POSEIDON Cyklon 5000 User manual

CYKLON 5000 Art. Nmbr 3950
SERVICE MANUAL V1.0

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
CYKLON 5000 - Article number 3950

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
TABLE OF CONTENT
Chapter Page
Important information 3
Function 4
Tools 5
Cyklon 5000 (art. nmbr 3950) specications 8
Second stage exploded view 9
Second stage parts list 10
First stage 3720 exploded view with parts list 11
First stage 3720 10 exploded view with parts list 12
Second stage disassembly instructions 13
Second stage assembly instructions 17
Second stage adjustments 22
First stage disassembly 23
First stage assembly with cleaning instructions 28
First stage settings and adjustment 33

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
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/oil are used:
Regulator Lubricant: Art no 8516
Oil: Silicon oil Art no 3139

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
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. 167 PSI/11,5 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, 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.
During diving in cold water, i.e, temperatures lower than +10°C (+50°Farenheit ), the outer spring housing
of the rst stage may be provided with an anti-freeze cap in order to prevent direct contact with the
water.This is necessary as the considerable cooling that takes place when the primary air expands in the
secondary chamber can otherwise cause ice to form and thereby prevent the springs and diaphragm
from functioning.
The second-stage functions in such a way that the underpressure created in the regulator housing
during each inhalation inuences a diaphragm actuated 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 as been provided with an ejector system for the purpose of keeping inhalation effort
to a minimum.
During the exhalation phase, the exhaled air goes out through the exhalation diaphragm on the
opposite side of the inhalation diaphragm into the ambient medium. The exhalation diaphragm closes
automatically when exhalation stops. Also, the exhalation diaphragm regulates the necessary pressure
compensation by closing when the ambient pressure is equal.The special construction of the exhalation
section of the regulator has been designed to obtain high capacity with low exhalation effort.
The second stage bas a built in purge button, for manual purging.

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
TOOLS
To service Poseidon Cyklon 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
3879 Tool kit

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
TOOLS
Poseidon specic tools continues.
Article nmbr. Description Picture
2112 Assembly tool
2299 Drift
3138 Holder for drift
8516 Regulator lubricant
3397 10 Fixture for rst stages

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
TOOLS
Standard tools
Article nmbr. Description Picture
Open end wrenches
Screwdriver, at
Awl
Allen keys, 4, 5, 6 mm

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
CYKLON 5000 Art No 3950
BREATHING REGULATOR
Primary pressure....................................................................................................................Max 4351 PSI / 300 BAR
Secondary pressure..............................................................................................................Max 167 PSI/ 11,5 BAR
Air ow....................................................................................................................................Approxemately 1050 l/min
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
FIRST STAGE VALVE Art No 3270, 3720 10
Description..................................................................................................................Diaphgram-actuatedbalancedwithshear
venturi boost. Release pressure approx.
217-247 PSI / 1,5-1,7 MPa / 15-17 bar
Connection threads for primary pressure........................................................G 5/8 -max 4350 PSI /300 bar accord.
SS 2600/K and DIN 477/5 or
yoke connection accord. SS 2603
and ANSI/CGA VI: 1987
Outlet connections:
One outlet marked R for second stage (max airow).......................................................UNF 3/8’’ - secondary pressure
Three outlets marked LP for drysuits, buoyancy
compensators, safety second stage etc.......................................................................UNF 3/8’’ -secondary pressure
drysuits, buoyancy compensators, Octopus, etc ........................................................UNF 3/8’’ -secondary pressure
One outlet marked HP.......................................................................................................UNF 7/16’’-primary pressure
One outlet marked S has restricted airow
and therefore is intended only for dry-suit or stabjacket ...........................................Intended for rst stage No. 3585
UNF 3/8’’ -secondary pressure
Two outlet marked HP for pressure gauge........................................................................UNF 7/16’’ -primary pressure
SECOND STAGE VALVE Art No 1133, 3536, 3354, 3354 M
Description.....................................................................................................Downstream type, diaphragm actuated.
Integral saftey valve opens at
approximatley 203 PSI / 14 bar.
Purge button for clearing.
REGULATOR HOSE Art No 2946
Length..................................................................................................................................................28 inch / 70 cm
TIGHTENING TORQUE
Primary DIN connection............................................................................................................20-22 Ibf.ft / 28-30 Nm
Valve cover................................................................................................................................20-22 Ibf.ft / 28-30 Nm
Connections marked LP-HP.....................................................................................................................6 Ibf.ft / 8 Nm
ANTI-FREEZE PROTECTION Art No 1286
Type ...........................................................................................................................................................Rubber cap

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
Exploaded view: 2nd stage 1133, 3354, 3354 M, 3536 - Cyklon 5000

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
Parts list: 2nd stage 1133, 3354, 3354 M, 3536 - Cyklon 5000
Art. Nmbr. Description
1 0010-353 (2782) O-ring
2 0010-009 (1156) O-ring
32946
2947
LP hose 70 cm Cyklon UNF 3/8”
LP hose 90 cm Cyklon UNF 3/8”
41166 Locking nut
51165 Valve seat
60010-347 (1164) O-ring
71162 Rubber plate
82429 Valve piston
9 1157 Pressure spring
10 1163 Valve housing
11 1155 Lever pin
12 0010-025 (1145) O-ring
13 2307 Ejector sleeve
14 1151 Control lever
15 1150 LP valve, complete (5-14)
16 3202 Mouthpiece**
17 1167 Locking strap
18 3200 10
3200 30
1146
Mouthpiece tube, black w. logo
Mouthpiece tube, yellow w. logo
Mouthpiece tube, metal
19 1144 Locking ring
20 1999 10
1999 30
Cover for exhale diaphragm, black
Cover for exhale diaphragm, Yellow
21 2579 Exhalation diaphragm, Silicone
22 1141 membrane housing
23 2577 Inhalation diaphragm
24 2001
2001 77
Inhalation cover
Inhalation cover, Cyklon Metal**
25 1140 Locking ring
26 2004 Purge button
27 2000 10 Diaphragm housing compl. Black (19-26)
2000 30 Diaphragm housing compl. Yellow (19-26)
2000 77 Diaphragm housing compl. Metal (19-26)**
**No longer available as a spare part

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
Exploaded view: 1st stage 3720 - Cyklon 5000
Art. Nmbr. Description
1 3417 Adjustmen screw
22802 10 Adjustment spring
32875 Locking screw
42814 Cover for valve housing
5 3419 Upper diaphragm center
63723 Valve center, upper
7 3724 Diaphragm
8 2816 Diaphragm centre, lower
92817 10 Valve needle
10 3722 Valve center, lower
11 0010-028 (3728) O-ring
13 0010-009 (1156) O-ring
14 2803 Seat
15 2820 Valve piston
16 1180 Pressure spring (2 pcs)
17 3160 Support washer, metal
18 0012-126 (1368) O-ring
19 2822 Support washer, teon
20 3721 Valve housing 1:st stage, Cyklon
21 2402 Protective cap for 1:st stage
22 3096 Locking screw
23 0010-006 (2656) O-ring
24 0012-028 (1007) O-ring
25 1377 Cup lter
26 2827 Connection stem
27 0010-013 (1839) O-ring
28 2828 Connection wheel G5/8”
29 2679 Blanking screw, LP
30 0010-353 (2782) O-ring x 3
31 2680 Blanking screw, HP
32 0010-354 (2918) O-ring x 2
33 3726 Valve sealing
34 3725 Valve piston, safety valve
35 3727 Locking screw, safety valve

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
Exploaded view: 1st stage 3720 10 - Cyklon 5000
Art. Nmbr. Description
1 3417 Adjustmen screw
22802 10 Adjustment spring
32875 Locking screw
42814 Cover for valve housing
5 3419 Upper diaphragm center
63723 Valve center, upper
7 3724 Diaphragm
8 2816 Diaphragm centre, lower
92817 10 Valve needle
10 3722 Valve center, lower
11 0010-028 (3728) O-ring
13 0010-009 (1156) O-ring
14 2803 Seat
15 2820 Valve piston
16 1180 Pressure spring (2 pcs)
17 3160 Support washer, metal
18 0012-126 (1368) O-ring
19 2822 Support washer, teon
20 3721 Valve housing 1:st stage, Cyklon
21 2402 Protective cap for 1:st stage
22 3096 Locking screw
23 0010-006 (2656) O-ring
24 2922 Yoke handle
25 1377 Cup lter
26 3472 Connection stem Yoke
27 0010-013 (1839) O-ring
28 3473 A-clamp, yoke
29 2679 Blanking screw, LP
30 0010-353 (2782) O-ring x 3
Art. Nmbr. Description
31 2680 Blanking screw, HP
32 0010-354 (2918) O-ring x 2
33 3726 Valve sealing
34 3725 Valve piston, safety valve
35 3727 Locking screw, safety valve
36 2277 Protective cap, yoke

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
DISASSEMBLY - 2nd STAGE 1133, 3224, 3354, 3354 M, 3536
Disconnect the low pressure hose from the
second stage with a 17 mm. open wrench.
Remove the oring (2) with an o-rings remover.
Remove the diaphragm housing (27) from the
mouth piece tube.
To release the exhalation cover, remove the
locking ring with a small screwdriver.
Remove the exhalation diaphragm (21).

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
Remove the locking ring (25) with an
awl. Support the diaphragm house,
see diagram. Make sure that the
sealing surface for the exhalation
diaphragm is not damaged.
Remove the cover (24) and the
inhalation diaphragm (23).
Removal: Push out the purge
button
IMPORTANT! The purge button
(26) should not be removed if it is
undamaged
Remove the connecting ring (4) and
the low pressure valve (15).
DISASSEMBLY - 2nd STAGE 1133, 3224, 3354, 3354 M, 3536

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
DISASSEMBLY - 2nd STAGE 1133, 3224, 3354, 3354 M, 3536
Cut off the locking strap (17) with cutting pliers.
Remove the mouth-piece (16) and the o-ring
(12).
Remove the lever pin (11).
Remove the operating device (14).
Remove the o-ring (12).
Unserew the valve seat (5) with an 8.5 mm
screwdriver. NOTE!
the valve seat has a very fragile sealing edge;
put the seat with the edge upwards.
Remove the valve piston (8) and the spring (9).
In order to protect the piston bond, the old
rubber plate should be kept until the new shall
be xed.
Remove the o-ring (6) with an oring remover.
Make sure the sealing surfaces are not
damaged.
IMPORTANT! The ejector sleeve should not be
removed if it is functional and undamaged.
Check to see that the sleeve can be rotated to
any position, but that it does not rotate freely.

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
DISASSEMBLY - 2nd STAGE 1133, 3224, 3354, 3354 M, 3536
When servicing the regulator the following parts
should be replaced:
• All o-rings, including the one in the low-pressure
hose.
• Rubber plate.
CLEANING:
If corrosion or salt deposits occurs, place all metal
parts in an ultra-sonic washer or in 15% Hydrochloric
acid solution for about 10 minutes.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.
BEFORE INSTALLING CHECK THE FOLLOWING:
• Diaphragms (21) (23). Check the sealing
surface of the diaphragm to see if it is even and
uncracked.
• The mouth-piece (16). Make sure that there are no
cracks.
• The purge button (26). Make sure there are no
cracks.
• Valve piston (8). Ensure that the ball joint is
working correctly by manipulating and rotating the
joint.
• Operating device (14).Make sure that the joint
articulates smoothly. Important: The operating
device must be replaced, if the lever tab is bent.
The tab should not be straightened, as this would
weaken it and make subsequent failure possible.
• Valve seat (5). Check to make sure the sealing
surfaces are undamaged.
• Low pressure hose (3). Check to make sure that
the sealing surface is undamaged, and that the
rubber does not show any aws.
• Diaphragm housing (22).Make sure that the
sealing surfaces are free from defeas and that the
track for the inhalation diaphragm is absolutely
clean and free from lubricant.

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
ASSEMBLY - 2nd STAGE 1133, 3224, 3354, 3354 M, 3536
Assembly:
This step is only performed if the ejector sleeve
has been removed.
Install the ejector sleeve (13) on the valve housing
(10). Press the sleeve into the low pressure valve
so the slits of the sleeve are exceedingly small.
Lubricate:
Grease:
Oil:
Install the o-ring (6) on the valve seat (5).Make
sure that the sealing surface is not damaged.
Lubricate the ball joint. Tilt the position head
according to the gure to ensure that it rotates
and articulates smoothly.
Remove the rubber plate (7) with an awl and
make sure the sealings surface on the valve is
clean. Install the new rubber plate.
Put the spring (9) on the valve piston (8).
Lubricate the spring
Install the valve piston/spring in the valve housing
with the at part of the valve piston upwards.

SERVICE MANUAL CYKLON 5000
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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
Place the valve housing on a drift seated
on a block. Press the valve housing down,
compressing the spring. Keep the at part of the
valve piston parallel with the horizontal slot in the
end of the valve housing. Move the valve piston
up and down a few times to check for freedom of
movement.
Press the valve housing down and slide an
o-ring remover through the hole in the valve
piston.
Lubricate the o-ring and the thread of the valve
seat. Screw in the valve seat with an 8.5 mm
screw driver until the o-ring remover comes
loose.
Install the operating device (14). Insert the lever
pin (11) through the slot, engaging the hole in
the operating device. Rotate the lever pin 90
degrees to lock it in place.
ASSEMBLY - 2nd STAGE 1133, 3224, 3354, 3354 M, 3536

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Service manual Cyklon - V. 1.0 - 10-03-22 Approved by: JN
ASSEMBLY - 2nd STAGE 1133, 3224, 3354, 3354 M, 3536
Install the o-ring (12). Lubricate. See
diagram.
Install the mouth piece (16) and the
plastic band (17). Tighten and cut off
plasticband with a plier.
Install the o-ring .(12)
Lubricate the threads on the mouth
piece
Install the low pressure valve (15) in
the mouth piece tube. Set the indent
notch at the top of the valve housing
against the key at the top of the mouth
piece tube. Screw on the connecting
ring (4).
Screw the valve seat down until
the highest part of the
operating device is even with
the level og the opening of the
mouth piece tube. Hold the
second stage valve vertically.
See g.