TWIN MANIFOLD

MAINTENANCE
J VALVE
MANIFOLD VALVES
Twin Manifold J-Valve

Single J-Valve
Single K-Valve

DIN
Valve

Single Z-Valves

• Twin Manifold, J Valve, K and Z Valves

 J VALVE TWIN MANIFOLD

• The Twin Manifold J Valve is a one piece valve for 2 bottles.

• It has a twist type on/off valve
• It has a lever reserve that holds back approximately 500 PSI in one cylinder
 INTRODUCTION
• This CD-ROM provides instruction for the maintenance
procedures of the Twin Manifold J-Valve. This CD-ROM is
not intended for untrained personnel. The procedures in this
CD-ROM are to be performed only by personnel who have
received factory training. If you do not completely understand
all of the procedures, contact Aqua Lung directly and speak
with a technical advisor.
• A complete Technical Repair Manual can be found on the
Aqua Lung Military web site at:
http://www.aqualung.com/military/datasheets.html
 GENERAL GUIDELINES

• Always use the maintenance manual or CD; Do not rely on

memory
• Work in well lit, clean area, with proper tools
• Do not intermix parts between units
• Use only genuine Aqua Lung replacement parts
• Do not reuse mandatory replacement parts
• Follow proper torque settings
• Follow each step in the order given
GENERAL INFORMATION
• Only use Christo-Lube MCG-111
– PN 820467 16 oz.
– PN 820466 2 oz.
• Only apply light film to o-rings; avoid excessive amounts
• The Twin Manifold overhaul kit is PN 280095
• This program demonstrates the Twin Manifold maintenance
procedures, however the Single Bottle J & K Valves are
similar.
• The Z Valve differs slightly, however the basic procedures
are the same for the Z Valve and can be found in the Valve
Maintenance Manual
 SECTION INDEX
• Click on the Box below for direct access to sections
Start Page Initial Testing Of Reserve Valve

Introduction Testing Reserve Valve Actuation Pressure

General Guidelines Attaching Valves To Cylinders

Disassembly Of The Twin Manifold Exploded View Drawings & Parts

Assembly Of The Twin Manifold

 DISASSEMBLY
• The Valve can be removed from cylinders in one of two ways:
• For Single valves
– use a 1 3/8” Crowfoot or Open End Wrench at the base of the valve if
flats are provided and unscrew the valve
– Lightly tap the valve handwheel with a rubber mallet in a
counterclockwise direction. Once loosened, unscrew the valve by hand
• For Twins
– lay the set down on a flat surface, grasp one cylinder base and rotate
in a counterclockwise direction. If necessary a strap wrench may be
used.
– After the first bottle is removed, stand up the other cylinder and tap the
valve with a rubber mallet in a counterclockwise direction. Once
loosened, unscrew the valve by hand
 DISASSEMBLY
• After removal of the Valve from
the bottles, insert it into the Valve
Adapter (PN 280036)
• This will protect the valve during
maintenance and provide a solid
working surface for disassembly
and reassembly
• The Valve Adapter can be bolted
to a work surface or held in a vice
REQUIRED TOOLS & CONSUMABLES
• ¾” Socket • Flex Wrench (Breaker Bar)
– Valve Bonnet – PN 9-44363
– End Plug • Inch Pounds Torque Wrench
• ½” Socket • Medium Modified Flat Blade
– Burst plug Screwdriver

• 5/8” Crowfoot – PN 9-47448

– Reserve Bonnet • Christo-Lube

• O-ring tool Kit – PN 820467 16 oz.

– PN 944022 – PN 820466 2 oz.

• Valve Adapter • Loctite 680

– PN 280036 – Replace Dip Tube

Bottle Valve O-Ring

• Remove the Bottle Valve O-Rings and discard

 DIP TUBES

DIP TUBES

• The Dip Tubes, if metal, do not need to be removed.

• If Plastic, refer to the Technical Service Manual for removal instructions
• These tubes are held in place by LocTite 680 and are supposed to be permanent
BURST PLUG DISASSEMBLY

• Remove the Burst Plug and discard. This is not reusable

BURST DISC DISASSEMBLY

Burst Disc Gasket

• Remove the Burst Disc

• Remove the Gasket
• Discard all these parts
PLUG AND GASKET DISASSEMBLY

PLUG

GASKET

• Using a ¾” socket, remove the Plug and gasket

form the end of the manifold body. Discard the
Gasket.
ON/OFF VALVE DISASSEMBLY

• Remove the Valve Handle Retainer with a modified screwdriver

 ON/OFF VALVE DISASSEMBLY
LEFT HAND THREADS

• NOTE: THE AFC BONNET HAS LEFT-HANDED THREADS, REVERSE

MOVEMENTS ARE REQUIRED TO LOOSEN
• Using a ¾” Socket, remove the Bonnet by unscrewing it
CLOCKWISE (Left hand Threads)
• Remove and discard the O-ring from the Bonnet
 STEM DISASSEMBLY

• Remove the Stem

• Remove the Back up ring and the O-ring from the stem. Discard these parts
• The Blue Thrust Washer must be replaced during service. If a white washer
is found, the Stem must also be replaced. Discard the Blue Thrust Washer
 BONNET DISASSEMBLY

Look Here

• If the Back up Ring is not on the stem, look in the Bonnet and
remove the Back up ring with the brass O-ring tool
 SEAT ASSEMBLY DISASSEMBLY

• Using the Stem or a Medium Blade screw driver, remove the Seat
Assembly from the Valve Body by turning the Seat assembly
counterclockwise. Discard the Seat Assembly.
• This concludes the disassembly of the K Valve portion
 RESERVE MECHANISM
DISASSEMBLY

• With the Reserve Lever in the OFF (up), unscrew the

Valve Handle Retainer with the modified Screwdriver
RESERVE LEVER DISASSEMBLY

• Remove the Spring, Reserve Handwheel and Washer

RESERVE BONNET DISASSAMBLY

• Using a 5/8” Open End wrench, remove the Reserve Bonnet

Assembly
 RESERVE BONNET DISASSEMBLY

• Remove the O-ring and Back up ring from the Bonnet. Discard the
O-ring and Back up Ring.
 RESERVE STEM DISASSEMBLY

• Remove the Stem, Gasket and O-ring. Discard the Gasket and O-
ring
 RESERVE MECHANISM
DISASSEMBLY

• Remove the Reserve Mechanism from the body. Remove the Body
from the Valve Adapter and tilt it so the mechanism can fall out. A
light tap with a screwdriver on the Valve Body may facilitate this.
• Remove the Washer and discard it.
 RESERVE MECHANISM INSPECTION

• If, after inspection, replacement of the Reserve

Assembly is called for, be sure the new Assembly fits
the Valve Body.
• PN 052508 is the correct Assembly for this body. It is
marked with black dye on the end
• Failure to install the correct Reserve Assembly could
cause a malfunction, resulting in loss of air supply to the
diver
• The Reserve Assembly is not rebuildable
 END OF DISASSEMBLY
• This concludes the disassembly of the Twin Manifold
• Before beginning reassembly, perform all cleaning and
lubrication procedures
 CLEANING METAL PARTS

• Degrease in vinegar and warm, soapy water. Rinse.

• Ultrasonically clean for 5 to 15 minutes
• Rinse in fresh water
• Blow dry with low pressure filtered air
 CLEANING PLASTIC PARTS
• Soak in warm, soapy water. Rinse with fresh water
• Use soft-bristle toothbrush to scrub away deposits
• Blow dry with low pressure filtered air

RETURN TO INDEX
 ASSEMBLY
• Perform the assembly in a clean area
• Ensure you have the correct parts kit for the valve
• Ensure you apply the correct torque or damage to parts is
very possible
• Apply a small amount of Christo-lube to all o-rings
• Apply a small amount of Christo-lube to all threaded parts
EXCEPT the Burst Plug & the End Plug. No Christo-lube
should be applied to the Burst Plug or the End Plug as it
adversely affects the applied Torque
TWIN MANIFOLD EXPLODED VIEW
INSTALL REGULATOR SEAL O-RING

• Insert the PN 820120 O-ring (12 ) into the face of the

valve body
BOTTLE SEAL O-RING(S)

• Install PN 820214 O-rings(s) on the Valve Body

 DIP TUBE INSTALLATION

• If the Dip Tube(s) (PN 051821) need to be installed, use LOCTITE 680
• One drop on the Dip Tube threads and screw it into the Valve Body hand
tight
• Allow to dry overnight to ensure it is completely cured before installing
onto a cylinder
 SAFETY DISC ASSEMBLY

• Drop the Gasket, (15b) into the body, ensure it is flat

• Repeat these steps for the second Safety Disc Assembly, if required
 SAFETY DISC ASSEMBLY

• Position the Burst Disc (15a) on the Valve Body red side up.
• Slide the Disc into the Valve Body, ensuring it is flat with the red side up
• Disc’s are color coded to ensure the correct disc is used
– RED for 3000 psi service
– BLACK for 2250 psi Service
• Repeat these steps for the second Safety Disc Assembly, if required
 SAFETY DISC ASSEMBLY

• Screw in the Safety Plug (15c). DO NOT LUBRICATE.

– This will adversely affect the applied Torque
• Insert the valve Body into the Valve Adapter
• Using a Torque wrench with a ½” socket, torque the Plug to
90 in.lbs (10.2 Nm)
• Repeat these steps for the second Safety Disc Assembly, if required
 Valve Body in Valve Adapter

• Valve Body installed into the Valve Adapter

 END PLUG ASSEMBLY

• The End Plug Assembly consists of

– PN 821011, Gasket (25)
– PN 050221, Plug (24)
• The End Plug Assembly is there to close the Valve Body from the
manufacturing process
 END PLUG ASSEMBLY

• Insert the Gasket (25) into the recess in the end of the Valve Body
• Screw in the Plug (24) into the Valve Body.
DO NOT LUBRICATE THE PLUG
 END PLUG ASSEMBLY

• Using a Torque Wrench with a ¾” socket, torque the End Plug to

90 in.lbs.(10.2 Nm)
Assembly of the Air Flow Control (AFC) Valve

• This is the Air Flow Control Valve exploded parts

 Assembly of the Air Flow Control (AFC) Valve

MANIFOLD
K-VALVE

J-VALVE

• The Seats (11) K-Valve, J-Valve, Z-Valve and the Twin Manifold are Different.
Failure to install the correct will to a malfunction when in use
– Manifold - PN 280013
– J-Valve - PN 052519
– K-Valve (Z-Valve) - PN 050109
 Assembly of the Air Flow Control (AFC) Valve

MANIFOLD K-VALVE

J-VALVE

• The K-Valve seat has a solid nylon surface, whereas the J-Valve & Manifold
seats have a pressure relief through-hole in the nylon surface
• This through-hole relieves any air pressure which may build up behind the
J-Valve Seat. This may be caused by air hitting the sealing surface of the
seat on an angle. Air can travel around the seat. If the seat was not
designed with a pressure relief through-hole, the seat could rupture, close
off or restrict air flow to the 1st stage regulator.
 Assembly of the Air Flow Control (AFC) Valve

• Lightly Lubricate the threads of the proper Seat (11) with Christo-Lube.
• Screw the Seat into the Valve Body with a medium blade screwdriver until
the Seat bottoms out.
• FAILURE TO DO THIS MAY CAUSE THE VALVE TO FAIL OR COME APART
 Assembly of the Air Flow Control (AFC) Valve

• Place PN 921019 Blue Thrust Washer (9) on PN 052521,

Stem (10)
 Assembly of the Air Flow Control (AFC) Valve

• Place PN 820010, O-ring (8) on the Stem (10)

• Place PN 957007, O-ring (6) on PN 050233, Bonnet (5)
• To continue, select one of the following

Primary Assembly Method Alternate Assembly Method

 Assembly of the Air Flow Control (AFC) Valve

PRIMARY AFC Valve Assembly Method

Concave side
against O-ring

• Install lightly lubricated PN 828510, Back-up Ring (7) on the Stem (10).
Ensure the concave side is against the o-ring
 Assembly of the Air Flow Control (AFC) Valve

• Insert the end of the assembled Stem (10) into the groove of the
Seat (11)

To continue Assembly click here

 Assembly of the Air Flow Control (AFC) Valve

Alternate AFC Valve Assembly method

• Turn the Bonnet (5) so the large opening is facing up

• Place the Back-up Ring (7) in the Bonnet (5) with the concave side
facing up. Ensure it is well seated and flat in the recess of the
Bonnet (5) using a blunt brass tool
 Assembly of the Air Flow Control (AFC) Valve

• Insert the assembled Stem (10) into the groove in the Seat (11)
 Assembly of the Air Flow Control (AFC) Valve

Left Hand Threads

• NOTE: THE AFC BONNET HAS LEFT-HANDED THREADS, REVERSE

MOVEMENTS ARE REQUIRED TO TIGHTEN
• Carefully place the Bonnet over the Stem (10)
• Screw the Bonnet (5) into the Valve Body counterclockwise by hand
• Using a Torque Wrench & ¾” socket, torque the Bonnet (5)
counterclockwise to 90 in.lbs. (10.2 Nm)
 Assembly of the Air Flow Control (AFC) Valve

• Install the Washer (4) over the stem on top of the Bonnet (5)
• Prior to installing the Spring (2) and Handle Retaining Nut (1), place
the Handwheel over the Stem(10) and fully OPEN the AFC Valve.
This will raise the Stem (10) and allow easier installation of the
Handle Retaining Nut (1)
 Assembly of the Air Flow Control (AFC) Valve

• Set the Spring (2) into the Handwheel (3)

• Start the Handle Retaining Nut by hand. CAUTION: DO NOT
CROSSTHREAD
 Assembly of the Air Flow Control (AFC) Valve

• Using the Modified Screwdriver, PN 9-47448, to secure the retainer. CAUTION: DO

NOT OVERTIGHTEN. Close, then Open the AFC Valve to ensure free movement.
• This completes the AFC Valve assembly
• This completes the K-Valve Assembly
 RESERVE VALVE ASSEMBLY

• If, after inspection, replacement of the Reserve Assembly is required, be

sure the new assembly is the proper one for the application.
• The part number for the standard Reserve Assembly is 052508 and is color
coded BLACK on the end
RESERVE VALVE ASSEMBLY

• Place the Washer (17) on the Reserve Assembly (16)

 RESERVE VALVE ASSEMBLY

Alignment
Bosses

• Install the Reserve Assembly (16) into the Body, making sure the
two alignment bosses fit into the matching grooves in the Valve
Body
 RESERVE VALVE ASSEMBLY

• Install lightly lubricated PN 820010, O-ring (8) in the groove on the J-

Valve Stem (18)
• Place PN 821014, Gasket (19) on the J-Valve Stem (18)
• Set assembly aside
 RESERVE VALVE ASSEMBLY

Concave side
against O-ring

• Place PN 828515, Back-up Ring (21) in the groove provided on PN 052515,

Bonnet (22). Ensure the concave side will face the O-ring( 20)
• Place PN 820015, O-Ring (20) in the groove provided on PN 052515, Bonnet
(22)
RESERVE VALVE ASSEMBLY

• Place the assembled J-Valve Stem (18) into the groove in the
Reserve Assembly (16)
• Slide the assembled Bonnet (22) over the J-Valve Stem (18)
RESERVE VALVE ASSEMBLY

• Tighten the Bonnet (22) by hand

• Using a torque wrench with a 5/8” crow-foot, torque the Bonnet (22) to
60 in.lbs. (6.7N.m)
• Do not over torque as damage will result to the Reserve Assembly (16)
 RESERVE VALVE ASSEMBLY

• Slide PN 845058, Washer (4) over the J-Valve Stem (18) to the
Bonnet (22)
• Install PN 280040, Reserve Handwheel (23) over the J-Valve Stem
(18) with the lever in the OFF (up) position. This assumes that the
Reserve Assembly was disassembled in the OFF position.
 RESERVE VALVE ASSEMBLY

• Insert PN 050107, Spring (2) into the Reserve Handwheel (23)

• Start PN 052518, Handle Retaining Nut (1) by hand. CAUTION: DO
NOT CROSSTHREAD
 RESERVE VALVE TESTING
• To ensure the Reserve Assembly is correctly assembled, perform
the following test
– Remove the Valve Body from the Valve Adapter
– Cycle the Reserve Lever to the ON (DOWN) position
– Ensure the AFC Valve is open
– Blow air into the Dip Tube on the reserve side of the Valve Body
– Air should pass through the Valve
– Next, Cycle the Reserve Lever to the OFF (UP) position
– Again, blow air into the Dip Tube on the reserve side of the Valve Body
– NO air should pass through the Valve
– If this does not work, the Reserve Valve Handwheel is in the wrong
position and needs to be removed and reinstalled 90 degrees from the
original position. Repeat the test.
 RESERVE VALVE ASSEMBLY

• Using the Modified Screwdriver PN 9-47448, tighten the Handwheel

Retainer Nut into place. DO NOT OVERTIGHTEN
• This concludes the assembly of the Reserve Valve
• This concludes the assembly of the TWIN MANIFOLD

Return To Section Index

 ATTACHING VALVE ASSEMBLY TO THE
CYLINDER

• Conduct all tests after the valve is attached to the cylinder as described
below.
• Apply a light amount of lubricant to the first five (5) threads of the body
which screw onto the cylinder.
• Single Valves: Screw the valve into the cylinder until hand tight. Attach a 1-
3/8” crow-foot to a torque wrench. Apply the wrench to the wrench flats and
tighten the valve to 30 +/- 10 foot-pounds or tap the handwheel lightly with a
rubber mallet to approximately 30 foot-pounds.
• Twin Valves: Thread one side of the twin valve into one of the cylinders.
Once hand tight, apply moderate force to the other end of the valve to
secure. Tap tight with rubber mallet. Lay the valve-cylinder assembly on a
flat bench top. Screw the other cylinder onto the other end of the valve.
Once hand tight, apply moderate force to secure the cylinder. Use strap
wrench to tighten.
• NOTE: Before filling twin cylinders, attach the backpack assembly for
safety.

Return to Section Index

 INSPECT SCUBA RESERVE “J” VALVE
ACTUATION PRESSURE

• Tools/test equipment required: Single hose, 2-stage balanced or

unbalanced diaphragm SCUBA regulator and a SCUBA cylinder
pressure gauge (submersible or non-submersible).
• NOTE: All inspecting is to be conducted under conditions of
standard temperature and pressure (68˚-72˚F and 14.7 ambient
pressure). Acceptable reserve actuation pressure ranges:
– (single cylinder) 500 +/- 50 psig,
– (double cylinder) 250 +/- 50 psig.
• NOTE: A balanced or unbalanced diaphragm first stage regulator
must be used to perform this maintenance. Piston type first stage
regulators will not be used to perform this maintenance.
 INSPECT SCUBA RESERVE “J” VALVE
ACTUATION PRESSURE
• Place reserve handwheel in “on reserve” (down)
position.
• Charge cylinder(s) or reduce cylinder pressure to
approximately 750-800 psig.
• Remove filler hose, if applicable.
• Attach standard single hose, 2-stage SCUBA regulator to
valve outlet.
• Return reserve handwheel to “start dive” (up) position.
• Fully open cylinder valve.
 INSPECT SCUBA RESERVE “J” VALVE
ACTUATION PRESSURE
• Gradually reduce cylinder pressure using one of the following
methods:
– a. Using second stage regulator, “breathe” system down until there is
a noticeable “restriction” or increase in inhalation resistance, or
– b. Fully depress purge button second stage as follows: 5 seconds
“on”, 2 seconds “off”, to be repeated until there is a noticeable
reduction in purge airflow rate. Immediately release purge button when
restriction becomes apparent.
• Rotate reserve handwheel to “on reserve” (down) position.
• If regulator is equipped with submersible pressure gauge (SPG)
read remaining cylinder pressure directly. This reading will
correspond with actual reserve actuation pressure.

Return To Section Index

 DRAWING INDEX
Click on the Index below for Drawings and Parts
Exploded View Twin Manifold

Parts List Twin Manifold

Exploded View J & K Valves

Parts List J & K Valves

Return to Section Index

EXPLODED VIEW TWIN MANIFOLD

Return to drawing index

 TWIN MANIFOLD PARTS
Key # Part # Description • 14----- 820214 O-ring
• 15----- 050241 Safety Disc Assembly,
• 1------ 052518 Nut, Handle Retaining 3000 psi
• 2------ 050107 Spring • ------- 050242 Safety Disc Assembly,
• 3------ 052541 Handwheel 2250 psi
• 4------ 845058 Washer • 16----- 052508 Reserve Assembly
• 5------ 050233 Bonnet • 17----- 845021 Washer
• 6------ 957007 O-ring • 18----- 052514 Stem, J-Valve
• 7------ 828510 Back-up Ring • 19----- 821014 Gasket
• 8------ 820010 O-ring • 20----- 820015 O-ring
• 9------ 921019 Thrust Washer • 21----- 828515 Back-up Ring
• 10----- 052521 Stem, K-Valve • 22----- 052515 Bonnet
• 11----- 280013 Seat, Std. Twin • 23----- 280040 Handwheel, Reserve
• 12----- 820120 O-ring • 24----- 050221 Plug
• 13----- 051821 Dip Tube • 25----- 821011 Gasket
• n/s----- 074305 Reserve Pull Rod
Part numbers in BOLD ITALICS indicate standard overhaul replacement part.

Return to Drawing Index

EXPLODED VIEW J & K VALVES

Return to Drawing index

 K & J VALVE PARTS
• Key # Part # Description • 12----- 820120 O-ring
• ------- 054500 J-Valve (3000 psi) • 13----- 051821 Dip Tube
• ------- NLA K-Valve (3000 psi), replaced by PN • 14----- 820214 O-ring
054295 • 15----- 050241 Safety Disc Assembly, 3000 psi
• 1------ 052518 Nut, Handle Retaining (2 req. on • ------- 050242 Safety Disc Assembly, 2250 psi

J-Valve) • 16----- 052508 Reserve Assembly

• 2------ 050107 Spring (2 req. on J-Valve) • ------- 052548 Reserve Assembly, Red (See

• 3------ 052541 Handwheel NOTE)

• 17----- 845021 Washer
• 4------ 845058 Washer (2 req. on J-Valve)
• 18----- 052514 Stem, J-Valve
• 5------ 050233 Bonnet, Left Handed Thread
• 19----- 821014 Gasket
• ------- 050216 Bonnet, Right Handed Thread
• 20----- 820015 O-ring
• 6------ 957007 O-ring
• 21----- 828515 Back-up Ring
• 7------ 828510 Back-up ring
• 22----- 214204 Bonnet
• 8------ 820010 O-ring
• 23----- 052540 Handwheel, Reserve
• 9------ 921019 Thrust Washer
• n/s----- 074305 Reserve Pull Rod, J-Valve
• 10----- 052521 Stem, K-Valve
• Key # Part # Description
• 11----- 052519 Seat, J-Valve
Part numbers in BOLD ITALICS indicate standard
• ------- 050109 Seat, K-Valve overhaul replacement part.

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