Reg. Service Manual 2001PDF VER
Contents
1. zeagig gt SYSTEMS INC y ap Te Regulator Service Manual For Zeagle Scuba Regulator Models 50D DS IV Flathead VI Ist Stages and ZX 2nd Stage ZX Octo Flathead VI 1st Stage Parts ITEM PART DESCRIPTION 1 341 0149 CL Environmental End Cap 2 341 0121 MC Hydrostatic Diaphragm clear 3 341 0148 AA Label for Flathead VI 4 341 0119 KA Hydro Transmitter 5 341 0103 CD Spring Adjuster 6 341 0122 CD Diaphragm Clamp 7 341 0140 VH Regulating Spring 8 341 0104 CD Spring Carrier 9 341 0105 TA Internal Diaphragm black 10 341 0106 VH Lifter 11 341 0109 CD Seat Support 12 341 0108 JA Seat orifice 13 160 0009 N9 O ring for seat 15 160 0011 N7 O ring for LP port plugs 16 341 0127 CD LP Port Plug includes O ring 17 341 0128 CD HP Port Plug includes O ring 18 160 0012 N9 O ring for HP port plugs 19 341 0129 AA DIN Cap 20 160 0111 N7 O ring for inlet of DIN bolt 21 341 0112 CD Din Connector Bolt 22 341 0139 BA Conical Filter 23 160 0011 N7 O ring for filter amp bolt 24 341 0142 AA DIN Wheel 25 341 0115 AA Yoke Knob Assembly 26 341 0117 LA Dust Cap 27 341 0111 CD Yoke Bolt 28 341 0113 DL Yoke Satin Finish 29 341 0146 SA Saddle Spacer 30 341 0107 VH HP high pressure Valve 31 341 0141 VA Valve Spring 32 160 0006 N7 O ring smallest O ring in HP balance plug 33 160 0905 N9 O ring middle sized O ring on HP balance plug 34 160 0016 N7 O ring largest sized O ring on HP2. 20 for inlet end of DIN bolt 21 160 0016 N7 34 for large end of HP balance plug 35 O _ 160 00 1 9 N7 40 for turret to turret bolt seal 160 0024 N7 37 for turret to body seal zeagle gt 4 0 SERVICE PROCEDURES FORTHE ZEAGLE MODEL DS IV non swiv el and 50D swivel turret and Flathead VI hi flow Ist STAGES 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 15 good quality adjustable wrench Zeagle Pin Spanner p n 347 0001 Ist 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 Intermediate Pressure Testing Gauge 4 2 DISASSEMBLY OF THE FIRST STAGE FOR OVERHAUL To view all of the parts used in the Flathead VI hi flow 50D swivel turret or DS IV non swivel first stage fold out t
3. balance plug 35 341 0151 CL HP Balance Plug 42 341 0145 CL Body Satin Finish for Flathead VI 1st stage 43 341 0147 AA Label 44 341 0150 SA Trim Ring 45 341 0152 SK Washer for DIN Wheel Flathead VI First Stage Assembly Yoke Model 310 4110 DIN Model 310 4120 zeagi o SYSTEMS INC An asterisk next to the Item 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 Zeagle gt 50D First Stage Assembly Yoke Model 310 2110 DIN Model 310 2120 Go to next page for Item Numbers ITEM PART DESCRIPTION Zeagles SYSTEMS INC I 341 01 18 SA Environmental End Cap 2 341 0121 MC Hydrostatic Diaphragm clear 3 341 0144 AA Label specify model to customer service 4 341 0119 KA Hydro Transmitter 5 341 0103 CD Spring Adjuster 6 341 0122 CD Diaphragm Clamp 7 341 0140 VH Regulating Spring 8 341 0104 CD Spring Carrier 9 341 0105 TA Internal Diaphragm black 10 341 0106 VH Lifter lI 341 0109 CD Seat Support 12 341 0108 JA Seat orifice 13 160 0009 N9 O ring for seat z 14 341 0101 CL EA i ae for DS IV non swivel style Ist stage An asterisk next to the Item Number means that part is 15 160 001 1 N7 O ring for LP port plugs included in the Standard Service Kit The Service Kit Part ts eee ees a toate CAG for the Ist Stage is 345 1000 The 2nd Stage Serv
4. 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 regu lator 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 pre dive position the regula tor will be relatively hard to inhale on but the purge dome must still purge when depressed 5 7 3 With the adjusting knob turned fully counter clockwise and the venturi lever in the full dive position the regulator will 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 delivery 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 under water breathing effort They also have design features that were influenced by the desire to make the regulator stable and resistant to freezing and free flows The regulato
5. unit yellow purge cover and 36 hose model assembly number 320 1110 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 H The number 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 11 p n 347 0111 Service Video Tape for this regulator p n 347 0101 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 fold out the back cover of this manual 5 2 1 Pull the nut cover 6 off of the nut 7 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 blow dry the interior bores of the hoses Replace the hose assembly if any cuts or crack
6. 5 behind the DIN wheel 4 2 14 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 15 Using a 5 32 Allen wrench remove all remaining port plugs 16 17 from the body 14 or 36 Discard the port plug O rings 15 18 4 3 Cleaning and Inspection of the Ist Stage 4 3 1 Clean 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 effec tiveness 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 and 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 regulator was leaking air because of scratches or wear replace the parts If some corrosion deposits persist care fully 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 lif
7. 7 over the external threaded end of the valve tube Tighten the nut snugly l 2 ft Ib 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 adjustment of the seat leaves the lever with just a little 2 3 degrees of arc free movement to allow for the natural wear of the seating seal 22 during the use of the regulator Adjust the seat 18 in while watching the tip of the lever while holding the housing so that the lever is faced upwards Stop turn ing the seat 18 as soon as the lever droops or is loose enough to have 2 3 degrees arc of free play See Photo 8 Without this free play the second stage will begin to hiss slightly after just a few hours use Note Depress the lever 19 while moving the seat with the wrench This prevents premature inden tation and wear of the seal 22 Photo 8 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 5 5 SET UP OF THE SECOND STAGE For the following adjustments the cover and diaphragm must be
8. 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 IMPORTANT Do not lubricate the O ring 9 that goes over the valve tube 21 male threaded end Zeagie gt d 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 11 1 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 outside of the valve tube 21 5 4 4 If the lever 19 was re
9. After reaching the proper pressure setting push the purge cover on the second stage again sever al times and watch how the intermediate pressure reading responds When the purge cover on the sec ond 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 pressure 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 shoot ing Section 6 lof this manual Note Never set the output pressure of the first stage above 145 psi 10 bar 4 6 FINAL ASSEMBLY OF THE FIRST STAGE 4 6 1 To finish installing the end cap on the first stage the pressure to the first stage must be left on to position all internal parts properly 4 6 2 With the regulator pressurized insert the hydro transmitter 4 into the body assembly 4 6 3 Install the new clear hydrostatic diaphragm 2 into the recess in the diaphragm clamping ring 6 over the hydro transmitter On the Flathead VI only install the trim ring 44 4 6 4 Install the end cap 1 onto the diaphragm clamping ring 6 Use a clean rag to help grasp the end cap Tighten the end cap firmly Use enough force so that the end cap cannot be loose
10. COMMENDATIONS 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 solution 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 special 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 clean ing 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 ultrasonic cleaning process for the rest of the parts 6 3 COMMONLY USED CLEANING SOLUTIONS SOLUTION COMMENTS Hot Soapy water Preferable Good for plastic silicone and plated metal parts Vinegar and water equal part solution weak Ingredients easily available Approx 15 min er 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 b
11. O ring 17 on seat 18 zeagle gt C WET BREATHING POSSIBLE CAUSE RECOMMENDED ACTION Diaphragm improperly installed or hole in Check position of diaphragm visually diaphragm Replace if holes found by holding up to a light Damaged or loose fitting exhaust valve Replace exhaust valve 14 Crack in housing 10 Replace housing Worn venturi lever O rings 15 27 Replace O rings 15 27 Scratched or worn venturi lever sealing surfaces Replace venturi lever 16 Scratched or worn housing 10 sealing surfaces Replace housing Extremely slow breathing allowing water to build up in housing rather than being Explain this result of slow breathing to diver blown out D HIGH FREQUENCY HUMMING OR BUZZING DURING INHALATION POSSIBLE CAUSE RECOMMENDED ACTION Harmonic resonance between the springs and other Ist stage components re install Replace spring or other components until ee e E LOW FREQUENCY FLUTTERING DURING INHALATION Above the surface only POSSIBLE CAUSE RECOMMENDED ACTION Harmonic resonance between the springs and Remove rotate and re install diaphragm or switch other 2nd stage components diaphragm with another Replace seating seal 22 Remove rotate and re install spring 25 Move venturi lever 16 towards position until harmonic resonance stops Explain to the customer that this is not harmful to the regulator and does not happen underwater Zeagie gt d 6 2 PARTS CLEANING RE
12. ON EFFORT AT SURFACE cracking effort in air POSSIBLE CAUSE RECOMMENDED ACTION Ist or 2nd stage Refer to sections 4 5 and 5 5 of this manual improperly adjusted 2nd stage spring The spring 25 can be conditioned to a lower thrust This is done by squeezing it force on high down with a vise or fingers to near solid height 350 where the space between end of range the coils is the same as the thickness of the spring wire Do 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 regulator more prone to hissing and will probably need more frequent adjusting If the spring is over squeezed during this conditioning so that the coils touch each other the 2nd stage may hiss when the adjust knob 29 is turned all of the way out Turning the knob 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 B CREEPING INTERMEDIATE PRESSURE POSSIBLE CAUSE RECOMMENDED ACTION Replace HP balance plug 35 or turret bolt 41 C HISSING FROM SECOND STAGE but intermediate pressure is OK POSSIBLE CAUSE RECOMMENDED ACTION Worn O ring 24 on piston 23 Worn
13. act 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 Model Numbers Model Description Flathead VI Yoke Ist Stage with ZX 2nd Stage 30 Hose 50D swivel turret Yoke Ist Stage with ZX 2nd Stage 30 Hose 350 4121 DS IV non swivel DIN Ist Stage with ZX 2nd Stage 30 Hose DIN Yoke Converter 320 1110 2nd Stage only ZX Octopus 2nd Stage with Yellow Cover 36 Hose 320 1115 2nd Stage only ZX Standard 2nd Stage with Gray Cover 30 Hose 310 1110 Ist Stage only Flathead VI Yoke 310 1120 Ist Stage only Flathead VI DIN 310 2110 Ist Stage only 50D swivel turret Yoke 310 2120 Ist Stage only 50D swivel turret DIN 310 4110 Ist Stage only DS IV non swivel Yoke Ist Stage 310 4120 Ist Stage only DS IV non swivel DIN Ist Stage 330 0001 DIN to Yoke Converter allows a DIN equipped regulator to be mounted on a Yoke Valve with no tools Zeagie gt d Ist Stage O Rings included in Kit 345 1000 60 0006 N7 32 for stem of HP Valve 30 O ____________ 160 0009 N9 13 for seat Orifice 13 O O O 160 001 1 N7 15 23 for LP ports 3 amp inlet filter 1 O O _ 160 0012 N9 18 for HP ports 2 O _________ 160 0905 N9 33 behind thread of HP balance plug 35 160 0111 N7
14. cations 2 2 Model Numbers 3 0 O rings Reference Chart 4 0 First Stage Procedures 4 1 Tools Required for First Stage Servicing 4 2 Disassembly of the 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 4 6 Final Assembly of the First Stage 5 0 ZX 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 Tips 7 0 Warranty and Maintenance Information 7 1 Proper Procedure for Warranty Paperwork 7 2 Scheduled Maintenance 7 3 Order Form sample Before You Begin zeae 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 equipment 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 If the serial num ber begins with B it i
15. e HP valve 4 4 26 Insert the valve and spring into the HP balance plug 35 4 4 27 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 28 Screw the HP balance plug into the body with a 1 4 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 29 Install the dust cap 26 and yoke knob 25 onto the yoke 4 4 30 Install new O rings 15 18 from the kit onto port plugs 16 17 and install the port plugs into the appropriate ports Zeagle gt 4 5 SET UP AND TESTING OF THE FIRST STAGE 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 pressure ports of the first stage and a functional 2nd stage into another low pressure port Plug any remaining 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 4 5 2 Attach the regulator to a tank valve giving a source pressure of between 2700 and 3500 psig 1 86 240 Bar 4 5 3 Turn the supply air on slowly while listening for a
16. e 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 or 36 See photo 3 The heel of the spanner can be wrapped in tape to help prevent damage to the chrome finish on the clamping ring Photo 3 50D shown 4 2 9 Remove the body assembly from the vise 4 2 10 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 or 36 Discard the diaphragm 9 A WARNING NEVER reuse the diaphragm in the first stage A used diaphragm will not clamp securly 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 read this warning may result in serious injury or death 4 2 11 Use a 3 16 Allen wrench to remove the seat support I 1 from the body 4 2 12 Remove the seat 12 the seat O ring 13 and discard both 4 2 13 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 4 Remove the yoke knob assembly 25 and the dust cap 26 from the yoke 28 Zeagie gt d Note If the regulator has a DIN wheel use a 1 4 Allen wrench to remove the DIN bolt 21 and DIN wheel 24 The Flathead VI also has a spacing washer 4
17. el TYPE Balanced Diaphragm Dry Environmental Seal with Hydrostatic Transmitter WEIGHT prnaos DS IV 1 9 Ib 86 kg 50D 2 1 Ib 95 kg Flathead VI 2 1 Ib 99 kg INTERSTAGE PRESSURE 130 145 psi 9 10 bar 135 psi 9 3 bar nominal LOW PRESSURE PORTS 4 3 8 24 UNF HIGH PRESSURE PORTS 2 7 16 20 UNF MATERIALS eiere Body CDA 360 Brass O rings Buna N Seat Advanced Polymer HP Valve Stainless Steel B ZX 2nd STAGE REGULATOR MEV 4 SPEEA NET A T tee Downstream valve balanced diaphragm Diver Adjustable Dive Pre Dive Venturi Lever and Resistance Control Knob WEIGH Toisinaan asini 26 Ib 54 kg w o hose HOSE LENGTH eee 30 in 76 mm MATERIALES o eaii Cover Flexible Thermoplastic Case Rigid Thermoplastic Poppet Seat Advanced Elastomer O rings Buna N Diaphragm Elastomeric Polymer Exhaust Valve Thermoplastic Elastomer Mouthpiece Silicone zeagle gt 2 1 Torque Specifications Description Item Torque Environmental End Cap l Hard hand tight with rag cushioning hand Diaphragm Clamp 6 25 30 ft lb 34 40 Nm with pin spanner DIN Bolt 21 20 25 ft lb 27 34 Nm with 1 Allen wrench Yoke Bolt 27 20 25 ft lb 27 34 Nm HP Balance Plug 35 2 3 ft lb 3 4 Nm with 1 4 Allen wrench Turret Bolt 4 2 3 ft lb 3 4 Nm with 1 4 Allen wrench Seat Support E snug metal cont
18. er is 1 4 to 1 8 64 to 32 cm from the lip of the mouth piece 5 7 12 Hold the regulator in this position for one minute and then slowly raise it out of the water 5 7 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 7 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 knob to the minimum breathing effort position 5 7 15 With the tank valve still turned off flood the second stage completely with water and then posi tion it mouthpiece up 5 7 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 A HIGH INHALATION EFFORT AT DEPTH POSSIBLE CAUSE RECOMMENDED ACTION Inlet filter clogged Replace the filter Air supply to Ist stage insufficient Verify the supply air pressure Make sure the customer had the air valve turned all the way on during the dive Ist or 2nd stage improperly adjusted Refer to sections 4 5 and 5 5 of this manual Zeagie gt d A HIGH INHALATI
19. he best source for current part numbers for any of the parts listed in this manual is your current parts and price list from Zeagle 1 5 Zeagle conducts seminars on a regular basis to train technicians in proper service and repair pro cedures 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 fea tures 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 Zeagie gt d NOTE You must be authorized by Zeagle to work on Zeagle Scuba equipment You can obtain prop er authorization by attending all appropriate seminars given in your area This is the only way you can become an authorized Zeagle technician 1 6 If you have any questions or need more information contact your Zeagle Scuba Sales Representative or Zeagle Customer Service You can E mail your technical questions to info zeagle com 2 0 SPECIFICATIONS Zeagle Models ZX Flathead VI ZX 50D and ZX DS IV AIR EL OW casneiaceinmancesenens 33 cu ft 935 liters min atmosphere INHALATION RESISTANCE 0 9 2 0 2 3 5 08 cm w c atmosphere adjustable EXHALATION RESISTANCE 0 6 1 52 cm w c max atm RECOMMENDED LUBRICANT LTI Christo Lube 11 A FIRST STAGE REGULATORS 50D swivel DS IV non swiv
20. he first page of this manual and view the exploded view appropriate for the model you are working on The bracketed numbers in the text refer to the corresponding circled item numbers on the exploded view drawing 4 2 1 Use 6 or 8 adjustable wrenches to disconne ct all hoses from the first stage Pull back the hose protector 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 Zeagie gt d 4 2 2 Unscrew and remove the environmental end cap 1 4 2 3 Remove and discard the clear silicone hydrostatic diaphragm 2 Remove the black hydro transmitter 4 Note The three first stage models covered in this section vary slightly The minor service procedure differences are covered If the regulator you are working on is a 50D swivel turret type skip to instruc tion 4 2 5 If it is a Flathead VI hi flow or DS IV non swivel type continue to the next step listed See the pictures on the front cover of this manual if you are not sure which type you have 4 2 4 Note For Flathead VI and DS IV non swivel only 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 rotat
21. he 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 RA fill your RA in here 37150 Chancey Road Zephyrhills Florida 33541 U S A 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 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 performance and satisfy warranty requ
22. ice Kit ort Plug includes O ring 18 160 0012 N9 O ring for HP port plugs Part is 345 2000 19 341 0129 AA DIN Cap 20 160 01 1 1 N7 O ring for inlet of DIN bolt 21 341 0112 CD Din Connector Bolt 22 341 0139 BA Conical Filter 23 160 001 1 N7 O ring for filter amp bolt 24 341 0142 AA DIN Wheel z AEA ka oe IMPORTANT Items 14 28 36 and 38 had a shiny 27 341 01 I I CD Yoke Bolt chrome finish in early models rather than the current satin 28 34 0113 DE Yoke Satin Finish chrome finish If you want to order these parts in a shiny AOS SA Spacer chrome finish instead of satin change the last letter in the 30 341 0107 VH HP high pressure Valve S 31 341 0141 VA Valve Spring part number from L to D These parts in a shiny chrome 32 160 0006 N7 O ring smallest O ring in HP balance plug finish will be subject to availability 33 160 0905 N9 O ring middle sized O ring on HP balance plug 34 160 0016 N7 O ring largest sized O ring on HP balance plug 35 341 0110 CD HP Balance Plug 36 341 0123 CL Body Satin Finish for 50D swivel style Ist stage 37 160 0024 N7 O ring for 50D body to turret 38 341 0124 CL Turret Satin Finish 95 39 341 0125 GA Thrust Washer 40 160 0019 N7 O ring for turret to turret bolt 4l 341 0120 CD Turret Bolt DS IV First Stage Assembly Yoke Model 310 4110 DIN Model 310 4120 TABLE OF CONTENTS 1 0 Introduction 2 0 Specifications 2 1 Torque Specifi
23. ing 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 Now skip to step 4 2 6 Photo HP Balance Plug Assembly removal Photo 2 Turret Bolt Assembly removal Flathead VI or DS IV DS IV shown 50D only 4 2 5 Note This step is for the 50D swivel model only Clamp the regulator carefully in a soft jawed vise with the turret bolt 41 facing up Position the regulator so that the yoke 28 or DIN wheel 24 is preventing the regulator from rotating as the turret bolt is loosened Use a 1 4 Allen wrench to loosen and remove the turret bolt assembly 30 31 32 33 40 and 41 from the turret 38 See Photo 2 Remove the turret assembly 37 38 39 from the body 36 4 2 6 If the regulator has severe internal corrosion due to salt water being forced through the inlet fil ter it may be necessary to carefully use a pair of pliers to remove the HP valve 30 from the HP bal ance plug 35 or turret bolt 41 If so pull the valve out straight and slowly taking care not to bend the stem of the HP valve Remove and discard all O rings 4 2 7 Re clamp the regulator carefully in a soft jawed vise with the diaphragm clamping ring 6 facing up Position the regulator so that the yoke 28 or DIN wheel 24 is preventing the regulator from rotating as the diaphragm clamping ring is loosened Zeagle gt d 4 2 8 Use a Zeagl
24. ing 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 knob assembly 29 5 4 12 Insert the spring adjuster knob assembly into the valve tube over the shuttle valve assembly you just installed 5 4 13 Turn the spring adjuster knob assembly 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 knob assembly out counter clockwise until it tightens against the pin 20 holding 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 Zeagie gt d 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 heat sink 8 over the external threaded end of the valve tube 5 4 21 Install the nut
25. irements 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 Zeagle Scuba Warranty Department zeagle gt 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 Rd Fa for ANY Warranty Servicing Zephyrhills FL 33541 Lil C3 813 782 5568 SYSTEMS INC You MUST contact Zeagle for an RA Fax 813 782 5569 www zeagle com Number to receive any Warranty Credit 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 Ist Stage Model Serial 2nd Stage Model Serial Octopus Model Serial Comments Description of Part Warranty Item Y N First Stage Service Kit Second Stage Service Kit Part Installed 345 1000 345 2000 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 Custome
26. llen wrench If it will not come out it can be pushed out with a soft wooden dowel however care must be taken not to damage 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 a 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 5 3 2 If necessary because of deposits or corrosion clean all metal parts of the second stage in an ultra sonic 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 heat sink 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 scratches 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 Look 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
27. moved carefully re fit it into the valve tube 21 To orient the lever prop erly 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 6 Work the lever into the valve tube one foot at a time so the lever legs are spread outwards as little as possible Photo 6 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 Zeagle gt 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 7 Photo 7 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 7 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 7 Push the assembly all of the way into the valve tube The first thing that might hang up on the tabs of the lever is the black seat
28. ned easily by hand On the Flathead VI only use the Zeagle Pin Spanner 347 0001 to tighten the cap snuggly Use an old Ist Stage diaphram as a cushion under the spanner to prevent marks from being made on the enviornmental end cap 4 6 5 Push the clear hydrostatic diaphragm 2 briefly with one finger while watching the intermediate pressure gauge The pressure should rise about psi for every pound of force For example five or ten psi 35 7 bar increase in intermediate pressure when the diaphragm is pushed with five or ten pounds 4 6 6 Turn off the supply pressure and depress the purge cover to release the air from the second stage When the intermediate pressure drops to zero you should see the clear hydrostatic diaphragm 2 pull into the body assembly If the regulator is re pressurized the clear diaphragm will push out to the flat position If by mistake the end cap I is loosened and then re tightened without pressure applied to the first stage the clear diaphragm will bulge outwards when the regulator is under pressure If this con dition exists follow steps 4 6 1 to 4 6 5 5 0 ZX SECOND STAGE SERVICE PROCEDURES The procedures covered in this manual section apply to the ZX second stage To access the exploded view of this model fold out the back page of this section of the manual This second stage is used as a primary unit gray or black purge cover and 30 hose model assembly number 320 1115 and as an advanced octopus
29. ny 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 pres sure 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 immedi ately 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 clock wise in 8 turn steps to raise the intermediate pressure and counter clockwise in 1 8 turn steps to lower it See Photo 5 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 opti mal 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 Zeagie gt d 4 5 7
30. odel is faced up 4 4 19 Note Steps 4 4 20 to 4 4 24 are for the 50D swivel model only Skip to step 4 4 25 if you are working on a DS IV non swivel Lightly lubricate the new O rings from the annual service kit with LT Christo Lube 11 Install O ring 37 onto the body 36 Install O rings 32 33 and 40 onto the turret bolt 41 4 4 20 Lightly lubricate the stem of the HP valve 30 Snap the end of the spring 31 over the ledge on the HP valve Insert the valve and spring into the turret bolt 41 4 4 21 Install the turret 38 onto the body 36 Re lubricate the cleaned white thrust washer 39 and install it into the turret 38 4 4 22 Install the turret bolt 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 23 Screw the turret bolt assembly into the body with a 1 4 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 Now skip to step 4 4 30 4 4 24 Note This and following steps 4 4 26 to 4 4 29 are for the Flathead VI hi flow and DS IV non swivel model only Lightly lubricate the new O rings from the annual service kit with LTI Christo Lube III and install them onto the HP balance plug 35 4 4 25 Lightly lubricate the stem of the HP valve 30 Snap the end of the spring 31 over the ledge on th
31. ondition 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 warnine 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 2 This manual gives breakdowns of regulator parts equipment specifications servicing instructions troubleshooting recommendations and guidelines for proper care of Zeagle regulators This manual is intended for use only by persons specially trained and authorized to service Zeagle Scuba equipment 1 3 Anyone attempting to service or repair Zeagle Scuba regulators must have a thorough under standing of the principles of operation of scuba regulators and valves as well as the appropriate mechan ical 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 manual 1 4 T
32. r is VERY easy breathing underwater and yet resists going into free flow by just being bumped on the surface One important result of this dual personality is that the Cracking Effort test on the surface will reveal a rela tively high compared to less stable regulators cracking effort of 1 4 to 2 36 51 mm water column This is deliberately designed into the regulator for stability and freezing resistance reasons and IN NO WAY relates to underwater performance If 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 reg ulator 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 7 8 Brand new exhaust valves will sometimes adhere slightly to the case causing a slight increase in exhalation effort This condition will disappear with use zeagle gt C LEAKTEST 5 7 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 wat
33. r 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 Zeagle gt 37150 Chancey Road Zephyrhills Florida 33541 U S A Zeagle Scuba the Zeagle symbol ZX 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 Contact Zeagle by E mail at info zeagle com 2001 Zeagle Systems Inc Printed in USA Part Number for this Manual p n 147 2000 ZeEagled SYSTEMS INC
34. reakage Simple Green and Water Simple Green is a readily available degreaser Read the product label for mixing ratios with water Cleaning solutions recommended by ultrasonic The preferred choice Check with the manufac cleaner manufacturers turer for strengths and recommended uses for their cleaners Choose soap solutions over acidic 6 4 HANDLING TIPS How your customers treat their regulators will directly influence the unit s function and durability Following are a few tips that you can pass on to your customers to help assure the durability 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 mount ing the regulator on the tank valve Slide the hose protectors back to inspect the areas of the hose nor mally covered Be sure all hose connections are tight zeagle 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 salt water being blown through the interior of the regulator is the number 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 connection is tight and the regulator body is aligned properly with no kinks in the hoses 6 4 4 Turn the tank valve on
35. removed 5 5 1 Turn the spring adjust knob assembly 29 out counter clockwise all the way Note Some models use a plastic spring adjust plug 35 instead of a knob assembly Use a 1 4 Allen wrench to turn the plas tic plug Zeagle gt 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 con nection 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 pres sure gauge into one of the low pressure ports 5 5 3 Carefully turn the air on After adjusting 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 7 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 Trouble
36. s a 50D swivel turret first stage If the serial number begins with F it is a Flathead VI first stage For further information contact Zeagle Zeagle gt 1 0 INTRODUCTION 1 1 The procedures in this manual apply to Zeagle Scuba Regulators There are two front cover fold outs inside containing exploded views of the first stages The one you fold out depends on which model you are sevicing One foldout is for the Flathead VI first stage The other is for the 50D swivel and DS IV non swivel model If you are not sure which first stage you are working on refer to the pictures on the front of this manual 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 read this warning may result in serious injury or death NEVER tighten the hose fitting to the first stage with more than 40 in lbs 4 5 Nm of torque The inlet hose fitting will be weakened by over tightening Failure to read 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 c
37. s 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 devel op If the mouthpiece is in good condition it can be reused 5 2 3 Remove the exhaust tee 13 from the case by pulling it back and off the top edge of the retain ing 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 one minute Zeagie gt d 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 7 For future reference look at the lever 19 at this time Notice how the pivot end of the lever is held into the valve tube 21 by two plastic flanges on the housing Note this positioning for re as
38. sem bly 5 2 8 Hold the diaphragm up to a light source Gently stretch the diaphragm and look for tears or pin holes If 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 heat sink 8 from the valve tube Note On some models instead of a metal heat sink there is a plastic bushing 34 5 2 11 Remove and discard the O ring 9 from the valve tube 5 2 12 Turn the spring adjust knob 29 fully counter clockwise until it comes to its stop 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 Turn the spring adjust knob 29 clockwise 1 2 turn The pin 20 will fall out of the valve tube or can now be easily removed 5 2 16 Turn the spring adjust knob assembly 29 counter clockwise to remove it from the valve tube Remove and discard the O ring 28 Note On some models there is a plastic spring adjuster plug 35 instead of an adjust knob assembly Use a 1 4 Allen wrench to remove it 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 piston will not fall out
39. shooting 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 mouthpiece 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 5 6 7 Slide the hose nut cover 6 back over the hose connection A Warning NEVER tighten the hose with more than 40 in lbs 4 5 Nm of torque The inlet hose fitting can be weakened by over tightening Zeagie gt d 5 7 TESTING OF THE SECOND STAGE A INHALATION EFFORT 5 7 1 With air pressure applied turn the spring adjuster knob fully counter clockwise Move the venturi lever to the position Depress and release the purge dome A large
40. 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 but ton above the water s surface is not an effective or thorough method for testing the function of the reg ulator 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 proce dures is another great cause of corrosion and wear in Scuba regulators 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 Shake 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 adeq
41. support 4 4 13 Install the new diaphragm 9 into the body A WARNING NEVER reuse the diaphragm in the first stage A used diaphragm will not clamp securly 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 read this warning may result in serious injury or death 4 4 14 Place the spring carrier 8 onto the center of the diaphragm 4 4 15 Place the main spring 7 onto the spring carrier 8 4 4 16 Screw the spring adjuster 5 about two turns into the diaphragm clamping ring 6 from the out side end of the diaphragm clamping ring 4 4 17 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 Zeagie gt d 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 34 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 secure ly clamped Use an old Ist Stage diaphragm as a cushion under the spanner to prevent marks from being made on the diaphragm clamping ring 4 4 18 Turn the body over carefully and re clamp it in the soft jawed vise so that the turret or HP bal ance plug end depending on m
42. t 4 4 Install the yoke bolt 27 into the yoke 28 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 bolt 27 4 4 4 Hand tighten the yoke yoke bolt and spacer into the body 14 or 36 4 4 5 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 If the regulator is a Flathead VI also install the spacer washer 45 4 4 6 Place the body 14 or 36 or 42 carefully into a soft jawed vise so that the yoke bolt or DIN bolt is facing up 4 4 7 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 8 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 9 Install the lightly lubricated O ring 13 onto the seat 12 4 4 10 Install the seat 12 into the body 14 or 36 from the diaphragm end The seat installs with the end with the notch and O ring groove towards the body 4 4 11 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 12 Install the lifter 10 into the seat
43. ter 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 Correct order of assembly is extremely important The diaphragm end MUST be assem bled 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 DISASSEMBLED so that the diaphragm end can be re assem bled first To determine the identity of each O ring in the Ist 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 corre sponding picture on the page and read the description Before installing new O rings into the regulator lightly lubricate the O rings with LTI Christo Lube 11 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 11 Rub the O rings and grease together in the bag until all the O rings are coated evenly Try not to wipe the lubri cation off the O rings when assembling them onto other parts ZEAMC g
44. 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 insert ed 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 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 zeagle gt 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 section of the O ring out of the groove with the fingernails Then flip the O ring off the end of the pis ton 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 turning counterclockwise at the same time The seat will usually come out on the end of the A
45. uate 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 7 1 3 Fill out the Zeagle Service Order Parts Request form PRINT CLEARLY If you use service 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 list ed on the form Zeagie gt d 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 Parts Request form 7 1 5 If a body or housing is replaced the replacement parts will have different new serial numbers 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 t
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