Second Stage

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©2006 Aqua Lung International, Inc 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

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

Product Features Go directly to disassembly

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

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

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

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

Exhausting!

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

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

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

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

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

Disassembly

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

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

Remove Hose O-rings

Inspect Hose Crimps

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

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

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

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

Remove Venturi Remove venturi O-ring

Remove Cam by Hand Reverse thread Turn cam clockwise to remove

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

Remove Shuttle Valve Assy

Separate Shuttle Valve Assy

Remove MP Seat & O-ring

Inspect Counter-Balance Chamber Inside sealing area

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

Slide Out Valve Body Hold lever down

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

Remove Crown O-ring

Critically Inspect Crown Sealing area O-ring groove

Remove Lever (optional)

Inspect Lever

Straighten Legs If Necessary

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

Inspect Exhaust Valve Replace if necessary

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

This Concludes Disassembly

Cleaning & Lubrication Go directly to Reassembly

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)

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 !

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

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

Reassembly

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

Install Crown O-ring

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

Install Valve Body into Case

Install O-ring & Heat Exchanger

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

Install O-ring & MP Seat

Assemble Shuttle Valve Assy

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

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

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

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

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

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

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

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

Insert Clip Into Groove

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

Adjusting

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

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 2nd stage should leak air with this test If 2nd stage does not leak, lever is to low Raise lever height by backing out crown slightly and recheck

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

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 !

Install O-ring & Cap

Install Mouthpiece Place mouthpiece onto oral boss with bridge facing up

Install Mouthpiece Clamp Make sure buckle is facing heat exchanger Buckle

Install Diaphragm & Washer

Install Retaining Ring Use retaining ring tool to tighten ring

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

Install Cover Ring

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

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

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

Install Exhaust Cover Push cover onto holding pin Push here

Final Testing

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

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

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.

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