POSEIDON Jetstream Mk3 Octopus User manual

JETSTREAM Mk3
Art. Nmbr 0100-005
SERVICE MANUAL V1.0

SERVICE MANUAL JETSTREAM Mk3
Page 1
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
TABLE OF CONTENT
1. IMPORTANT............................................................................................................................................................................................................... 2
2.TOOLS.............................................................................................................................................................................................................................3
3. JETSTREAM Mk3.................................................................................................................................................................................................... 5
4. DISASSEMBLY INSTRUCTIONS - SECOND STAGE ......................................................................................................................................... 9
5. CLEANING INSTRUCTIONS ............................................................................................................................................................................. 11
6. ASSEMBLY INSTRUCTIONS - SECOND STAGE.......................................................................................................................................... 12
7. DISASSEMBLY INSTRUCTIONS - FIRST STAGE ........................................................................................................................................ 14
8. ASSEMBLY INSTRUCTIONS - FIRST STAGE ......................................................................................................................................... 19
9. SETTINGS AND ADJUSTMENT ................................................................................................................................................................... 23

SERVICE MANUAL
Page 2
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
1. IMPORTANT
This manual contains preliminary servicing instructions for the Poseidon breathing regulators. It is intended to
serve as a guide for repairs and servicing carried out by Poseidon Diving Systems. The instructions given in this
manual are based on the assumption that special tools are used and are based on our experience.The work
should be done in the same order as shown in these instructions.
TYPE DESIGNATIONS
In all correspondence concerning breathing regulators, indicate the type designation and serial number. All
products in this servicemanual that requires a CE-approval are of course CE-approved. CE approval represents
only a minimum level of product quality and manufacturing standards. At Poseidon we put each new addition
through rigorious testing procedures our selves. This is the only proper method to ensure that your equipment will
live up to our claims.
CLEANING
If corrosion or salt deposits occurs, place all metal parts in concentrated Hempocid* or 15% Hydrochloric acid for
about 10 minutes. If available, all metal parts can be placed in an ultrasonic washer and cleaned in accordance
with the instructions of the cleaning solution used.
Then, rince the parts thoroughly and blow dry with air. The synthetic parts in the second stage must not be treated
with solvent. They shall be cleaned in freshwater only.
*Hempocid = Acid Liquid Detergent Containing phosphoric acid (5 - 10%) and bactericid for desinfectant cleaning.
LUBRICANTS USED
The following lubricant is used:
Regulator Lubricant: Art No: 8516
FUNCTION
POSEIDON breathing regulator is a two-stage regulator where the rst stage is a diaphragm-actuated
reducing valve, whith reduces the primary pressure (Cylinder pressure) to approx. 123 PSI/8.5 BAR. The reduced
pressure (the secondar’y pressure) then goes via the regulator hose to the second stage where the air
supply is automatically regulated to the convenience of the diver.
The rst-stage always holds the adjusted pressure above the ambient pressure which is necessary to the
function of the breathing regulator. This is brought about by the outer springloaded diaphragm being in
contact with the ambient pressure. It automatically responds to this pressure acting it and thereby
regulates all changes in pressure.
The second-stage functions in such a way that the underpressure created in the regulator housing
during each inhalation inuences a servo valve system, which will supply the necessary
air as long as the inhalation phase lasts. The automatic pressure compensation takes place in the same
way as in the rst stage, the outer diaphragm surface being in direct contact with ambient pressure, and
the pressure on the inside of the diaphragm must correspond to ambient pressure before the diaphragm
can return to its position. The diaphragm retums to its rest position and shuts off the air owing in as
soon as the inhalation phase has been broken off and the air pressure in the regulator housing has
become equal to ambient pressure.
The second stage has a built in purge button, for manual purging.

SERVICE MANUAL
Page 3
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
To service Poseidon Jetstream regulators, a mix of standard tools and specic Poseidon special tools are needed.
The list below shows what specic Poseidon tools and what standard tools are needed.
Poseidon specic tools
Article nmbr. Description Picture
2297 O-ring remover
3460 Regulator test
3773 Torque wrench set
2706 Allen key 1,5 mm
3605 Combination tool 1
3606 Combination tool 2
4591 Tool NV 17 Xstream
2. TOOLS

SERVICE MANUAL
Page 4
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
Poseidon specic tools continues.
Article nmbr. Description Picture
8516 Regulator lubricant
2705 Adjustment tool
TOOLS LIST
Standard tools
Article nmbr. Description Picture
Open end wrenches
Screwdriver, philips head
Allen keys 2,5, 4, 5 mm

SERVICE MANUAL
Page 5
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
3. JETSTREAM Mk3 Art No 0100-005
JETSTREAM SECOND STAGE VALVE Art No 0120-005
Description..........................................................................................Upstream diaphragm actuated. servo assisted
with safety relief, xed ejector system.
Purge button for clearing.
Sensivity switch for added control.
REGULATOR HOSE Art No 0130-000
Length..................................................................................................................................................28 inch / 70 cm
Art No 0130-002
Length..................................................................................................................................................35 inch / 90 cm
FIRST STAGE XSTREAM DEEP G5/8 Art No 0110-000
Description..................................................................................... Ball sealed 1st stage, approved for 21% Oxygen.
Built in OPV with a release pressure of
232 - 304 PSI (16 - 21 Bar.)
Connection threads for primary pressure................................................... G5/8” - Max 4350 PSI / 30 MPa / 300 bar
Five outlets marked IP.................................................................................................. UNF 3/8” - Low pressure
Two outlets marked HP..................................................................................................UNF 7/16” - High pressure
SERVICE KITS
First stage..................................................................................................................................................Art nr 4822
Second stage.............................................................................................................................................Art nr 3549
BREATHING REGULATOR
Primary pressure....................................................................................................................Max 4351 PSI / 300 BAR
Secondary pressure..............................................................................................................Max 145 PSI/ 10 BAR
Inhalation resistance at 115 l/min......................................................................................Max. 40 mm of water
Exhalation recistance............................................................................................................Max. 20 mm of water
The above data apply when measuring at atmospheric pressure

SERVICE MANUAL
Page 6
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
EXPLODED VIEW - SECOND STAGE 0120-005 (and color variants)

SERVICE MANUAL
Page 7
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
PARTS LIST SECOND STAGE 0120-005 (and color variants)
Art. Nmbr. Description
1 0010-353 (2782) O-ring
2 0000-130 LP hose adapter 9/16”
3 3088 Low pressure valve, complete
4 0010-355 (2856) O-ring
5 2857 LP valve house
6 0010-028 (1145) O-ring
7 3440 Valve insert
8 0012-007 (1233) O-ring
9 2947 Valve house nut
10 2875 Stop screw M3x4
11 2787 Rubber plate
12 0015-019 (2876) O-ring
13 2839 Valve tube, Jetstream
14 0010-002 (1896) O-ring
15 2786 Servo valve Jetstream, complete
16 4532 Mouthpiece
17 1167 Locking strap
18 3122
3132
0005-170
0005-171
0005-172
Housing with switch, Black
Housing with switch, Yellow
Housing with switch, Blue
Housing with switch, Red
Housing with switch, Grey
19 2578 Membrane with washer
20 2707
2989
0000-775
0000-776
0000-777
Cover 2nd stage Jetstream, Black
Cover 2nd stage Jetstream, Yellow
Cover 2nd stage Jetstream, Blue
Cover 2nd stage Jetstream, Red
Cover 2nd stage Jetstream, Grey
21 2851 Screw M2x8
22 2853 Purge button
23 2961 05
3546 05
0005-165
0005-166
0005-167
LP Valve Jetstream, Black
LP Valve Jetstream, Yellow
LP Valve Jetstream, Blue
LP Valve Jetstream, Red
LP Valve Jetstream, Grey
24 2711 Switch
25 0010-018 (1851) O-ring
26 3120
3130
0000-771
0000-772
0000-773
Demand valve housing, Black
Demand valve housing, Yellow
Demand valve housing, Blue
Demand valve housing, Red
Demand valve housing, Grey
27 2794 Lock washer
28 2712 Diaphragm cam
*Only hose with built in OPV can be used.

SERVICE MANUAL
Page 8
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
EXPLODED VIEW & PARTS LIST- FIRST STAGE 0110-000
Item # Description Qty 0012-028 (1007) O-ring, 1 4778 Conn. stem 1.stage 90 Xstream 1 4552 Cup type filter long Xstream 90 1 0010-354 (2918) O-ring 3 6010-233 Line protector Xstream, black 1 4754-5IP Housing 1.stage 1 4555 Spring for ball Xstream 1 0000-149 Ruby ball 1.stage Xstream 1 0015-059 (4557) O-ring 1 4758 Zytel valve seat Xstream 1 4760 Valve seat holder Xstream 1 4761 Valve seat spring Xstream 1 4777 Lower pin guide Xstream 1 4563 Pin bushing 1.stage Xstream 1 0015-012 (4423) O-ring 1 4762 Upper pin guide Xstream 1 4559 Actuating pin, Xstream 1 4564 Roll.diaphragm 1.stage Xstream 1 4565 Pressure plate 1.stage Xstream 1 4766 Adjust. spring 1.stage Xstream 1 4570-BK Barrier 1.stage Xstream, black 1 0000-140 Cover Xstream 1st stage, satin 1 4568 Screw cover M3x10 Xstream 3
4798-CH Adjustment screw, chrome 1
2680 Blindscrew UNF7/16 2 2679 Blindscrew UNF3/8 5 0010-353 (2782) O-ring 5 4576 BK Wheel G5/8” Xstream, black 1 3726 Valve sealing 1 3725 Valve piston 1 1180 Pressure spring 1 3727 Locking screw 1

SERVICE MANUAL
Page 9
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
4. DISASSEMBLY INSTRUCTIONS - SECOND STAGE 0120-005
Step Parts Tools/Instructions Replace Picture
1
0000-130
Disconnect the low pressure hose from the LP
hose adapter and remove the LP hose adapter
2
3088
Remove the low pressure valve from the
housing with a screwdriver.Make sure the servo
valve needle is not bent. Be sure to hold the low
pressure valve carefully, to avoid dropping it
(see figure).
3
3202
1167
Cut off the locking strap (17) with cutting pliers.
Remove the mouth piece (16).
4
2851
Unscrew the 4 screws (26) with a 3.5 mm
screwdriver.
5
2578
2989
Remove the cover (25) and the diaphragm (24).
6
2853
Remove the purge button (27).
7
2711
1851
2794
2712
IMPORTANT
The switch should not be removed if it is
undamaged.
Removal:
1. Pull out the diaphram cam (22).
2. Cut off the switch (18) with a pair of cutting
pliers close to the locking washer (21). Remove
the switch.
3. Remove the o-ring (19).


SERVICE MANUAL
Page 10
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
Step Parts Tools/Instructions Replace Picture
8
2786
Remove the servo valve (14).
9
2875
2876
2839
1896
2787
Unscrew the stop screw (9) and remove the
valve tube (12). Remove the o-rings (11) (13)
with an o-ring remover.Make sure the sealing
surfaces are not damaged.
Remove the rubber plate (10).
10
2857
Place the valve housing in the
tool. Unscrew the valve housing
(4) with a special spanner.
11
1233
Remove the o-ring (7) with an oring remover.
Make sure the sealing surfaces are not
damaged.
12
3440
Remove the valve insert.
13
2856
1145
Remove the o-rings (5) (3) with an o-ring
remover.Make sure the sealing surfaces are not
damaged.


SERVICE MANUAL
Page 11
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
5. CLEANING INSTRUCTIONS
Jetstream Mk3
If corrosion or salt deposits occurs on metallic parts, place them in an ultrasonic washer for
the period of time recommended by the manufacturer of the liquid used or immerse part in
concentrated Hempocid* or 15% Hydrochloric acid for about 10 minutes. Then rinse them
thoroughly in fresh water and blow them dry with air. The synthetic parts must not be treated
with solvents and must only be cleaned with fresh water.
*Hempocid=Acid Liquid detergent containing phosphoric acid (5-10%) and bactericide for
disinfectant cleaning
The safety of your customer and yourself depends on you carefully and strictly following these instructions.
Negligence in any step can cause serious injury or even death.
Make absolutely sure Hydrochloric acid is NOT poured into the ultra-sonic cleaner. It would then destroy the
ultra-sonic cleaner and the parts attempted to be cleaned.

SERVICE MANUAL
Page 12
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
6. ASSEMBLY INSTRUCTIONS - SECOND STAGE 0120-005
Lubricants shall be used sparsely. Excessive quantities of lubricant can trap particulate and other
contaminants developing apotential re hazard.
Parts marked with the symbol are parts that must be replaced at every service. New parts should be
stored in it’s original packing until it is time for assembly.
Step Parts Tools/Instructions Replace Picture
1
2578
Diaphragm (24). Check that the sealing surface
of the diaphragm is even. Also check that there
are no holes in the diaphragm and that the
diaphragm washer is properly fixed in position.
2
3202
The mouth piece (16). Make sure there are no
cracks.
3
2853
The purge button (27).Make sure
there are no cracks. Check to make sure
the spring is undamaged.
4
2786
Servo valve (14). Check to make sure that the
valve bar is not bent.
5
The switch: Put the switch into - and +position.
It should be moved rather slowly, control the
position of the diaphragm and that it is properly
tighten.
BEFORE ASSEMBLY, CHECK THE FOLLOWING

SERVICE MANUAL
Page 13
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
Step Parts Tools/Instructions Replace Picture
1
2856
2857
Mount the o-rings (5,3) on the valve housing (4).
Use the tools. See picture.
2
2857
3440 Install the valve insert (6) in the valve housing
(4). Do not use any lubricant on the valve insert
(4), use only soap and water.
3
2857
1233
2974
Place the o-ring (7) in the groove of the valve
insert (6).
Lubricate the thread. Install the valve housing
nut (8).
4
2857
2974
Place the valve housing in the handle. Tighten
with a tool. See picture.
5
2876
2839
1896 Install the o-rings (11,13) on the valve tube (12).
Lubricate the threads and the o-rings.
6
2839
Screw in the valve tube (12) until about 2 mm
space remains as illustrated.

ASSEMBLY



SERVICE MANUAL
Page 14
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
Step Parts Tools/Instructions Replace Picture
7
2857
2787
Install the rubber plate (10). Screw in
the stop screw (9). Tighten the stop screw to a
point where you can still turn the valve tube (12).
8
2786
Screw the servo valve (14 ) on to valve tube
(12).Tighten up. Be careful not to bend the valve
needle.
9
2711
1851 SWITCH (Only if the switch is damaged)
Fit in o-ring (19) and lubricate it.
Fit in the switch with the narrow part against
the - minus sign on the second stage valve. See
Picture.
10
2711
1851
2794
2712
Install the locking washer (21) on the switch (18).
Press it on a drift. Tighten the locking washer so
that there is sufficient resistance when
setting the switch.
Fix the diaphragm cam (22) upon the switch
(18). Set switch at - (minus), press the
diaphragm cam into correct position per the
diagram.
11
The distance from the top of the diaphragm
cam to the housing should be 2 mm, concerns
diaphragm of silicone rubber, see diagram.
Carefully push diaphragm cam into the right
position. Note the cam should be pushed slowly
on to the switch so that the switch is not moved.


SERVICE MANUAL
Page 15
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
Step Parts Tools/Instructions Replace Picture
12
3088 Insert the low pressure valve in to the second
stage housing and secure it with the LP hose
adapter.
13
2707
2853 Fit the purge button in the cover (25) for the
second stage.Make sure that the spring is
undamaged.
14
2578
Position the diaphragm (24) with the diaphragm
washer facing down wards and the hole
positioned as illustrated.
15
2989
2851 x 4 Position the cover (25) for the second stage
according to the adjacent illustration. Lubricate
the screw and tighten (27) with a screwdriver.
16
3202
1167 Install the mouth piece (16) and the locking strap
(17). Tighten up and cut off with plastic band
pliers.
17
Checking the second stage for leaks:
Place the mouth piece against your lips and
cover the low pressure hose connection with
your thumb and inhale lightly.This will create a
partial vacuum inside the second stage. If the
pressure does not equalize in 5 second stage
leaks. Then you need to check to make sure you
have mounted all o-rings.

SERVICE MANUAL
Page 14
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
7. DISASSEMBLY INSTRUCTIONS - FIRST STAGE
A service includes the following 5 steps:
1. Complete disassembly of the first stage.
2. Inspection of disassembled parts.
3. Cleaning prior to assembly.
4. Assembly.
5. Final inspection and adjustment.
Do not disassemble the regulator in the clean room environment. All parts shall be
taken to the clean room environment after inspection and after the pre-cleaning process
if such is needed. Otherwise you risk to contaminate the clean room environment. New
parts should be stored in it’s original packing until it is time for assembly.
To remove o-rings, ONLY use o-ring remover tool 2297. Make sure not to damage
o-ring and sealing surfaces!!
Step Parts Tools/Instructions Replace Picture
1
2680 Blindscrew UNF 7/16” 2 pcs
2679 Blindscrew UNF 3/8” 5 pcs
2
4568 Screw M3x10 Xstream 3 pcs
3
0000-140 Cover Xstream first
stage satin
4
4763 Press. spring 1.stage
Xstream
6
5
4565 Pressure plate 1.stage
Xstream

SERVICE MANUAL
Page 15
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
Step Parts Tools/Instructions Replace Picture
6
4570-BK Barrier 1.stage Xstream
black
7
4564 Roll. diaphragm 1.stage
Xstream Only use fingers. Tools
may puncture the
diaphragm
8
Pin guide assembly
9
4764 Valve seat spring Xstream
10a
4760 Valve seat holder Xstream
4758 Zytel valve seat Xstream
10b
4760 Valve seat holder Xstream
4758 Zytel valve seat Xstream
The seat/seat holder
may also be removed
using compressed air,
as shown in the picture.

SERVICE MANUAL
Page 16
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
Step Parts Tools/Instructions Replace Picture
11
0012-028 O-ring
12
4778 Conn. stem 1.stage 90
Xstream
13
4576-BK Line protector, black
14
0010-354 O-ring
15
4576- BK Wheel G5/8” black
16
4552 Cup type filter long
17
Over pressure valve
3726 Valve sealing
3725 Valve piston
1180 Pressure spring
3727 Locking screw
1. Remove the locking
screw with a 4mm Allen
wrench. Remove the
pressure spring and the
valve piston.
2. Remove the valve
sealing from the valve
piston with an o-ring
remover.

SERVICE MANUAL
Page 17
Service manual Jetstream Mk3 - V. 1.0 - 11-02-08 Approved by: JN
JETSTREAM Mk3
Step Parts Tools/Instructions Replace Picture
18
0000-149 Ruby ball 1.stage
Xstream
19
4555 Spring for ball Xstream
20
4559 Actuating pin, Xstream
21
4777 Lower pin guide Xstream
6 mm
22
4563 Pin bushing 1.stage
Xstream
Do not pull out nor replace
the Pin bushing while
servicing.
23
0015-012 O-ring
24
0015-059 O-ring