Aqua Lung CORE User manual

Service Manual Core 2nd stage 1Rev. 05/2015
SERVICE MANUAL
CORE
SECOND STAGE
Copyright © 2015 Aqua Lung France

Service Manual Core 2nd stage
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Rev. 05/2015 2
Date
Revision description
02/2015
Document creation

Service Manual Core 2nd stage
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Rev. 05/2015 3
CONTENT
COPYRIGHT......................................................................................................................................................... 4
INTRODUCTION .................................................................................................................................................. 4
WARNINGS, ATTENTION, NOTES......................................................................................................................... 4
MAINTENANCE ................................................................................................................................................... 4
GENERAL INSTRUCTIONS .................................................................................................................................... 5
GENERAL CONVENTIONS .................................................................................................................................... 5
DISASSEMBLY PROCEDURE ................................................................................................................................. 6
REASSEMBLY PROCEDURE .................................................................................................................................. 8
CONTROLE FINAL.............................................................................................................................................. 11
FINAL REASSEMBLY........................................................................................................................................... 11
APPENDIX ......................................................................................................................................................... 12
Table 1. Troubleshooting Guide ................................................................................................................................................ 12
Table 2. Tools and service kits list ............................................................................................................................................. 13
Table 3. Recommended cleaners and lubricants ....................................................................................................................... 14
Table 4. Torque values .............................................................................................................................................................. 15
Table 5. Checking specifications ................................................................................................................................................ 15
Procedure A –Cleaning and Lubricating.................................................................................................................................... 16
Maintenance Notes .................................................................................................................................................................. 17

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COPYRIGHT
This manual is the property of Aqua Lung France. Any copying, photocopying, reproduction, translation, electronic distribution (email,
Internet...), even partial, and in whatever format, is expressly forbidden without the written consent of Aqua Lung France.
©2015 Aqua Lung France.
INTRODUCTION
This manual gives the instructions and the recommendations for the disassembly, the cleaning, the checking, the reassembly and
the adjustment of an Aqua Lung regulator. This manual is not an instruction manual for unqualified personnel. The procedures
described in this manual are intended only for qualified personnel who have been trained in the servicing of Aqua Lung equipment
during a specialised course.
If you do not understand certain procedures in this manual you should contact an Aqua Lung service consultant before undertaking
any operation.
WARNINGS, ATTENTION, NOTES
Certain icons have been used to facilitate the reading and understanding of this manual. They have the following meanings:
.
MAINTENANCE
In order to conform with the Aqua Lung Regulator Lifetime Guarantee, all servicing (inspection, servicing and repairs)
should be recorded in the Service Record incorporated in the regulator User Manual.
WARNING: Indicates situations that could result in
serious or fatal accidents if the advice given is not
followed correctly.
ATTENTION: Indicates a situation or action that
could cause serious damage to the product,
making it dangerous if the advice given is not
followed correctly.
NOTE: Notes are used to emphasize important
points as well as information which needs to be
remembered.
ATTENTION: According to Aqua Lung
specifications, any regulator should undergo
servicing at least once every two years and visual
inspection at least once per year. These two
checks must be performed by an authorized Aqua
Lung dealer. Depending on the conditions and the
number of dives, the regulator may need to be
serviced more often.

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GENERAL INSTRUCTIONS
1. In order to carry out the procedures described in this manual correctly, it is important that you follow the steps in the exact order
indicated. Read the manual through completely so that you become familiar with all the procedures, the special tools and the
replacement parts, before starting to disassemble the product. Keep this manual open near to you so that you can refer to it step
by step. Do not rely on your memory.
2. All servicing and repair procedures should be carried out in a workshop that is clean, well lit, easy to access and specially fitted
for the purpose.
3. The regulator body should never be directly held in the jaws of a vice. To hold the body, screw the tool (116230) into a HP or
MP port and then grip the tool with the vice.
4. Once the regulator has been disassembled, the re-usable components should be separated from the components that need to
be replaced. Fragile items with seats or crowns with critical sealing surfaces should be separated and protected during servicing
in order to prevent any damage.
5. Use only spare parts from Aqua Lung service kits. Never replace an Aqua Lung part with one from another manufacturer, even
if it appears similar.
6. Never re-use regulator parts which should be replaced on the pretext that the regulator has seen little use since its manufacture
or since its last service.
7. When reassembling, check that the torque used conforms with that shown in Table 4. Torque values. Some parts can be
irretrievably damaged if the acceptable torque is exceeded.
GENERAL CONVENTIONS
The conventions described below define the actions to be carried out when an instruction is given.
1. Unscrew: to unscrew a threaded part, turn it anti-clockwise.
2. Screw: to screw a threaded part, turn it clockwise.
3. Remove the O-ring: To remove an O-ring follow the method below, using the special tool (506001) provided for this purpose.
Any tool that could damage the O-ring should be avoided. In every case, replace the O-ring removed with a new one.
4. The acronyms used:
LP: Low Pressure
MP: Medium Pressure (or IP: Intermediate Pressure)
HP: High Pressure
5. Bracket numbers indicate components references from exploded views.
Press simultaneously on the two sides
of the O-ring in order to form an ‘eye’.
Insert the special tool (506001) into this
eye to remove the O-ring.

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DISASSEMBLY PROCEDURE
1. Using two 11/16’’ keys, block
the insert screw (127818) for
standard version or the heat
exchanger (129914) for
supreme version and octopus
and unscrew the end nut on
the hose (124567).
2. If the regulator is a supreme
version, remove the lip
shield (125613). Remove
the mouthpiece strap
(129154) and then the
mouthpiece (123697 for
standard and supreme
versions, 123698 for
octopus).
3. Unscrew the front cover holder
(129913) using a lug spanner
(129198). Remove the front
cover (129912, 129917 or
129918).
4. Using the tool (129001), unscrew the diaphragm retainer
(129195). Remove the washer (129133) and the second
stage diaphragm (129150).
5. Using an 11/16’’ key, unscrew the insert screw (127818)
for standard version or the heat exchanger (129914) for
supreme version and octopus.
6. While holding the lever (129178) down against the valve
spindle (129146), push the valve spindle assembly
outside the case (129931 or 129932).
If the Venturi plug (129911) has not fell down itself,
remove it.
Remove O-ring (124706), hose side.
7. Remove the Venturi lever (129909) from the case
(129931 or 129932).
Remove the Venturi lever O-ring (AP1438). This O-ring
could have stayed in the case, during the Venturi lever
removing.
8. Using a 4 mm Allen key, lightly
screw the adjusting screw
(129162), and then remove the
tension pin (AP1151).
9. Using a 4 mm Allen key, unscrew and
remove the adjusting screw (129162).
With the tool (506001), remove the O-
ring (124703) from the adjusting
screw.
NOTE: Before commencing disassembly,
consult the exploded view to check the reference
numbers of all parts requiring replacement.
These parts should all be replaced by new parts
and should not be re-used on the pretext that the
regulator has seen little use since its
manufacture or since its last service.
ATTENTION: Use only the special tool (506001)
when removing O-rings in order to avoid damaging
the seal recess. The slightest scratch on a sealing
surface could cause a leak. If a surface should be
damaged then this part should be replaced with a
new one. Do not use any pointed instrument or
metal tool to remove O-rings.

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10. With the tool (506001),
remove the O-ring (124706)
from the valve spindle
(129146).
11. Insert a 4 mm Allen key in the valve spindle (thread side)
and push out the shuttle valve assembly. Separate the
components of the valve seat.
12. Use a fingernail to remove the rubber seating (129638)
and the small O-ring (AP2041) of the shuttle valve
(AP2036).
13. Using a flat screwdriver, unscrew the valve seat (AP2033)
until feeling thread end. Insert metallic part of the tool
(116236) in the valve spindle (not threaded side). Grab
the tool metallic part on the other side, pull the valve seat
out.
Using the tool (506001), remove the O-ring (444243) from
the valve seat.
14. By hand or with a coin, unclip the exhaust tee (129908).
Be careful not to damage the case (129931 or 129932).
15. Lift the exhaust valve
(129174). Check that the
contact surface is clean
and free of scratches. The
exhaust valve should be
clean, flexible and should
have clean edges.
If it is in good condition, it is not necessary to remove it
and it can be re-used. If there is any sign of deterioration,
it must be replaced.
Do not remove the baffle (129648) from the case
(129931 or 129932).
DISASSEMBLY END
Before starting to re-assemble the regulator,
make sure that all replacement parts have been
cleaned and lubricated in accordance with
Procedure A –Cleaning and Lubricating, page
15.

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REASSEMBLY PROCEDURE
1. If the exhaust valve (129174) has been removed, pass
the valve tail through the case hole (129931 or 129932),
from outside and pull gently until the notch is inside the
case. If it is a new exhaust valve, one installed, cut off any
excess tail leaving about 5mm.
2. Place the exhaust tee
(129908) on both case
notches (129931 or
129932) and pull on its
low part to clip it.
3. Fit a new O-ring (AP2041) in the shuttle valve groove
(AP2036). Insert a new rubber seating (129638) in the
shuttle valve. With a brush, lubricate the shuttle valve tail
(O-ring side).
4. Insert the spring (AP2021) in the counter balance cylinder
(129784). Guide carefully the shuttle valve tail (AP2036)
inside the spring and insert it in the counter balance
cylinder.
5. If the lever (129178) has
been removed, place it again,
take care to install it at the
same side as the valve
spindle punch (129146).
6. Fit a new lubricated O-ring
(124706) on the valve spindle
(129146).
7. Fit a new lubricated O-ring (124703) on
the adjusting screw (129162).
8. Fit a new lubricated O-ring (444243) on the
valve seat (AP2033).
Insert the valve seat, thread first, inside the valve spindle
(129146), thread side, and push until stop.
9. Insert the assembled shuttle valve in the valve spindle
(129146), not threaded side. Shuttle valve notches should
be at the opposite side of the lever.
With the plastic side of the tool (116236), push on the
counter balance cylinder (129784) and check that the
lever raise.
10. Insert the adjusting screw
(129162) in the valve spindle
(129146), not threaded side.
There should be a tension on
the lever (due to the spring).
Using a 4 mm Allen key, screw
the adjusting screw until the
tension pin hole is clear.
Clear hole

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Fit the tension pin (AP1151) into its
position, centre it. Gently unscrew
the adjusting screw until it applies
sufficient tension on the tension pin
that prevent it from falling out.
11. Fit a new lubricated O-
ring (AP1438) on the
Venturi lever (129909).
12. While holding the lever (129178) down, insert the valve
spindle (129146) in the Venturi lever (129909).
13. While holding the lever (129178) down, and placing the
Venturi lever up, insert the assembly in the case (129931
or 129932) until stop.
Make sure the valve
spindle planes (129146)
are well placed in case
planes.
14. Fit a new lubricated O-ring
(124706) on the valve
spindle, thread side and
push it against the case
(129931 or 129932).
For standard version: screw
the insert screw (127818) on
the valve spindle. Tighten to
0.3 m.kg (2.17 ft.lb).
For supreme version and
octopus: screw the heat
exchanger on the valve
spindle. Tighten to 0.5 m.kg
(3.7 ft.lb).
15. While placing the flat side of the case (129931 or 129932)
at eye level, screw the valve seat (AP2033) with a flat
screwdriver, until the lever (129178) lever is about 4mm
below the level of the case edge.
Unscrew the valve seat to raise the lever up.
Screw the valve seat again until the lever slightly move.
16. Using a 4 mm Allen key, screw the adjusting screw
(129162) of :
-3/4 of turn for standard version
-1 turn and 1/4 of turn for supreme version and
octopus
17. Lever adjustment:
Connect the tool (122046 + 122041) on the 2nd stage and
the hose (124567) on the tool. Connect this system to its
1st stage.
Put the regulator under
pressure. Slide tool (125727)
flat side (without drop) along
the top edge of the case. The
lever should touch the tool but
it should not produce an
airflow. Screw or unscrew the
valve seat (AP2033) thanks to
the tool (122046 + 122041).
Screwing the valve seat, take down the lever.
Unscrewing the valve seat, raise the lever.
Turn off the air supply and purge the second stage.

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18. Fit the diaphragm (129150) in the case (129931 or
129932). Press all around the edges with a finger to
ensure that it is in place. Fit the washer (129133) directly
in contact with the diaphragm.
19. Manually screw the diaphragm
retainer (129195), flat face
toward the diaphragm
(129150), until stop.
Using the tool (129001) tighten
it an additional 1/4 of turn.
Align a diaphragm retainer fin
with the valve spindle axis
(129146).
Good alignment Wrong alignment
After tightening the diaphragm retainer, hold the top of the
diaphragm and gently pull it in all directions to ensure that
it is firmly in place in the housing. If not, refit it.
20. Fit the front cover (129912, 129917 or 129918) and align
the marking with the valve spindle axis (129146). Screw
by hand the front cover holder (129913) on the case until
stop. Tighten it using a lug spanner (129198).
21. Turn off the air supply and purge the second stage.
Remove the tool (122046 + 122041).
Move the end nut of the hose (124567) into the insert
(129146).
For standard version:
Using one 11/16’’ key, block the insert screw and, using
a 11/16’’ fitting, tighten the end nut of the hose to
0,3 m.Kg (2.17ft-lb).
For supreme version and octopus:
Using one 11/16’’ key, block the heat exchanger and,
using a 11/16’’ fitting, tighten the end nut of the hose to
0,5 m.Kg (3.7 ft-lb).
REASSEMBLY END

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CONTROLE FINAL
1.Put the regulator under pressure at 200 bar (±10 bar).
2.Opening effort check. Apply an increasing inhalation
flow. When the MP starts to fall, note the opening effort
reading and compare it with the limits shown on Table 5.
Checking specifications. If the opening effort is outside
the limits then check Table 1. Troubleshooting Guide.
3.Flow/effort test. Place the Venturi lever (129909) on the
MAX position. Apply an inhalation flow of 400 l/min and
check that the effort does not exceed 15 mbar. If the effort
exceeds this then check Table 1. Troubleshooting Guide.
4.Leak test. Connect the first stage to a cylinder charged
to 200 bar, open the cylinder valve and immerse the set
in a fresh water bath for one minute. Check that there are
no leaks.
If a leak is detected, disassemble the entire 2nd stage;
check all sealing surfaces and the correct positioning of
all parts.
FINAL REASSEMBLY
1. Fit the Venturi plug (129911).
2. Fit the mouthpiece (123697 for standard and supreme
versions, 123698 for octopus) on the case (129931 or
129932). If it is a Comfobite mouthpiece (123697), check
that the support section is on top.
Fit the mouthpiece strap
(129154) into its groove.
The collar lever should
point down on the hose
side.
3. If the regulator is a supreme version, fit the lip shield
(125613) over the mouthpiece and against the
mouthpiece strap (129154).
FINAL REASSEMBLY END
NOTE: Tests 2, 3 and 4 require the use
of a Regulator Test bench.
NOTE: Do not confuse bubbles trapped
in the regulator with a leak. In case of
leak, bubbles should appear constantly.

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APPENDIX
Table 1. Troubleshooting Guide
SYMPTOM
POSSIBLE CAUSE
TREATMENT
1. The MP is too high
1. Refer to First stage Troubleshooting
Guide
2. The rubber seating (129638) is worn or
damaged
2. Replace the rubber seating
Leak or free flow at 2nd stage
3. The valve seat (AP2033) is not correctly
adjusted
3. Readjust the valve seat
4. The lever (129178) is bent
4. Replace the lever
5. The sealing face of the valve seat
(AP2033) is damaged
5. Replace the valve seat
6. The spring (AP2021) is damaged
6. Replace the spring
Insufficient purge flow or work of
breathing too high
1. The MP is too low
1. Refer to First stage Troubleshooting
Guide
2. The valve seat (AP2033) is not correctly
adjusted, the lever adjustment is too low
2. Readjust the lever and the valve
seat
3. The MP hose is obstructed
3. Clean or replace the hose
4. The lever (129178) is bent
4. Replace the lever
Water leak
1. There is an hole in the mouthpiece
(123697 or 123698)
1. Replace the mouthpiece
2. The diaphragm (129150) is damaged
6. Replace the diaphragm
3. The exhaust valve (129174) is damaged
7. Replace the exhaust valve
4. The Venturi lever O-ring (AP1438) is
dirty, worn or damaged
4. Replace the O-ring
5. The diaphragm is not correctly fitted
between the case (129931 or 129932) and
the washer (129133)
5. Disassemble the front cover and refit
the assembly correctly
6. The case (129931 or 129932) is
damaged
6. Check the sealing face of the
exhaust valve. Replace the case.
7. The valve spindle O-ring (124706) is
damaged
7. Replace the O-ring

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Table 2. Tools and service kits list
REF
DESCRIPTION
PICTURES
APPLICATION
US PART
NO.
506001
O-ring tool
Fitting and removing O-rings
944022
116236
Disassemble tool HP
club
Seat assembly / disassembly
109437
129198
Hook wrench
Front cover holder screwing /
unscrewing
129198
129001
2nd stage LX tool
Diaphragm retainer screwing /
unscrewing
129001
125727
Lever / crown
adjustment tool
Lever adjustment
125727
122154
Torque wrench SAM
Insert screw or heat exchanger
screwing
n/a
122046
+
122041
Adjusting tool artic
+
Adapter adjust tool micra
Lever adjustment under
pressure
n/a
n/a
11/16’’ open end torque
wrench
Insert screw or heat exchanger
screwing
n/a
n/a
Medium flat screwdriver
Valve seat screwing /
unscrewing
n/a
n/a
Two 11/16’’ keys
Hose nut and insert screw or
heat exchanger screwing /
unscrewing
n/a
n/a
Allen 4mm Allen key
Adjusting screw screwing /
unscrewing
Pushing of shuttle valve
outside valve spindle
n/a
128019
Service kit second stage balanced
BP Core, BP Core supreme, BP Octopus
n/a

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Table 3. Recommended cleaners and lubricants
LUBRICIANT / CLEANER
APPLICATION
SOURCE
Christo-Lube MCG 111
All O-rings
Aqua Lung, ref. 480025
Oakite #31
Acid bath for cleaning brass and stainless
steel parts
Oakite Products, Inc.
NETALU
Acid bath for cleaning brass and stainless
steel parts
Aqua Lung, ref. 455001
Diluted white vinegar
Acid bath for cleaning brass and stainless
steel parts
Household stores
Washing-up liquid (diluted with hot water)
Degreases brass and stainless steel parts;
general cleaning of plastic and rubber
parts
Household stores
Disinfectant STERANIOS 2%
Disinfectant for all plastic and metal parts
Aqua Lung ref : 382062
ATTENTION: Silicone parts do not require lubrication. Do not grease them. Greasing
silicone parts can change their molecular construction and cause premature
degradation of the material.
ATTENTION: Do not use hydrochloric acid for cleaning parts. Hydrochloric acid, even
when well diluted, attacks the coating of metal parts and leaves a corrosive deposit that
damages plastic parts and O-rings.

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Table 4. Torque values
N° REFERENCE
DESCRIPTION
COUPLE
127818
Insert screw
0.3 m.kg (2.17 ft.lb)
129914
Heat exchanger
0,5 m.kg (3.7 ft.lb)
124567
Hose, 2nd stage side
0,3 m.Kg (2.17 ft.lb) when tight against
the plastic screw
0,5 m.Kg (3.7 ft.lb) when tight against the
metal heat exhanger
Table 5. Checking specifications
TEST
INSTRUCTIONS
SPECIFICATIONS
Leak Test
160 bar < Working pressure < 200 bar
No leak
Medium Pressure
160 bar < Working pressure < 200 bar
MP at 9.5 bar ± 0.5 bar : Core
MP at 8.5 bar ± 0.5 bar : Core supreme
Opening effort
160 bar < Working pressure < 200 bar
Between 2.5 mbar and 3.5 mbar : Core
Between 3.3 mbar and 4.3 mbar : Core supreme and
Octopus
Effort / Flow
MP at 9.5 bar ± 0.5 bar : Core
MP at 8.5 bar ± 0.5 bar : Core supreme
and Octopus
15 mbar maxi at 400 L/min

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Procedure A –Cleaning and Lubricating
(All Aqua Lung regulators)
Cleaning brass and stainless steel parts.
1. Pre-clean by soaking in NETALU diluted to 25%.
2. Cleaning in an ultra-sonic bath filled with a mixture of washing-up liquid + hot water. If some resistant deposits remain then
fill the ultrasonic bath with diluted white vinegar and repeat. DO NOT put plastic, rubber, silicone or anodised aluminium
parts in contact with vinegar.
3. Rinse in demineralised or fresh water to avoid calcium deposits. Soak for 10 minutes. Dry with filtered low pressure air and
then check that their condition is now suitable for re-use.
Cleaning plastic, rubber and anodised aluminium parts.
For anodised aluminium parts: soak in a « NETALU diluted to 25% ». Rinse in fresh water and dry with low-pressure filtered air.
For plastic parts. (casings, plugs...): clean in an ultrasonic bath containing a mixture of washing-up liquid and hot water. Use only a
toothbrush with nylon bristles to remove any deposits. Rinse in fresh water and dry with low-
pressure filtered air.
Disinfecting parts
For disinfection, leave plastic and metal parts to soak for 20 minutes in a bath of STERANIOS 2% ref. 382062 (ready to use). Rinse
the parts thoroughly after soaking. Toxic product, follow the instruction for its use.
Cleaning parts for Nitrox/O2 use.
1. Metal parts: Pre-clean by soaking in NETALU diluted to 25%.
2. Ultrasonic cleaning in Promoclean TP108 diluted at 5%.
3. Rinse in demineralised water. Soak for 10 min.
4. Dry in the open air in a clean and dust-free atmosphere. Place the parts on a white cloth, allow to dry and check after drying
that the cloth shows no grease deposits and that the condition of the parts is appropriate for re-use with Nitrox/O2.
Cleaning hoses.
Refer to support “Hose inspection and cleaning procedure”.
Wiping.
To wipe parts, use a white filter paper, a pure cotton cloth or any other material that does not produce fluff.
Inspection.
Visually check under a white light (day light or artificial light).
The parts are completely free of any traces of:
1. organic materials (oil, grease, paint, rust…)
2. cleaning agents
3. dust
4. humidity
Lubrication.
When handling O-rings wear unpowdered latex gloves. It is important not to allow contact between the internal components and the
skin or any other source of contamination when the regulator is being prepared for Nitrox use. All seals should be lubricated with
Christolube MCG111. Cover the seals with a light film of grease and remove any excess by rolling the seal between fingerand thumb.
Do not use an excess of grease; this can have the effect of accumulating particles that could damage the O-rings.
ATTENTION: Do not place plastic and rubber parts in contact with acid solutions. This could alter their physical
properties and cause degradation and premature breakdown.

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Maintenance Notes

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1ere Avenue –14erue –BP 148
06513 CARROS cedex –France
00.33.(0)4.92.08.28.88
FAX [phone]