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Second Stage. Please Turn Off The Cell Phones Copyright Notice This program is copyrighted, all rights reserved. It may not in whole or in part, be copied,

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Presentation on theme: "Second Stage. Please Turn Off The Cell Phones Copyright Notice This program is copyrighted, all rights reserved. It may not in whole or in part, be copied,"— Presentation transcript:

1 Second 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 Kronos 2nd Stage Service Program ©2006 Aqua Lung International, Inc Kronos 2nd 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 944022

5 Product Features Go directly to disassembly

6 Features Pneumatically Balanced Second Stage Dual-Cam Controller Asymmetrical Side-X Exhaust EN 250 Coldwater Approved Nitrox Compatible to 40%

7 Features (Balanced) Pneumatically Balanced Second Stage –For increased performance at any depth or cylinder pressure

8 Features (Dual-Cam) Dual-Cam Controller –Combined venturi and breathing resistance control for fast and simple diver adjustments

9 Features (Side-X Exhaust) Asymmetrical Side-X Exhaust –Routes bubbles out of your viewing area –Directs warm exhaled air over the 2 nd stage valve for increased freezing resistance

10 Exhausting!

11 Features (Coldwater) The Kronos 2 nd stage is EN 250 approved for cold water use when used with the Kronos Supreme model 1 st stage Due to the Side-X exhaust, exhaled gases warm the mechanism as it goes through the baffle

12 Features (Nitrox) The Kronos 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) 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) 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) 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

17 Remove Exhaust Cover Use small bladed screwdriver Peel cover off by hand –Lift up on end of cover –Slide down hose

18 Remove MP Hose Use two 11/16” open end wrenches

19 Remove Hose O-rings

20 Inspect Hose Crimps

21 Remove Cover Ring Use adj. face spanner (p/n:129198) Lift out purge cover

22 Remove Retaining Ring Use retaining ring tool (p/n:129001) Lift out washer and diaphragm

23 Remove Plug & O-ring Use retaining ring tool to remove plug

24 Remove Venturi Clip Locate red clip Use a small bladed screwdriver –Carefully lift clip out of groove in venturi

25 Remove Venturi Remove venturi O-ring

26 Remove Cam by Hand Reverse thread –Turn cam clockwise to remove

27 Remove Fine Adjustment Screw Use small 2.5mm bladed screwdriver Remove O-ring

28 Remove Shuttle Valve Assy

29 Separate Shuttle Valve Assy

30 Remove MP Seat & O-ring

31 Inspect Counter-Balance Chamber Inside sealing area

32 Remove Heat Exchanger & O-ring Use 11/16” wrench

33 Slide Out Valve Body Hold lever down

34 Remove Crown Use a medium bladed screwdriver Carefully push out crown with seat tool (p/n:109437) –Loosen crown 6-7 turns to disengage threads

35 Remove Crown O-ring

36 Critically Inspect Crown Sealing area O-ring groove

37 Remove Lever (optional)

38 Inspect Lever

39 Straighten Legs If Necessary

40 Remove Mouthpiece Lift up and remove mouthpiece clamp Pull off mouthpiece –Inspect mouthpiece for any holes or tears and replace if needed

41 Inspect Exhaust Valve Replace if necessary

42 Technician Features No o-ring on valve body New counter-balance chamber New diaphragm and lever Reverse thread on cam –Wrench flats on cam that engage with venturi. This allows venturi adjustment to increase or decrease spring tension (DUAL CAM) Red clip holding venturi in place Side-X exhaust cannot be completely removed without first removing mp hose

43 This Concludes Disassembly

44 Cleaning & Lubrication Go directly to Reassembly

45 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 lp hydrocarbon free gas (for EAN use)

46 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 !

47 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

48 Lubrication Procedures Lubrication –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

49 Reassembly

50 Replace Exhaust Valve Insert new exhaust valve thru center hole Using side cutters –Leave 5mm end after trimming –Make sure barb is all the way thru Barb

51 Install Crown O-ring

52 Insert Crown Into Valve Body Screw in crown until tool disengages Use crown/lever adj tool (p/n 127686)

53 Install Valve Body into Case

54 Install O-ring & Heat Exchanger

55 Torque Heat Exchanger Tighten heat exchanger by hand until snug Use in/lb torque wrench & 11/16” crow-foot –Torque to 45 in/lbs (5 Nm) Torque: 45 in/lbs 5 Nm

56 Install O-ring & MP Seat

57 Assemble Shuttle Valve Assy

58 Install Shuttle Valve Assy Make sure lever is perpendicular to valve body –With shuttle valve feet facing down & away from lever, slide assy into valve body

59 Install Cam into Valve Body Turn cam counter- clockwise to install Turn in by hand until it stops

60 Install Venturi O-ring Make sure O-ring is placed into correct groove

61 Slide Venturi onto Tool Use crown/lever tool –Slide venturi onto tool

62 Install Venturi Engage tool with cam –Turn tool counter- clockwise until cam stops turning –Turn tool back clockwise ¼ turn and hold in place

63 Install Venturi Slide venturi into place in the plus + position –Make sure the octagonal flats on the cam and the lever match up before pushing the venturi into place

64 Confirm Proper Installation Make sure flat edge of cam is 1-2.5 mm below flat edge of venturi Flat edge of cam Flat edge of venturi

65 Confirm Proper Installation Press on lever to confirm proper return of lever

66 Insert Clip Into Groove

67 Install O-ring & Adj Screw Use small bladed screwdriver Screw in until adj screw is flush & O-ring is not visible

68 Adjusting

69 Adjust Lever Height –Attach to a properly adjusted 1 st stage or test bench, slowly Pressurize to 3000 psi Attach inline adj tool (p/n 100190) to 2 nd stage

70 Adjust Lever Height (max) Use the crown/lever tool –Place the tool onto the case in the max position, (larger raised part facing down) –Slide tool across lever –2 nd stage should leak air with this test –If 2 nd stage does not leak, lever is to low –Raise lever height by backing out crown slightly and recheck

71 Adjust Lever Height (min) Use the crown/lever tool –Turn the tool over & place onto the case slide tool across lever –2 nd stage should not leak air with this test –If 2 nd stage does leak, lever is to high –Lower lever height by turning in crown slightly and recheck

72 Set Adjustment Screw While still under pressure, loosen adj screw until small leak is heard –Turn adj screw back in 1.5 turns –Depressurize & remove inline tool CAUTION: If no leak is heard, cam was not installed correctly !

73 Install O-ring & Cap

74 Install Mouthpiece Place mouthpiece onto oral boss with bridge facing up

75 Install Mouthpiece Clamp Make sure buckle is facing heat exchanger Buckle

76 Install Diaphragm & Washer

77 Install Retaining Ring Use retaining ring tool to tighten ring

78 Install Purge Cover Check alignment of purge cover –If cover is not aligned properly, tighten or loosen retaining ring slightly to allow proper position of purge cover

79 Install Cover Ring

80 Install MP Hose Install hose onto heat exchanger hand tight Slide hose thru exhaust cover

81 Tighten MP Hose Use torque wrench and 11/16” crow foot –While holding heat exchanger steady with 11/16” open end wrench, torque MP hose to 40 in/lb (4.5Nm) Torque: 40 in/lbs 4.5 Nm

82 Install Exhaust Cover Inspect cover for proper seating Slide exhaust cover into place

83 Install Exhaust Cover Push cover onto holding pin Push here

84 Final Testing

85 Attach 2 nd stage to a properly adjusted 1 st stage or test bench, slowly pressurize to 3000 psi (232 bar)

86 Final Testing Specifications at 2500-3000 psi (160-232 bar) –Medium pressure: 130-145 psi (9-10 bar) –Opening effort: 1.1-1.5 in/H2o (2.8-3.8 mbar) Opening Effort: 1.1-1.5 in/H2o 2.8-3.8 mbar

87 Final Testing Check for leaks –Immerse second stage U/W – Look for streaming bubbles; don’t mistake trapped air for leaks –Note leak source; refer to troubleshooting table in service manual 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.

88 This Concludes Servicing Of The Kronos 2 nd Stage Rev 07/10/07


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