwdriver to secure the retainer DO NOT over tighten This concludes the reassembly of the air flow control valve J K Twin Manifold Valve Service Manual RESERVE VALVE ASSEMBLY CAUTION If after inspection replacement of the reserve assembly is called for be sure the new assembly fits the body On valve bodies which have Japan stamped on the base use only reserve assemblies with PN 052548 This part will have a red dye marking to make identi fication easier Bodies without Japan markings call for reserve assemblies numbered 052508 These are dyed black on the end WARNING Failure to install the correct reserve assembly could result in loss of air supply to the diver and possible serious injury or death 13 Place the washer 17 on the reserve assembl
12. washer is found instead the stem 10 must also be replaced Do not reuse these parts 11 Remove and discard the blue thrust washer 9 from the shank of the stem 10 12 Use the medium flat bladed screwdriver to remove the seat assembly 11 from the valve body by turning the screw driver counterclockwise Discard the used seat Now remove the valve or manifold from the adapter or empty cylinder This concludes the disassembly of the K Valve J K Twin Manifold Valve Service Manual REASSEMBLY 1 Insert an unlubricated O ring 12 into the valve body face Install the O rings 14 onto the valve body WARNING Observe the manufacturer s pro cedures and safety precautions when using cyanoacrylate adhesives 2 the dip tube 13 is to be replaced place a small amount of LocTite 6806 on the tube s threads Then manually screw the tube into the bottom of the body and tighten until handtight Allow to dry for 12 hours before assembling onto bottles For more on removal and installation of dip tubes see Appendix A NOTE The safety disc assembly 15 includes three components the plug disc and gasket The complete assembly must be installed during service 3 First drop the gasket 15b into the body Then drop in the safety disc 15a with color side out Now thread the new safety plug 15c into the orifice Do not lubricate the safety plug If reassembling a twin manifold repeat this procedure for
13. NOTE The Z Valve was Sold with a green handwheel by U S Divers 1997 1999 is still supported with an overhaul parts kit part number 900209 All other parts are no longer available The EAN Z Valve uses parts that are not shown in the schematic on this page Key Part Description Key Part Description 054295 Z Valve 3 000 psi Air 11a N A Body K Valve 5240 KIT Service Kit K or Z Valve 3000 psi Only 11b N A Body DIN Valve 1 054207 Locknut Handwheel 11c N A Body Z Valve 2 054209 Spring Handwheel 12 820014 O ring Outlet 3 52406A Handwheel 13 054215 Dip Tube 4 054212 Washer Handwheel 14a 820214 O ring K Valve 5 054204 Bonnet 14b 054114 O ring DIN Valve 6 054205 Washer Packing 15 054201 Safety Plug Kit 3 000 psi Aluminum Tass 820010 O ring Stem 0000 777 054261 Safety Plug Kit 3 500 psi HP Steel 8 054208 054221 Safety Plug Kit 2 400 psi LP Steel Qas 054203 Seat Assembly c7 054211 Safety Plug Kit 2 250 psi LP Steel 10 054216 Gasket Bonnet n s 42485 Dust Cap K Valve n s 054228 Dust Cap Z Valve J K Twin Manifold Valve Service Manual 16 po A A A a Table 1 Recommended Tools List J and Twin Manifold Valve PART NO DESCRIPTION APPLICATION N A 5 8 crow foot and open end Bonnet 5 Used with torque wrench wrench 9 43226 3 4 socket Bonnet 5 Manifold plug It
14. Test 3 000 100 psig No leaks allowed Reserve Mechanism 750 800 psig maximum 450 psig single cylinder minimum Single Cylinder Reserve Mechanism 750 800 psig maximum 250 psig minimum Double Cylinder K and Z Valve TEST CONDITION ACCEPTABLE RANGE Leak Test 3000 100 psig inlet No leaks allowed pressure Valve Inlet Flow Test 100 10 psig inlet pressure 300 SCFM minimum 19 AQUALUNG Table 5 Troubleshooting Guide J and Twin Manifold Valve SYMPTOM POSSIBLE CAUSE TREATMENT Air leakage from on off 1 Trapped air Remove handwheel and recheck handwheel in water 2 Check torque specs on bonnet 5 Tighten bonnet to 90 inch pounds 3 inch pounds 3 Torque or O ring on bonnet Remove bonnet and check O ring Replace O ring if necessary Rein stall and torque to 90 inch pounds 4 Stem leak Remove bonnet and check for missing parts Replace O ring and or backup ring if necessary Reassemble and torque to 90 inch pounds Air leakage from reserve 1 Check torque specs on bonnet 5 Tighten bonnet to 60 inch pounds lever 3 inch pounds 2 O ring or backup ring on bonnet Remove bonnet and check O ring Replace O ring if necessary Rein stall and torque to 60 inch pounds 3 Stem leak Remove bonnet and check for missing parts Replace O ring if necessary Reassemble and torque to 60 inch pounds Air leakage from valve 1 Check seat assembly 11 or seating orifice machined Replace any
15. Valve Air and DIN Valve and Twin Manifold Valve It is not intended to be used as an instructional manual for untrained personnel The procedures outlined within this manual are to be performed only by personnel who have received factory autho rized training through an Aqua Lung Service amp Repair Seminar If you do not completely understand all of the procedures outlined in this manual contact Aqua Lung to speak directly with a Technical Advisor before proceeding any further WARNINGS CAUTIONS AND NOTES Pay special attention to information provided in warnings cau tions and notes that are accompanied by one of these symbols WARNINGS indicate a procedure or situation that may result in serious injury or death if instructions are not followed correctly CAUTIONS indicate any situation or technique A that will result in potential damage to the prod uct or render the product unsafe if instructions are not followed correctly ce NOTES are used to emphasize important points tips and reminders SCHEDULED SERVICE Since the personal safety of the user is dependant upon the mechanical integrity of the valve the complete assembly should be serviced at a professional facility At the minimum a thorough overhaul is recommended every 36 months Equipment used frequently and or in polluted or chlorinated water may require professional maintenance more frequently Maintenance Procedures for the User 1 After each dive the cy
16. Z Out and thread the EZ Out up into the valve as shown in Figure A 2 This position will help prevent nylon chips from the tube from dropping into the valve assembly To remove any nylon chips or adhesive residue from the threads screw a 5 16 18 thread tap clockwise up into the valve base See Figure A 3 Repeat this step until the threads are clean WARNING Air pressure must be less than 30 psig when blowing out parts Use of safety glasses is also required CAUTION To prevent particles from entering the valve mech A anism it is necessary to blow out chips of nylon as described in Step 4 When performing this procedure be sure to blow air only through the outlet port This will allow all chips of nylon to fall only through the base of the valve thereby not contaminat ing the valve assembly lt Figure A 3 23 LUNG 4 Using filter air blow out valve body This is done by first opening the cylinder valve handwheel and then blowing air through the outlet boss of the valve body see Figure A 4 If the dip tube is being removed from the reserve or J valve ensure that the reserve lever is in the on or down position prior to blowing out the valve 5 Inspect female threads at the base of the valve body for nylon chips If any debris is evident repeat steps 3 and 4 until the threads are clean C INSTALLATION OF BRASS DIP TUBE Figure A 4 WARNING Observe adhe
17. c parts 50 Valley Road Berkeley Heights NJ 07922 White distilled vinegar 100 gr Brass and stainless steel Household grade parts NOTE Both Oakite 31 and distilled vinegar are suitable for cleaning especially heavy corrosion verdigris and mineral deposits DO use muriatic acid for the cleaning of any parts acid even when strongly diluted can harm chrome plating and may leave a residue that is harmful to O ring seals and other parts Liquid dishwashing detergent All reusable parts Household grade diluted with warm water Snoop Leak testing Nupro Company 4800 E 345th Street Willoughby OH 44094 440 473 1050 J K Twin Manifold Valve Service Manual 18 A i 1 Table 3 Torque Specifications J and Twin Manifold Valve PART NO DESCRIPTION KEY NUMBER TORQUE 050241 or Safety plug 15 90 inch pounds 050242 050233 AFC Bonnet 5 90 inch pounds 052515 Reserve Bonnet 22 60 inch pounds 050221 Plug Item M1 90 inch pounds 280000 or Twin Manifold approximately 30 10 foot pounds 280020 tap with rubber mallet strap wrench K and Z Valve PART NO DESCRIPTION KEY NUMBER TORQUE 0542 04 Bonnet 5 35 40 foot pounds 0541 16 Burst Plug 15 90 10 inch pounds 0542 18 Body 11a b c 30 10 foot pounds approximately Table 4 Test Bench Specifications J and Twin Manifold Valve TEST CONDITION ACCEPTABLE RANGE Leak
18. cratch the rubber or plastic parts Ultrasonic Cleaning 1 Routine replacement parts need not be cleaned Clean all metal parts in an ultrasonic cleaning tank with a suitable detergent 2 ultrasonic cleaning tank is not available the following and less preferred method can be substituted Remove any dirt or flaking material with a soft bristle brush NEVER USE A WIRE BRUSH Place metal parts in a recommended acid bath solution such as vinegar or Oakite 31 see Table 2 and gently agitate for three to four minutes those recommended may damage plated parts CAUTION Excessive cleaning times beyond Only brass plated brass and stainless steel parts should be immersed in an acid cleaning solution Do not allow a soaking period in acids or basic solutions to exceed ten minutes WARNING Air pressure must be less than 30 psig when blow drying parts Safety glasses must also be worn 3 Remove parts from the bath rinse with clean fresh water and blow dry with filtered low pressure air 30 psig Plastic Parts Parts made of plastic such as handwheels may be soaked and cleaned in a solution of warm water mixed with mild dish soap Use only a soft nylon toothbrush to scrub away any deposits Rinse in fresh water and thoroughly blow dry using low pressure filtered air CAUTION Do not place plastic parts in acid solu tions Doing so may alter the physical properties of the component causing it to prematur
19. d in the off or up position No air should pass through 18 Add the spring 2 to the reserve handwheel Using the modified screwdriver PN 947448 tighten the retainer 1 into place DO NOT overtighten This concludes reassembly of the reserve valve ATTACHING VALVE ASSEMBLY TO THE CYLINDER Conduct all tests after the valve is attached to the cylinder as described below 1 Apply a light amount of lubricant to the first five 5 threads of the body which screw onto the cylinder 2 Single Valves Screw the valve into the cylinder until hand tight Attach a 1 3 8 crow foot to a torque wrench Apply the wrench to the wrench flats and tighten the valve to 30 10 foot pounds or tap the handwheel lightly with a rubber mallet to approximately 30 foot pounds Twin Valves Thread one side of the twin valve into one of the cylinders Once hand tight apply moderate force to the other end of the valve to secure Tap tight with rubber mallet Lay the valve cylinder assembly on a flat bench top Screw the other cylinder onto the other end of the valve Once handtight apply moderate force to secure the cylinder Use strap wrench to tighten e NOTE Before filling twin cylinders attach the backpack assembly for safety AQUALUNG TESTING After the valve is thoroughly cleaned inspected and reas sembled Aqua Lung recommends that the following test be performed by using either a test bench and or by slowly pressur
20. damaged parts clean outlet valve closed in valve body any parts that may be dirty or cor roded Air leakage from safety 1 Check torque of safety plug 15 NOTE Must be done Tighten safety plug to 90 10 plug disc assembly when valve is NOT pressurized inch pounds 2 Examine gasket 19 disc 15a plug seating surface Replace damaged parts clean any 15 and gasket seating surface in valve body parts that may be dirty or corroded Not holding back air while 1 Examine seating surface in valve body 1 on reserve Replace or clean valve body reserve is in up position side 2 Examine seat swedged to reserve mechanism 16 Replace reserve mechanism 3 Spring tension in reserve mechanism 16 Replace reserve mechanism 4 Incorrect reserve mechanism 16 Install proper reserve mechanism No flow or restricted flow 1 Check reserve mechanism 16 for damaged or worn Replace reserve mechanism of air when reserve is in parts down position valve handwheel open 2 Handle was installed incorrectly jen and replace in correct J K Twin Manifold Valve Service Manual 20 A A ENSIS A 2 Valve Problem Probable Cause Recommendation Air leaks from Bonnet 5 not fully tightened Tighten bonnet to 35 40 foot pounds on off handwheel valve closed e Seat 9 O ring 7 washer Check parts and replace if necessary 6 dirty damaged or worn O ring sealing sur
21. e the threads of the seat 11 with Christo Lube then screw the seat into the body with a medium flat bladed screwdriver until it bottoms out Failure to do so may cause the valve to fail or come apart Primary AFC Valve Assembly Method 7 Place the blue thrust washer 9 on the stem 10 followed by the O ring 8 and the new back up ring 7 Be sure the concave side of the back up ring is against the O ring as shown in Figure 4 Backup ring O ring Blue thrust washer Figure 4 8 Mount the valve body on the valve adapter or an EMPTY cylinder 9 Install the O ring 6 over the threads of the bonnet 5 set this assembly aside 10 Insert the end of the assembled stem 10 into the groove of the seat 11 Continue to Step 11 Alternate Assembly Method Place the new Blue Thrust Washer 9 on the stem 10 Place the new lubricated o ring 8 on top of the thrust washer Set aside O ring Blue thrust washer Figure 4a 8a Turn the bonnet 5 so the large opening is up Place the back up ring 7 in the bonnet with the concave side up Ensure it is well seated and flat in the recess of the bonnet using a blunt brass tool 9a Slip the new lubricated o ring 6 over the threads of the bonnet 10a Insert the end of the assembled stem 10 into the groove of the seat 11 Continue to Step 11 e NOTE Since the AFC valve bonnet has left handed threads reverse movements are requirea to loosen and
22. eel 17 845021 Washer 4 845058 Washer 18 052514 Stem J Valve 5 050233 Bonnet 19 821014 Gasket 6 957007 O ring 20 820015 O ring 7 828510 Back up Ring 21 828515 Back up Ring 8 820010 O ring 22 052515 9 921019 Thrust Washer 23 280040 Handwheel Reserve 10 052521 Stem K Valve 24 050221 Plug 11 280013 Seat Std Twin 25 821011 Gasket 12 820120 O ring n s 074305 Reserve Pull Rod 13 051821 Dip Tube J K Twin Manifold Valve Service Manual 12 NENNEN A A a K VALVE DIN VALVE 2 VALVE 4 Using a 3 8 inch socket wrench turn the safety plug 15 counterclockwise and remove it Discard the safety plug 5 Turn the on off handwheel 3 counterclockwise until the valve AUTHORIZED DISASSEMBLY is completely open This will assist in removing the seat as sembly 9 later in the disassembly procedure Disassembly of this valve should be performed in an area set up and equipped for the task Adequate lighting cleanliness and easy access to parts and tools are essential for an efficient repair facility Be sure to keep reusable parts separate from those to be discarded and do not allow parts from different valves to become intermixed 6 a Using the Valve Handle Retaining Tool PN 053035 or modified screwdriver PN 947448 remove the lock nut 1 by turning it counterclockwise b Remove the spring 2 c R
23. einspect the entire valve before using after extended storage GENERAL GUIDELINES 1 In order to correctly perform the procedures outlined in this manual it is important to follow each step exactly in the or der given Read over the entire manual to become familiar with all procedures before attempting to disassemble the valve and to learn which specialty tools and replacement parts will be required Keep the manual open beside you for reference while performing each procedure Do not rely on memory 2 Allservice and repair should be carried out in a work area specifically set up and equipped for the task Adequate lighting cleanliness and easy access to all required tools are essential for an efficient repair facility 3 NEVER SECURE THE VALVE BODY DIRECTLY INA VISE Instead install in a valve adapter PN 280036 attached to the work bench or back into the cylinder 4 Asthe valve is disassembled reusable components should be segregated and not allowed to intermix with nonreusable parts or parts from other units J K Twin Manifold Valve Service Manual 5 Use only genuine Aqua Lung parts provided in the overhaul parts kit DO NOT attempt to substitute an Aqua Lung part with another manufacturer s regardless of any similarity in shape or size 6 Do attempt to reuse mandatory replacement parts under any circumstances regardless of the amount of use the product has received since it was manufactured or las
24. ely degrade and or break PARTS INSPECTION 1 Since all soft seal parts in the valve are to be replaced dur ing a general overhaul these do not require inspection In addition any parts showing excessive wear should also be replaced CAUTION All components to be reused must be given a meticulous visual check before reassem bly Use a high intensity light and magnifier for all steps in this section 2 Visually inspect all new soft seals especially O rings for any imperfections before you install them 3 Visually inspect all reusable parts for cracks burrs scoring and corrosion 4 Inspect all threaded parts for deformation galling cross threading or stripping Replace the parts if necessary 5 Closely inspect all plastic parts for distortion cracking defor mation or solvent attack Replace the parts if necessary 6 All O ring sealing surfaces must be completely smooth and free of nicks burrs scoring corrosion and pitting Replace the parts if necessary Lubrication and Dressing All O rings should be lubricated with Christo Lube amp MCG 111 Dress the O rings with a very light film of grease and remove any visible excess by running the O ring between the thumb and the forefinger Avoid applying excessive amounts of Christo Lube grease as this will attract particulate matter that may cause damage to the O ring Soapy water is defined as household grade liquid dishwashing deterge
25. em M1 Used with torque wrench Smpwrenhes soted Rubermatet K and Z Valve PART NO DESCRIPTION APPLICATION Removal of valve bonnet item 5 _ Footpound torque wrench 9 43001 3 8 in socket Tightening burst plug item 15 used with ft Ib torque wrench 9 43625 11 16 in crow foot or socket Tightening bonnet item 5 used with ft lb torque wrench EBEN Inch pound torque wrench Tightening parts on reassembly 280036 Valve adapter Holding valve during disassembly and reassembly 17 AQUA LUNG Table 2 Recommended Lubricants amp Cleaners LUBRICANT CLEANER APPLICATION SOURCE S Christo Lube MCG 111 All O rings threaded metal Aqua Lung PN 820467 16 0 oz pure silicone grease parts or 820466 2 0 oz Lubrication Technologies 7595 Gallia Pike Franklin Furnace OH 45629 800 477 8704 CAUTION Silicone rubber requires no lubrication or preservative treatment DO NOT apply grease spray to silicone rubber parts Doing so may cause a chemical breakdown and premature deterioration of the material Ultrasonic cleaning tank with Metal reusable plastic and Various List of suppliers available ultrasonic detergent rubber parts from Aqua Lung NOTE Use of an ultrasonic cleaning tank with an ultrasonic detergent is the preferred and recommended method of cleaning metal parts Oakite 31 Brass and stainless steel Chemetall Oakite Products In
26. emove the handwheel 3 d Remove the washer 4 You will need the following tools to perform the procedures described CAUTION To remove the bonnet 5 secure the valve into a table mounted valve adapter PN a Rubber mallet b 3 8 inch socket wrench PN 9 43001 280036 screw it back into the cylinder NEVE c O ring tool PN 9440 22 secure the valve in a vise A vise will damage the d Valve Handle Retaining Tool PN 053035 or valve body and require replacement modified screwdriver PN 947448 e 11 16 inch wrench PN 9 44388 7 a Using an 11 16 inch wrench remove the bonnet 5 by f Foot pound torque wrench with turning the bonnet counterclockwise NOTE The bonnet 1 11 16 inch socket or crow foot is torqued to 35 40 foot pounds and requires considerable g Inch pound torque wrench with strength to disengage 1 3 8 inch socket b In most cases the stem 8 will remain in the bonnet If this h Flex handle PN 9 44363 happens gently press on the threaded end of the stem i Valve adapter PN 280036 Optional and separate it from the bonnet 5 c In most cases the teflon washer 6 will remain inside WARNING Before removing the valve from the the bonnet 5 Using the O ring extractor tool carefully remove the teflon washer Discard the washer d Remove the stem o ring 7 cylinder vent all air out of the cylinder Failure to vent all the air will cause damage to the valve cylinder and wha
27. faces on Check parts and replace if necessary bonnet 6 or stem 3 dam aged Air leaks from Seat 9 dirty damaged or Replace seat valve outlet valve worn closed Machine seating orifice in Clean or replace part valve body dirty or damaged Air leaks from e Safety plug 15 dirty Replace safety plug safety plug damaged or worn Safety plug not tightened Torque to 90 10 inch pounds Machined seating orifice Clean or replace part dirty or damaged Air leakage Valve not tightened in Tighten valve to 30 10 foot pounds between valve cylinder Loosen and re tap and cylinder e O ring 14 dirty damaged or Replace O ring worn O ring sealing surfaces on Clean or replace parts valve and cylinder dirty or damaged 21 Procedure A Cleaning and Lubrication CAUTION NEVER use any type of solvent to clean any rubber or plastic part of the valve Be especially careful not to expose any soft parts of the valve to silicone spray because some aerosol propellants attack or degrade the rubber and plastic materials that are used for seats and seals within the valve WARNING When working with solvents and cleaners observe all procedures and safety pre cautions given by the manufacturer Degreasing Reusable metal parts should be degreased with a warm soapy water solution see Table 2 A soft nylon bristle brush may also be used taking care not to s
28. h with end of the stem 9 a Remove from valve adapter or cylinder Install a new O ring 14 onto the threaded end of the valve body 11 b Install a new valve outlet O ring 12 This concludes reassembly of the 054295 cylinder valve ATTACHING VALVE ASSEMBLY TO THE CYLINDER Attach the valve to the cylinder as described below 1 Apply a small amount of Christo Lube amp MCG 111 to the first five 5 threads of the body 11 which screw into the cylinder 2 Thread the valve clockwise into the cylinder until hand tight Using a torque wrench tighten the valve to 30 foot pounds or use a rubber mallet and lightly tap to about 30 foot Ibs 3 Fill the cylinder to 100 psig and check for leaks If no leaks are detected fill the cylinder to its rated capacity This concludes the overhaul of the 054295 Z Valve TESTING After the valve is thoroughly cleaned inspected and reas sembled Aqua Lung recommends that the following test be performed by using either a test bench and or by slowly pressur izing a cylinder To install the valve into a cylinder see Reinstall ing the Valve into the Cylinder on this page WARNING Pressurize the valve assembly only up to the working pressure designated for the valve and safety disc system This manual has been written for up to 3500 psig valves Leakage Test NOTE If tests are run on a flow test bench it will be impossible to submerge the valve in water To
29. linder and valves should be rinsed with fresh tap water This rinsing will prevent excess build up of corrosive salts and verdigris 2 After rinsing allow the valve body to air dry When the exterior of the valve appears dry release a small amount of air through the valve by slowly turning the on off handwheel counterclockwise This venting process will remove any moisture or dirt particles that may have entered the outlet orifice of the body Once the valve is vented close the valve by turning the handwheel clockwise CAUTION Never use any type of solvent to clean any part of the valve Be especially careful not to expose any soft parts to silicone spray since some aerosol propellants attack and de grade the rubber and plastic materials which are used for seats and seals within the valve CAUTION Never lubricate any part of the valve with hydrocarbon based products such as Vase line amp household oil or motor oil 3 For Certified Technicians Only Inform the user that inspection of the filter in the SCUBA regulator might indicate that the valve and or cylinder is experiencing corrosion If the filter appears discolored the regulator valve and cylinder may need a general overhaul which will require the replacement of all soft seals and non reusable components CAUTION Since either prolonged or improper storage can cause internal corrosion and or de terioration of O ring seals it is very important to always r
30. nt diluted in warm water J K Twin Manifold Valve Service Manual Appendix A Replacement of Nylon Dip Tubes Aqua Lung J K and Twin Manifold Valves All nylon dip tubes PN 052532 are to be replaced with brass dip tubes PN 051821 The replacement of the nylon tubes which may be found on older Aqua Lung valve assemblies 054500 and 054000 must be done on or before the twelve 12 month visual inspection requirement for valves The procedure for removal and replacement is detailed below A REMOVAL OF THE VALVE FROM THE CYLINDER VENT OFF ALL AIR IN THE CYLINDER OR UNTIL THE CYLINDER IS EMPTY FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH 2 Unscrew the valve counterclockwise using the procedures outlined on page 4 Removal of Valve Assembly Remove the valve from the cylinder B REMOVAL OF NYLON DIP TUBES With a pair of pliers unscrew the tube counterclockwise and remove it See Figure A 1 If the tube will not unscrew soak the valve assembly in hot wa ter If soaking does not break the adhesive use pliers to snap off the tube flush with the base of the valve NOTE If the tube unscrews and there is no evidence of nylon chips or adhesive residue in the threads proceed to step 3 After snapping off the tube use Sears No 4 EZ Out or equivalent tool to loosen the threaded portion of the tube remaining in the base of the valve Figure A 2 To do this hold the valve over the E
31. onds on 2 seconds off to be repeated until there is a noticeable reduction in purge airflow rate Immediately release purge button when restriction becomes apparent Rotate reserve handwheel to on reserve down position If regulator is equipped with submersible pressure gauge SPG read remaining cylinder pressure directly This reading will correspond with actual reserve actuation pressure If regulator is not equipped with SPG close cylinder valve bleed down and remove regulator and read remaining cylin der pressure with separate tank pressure gauge This read ing will correspond with actual reserve actuation pressure J K Twin Manifold Valve Service Manual 10 2 1 J amp K VALVES 90 inch 108 NOTE K valve no longer available replaced by Z valve PN 054295 NOTE Reserve Assembly PN 052548 is to be used on valves which have Japan stamped on the base of the valve body If replacement of the reserve assembly is required do not use the 052508 reserve assembly in valves stamped with Japan The 052548 reserve assembly is dyed red to differentiate between the reserve assemblies Key Part Description Key Part Description 054500 J Valve 3000 psi 12 820120 O ring K Valve 3000 psi replaced by PN 054295 13 051821 Dip Tube 1 052518 Nut Handle Retaining 2 req on J Valve 14 820214 O ring 2 050107 Spring 2 req on J Valve 15
32. rdless of the age of the valve or how much use it has received since it was last serviced CAUTION Use only a plastic or brass o ring removal tool PN 944022 when removing o rings to prevent damage to the sealing surface Even a small scratch across an o ring sealing surface could result in leakage Once an o ring sealing surface has been damaged the part must be replaced with new DO NOT use a dental pick or any other steel instrument REMOVAL OF VALVE ASSEMBLY FROM CYLINDER AND DISASSEMBLY OF BODY WARNING All air must be vented from the SCUBA cylinder BEFORE the valve assembly can be removed Failure to do so will cause dam age to the valve and cylinder assemblies and could cause serious injury or death 1 Bleed all air from the cylinder Leave valve open and reserve valve down 2a Single Valve Using a flex handle PN 9 44363 and a 1 3 8 crow foot loosen the valve from the wrench flats at the base of the valve If no flats are available tap the valve with a rub ber mallet in a counterclockwise direction Once loosened remove the valve by hand 2b Twin Manifolds Lay the cylinder assembly on a flat bench top Grasp the cylinder base and rotate in a counterclock wise direction If necessary a large strap wrench may be used After the first cylinder is removed stand up the other cylinder and tap the valve with a rubber mallet in a counter clockwise direction Once loosened unscrew the valve by hand Remo
33. sive manufacturer s procedures and safety precautions when using cyanoacrylate adhesives 1 Place a small amount of LocTite 6806 on male threads of brass dip tube 2 Thread the tube clockwise into the cylinder valve Then tighten the tube until it is handtight Allow to dry overnight before reinstalling into cylinder D INSTALLATION OF VALVE ONTO CYLINDER For installation instructions turn to page 13 Attaching Valve Assembly to the Cylinder VALVE ADAPTER PN 280036 sold separately Aqua LUNG Aqua Lung 2340 Cousteau Court Vista 92081 Telephone 760 597 5000 Fax 760 597 4900 www aqualung com military
34. t serviced 7 When reassembling it is important to follow every torque specification prescribed in this manual using a calibrated torque wrench Most parts are made of either marine brass or plastic and can be permanently damaged by undue stress GENERAL CONVENTIONS Unless otherwise instructed the following terminology and techniques are assumed 1 When instructed to remove unscrew or loosen a threaded part turn the part counterclockwise 2 When instructed to install screw in or tighten a threaded part turn the part clockwise 3 When instructed to remove an O ring use the pinch method see figure if possible or use a brass or plastic O ring removal tool Avoid using hardened steel picks as they may damage the O ring sealing surface All O rings that are rem oved are discarded and replaced with brand new O rings Pinch Method Press upwards on sides of O ring to create protrusion Grab O ring or insert O ring tool at pa protrusion to remove 4 Numbers in parentheses reference the key numbers on the exploded parts schematics For example in the statement remove the stem 10 from the the number 10 is the key number to the stem part number 052521 DISASSEMBLY PROCEDURE NOTE Before performing any disassembly refer to the exploded parts drawing which references all mandatory replacement parts These parts should be replaced with new and must not be reused under any circumstances rega
35. t is more important cause 8 Using an O ring extractor tool carefully remove the gasket serious injury or death 10 from inside the valve body Be careful not to damage the threads as you lift the gasket out 1 Slowly vent all air from the cylinder Venting air out of the 9 cylinder too fast causes moisture condensation that leads to undesireable oxidation rust or aluminum oxide Using the slotted end of the stem remove the seat assembly 9 by turning it counterclockwise Discard the seat assembly Remove the valve body 11 from the adapter or cylinder 2 Remove the valve assembly from the cylinder by tapping it gently with a rubber mallet and unscrewing it counterclock This concludes the diassembly of the 054295 2 Valve wise Set the cylinder aside 3 Using an O ring removal tool PN 944022 remove and discard the valve outlet O ring item 12 b Remove and discard the valve body O ring 14 For parts cleaning please refer to Procedure A Cleaning and Lubrication CAUTION To remove the safety plug item 15a secure the valve by placing it into a table mounted valve adapter or screwing it back into the cylinder NEVER secure the valve in a vise A vise will damage the valve body and require replacement 13 AQUALUNG LUBRICATION with hydrocarbon based products such as Vase line motor oil or silicone i CAUTION NEVER lubricate any part of a valve 1 Lightly lubricate
36. the second burst disc assembly 4 Using an in Ibs torque wrench and a 1 2 inch socket tighten the safety disc s to 90 in Ibs 5 f you are reassembling a twin manifold place the new gas ket 25 on the end plug 24 Do not lubricate the end plug Then screw the plug onto the manifold body Using an in lbs torque wrench and a 3 4 inch socket tighten the plug to 90 in Ibs REASSEMBLY OF THE AIR FLOW CONTROL AFC VALVE AND HANDWHEEL CAUTION The seats 11 required by the K valve J valve Z valve and the Twin Manifold are all different Failure to install the correct seat in each valve will lead to malfunction when in use The K valve seat shown in Figure 2 has a solid nylon surface whereas the J valve seat has a pressure relief through hole in the nylon surface This through hole relieves any air pressure which may build up behind the J valve seat This can be caused by air hitting the sealing surface on an angle Figure 3 Air can travel around the seat If the seat was not designed with a pressure relief through hole the seat could rupture close off or restrict air flow to the first stage regulator The K valve seat does not require an air pressure relief through hole because air hits the sealing surface directly The part numbers for the different seats are as follows J valve seat PN 052519 K valve seat PN 050109 Manifold seat PN 280013 C3 Figure 2 Figure 3 AQUALUNG 6 Lightly lubricat
37. ve the O rings 12 and 14 from the valve bogy 4 Ifthe dip tube s 13 is made of plastic replace it with a brass tube For complete information on how to replace a plastic tube s see Appendix A in this manual ce NOTE Prior to removal of the safety plug 15c the Air Flow Control AFC valve or the reserve assemblies the valve body must be properly secured The preferred method is to mount the valve body in a table mounted valve adapter PN 280036 or as an alternative to install the valve body into an EMPTY cylinder NEVER place the valve body in a vise A vise will dam age the body and necessitate replacement 5 Remove the safety plug 15c with the 1 2 inch wrench by turning the wrench counterclockwise 6a Safety disc removal recommended method To remove the safety disc 15a Aqua Lung recommends to blow it out with an air nozzle To do this first remove the valve from the cylinder or valve adapter Close the on off valve While covering the safety disc hole with a cloth or rag insert the end of the air nozzle into the dip tube and apply a short blast of air to blow out the safety disc Lift out the gasket 15b Discard the plug disc and gasket Reinstall the valve into the table mounted valve adapter PN 280036 or cylinder 5 LUNG CAUTION When removing the safety disc and Disassembly or Reserve Mechanism gasket 15a and 15b with an O ring tool take J Valve and Twin Manifold only care
38. y 16 Install the reserve assembly into the body making sure the two alignment bosses fit into the matching grooves in the valve body CAUTION The reserve assembly 16 has two alignment bosses that must fit into matching grooves in the valve body See Figure 5 Figure 5 14 Install O ring 8 onto the stem 18 Place the gasket 19 on the shank of the stem NOTE Be sure that the concave side of the backup ring 21 faces the O ring 20 when as sembling the bonnet assembly 22 15 Install the new back up ring 21 and O ring 20 on the bonnet 22 Refer to drawing for correct placement Set this assembly aside Then place the stem 18 into the groove of the reserve mechanism assembly 16 16 Install the bonnet 22 by hand until snug Using in lIb torque wrench and a 5 8 crow foot torque to 60 in Ibs CAUTION Over torque of the bonnet will cause damage to the reserve assembly 17 Position the washer 4 and reserve handwheel 23 over the bonnet The reserve handwheel should be in the down position NOTE If a new reserve mechanism is installed the handwheel needs to be installed in the up position CAUTION To assure that the reserve handwheel is positioned properly on the assembly open on off handwheel 3 Then pull lever down to on position and blow through the dip tube 13 Air should pass through the valve Then try blowing through the dip tube with the lever place
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