Envoy Service Manual
Contents
1. Regulator Service Manual For Zeagle Envoy 1st and 2nd Stage Scuba Regulators ITEM PART 341 341 341 341 341 341 341 341 341 0152 AA 0103 CD 0102 CD 0140 VH 0104 CD 0105 TA 0106 VH 0109 CD 0108 JA 160 0009 N9 341 0101 CL 160 0011 N7 341 341 0127 CD 0128 CD 160 0012 N9 341 0129 AA 160 0111 N9 341 341 0112 CD 0139 BA 160 0011 N7 341 341 341 341 341 341 341 341 0142 AA 0115 AA 0117 LA 0111 CD 0113 DL 0146 SA 0107 VH 0141 VA 160 0006 N9 160 0905 N9 160 0016 N7 341 0151 CL Envoy 1st Stage Parts DESCRIPTION Label Spring Adjuster Diaphragm Clamp Regulating Spring Spring Carrier Internal Diaphragm black Lifter Seat Support Seat orifice O ring for seat Body Satin Finish O ring for LP port plugs LP Port Plug includes O ring HP Port Plug includes O ring O ring for HP port plugs DIN Cap O ring for inlet of DIN bolt Din Connector Bolt Conical Filter O ring for filter amp bolt DIN Wheel Yoke Knob Assembly Dust Cap Yoke Bolt Yoke Satin Finish Saddle Spacer HP high pressure Valve Valve Spring O ring smallest O ring in HP balance plug O ring middle sized O ring on HP balance plug O ring largest sized O ring on HP balance plug HP Balance Plug Envoy First Stage Assembly Yoke Model 310 3210 DIN Model 310 3220 An asterisk next to the It2. 15 16 17 18 19 20 21 pot 23 24 25 26 o7 28 29 30 31 32 ao 34 35 342 0210 KA 342 0209 LG 342 0209 LY 342 0209 LK 342 0208 KA 342 0207 AA 342 0225 KA 342 0221 CD 342 0222 SA 160 0015 N7 342 0201 KA 111 4002 342 0216 U 342 0217 LA 342 0218 MA 160 0019 N7 342 0203 KA 160 0010 N7 342 0212 HB 342 0206 WH 342 0228 UA 342 0202 CD 342 0213 LA 342 0214 HA 160 9532 N7 342 0220 VH 342 0215 HA 160 0015 N7 160 0011 N7 342 0230 SA 165 1034 160 0011 N7 342 0229 LA 160 0010 N7 342 0222 SA 342 0230 SA DESCRIPTION Cover Ring Purge Dome GRAY standard color Purge Dome YELLOW octopus color Purge Dome BLACK Diaphragm Cover Diaphragm Deflector Nut Bushing O ring bushing to housing Housing Tie Wrap 2 needed Mouthpiece Exhaust Tee Exhaust Valve O ring control lever to housing Venturi Control Lever O ring for seat Seat orifice Lever Pin Valve Tube Seating Seal Piston O ring for piston Spring Balancing Cylinder O ring for valve tube O ring for spring adjuster Spring Adjust Plug 30 Hose Assembly other lengths available O ring hose inlet end Hose Protector O ring hose outlet end Plastic Bushing replaces Heat Sink 8 in some models Plastic Spring Adjuster Plug replaces the Spring Adjust Knob Assembly 29 in some models e An asterisk next to the Item Number means that part is included in the Standard Service Kit The Servic
3. 30 hose model assembly number 320 3115 and as an advanced octopus unit yel low purge cover and 36 hose model assembly number 320 3110 See the picture on the front page of this manual section to identify this model type The serial number for this model always starts with J The num ber can be seen by curling back the mouthpiece and looking at the end of the mouth tube 5 1 TOOLS REQUIRED FOR SECOND STAGE SERVICING Two good quality 6 or 8 15 or 20 cm adjustable wrenches Side cutting pliers 3 16 Allen Wrench p n 347 0316 2nd Stage Inline Adjusting Tool 3 16 Hex p n 347 0002 2nd Stage Annual Service Kit p n 345 2000 Clean Shop Rags LTI Christo Lube 111 p n 347 0111 Service Video Tape for this regulator p n 347 0101 or Service CD ROM p n 347 0102 or DVD p n 347 0103 5 2 DISASSEMBLY OF THE SECOND STAGE A WARNING NEVER tighten the hose fitting to the first stage with more than 40 in lbs 4 5 Nm of torque The inlet hose fitting can be weakened by over tightening To view the complete parts list of the second stage open the back cover of this manual 5 2 1 Use the 6 and 8 adjustable wrenches to loosen the hose nut from the valve tube 21 Remove the hose assembly 30 from the second stage Inspect the hose assembly for any cuts or cracks especially on the hose at the metal ferrules Remove and discard the O rings from each end of the hose Clean rinse and blo
4. condition will disappear with use 20 zeago C LEAK TEST 5 9 Disconnect the air supply Purge the regulator of all positive air pressure 5 7 10 Slowly immerse the second stage in a pan of water with the mouthpiece pointing straight Up 5 7 11 Immerse the regulator until the water is 1 4 to 1 8 64 to 32 cm from the lip of the mouthpiece 5 7 12 Hold the regulator in this position for one minute and then slowly raise it out of the water 5 13 Tip the regulator mouthpiece downward and watch the inside of the mouthpiece tube If any water escapes from the mouthpiece tube check for the source of the leakage D INTERMEDIATE PRESSURE AIR LEAKS 5 14 Attach the regulator first stage to a tank short enough to totally submerge the first and second stage in your filling station cooling water Adjust the breathing effort adjustment plug to the minimum breathing effort position 5 15 With the tank valve still turned off flood the second stage completely with water and then position it mouthpiece up 5 16 Turn the tank air valve on slowly and then watch for any leaks in the first or second stage If leaks are seen coming from the second stage repeat the test with the cover assembly removed You will be able to see more clearly exactly where the leak is coming from 5 7 17 Repair any leaks 6 0 HELPFUL HINTS 6 1 TROUBLESHOOTING POSSIBLE CAUSE RECOMMENDED ACTION Inlet filter clogged Replace the filter Air supply
5. ft lb 3 4 Nm with 1 4 Allen wrench Seat Support 11 snug metal contact with 3 16 Allen wrench Port Plugs 16 17 2 3 ft lb 3 4 Nm with 5 32 Allen wrench Hose inlet end 30 2 3 ft lb 3 4 Nm Hose outlet end 30 2 3 ft lb 3 4 Nm 2nd Stage Nut 7 1 2 ft lb 2 3 Nm 2 2 Zeagle Scuba Regulator Model Numbers Model Description DS IV Yoke 1st stage with ZX 2nd Stage 30 Hose Envoy DIN 1st stage with Envoy 2nd Stage 30 Hose DIN to Yoke Converter 2nd stage only ZX Octopus 2nd Stage with yellow cover 36 hose 2nd stage only ZX 2nd Stage with gray cover 30 hose 2nd stage only Envoy 2nd Stage with gray cover 30 hose 2nd stage only Envoy Octopus 2nd Stage with yellow cover 36 hose 1st stage only Flathead VI DIN 310 2110 310 3210 1st stage only Envoy Yoke 310 3220 1st stage only Envoy DIN 330 0001 DIN to Yoke Converter allows a DIN equipped regulator to be mounted on a Yoke Valve with no tools 4 ZEAMIEd 3 0 1st Stage O Rings included in Kit 345 1000 oO sm 60 0006 N9 32 for stem of HP Valve 30 O _______ _ 1 60 0009 N9 13 for seat Orifice 13 O O O 160 0011 N7 15 23 for LP ports 3 amp inlet filter 1 C O 160 0012 N9 18 for HP ports 2 O 160 0905 N9 33 behind thread of HP balance plug 35 160 0111 N9 20 for inlet end of DIN bolt 21 160 0016 N7 34 for large end of HP balance plug 35 160 0019 N7 40 f
6. piston will not fall out the lever 19 can be moved through its full arc If the piston still does not come out a 5 32 4 5 mm Allen wrench can be inserted through the male threaded end of the valve tube through the seat 18 to gently push the piston out 5 2 18 Remove and discard the O ring 27 from the outside of the valve tube 21 14 _ zeagie gt 5 2 19 The lever 19 should not be removed from the valve tube unnecessarily However it can be removed from the valve body by carefully springing out one of the feet and pivoting it over the valve tube body Do not over bend the lever legs Straighten the legs if they are bent outward from parallel 5 2 20 Remove and discard the seating seal 22 from the piston 23 5 2 21 Remove and discard the very small O ring 24 from the piston This can be done by pinching a sec tion of the O ring out of the groove with the fingernails Then flip the O ring off the end of the piston stem DO NOT USE SHARP METAL PICKS Metal tools will damage the O ring groove which will cause a small continuous second stage leak 5 2 22 Use a 3 16 Allen wrench or the Zeagle 2nd Stage Inline Adjusting Tool 3 16 Hex p n 347 0002 to turn the seat 18 counterclockwise enough turns to fully disengage the threads from the valve tube 21 5 2 23 After the threads are disengaged remove the seat 18 from the valve tube 21 by pulling and turn ing counterclockwise at the same time The seat will usually
7. salt water being blown through the interior of the regulator is the num ber one source of internal corrosion and problems with Scuba regulators 6 4 3 Before turning on the tank air valve check to make sure that the yoke nut or DIN con nection is tight and the regulator body is aligned properly with no kinks in the hoses 6 4 4 Turn the tank valve on slowly and listen for leaks If any leaks are found replace or repair parts as recommended 6 4 5 Never lift the tank BCD assembly by the regulator or hoses 6 4 6 Surface test the regulator by breathing lightly through the mouthpiece Depressing the purge button above the water s surface is not an effective or thorough method for testing the function of the regulator B POST DIVE CARE 6 4 7 After the dive blow all water out of the dust cap with clean dry air or dab the water out with an absorbent cloth and place the cap securely on the regulator inlet On multiple tank dives use great care to keep salt water out of the regulator inlet when tanks are changed Neglecting these simple procedures is another great cause of corrosion and wear in Scuba reg ulators Zeagle s Dry Seal System keeps all other water borne contamination out of the first stage body 6 4 8 With the dust cap securely in place rinse the first and second stages in clean fresh water DO NOT depress the purge button before or during rinsing since this may introduce water into the second stage and the low pressure hose S
8. six weeks before or after the anniversary of the date of purchase by an authorized Zeagle Dealer Failure to do so invalidates the warranty 7 2 2 Even with infrequent use the regulator should be serviced annually to ensure proper per formance and satisfy warranty requirements 7 2 3 After calling Zeagle Customer Service at 813 782 5568 for an RA number Zeagle Scuba parts and warranty forms are sent to the following address RA fill your RA in here 37150 Chancey Road Zephyrhills Florida 33541 U S A 26 zeago 7 3 Order Form sample This is a copy of the Service Parts Request Form The actual form is a three page carbon copy that is available by request from Zeagle Customer Service If you do not have any forms on hand you may photocopy this page and use it to receive warranty parts credit service Order Parts Request Form This form must be used by the Service Center 37150 Chancey Rad for ANY Warranty Servicin Zephyrhills FL 33541 CAME gt Aiteees You MUST contact Zeagle for an RA Fax 813 782 5569 SYSTEMS INC Number to receive any Warranty Credit www zeagle com Zeagle Service Center City State Prov Country Phone E mail Date Serviced Technician Name PRINT Technician Number Customer Name Address City State Prov Country Phone E mail RA call Zeagle 1st Stage Model Serial 2nd Stage Model Serial Octopus Model Serial Comments Part Installed Descri
9. with more than 40 in lbs 4 5 Nm of torque The inlet hose fitting will be weakened by over tightening Failure to heed this warning may result in serious injury or death NOTE All Zeagle Scuba Regulators have service kits available which contain the parts which must be changed at every annual service no matter what their condition The standard annual service kit part numbers are shown in the parts list All other parts not contained in these kits must be inspected by the technician and changed under warranty only if they have failed due to problems with material or workmanship A WARNING Zeagle Scuba Regulators are manufactured using materials suitable for use with oxygen enriched gases i e Nitrox etc providing the oxygen content does not exceed 40 Equipment intended for enriched air Nitrox use must not be used with regular compressed breathing air or other gases Regulators intended for enriched air use can be serviced only by technicians trained by one of the major oxygen enriched air training agencies Failure to heed this warning may result in serious injury or death 1 0 2 This manual gives breakdowns of regulator parts equipment specifications servicing instructions troubleshooting recommendations and guidelines for proper care of Zeagle regula tors This manual is intended for use only by persons specially trained and authorized to service Zeagle Scuba equipment 1 0 3 Anyone attempting to service or repair Zeagle
10. B CREEPING INTERMEDIATE PRESSURE POSSIBLE CAUSE RECOMMENDED ACTION Worn O ring 82 on HP valve stem C HISSING FROM SECOND STAGE but intermediate pressure is OK Worn O ring 24 on piston 23 Worn O ring 17 on seat 18 Seat 18 out of adjustment 22 zeago C WET BREATHING POSSIBLE CAUSE Diaphragm improperly installed or hole in diaphragm Damaged or loose fitting exhaust valve Crack in housing 10 Worn venturi lever O rings 15 27 scratched or worn venturi lever sealing surfaces scratched or worn housing 10 sealing surfaces Improper clearing techniques by diver Extremely slow breathing allowing water to build up in housing rather than being blown out RECOMMENDED ACTION Check position of diaphragm visually Replace if holes found by holding up to a light Replace exhaust valve 14 Replace housing Replace O rings 15 27 Replace venturi lever 16 Replace housing Instruct diver on clearing techniques Explain this result of slow breathing to diver D HIGH FREQUENCY HUMMING OR BUZZING DURING INHALATION POSSIBLE CAUSE RECOMMENDED ACTION Remove the main spring 7 flip it over and other 1st stage components and re install umasapa Pee until resonance stops E LOW FREQUENCY FLUTTERING DURING INHALATION Above the surface only POSSIBLE CAUSE RECOMMENDED ACTION Harmonic resonance between the springs Remove rotate and re install diaphragm or and other 2nd s
11. Scuba regulators must have a thorough understanding of the principles of operation of scuba regulators and valves as well as the appro priate mechanical ability The technician must be properly trained in the safe use of compressed air and the various tools and cleaning solutions involved in the procedures outlined in this manu al 1 0 4 The best source for current part numbers for any of the parts listed in this manual is your current parts and price list from Zeagle 2 zeagies 1 0 5 Zeagle conducts seminars on a regular basis to train technicians in proper service and repair procedures for all current Zeagle regulators In addition all Zeagle dealers and their staff members are encouraged to attend the seminars to gain an in depth understanding of the construction special features and operation of Zeagle regulators For information on the dates and locations of upcoming Zeagle service seminars near you contact Zeagle or a Zeagle Sales Representative NOTE You must be authorized by Zeagle to work on Zeagle Scuba equipment You can obtain proper authorization by attending all appropriate seminars given in your area This is the only way you can become an authorized Zeagle technician 1 0 6 If you have any questions or need more information contact your Zeagle Scuba Sales Representative or Zeagle Customer Service You can e mail you technical questions to tech zeagle com 2 0 SPECIFICATIONS Zeagle Envoy AIR FLOW sanarasannicocianns
12. See Photo 4 Always push the purge cover briefly between each adjustment step Do not push on the diaphragm with the tip of the Allen wrench or a false higher reading will occur The optimal intermediate pressure for Zeagle regulators is 135 psi 9 3 bar but any setting between 130 and 145 psi 9 10 bar will provide good stable performance Photo 4 4 5 7 After reaching the proper pressure setting push the purge cover on the second stage again sev eral times and watch how the intermediate pressure reading responds When the purge cover on the second stage is depressed the intermediate pressure reading will drop When the purge cover is released the pressure should return immediately to the proper lock up pressure and stay there 4 5 8 Let the regulator sit with the tank valve turned on for several minutes The intermediate pres sure reading may rise about 3 psi in the first three seconds after lock up but after that it should not rise more than another 4 psi 3 bar in five minutes If it rises more than 4 psi refer to the Trouble shooting Section 6 10f this manual Note Never set the output pressure of the first stage above 150 psig 10 2 bar 12 zeagie gt 5 0 ENVOY SECOND STAGE SERVICE PROCEDURES The procedures covered in this manual section apply to the ENVOY second stage To access the exploded view of this model open the back cover of this manual This second stage is used as a primary unit gray or black purge cover and
13. You will hear a hiss of air coming from the second stage Turn the seat clockwise toward the seal As soon as the seat makes contact with the seal the air will stop flowing through the second stage Adjust the seat further so that there is no hissing noise and the lever has at least 1 8 3 2 mm loose end play Note Depress the lever 19 while moving the seat with the wrench This prevents premature indentation and wear of the seal 22 Photo 7 5 4 25 Install the exhaust tee 13 onto the case by hooking the tee over the flat part of the flange and then working it over the rest of the flange This operation is made much easier if the tee is immersed for one minute in hot tap water to soften it temporarily 18 zeanie gt 5 5 SET UP OF THE SECOND STAGE For the following adjustments the cover and diaphragm must be removed 5 5 1 Turn the spring adjust knob plug 29 out counter clockwise all the way then back in clockwise one turn 5 5 2 Install the new O rings 31 33 onto the hose assembly 30 Install the hose between a serviced first stage and the second stage tighten snugly Use two wrenches to tighten the second stage hose connection Note Attach the second stage to the overhauled and properly adjusted first stage that it is going to be used with mounted on an air tank filled to between 2700 and 3500 psi Install an intermediate pressure gauge into one of the low pressure ports 5 5 3 Carefully turn the airon After adjus
14. able wrenches to disconnect all hoses from the first stage Pull back the hose pro tector from the inlet end of the hose Inspect the hoses for wear Pay particular attention to the area where the metal ferrules meet the rubber hose material Remove and discard the O rings from each end of the hose Clean rinse and blow dry the interior bores of the hoses Replace the hoses if necessary 6 ZEAMIE gt d 4 2 2 Clamp the regulator carefully in a soft jawed vise with the HP balance plug 35 facing up Position the regulator so that the yoke 28 or DIN wheel 24 is preventing the regulator from rotating as the HP balance plug is loosened Use a 1 4 Allen wrench to loosen and remove the HP balance plug assembly 30 31 32 33 34 and 35 from the body 14 See Photo 1 Photo 1 HP Balance Plug Assembly removal 4 2 3 If the regulator has severe internal corrosion due to salt water being forced through the inlet filter it may be necessary to carefully use a pair of pliers to remove the HP valve 30 from the HP balance plug 35 If so pull the valve out straight and slowly taking care not to bend the stem of the HP valve Remove and discard O rings 4 2 4 Use a Zeagle pin spanner p n 347 0001 installed in the hole in the diaphragm clamping ring 6 to loosen and remove the diaphragm clamping ring from the body 14 See photo 2 The heel of the spanner can be wrapped with tape to help prevent damage to the chrome fin ish on the c
15. bolt 27 4 4 4 Hand tighten the yoke yoke bolt and spacer into the body 14 Note If the regulator has a DIN connection install the DIN bolt 21 with a new O ring 20 DIN wheel 24 and spacer 29 into the body as described for the yoke assembly 4 4 5 Place the body 14 carefully into a soft jawed vise so that the yoke bolt or DIN bolt is facing up 4 4 6 Tighten the yoke bolt with a 10 adjustable wrench or the DIN bolt with a 1 4 Allen wrench Tighten to 20 25 ft lb 27 34 Nm 4 4 7 Re position the body in the soft jawed vise until the diaphragm opening faces up Position the body so that the yoke or DIN wheel will prevent the body from turning as you tighten the parts clockwise 4 4 8 Install the lightly lubricated O ring 13 onto the seat 12 4 4 9 Install the seat 12 into the body 14 from the diaphragm end The seat installs with the end with the notch and O ring groove towards the body 4 4 10 Use a 3 16 Allen wrench to install the seat support 11 over the seat Tighten the seat support until you feel it make full contact with the body Do not tighten beyond that point 4 4 11 Install the lifter 10 into the seat support 4 4 12 Install the new diaphragm 9 into the body A WARNING NEVER reuse the diaphragm in the first stage A used diaphragm will not clamp securely as required A used diaphragm may come loose during use causing a severe regulator malfunction This is true with all diaphra
16. come out on the end of the Allen wrench If it will not come out it can be pushed out with a soft wooden dowel however care must be taken not to dam age the seat if it is pushed out 5 2 24 Remove and discard the O ring 17 from the seat 5 3 CLEANING AND INSPECTION OF THE 2nd STAGE 5 3 1 Rinse all plastic and silicone parts in fresh warm soapy water solution Rinse with clean warm water and then blow the parts dry with compressed air to remove any sand and dust particles A I WARNING DO NOT use vinegar or other acid solutions on the plastic parts since this will cause the plastic to become brittle 5 3 2 If necessary because of deposits or corrosion clean all metal parts of the second stage in an ultrasonic cleaner or cleaning solution See Section 6 3 for recommendations on cleaning solutions 5 3 3 Inspect the housing 10 for any cracks or nicks Look particularly closely at the area where the exhaust valve 14 seals and where the bushing 8 clamps Replace the housing if any cracks are found 5 3 4 Inspect the sealing surface on the seat 18 where the seating seal 22 seals for any nicks or scratch es Replace the seat 18 if any serious defects are found at the sealing area or if the threads appear worn Out 5 3 5 Blow all dust and debris out of the orifice with clean compressed air 5 3 6 Inspect the exhaust valve 14 Look carefully at the base of the barbed nipple where it comes out of the middle of the valve Loo
17. e Kit Part for the 1st Stage is 345 1000 The 2nd Stage Service Kit Part is 345 2000 Zeagle SYSTEMS INC 37150 Chancey Road Zephyrhills Florida 33541 U S A Zeagle Scuba the Zeagle symbol ZX Envoy 50D DS IV and Flathead VI are trademarks of Zeagle Systems Inc All other names are trademarks of their respective owners All products subject to change without notice Zeagle Web Site www zeagle com E mail all technical questions to Zeagle at tech zeagle com 2002 Zeagle Systems Inc Printed in USA Part Number for this Manual p n 347 2002 Zeale 5 SYSTEMS INC
18. e first thing that might hang up on the tabs of the lever is the black seating seal Wiggle the lever to get this past the tabs When the L shaped feet get to the lever tabs they will lift the lever outwards as you push the assembly in 5 4 11 Install a new well lubricated O ring 28 onto the spring adjuster plug 29 5 4 12 Insert the spring adjuster plug into the valve tube over the shuttle valve assembly you just installed 5 4 13 Turn the spring adjuster plug clock wise until the O ring and flange have passed the hole where the pin 20 is installed 5 4 14 Install the pin 20 into the valve tube 21 5 4 15 Back the spring adjuster plug out counter clockwise until it tightens against the pin 20 hold ing it in place 5 4 16 Install the new O ring 15 onto the venturi control lever 16 5 4 17 While holding the tabs in place in the valve tube with two fingers depress the lever 19 and the slide the venturi control lever 16 into place on the valve tube 21 5 4 18 Install the valve tube assembly into the housing 10 After assembly make sure that the pivot end of the lever is held into the valve tube 21 by two plastic flanges on the housing just as they did when you took the housing apart see step 5 2 7 17 zezao 5 4 19 Install the O ring 9 over the external threaded end of the valve tube 21 IMPORTANT Do not lubricate this O ring 5 4 20 Install the bushing 8 over the external threaded end of the valv
19. e tube 5 4 21 Install the nut 7 over the external threaded end of the valve tube Tighten the nut snuggly 1 2 ft lb 2 3 Nm with a wrench 5 4 22 Install the new lubricated O ring 17 onto the seat 18 5 4 23 Use the 3 16 Allen wrench or the 2nd Stage Inline Adjusting Tool 3 16 Hex p n 347 0002 to install the seat into the valve tube 5 4 24 Tighten the seat 18 clockwise with the Allen wrench or inline tool It is important that the final adjust ment of the seat leaves the lever with about 1 8 8 2mm free movement at the end to allow for the natu ral wear of the seating seal 22 during the use of the regulator Adjust the seat 18 in while moving the end of the lever up and down with the tip of your finger When the seat is too far out counterclockwise you will feel a firm springiness with no free movement When the seat is too far in clockwise you will feel a great deal of looseness at the end of the lever You want the seat 18 to be positioned so that you feel the 1 8 free play when you move the tip with your finger See photo 7 Inline Adjusting Tool Method Install the Zeagle Inline Adjusting tool p n 347 0002 between the hose and the 2nd stage body Turn the plastic spring adjuster plug 29 on the regulator all of the way out counter clockwise Use the inline tool to just begin to thread the seat 18 into the valve tube CAREFULLY turn the tank air on just barely enough to let airflow through the regulator
20. ect order of assembly is extremely important The diaphragm end MUST be assembled before the HP balance plug end Incorrect assembly order will result in damage to the first stage lifter 10 and seat 12 If the diaphragm end of the regulator is opened for any reason such as replacing the HP seat 12 The other end of the regulator turret or HP balance plug MUST BE DISASSSEMBLED so that the diaphragm end can be re assembled first To determine the identity of each O ring in the 1st Stage Service Kit remove them from the bag and use the O ring Identification Chart on the front page of this manual Lay each O ring over its corresponding picture on the page and read the description Because the kit covers several mod els there will be O rings left over For example the kit 345 1000 contains turret O rings for the 50 D which are not used in the Envoy Before installing new O rings into the regulator lightly lubri cate the O rings with LTI Christo Lube 111 The most effective way to lubricate the kit O rings is to put them in a small plastic bag with a pea sized amount of LTI Christo Lube 111 Rub the O rings and grease together in the bag until all the O rings are coated evenly Try not to wipe the lubrication off the O rings when assembling them onto other parts 4 4 1 Install the yoke bolt 27 into the yoke 4 4 2 Install the spacer 29 onto the yoke bolt 27 4 4 3 Install the new inlet filter 22 and filter O ring 23 into the yoke
21. em Number means that part is included in the Standard Service Kit The Service Kit Part for the 1st Stage is 345 1000 The 2nd Stage Service Kit Part is 345 2000 IMPORTANT The high and low pressure ports are not identified with HP or LP lettering However the low pressure ports have a smaller 3 8 24UN thread and the high pressure ports have a larger 7 16 20UN thread These threads are standard through the industry and items made for high or low pressure service are not installable in the wrong port for this reason This is the reason that the HP ports are not stamped HP Zeagle TABLE OF CONTENTS 1 0 Introduction 2 0 Specifications 2 1 Torque Specifications 2 2 Model Numbers 3 0 O rings Reference Chart First Stage 4 0 First Stage Procedures 4 1 Tools Required for First Stage Servicing 4 2 Disassembly of First Stage 4 3 Cleaning and Inspection of the First Stage 4 4 Preliminary Assembly of the First Stage 4 5 Set up and Testing of the First Stage 5 0 Envoy Second Stage Service Procedures 5 1 Tools Required for Second Stage Servicing 5 2 Disassembly of the Second Stage 5 3 Cleaning and Inspection of the Second Stage 5 4 Preliminary Assembly of the Second Stage 5 5 Set up of the Second Stage 5 6 Final Assembly of the Second Stage 5 7 Testing of the Second Stage 6 0 Helpful Hints 6 1 Troubleshooting 6 2 Parts Cleaning Recommendations 6 3 Commonly Used Cleaning Solutions 6 4 Handling T
22. gm first stages Failure to head this warning may result in serious injury or death 4 4 13 Place the spring carrier 8 onto the center of the diaphragm 4 4 14 Place the main spring 7 onto the spring carrier 8 4 4 15 Screw the spring adjuster 5 about two turns into the diaphragm clamping ring 6 from the outside end of the diaphragm clamping ring 4 4 16 Place the diaphragm clamping ring over the top of the main spring 7 carefully to avoid pushing the spring and spring carrier out of position on the center of the diaphragm Tighten the ring down by hand as far as possible 10 zeanie gt Use the pin spanner wrench Zeagle p n 347 0001 to tighten the diaphragm clamping ring the rest of the way down Tighten to 25 30 ft lb 84 40 Nm torque or until the edge of the diaphragm clamping ring and the body meet metal to metal This is essential to ensure that the diaphragm is securely clamped Use an old 1st stage diaphragm as a cushion under the spanner to pre vent marks from being made on the diaphragm clamping ring 4 4 17 Turn the body over carefully and re clamp it in the soft jawed vise so that the HP balance plug end is faced up 4 4 18 Lightly lubricate the new O rings from the annual service kit with LTI Christo Lube 111 and install them onto the HP balance plug 35 4 4 19 Lightly lubricate the stem of the HP valve 30 Snap the end of the spring 31 over the ledge on the HP valve 4 4 20 Insert the valve and spr
23. hake or blow all excess water from the second stage and allow the entire regulator to air dry before storing 6 4 9 Store regulator in a clean bag or storage box away from sunlight excessive heat and humidity 7 0 WARRANTY AND MAINTENANCE INFORMATION 7 1 PROPER PROCEDURE FOR SERVICE PAPERWORK USA 7 1 1 Make sure your service location has an adequate supply of the three part Zeagle Service Order Parts Request forms One of these carbon paper forms is required to get credit for parts used in any warranty replacement Contact Zeagle Customer Service for replacement forms 7 1 2 When the regulator is received from the customer for servicing verify that they are the Original retail owner of the regulator and that they have had the regulator serviced annually at an Authorized Zeagle Dealer You can use your records for this or receipts they have If they are not the original owner or have not had the regulator serviced annually the warranty is no longer in effect 25 zeago 7 1 3 Fill out the Zeagle Service Order Parts Request form PRINT CLEARLY If you use serv ice kits you only have to use the service kit part number s to represent all of the parts in that kit Parts other than those in the kits have to be listed individually The reason for replacing the part also has to be listed on the form 7 1 4 Attach all of the old parts that were replaced under warranty in a plastic bag and attach it to the Zeagle Service Order Part
24. i 33 cu ft 935 liters min 1 atmosphere INHALATION RESISTANCE 0 9 2 0 2 3 5 08 cm w c 1 atmosphere adjustable EXHALATION RESISTANCE 0 6 1 52 cm w c max 1 atm RECOMMENDED LUBRICANT LTI Christo Lube 111 A FIRST STAGE REGULATOR TYPE Balanced Diaphragm Dry Environmental Seal with Hydrostatic Transmitter WEIGHT sasonuacann 1 88 Ib 85 kg INTERSTAGE PRESSURE 130 145 psi 9 10 bar 135 psi 9 3 bar nominal LOW PRESSURE PORTS 5 3 8 24 UNF HIGH PRESSURE PORTS 2 7 16 20 UNF MATERIALS stecutevesicitaedt douse Body CDA 360 Brass O rings Buna N Seat Advanced Polymer HP Valve Stainless Steel B ZX 2nd STAGE REGULATOR TYPE sasono E Downstream valve balanced diaphragm Diver Adjustable Dive Pre Dive Venturi Lever and Technician Externally Adjustable Resistance Control Knob 3 ZEAMIE gt d WEGE ee 42 lb 19 kg w o hose HOSE LENGT Hires 30 in 76 mm MATERIALS escort vieseerss lone Cover Flexible Thermoplastic Case Rigid Thermoplastic Poppet Seat Advanced Elastomer O rings Buna N Diaphragm Elastomeric Polymer Exhaust Valve Thermoplastic Elastomer Mouthpiece Silicone 2 1 Torque Specifications Description item Torque Diaphragm Clamp 6 25 30 ft lb 84 40 Nm with pin spanner DIN Bolt 21 20 25 ft lb 27 34 Nm with 1 4 Allen wrench Yoke Bolt 27 20 25 ft lb 27 34 Nm HP Balance Plug 35 2 3
25. iece so that the overbite where the top teeth fit is on the top 5 6 6 Install the TWO new mouthpiece ties 11 from the service kit Position one of the tie locks on each side of the mouthpiece Tighten both ties securely and cut off excess A WARNING NEVER tighten the hose with more than 40 in Ibs 4 5 Nm of torque The inlet hose fitting can be weakened by over tightening 19 zeagie gt 5 7 TESTING OF THE SECOND STAGE A INHALATION EFFORT 5 7 1 With air pressure applied turn the spring adjust plug 29 fully counter clockwise Move the ven turi lever to the position Depress and release the purge dome Alarge continuous free flow should result Move the venturi lever towards the position With no other intervention by the time you get the lever 2 3 of the way to the position the free flowing should stop This test shows the regulator is performing as it should It is not necessary but you can perform further inhalation tests 5 7 2 If you have no instrumentation breathe on the regulator to test the breathing effort With the adjusting knob turned fully clockwise and the venturi lever in the full ore dive position the regu lator will be relatively hard to inhale on but the purge dome must still purge when depressed 5 3 With the spring adjust plug turned fully counter clockwise then one full turn in clockwise and the venturi lever in the full dive position the regulator w
26. ill be easy to inhale on It is important to note that although the breathing efforts are very different in these two positions the ultimate air deliv ery capacity of the regulator is essentially the same in either position 5 7 4 If a water column or water manometer is used to check Inhalation effort it should not exceed 2 50 mm w c at cracking with the adjuster knob in the minimum effort position Note These Zeagle regulators have been designed and built to perform with the Best of the Best in underwater breathing effort They also have design features that were influenced by the desire to make the regulator stable The regulator is VERY easy breathing underwater and yet resists going into free flow by just being bumped on the surface lf the technician wants to lower the cracking effort to the lower end of the range refer to the trouble shooting section of this manual 6 1 5 7 5 Move the venturi adjusting lever 16 through its full range of movement while inhaling on the regulator You should feel an easier inhalation effort in the position than the position B EXHALATION EFFORT 5 7 6 If you do not use instruments to check the exhalation effort the flow should feel smooth and unrestricted 5 7 7 If you use a water column it should not exceed 1 2 w c 13 mm at one atmosphere 5 8 Brand new exhaust valves will sometimes adhere slightly to the case causing a slight increase in exhalation effort This
27. ing into the HP balance plug 35 4 4 21 Install the HP balance plug and valve assembly onto the end of the regulator Take care to insure that the HP valve 30 fits over the stem of the lifter 10 as you install the assembly into the body 4 4 22 Screw the HP balance plug into the body with a _ Allen wrench Tighten to 2 3 ft lb 3 4 Nm torque or just until you feel firm metal to metal contact stopping the rotation of the parts 4 4 23 Install the dust cap 26 and yoke knob 25 onto the yoke 4 4 24 Install new O rings 15 18 from the kit onto port plugs 16 17 and install the port plugs into the appropriate ports 4 5 SET UP AND TESTING OF THE FIRST STAGE After the first stage is assembled but before any port plugs or hoses are installed mount the first stage onto a tank valve Open the tank valve in several short bursts This will blow out particles of debris that may be lodged inside the regulator These particles will be more easily blown through the regulator when all ports are open and the main valve is fully open because intermediate pressure cannot build up NOTE For safety always test the first stage regulator with at least one second stage installed The demand valve on the second stage acts as a relief valve in case of a malfunction 4 5 1 Install an intermediate pressure test gauge into one of the low pressyre ports of the first stage and a functional second stage into another low pressure port Plug any remaini
28. ips 7 0 Warranty and Maintenance Information 7 1 Proper Procedure for Warranty Paperwork 7 2 Scheduled Maintenance 7 3 Order Form sample 7 4 O rings Reference Chart Second Stage Before You Begin Read these instructions completely before you begin servicing the regulator These instructions are intended for people who have been AUTHORIZED by Zeagle to repair Zeagle Scuba equip ment If you are not so authorized STOP FIRST STAGE The letter at the beginning of the serial number on the first stage indicates the model of that first stage If the serial number begins with A it is a DS IV non swivel first stage e g A001324 B is a 50D swivel turret first stage C is an Envoy first stage and F is a Flathead VI first stage For further information contact Zeagle 1 Zeamle gt d 1 0 INTRODUCTION 1 0 1 The procedures in this manual apply to Zeagle Scuba Regulators Refer to the exploded view as you read the service section of the manual The Item Numbers referred to in the service section are those seen in the exploded view A WARNING NEVER reuse the diaphragm in the first stage A used diaphragm will not clamp securely as required A used diaphragm may come loose during use causing a severe regulator malfunction This is true with all diaphragm first stages Failure to heed this warning may result in serious injury or death A WARNING NEVER tighten the hose fitting to the first stage
29. k for any tearing at this point Replace the valve if any tears are found Replace the valve if nicks or tears are found at the sealing edges of the valve 5 3 7 During an Annual Overhaul all parts included in the Annual Service Kit are replaced no matter what the condition of those parts Carefully examine all other parts of the second stage for signs of deterioration Replace those parts too where necessary 15 zezgle gt 5 4 PRELIMINARY ASSEMBLY OF THE SECOND STAGE 5 4 1 Ensure that all parts are clean To determine the identity of each O ring in the Second Stage Service Kit remove them from the bag and use the O ring Identification Chart on the back page of this section Lay each O ring over its corresponding picture on the page and read the description IMPORTANT Do not lubricate the O ring 9 that fits over the end of the valve tube 21 Before installing new O rings into the regulator lightly lubricate the O rings with LTI Christo Lube 111 EXCEPT O ring 9 that goes over the valve tube 21 male threaded end 5 4 2 Install the exhaust valve 14 into the case by inserting the nipple into the square hole from the outside of the case Reach inside the case and pull the nipple firmly with the fingers until you hear or feel it click into place Inspect the exhaust valve to see that it is properly seated Take care not to get any lubricating grease on the exhaust valve during this procedure 5 4 3 Install a new O ring 27 onto the
30. lamping ring Photo 2 4 2 5 Remove the body assembly from the vise 4 2 6 Use a 1 4 Allen wrench to remove the spring adjuster 5 from the diaphragm clamping ring 6 Remove the spring 7 spring carrier 8 diaphragm 9 and lifter 10 from the body 14 Discard the diaphragm 9 A WARNING NEVER reuse the diaphragm in the first stage A used diaphragm will not clamp secure ly as required Aused diaphragm may come loose during use causing a severe regulator mal function This is true with all diaphragm first stages Failure to head this warning may result in serious injury or death 4 2 Use a 3 16 Allen wrench to remove the seat support 11 from the body 4 2 8 Remove the seat 12 the seat O ring 13 and discard both 4 2 9 Re clamp the body carefully in a soft jawed bench vise Use a 10 adjustable wrench to loosen and remove the yoke bolt 27 and spacer 29 See Photo 3 Remove the yoke knob assembly 25 and the dust cap 26 from the yoke 28 Photo 3 Note If the regulator has a DIN wheel use a _ Allen wrench to remove the DIN bolt 21 and DIN wheel 24 4 2 10 Remove and discard the inlet filter 22 the filter O ring 23 and the DIN inlet O ring 20 if the regulator is DIN equipped 4 2 11 Using a 5 32 Allen wrench remove all remaining port plugs 16 17 from the body 14 Discard the port plug O rings 15 18 4 3 Cleaning and Inspection of the 1st Stage 4 3 1 C
31. le Good for plastic silicone and plated metal parts Vinegar and water equal part solution Ingredients easily available Approx 15 min weaker solution in Ultrasonic Cleaner cleaning time May damage chrome finish Never use on plastic parts Vinegar dissolves the plastics in most polymers making them brittle and more prone to breakage Simple Green and Water simple Green is a readily available degreaser Read the product label for mixing ratios with water Cleaning solutions recommended by ultra The preferred choice Check with the manu sonic cleaner manufacturers facturer for strengths and recommended uses for their cleaners Choose soap solutions over acidic ones 6 4 HANDLING TIPS How your customers treat their regulators will directly influence the unit s function and durabili ty Following are a few tips that you can pass on to your customers to help assure the durabil ity of their Zeagle Scuba Regulator A PRE DIVE CHECKS 6 4 1 Check the hoses and hose connections for cuts abrasions or other signs of damage before mounting the regulator on the tank valve Slide the hose protectors back to inspect the areas of the hose normally covered Be sure all hose connections are tight 24 zeagie gt 6 4 2 Just before mounting the regulator on the valve always turn the valve on briefly to blow any trapped water out of the valve There is often salty water trapped in the outlet side of the valve This entrapped
32. lean all metal parts of the first stage in an ultrasonic cleaner or cleaning solution See section 6 3 for recommendations on cleaning solutions Remove the O rings before cleaning any metal parts since the soft O ring material will absorb cleaning energy from the ultrasonic cleaner reducing its effectiveness If major visible corrosion or deposits exist on parts use a bristle brush wooden or plastic stick to rub the deposits off Allowing acidic cleaning solutions to do all of the work if deposits are severe will result in damage to internal chrome plating which will make parts even more susceptible to future corrosion 4 3 2 Remove the regulator parts from the cleaning solution Rinse with clean fresh water then blow internal passageways dry with clean dry compressed air 4 3 3 Inspect the diaphragm sealing surfaces and O ring grooves for scratches or wear If the reg ulator was leaking air because of scratches or wear replace the parts If some corrosion deposits persist carefully wipe them away with a plastic scrubbing cloth Blow any resulting dust out of the regulator parts 4 3 4 Roll the stem of the lifter 10 along the square edge of a table or similar surface to check the stem for straightness If the head of the lifter wobbles as the stem is rotated the lifter must be replaced The most common cause of lifter stem bending is assembling the regulator in the wrong order See 4 4 4 4 PRELIMINARY ASSEMBLY OF THE FIRST STAGE Corr
33. lve tube 21 by two plastic flanges on the housing Note this positioning for re assembly 5 2 8 Hold the diaphragm up to a light source Gently stretch the diaphragm and look for tears or pinholes lf any are found replace the diaphragm 5 2 9 Loosen and remove the nut 7 from the valve tube 21 5 2 10 Remove the plastic bushing 8 from the valve tube 5 2 11 Remove and discard the O ring 9 from the valve tube 5 2 12 Use a 1 4 Allen Wrench to turn the black plastic spring adjust plug 29 fully counter clockwise until it comes to its stop Do not use an unreasonable force to do this Stop turning the plug as soon as a resist ance is felt 5 2 13 Depress the lever 19 fully onto the valve tube Grasp the tab of the venturi control lever 16 While pulling on the venturi control lever push the valve tube assembly out of the housing 10 5 2 14 Remove the venturi control lever 16 from the valve tube assembly Remove and discard the O ring 15 from the venturi control lever 5 2 15 Use a 1 4 Allen wrench to turn the spring adjust plug 29 clockwise 1 4 turn The pin 20 will fall out of the valve tube or can now be easily removed 5 2 16 Turn the spring adjust plug 29 counter clockwise to remove it from the valve tube Remove and dis card the O ring 28 5 2 17 The balancing chamber 26 spring 25 and piston 23 are removed at this time They will often fall out if the valve tube is tipped on its end If the
34. ng open outlet ports with suitable port plugs NOTE The following test determines the regulator s lock up pressure the pressure put out by the first stage during a no flow condition 11 Zeagle gt 4 5 2 Attach the regulator to a tank valve giving a source pressure of between 2700 and 3500 psig 186 240 Bar 4 5 3 Turn the supply air on slowly while listening for any unusual air leaks If any are heard turn the air off immediately and determine the source of the leak If no leaks are found watch the intermediate pressure gauge reading rise as you continue turning the air on slowly It should stop before 145 psig 10 bar since the intermediate pressure has not been set yet 4 5 4 If the pressure gauge continues to rise above 155 psig 10 4 bar turn the air supply off imme diately and inspect the regulator to determine the cause 4 5 5 Depress the purge cover fully then release it several times to clear particles from the regulator and to work the internal parts into place To prevent uncontrolled free flows after pushing the purge cover keep the venturi control lever on the second stage in the negative position 4 5 6 The pressure range for Zeagle Regulators is 130 145 psi 9 10 bar Use a 1 4 Allen wrench installed into the spring adjuster 5 to change the intermediate pressure Turn the spring adjuster clockwise in 1 8 turn steps to raise the intermediate pressure and counter clockwise in 1 8 turn steps to lower it
35. or turret to turret bolt seal 160 0024 N7 37 for turret to body seal 5 Zeamle gt d 4 0 SERVICE PROCEDURES FOR THE ZEAGLE ENVOY 1st STAGE 4 0 1 Before you begin disassembly of the regulator test the first and second stages for output pressures and leakage Pre testing in this way will help the technician to pinpoint any specific problems requiring repair 4 0 2 The work area must be clean and well lighted with clean compressed air available to blow sand and dirt from parts 4 1 TOOLS amp ITEMS REQUIRED FOR FIRST STAGE SERVICING Soft jawed bench vise bench vise with rubber plastic aluminum or plastic jaw inserts 1 4 Allen wrench p n 347 0104 3 16 Allen wrench p n 347 0316 5 32 Allen wrench p n 347 0532 6 or 8 good quality adjustable wrenches for hose connections 10 or 15 good quality adjustable wrenches for the Yoke Bolt Zeagle Pin Spanner p n 347 0001 1st Stage Annual Service Kit p n 345 1000 Clean Shop Rags LTI Christo Lube 111 p n 347 0111 Service Video Tape for this regulator p n 347 0101 or Service CD ROM p n 347 0103 or DVD p n 347 0105 Intermediate Pressure Testing Gauge 4 2 DISASSEMBLY OF THE FIRST STAGE FOR OVERHAUL To view all of the parts used in the Envoy first stage look at the inside front cover of this manual The brack eted numbers in the text refer to the corresponding circled item numbers on the exploded view drawing 4 2 1 Use 6 or 8 adjust
36. outside of the valve tube 21 5 4 4 If the lever 19 was removed carefully re fit it into the valve tube 21 To orient the lever properly hold the valve tube with the external threads to the right Turn the valve tube until you can see the hole where the air exits the valve tube indicated by pencil tip in photo The lever is inserted so that it leans to the left See Photo 5 Work the lever into the valve tube one foot at a time so the lever legs are spread outwards as little as possible Photo 5 5 4 5 Insert the new seating seal 22 into the white piston 23 5 4 6 Install the lubricated small O ring 24 onto the piston tip 5 4 7 Install the spring 25 onto the piston and the balance cylinder 26 onto the piston to make the shuttle valve assembly 5 4 8 Insert the shuttle valve assembly you have just assembled into the valve tube 21 at the end with the raised collar opposite the external threaded end See Photo 6 16 zeagie gt Photo 6 5 4 9 When the shuttle assembly is inserted into the valve tube it is important that the L shaped foot on the piston section engages properly with the lever tabs that extend through the holes in the valve tube In Photo 6 the L shaped foot has been highlighted with black marker so you can see the L clearly The piston is normally all white 5 4 10 Insert the shuttle valve assembly as shown in Photo 6 Push the assembly all of the way into the valve tube Th
37. ption of Part Warranty Item Y N 45 1000 rst Stage Sevice Kt lt O fo o ooo 45 2000 econd Stage Service Kt O O OOOO Note If a body or housing is replaced note the new serial in Description of Part am the original first owner of this equipment being serviced Yes No Customer s Signature Date The customer must provide proof of original ownership receipts etc before any in Warranty service can be performed Service Center Be sure this form is completely filled out signed by the customer and returned to Zeagle for credit on warranty parts 2 zeagie gt 7 4 2nd Stage O Rings included in Kit 345 2000 O O 160 9532 N7 24 for piston 23 to balancing cylinder 26 160 0010 N7 17 33 for seat orifice 18 amp hose 30 outlet end 160 0011 N7 28 31 for spring adjuster 29 amp hose 30 inlet end 160 0015 N7 9 27 for valve tube 21 at venturi lever amp heat sink 8 160 0019 N7 15 outside of venturi control lever 16 Zeagle gt SECOND STAGE REGULATOR 30 inch Regulator Hose Assembly bo includes the hose with both O rings and hose protector The letter at the beginning of the serial number on the second stage indicates the model of that second stage If the serial number begins with J e g J001324 it is an Envoy second stage with venturi control For further information contact Zeagle ITEM PART NOR WONMNND CO 9 10 11 12 13 14
38. s Request form 7 1 5 If a body or housing is replaced the replacement parts will have different new serial num bers Note the new serial in Description of Part section of the Zeagle Service Order Parts Request form Write the old number in the Serial section The dive store and the customer should keep records of this serial number change Use the new numbers in future warranty claims 7 1 6 Contact Zeagle Customer Service and ask for an RA Return Authorization number for each group of Zeagle Service Order Parts Request forms you are going to send in YOU MUST GET A RA BEFORE RETURNING ANY PARTS TO ZEAGLE Due to high volume and a desire to move promised items through the service department quickly boxes arriving without a RA will be put at the end of the line and will be opened when all other work on properly RA numbered items is finished This could delay your items by weeks during peak season 7 1 7 Write the RA number on the Zeagle Service Order Parts Request form Mail the forms with attached parts bags to Zeagle You will receive credit or replacement parts ONLY if an RA number is printed on the form 7 1 8 If you are servicing Zeagle regulators outside of the United States your return procedures may be different Check with your regional Zeagle Distributor for details 7 2 SCHEDULED MAINTENANCE 7 2 1 To keep the owner warranty in effect your customers must have their regulators inspected and serviced annually within
39. tage components switch diaphragm with another Po Replace seating seal 22 Po Remove rotate and re install spring 25 regulator and does not happen underwater the regulator and does not happen underwater Move venturi lever 16 towards position until ee harmonic resonance stops 23 zeago 6 2 PARTS CLEANING RECOMMENDATIONS 6 2 1 Regulators that see heavy use particularly those used in salt water often require extra effort to remove dirt and corrosion from the parts of the regulator Some suggested cleaning solutions are listed at the end of this section and there are probably many others being used successfully The following are a few general suggestions we can make 6 2 2 Don t expect your cleaning solution to do all the work in a matter of seconds If the solu tion cleans extremely rapidly it is probably too strong and is etching the finish on the parts Use a wooden or plastic stick or a soft bristle brush to help get rid of the thickest deposits Take spe cial care not to damage orifice sealing areas 6 2 3 Soft parts absorb ultrasonic energy Remove all O rings and seals from metal parts before cleaning them If possible do not clean plastic parts with the metal parts or at least understand that every plastic part you put into the ultrasonic cleaner is slowing down the ultra sonic cleaning process for the rest of the parts 6 3 COMMONLY USED CLEANING SOLUTIONS SOLUTION COMMENTS Hot Soapy water Preferab
40. ting the second stage as outlined in assembly step 5 4 24 in this manual the lever 19 should be should be slightly loose against the L shaped foot of the shuttle valve assembly See Photo 6 There should be about 1 32 8 mm of free play at the end of the lever There should be no air leaking from the second stage with proper intermediate pressure applied to the hose If there is air leaking from anywhere on the second stage correct the problem before going further The best test to check for the slightest leaks is to immerse the second stage with no cover or diaphragm installed under pressure in water and look for bubbles indicating a leak Correct the problem if leaks are found See Troubleshooting section 6 1 for help 5 5 4 Work the lever up and down a few times while the regulator is pressurized Each time the lever is released no air hissing should be heard 5 6 FINAL ASSEMBLY OF THE SECOND STAGE 5 6 1 Install the diaphragm 4 into the housing 10 so that it sits evenly on the ledge 5 6 2 Install the diaphragm cover 3 over the diaphragm Push the cover firmly over the diaphragm so the diaphragm is seated properly 5 6 3 Install the purge dome 2 into the cover ring 1 5 6 4 Screw the purge dome and cover ring into housing Adjust the purge dome in the cover ring so that the Zeagle logo sits properly when the cover ring is tightened firmly hand tight 5 6 5 Install the mouthpiece 12 Be sure to position the mouthp
41. to 1st stage insufficient Verify the supply air pressure Make sure the customer had the air valve turned all the way on during the dive 1st or 2nd stage improperly adjusted Refer to sections 4 5 and 5 5 of this manual 21 zeagie gt A HIGH INHALATION EFFORT AT SURFACE cracking effort in air POSSIBLE CAUSE RECOMMENDED ACTION 1st or 2nd Refer to sections 4 5 and 5 5 of this manual Stage adjusted improperly 2nd stage The spring 25 can be conditioned to a lower thrust This is done by squeez spring force on ing it down with a vise or fingers to near solid height 350 where the high end of Space between the coils is the same as the thickness of the spring wire Do range not squeeze the spring coils completely closed as this will result in too low a cracking effort Note This will lower the cracking effort in air but will have little or no effect on the underwater performance It is usually not necessary and should only be done if the customer understands that a low cracking effort makes a reg ulator more prone to hissing and will probably need more frequent adjusting lf the spring is over squeezed during this conditioning so that the coils touch each other the 2nd stage may hiss when the adjust plug 29 is turned all of the way out Turning the plug in clockwise slightly will stop the hissing if this is the case If the hissing does not stop the seat 18 needs adjusting or the seal 22 needs replacing
42. w dry the interior bores of the hoses Replace the hose assembly if any cuts or cracks are found 5 2 2 Remove the mouthpiece 12 by cutting the two mouthpiece ties 11 with side cutting pliers Discard the old mouthpiece ties Examine the condition of the mouthpiece Pay particular attention to the area on top just behind where the old ties tightened This is a prime area for small holes to develop If the mouth piece is in good condition it can be reused 13 zeagie gt 5 2 3 Remove the exhaust tee 13 from the case by pulling it back and off the top edge of the retaining flange on the housing Note The exhaust tee can be removed more easily if hot water from a tap is run over and through it for about 1 minute 5 2 4 Before removing the exhaust valve 14 from the housing 10 bend the valve over as far as it will go from the top bottom left and right sides If it fails to snap back quickly and does not lie perfectly flat against the housing exhaust grid the valve should be replaced If it does snap back satisfactorily remove it by pulling it out with your fingers Inspect the sealing edges If they appear smooth and the locking tab on the nipple is good the valve can be reused 5 2 5 Unscrew the cover ring 1 from the housing 10 5 2 6 Remove the diaphragm cover 3 and diaphragm 4 from the housing 10 5 2 For future reference look at the lever 19 at this time Notice how the pivot end of the lever is held into the va
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