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Zeagle 320-7200BK Service Manual

Summary of 320-7200BK

  • Page 1

    Regulator service manual for zeagle octo-z regulator/inflator manual p/n 347-3020, copyright 2008 important: read about the octo-z’s bi-annual visual inspection / service schedule item 4.2 on page 6 p/n 320-7200

  • Page 2: Danger:

    This service manual uses signal words recommended by the american national standards institute (see ansi z535.4) to designate levels of hazard seriousness. These signal words and their designations are as follows: danger: indicates an imminently hazardous situation which, if not avoided, will result...

  • Page 3

    * an asterisk next to the item number means that part is included in the standard service kit. The service kit part # for the octo-z is 345-7000. Zeagle octo-z model: 320-7200yl (yellow) model: 320-7200bk (black) octo-z parts item # part # description...... 1 165-1127 inflator hose complete (27”) 2 ...

  • Page 4

    Table of contents 1.0 introduction 2.0 specifications 2.1 model numbers 3.0 o-rings reference chart (octo-z) 4.0 service procedures for the octo-z 4.1 tools required for first stage servicing 4.2 discription of the bi-annual service intervals 5.0 visual inspection procedures 6.0 full overhaul proced...

  • Page 5

    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 ! Warning ! Never reuse the main diaphragm in a dia...

  • Page 6

    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, speci...

  • Page 7

    2.1 zeagle scuba regulator model numbers: model # description 350-1110 flathead-vi yoke 1st stage, with zx 2nd stage - 30” hose 350-1121 flathead-vi din 1st stage, with zx 2nd stage - 30” hose + din to yoke converter 350-2110 50d (swivel turret), yoke 1st stage with zx 2nd stage - 30” hose 350-2121 ...

  • Page 8

    160-2819-n7 (32) for stem of inflate valve (??) 160-4502-n7 (13) for stem of deflate valve 160-0114-n7 (20) for corrugate hose coupling (21) 160-0017-n7 (33) for inflate valve cap (35) 160-0109-n7 (18) for valve tube (2) 160-0010-n7 (3) for orifice (seat) (1) o- ring identification page (o-rings inc...

  • Page 9

    4.0 service procedures for the zeagle octo-z 4.0.1 before you begin disassembly of the octo-z, attach it to a 1st stage and test it for function and leaks . 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...

  • Page 10

    5.0.0 visual inspection procedure 5.0.1 visually inspect the exterior of the octo-z and its inflator hose, looking for cracks, tears or defects in the materials that would negatively affect the function of the octo-z. If any are found that are not warranty related, inform the customer that the affec...

  • Page 11

    8 5.0.4 replace the purge cover assembly onto the octo-z. 5.0.5 attach the octo-z to a bc using the bx coupling. 5.0.6 orally inflate the bc with the octo-z by putting the mouthpiece in the mouth and exhaling while depressing the oval deflate/oral inflate button. Release the button between breaths. ...

  • Page 12

    9 5.0.16 note: if the octo-z did not exhibit any problems during the visual inspection, then the pro- cedure is finished and the octo-z cab be returned to the customer. If minor problems are found, they can be corrected during this inspection. If major problems are found, then the technician should ...

  • Page 13

    6.1.4 use a slotted screwdriver to loosen and remove the inflate valve cover (32) from the body (25). 6.1.5 hold the round inflate button in place with one finger, while loosening the sealing nut (29) with a slotted screwdriver (see photo 5) 6.1.6 when the nut (29) is disengaged from the threads of ...

  • Page 14

    11 6.1.8 remove the valve grate (41) from the body (25) by turning the grate counter-clockwise. 6.1.9 temporarily flip the edges of the exhaust valve (40) to expose the legs of the valve support (39) underneath. Use your fingers or needle nosed pliers to turn the valve support counter-clockwise unti...

  • Page 15

    6.1.13 the selector valve (36) is removed from the body (25) by passing it through the opening that usu- ally holds the front cover. (see photo 9). For later reassembly, notice when you remove it that it is properly oriented when the silver imbedded washer is facing up. 6.1.14 remove the qd plug (7)...

  • Page 16

    6.1.15 use a flat bladed screwdriver to remove the cir-clip (8) that holds the qd tube (16) in the body. (see photo 11) 6.1.16 to remove the qd tube (16) assembly from the body (25), push the tip of the qd against a hard surface. (see photo 12) 13 photo 11 photo 12.

  • Page 17

    6.1.17 while removing the qd tube, look into the open end of the body and notice that the lever (20) is indexed into its proper position by engaging the flat part of the lever support (22) with three raised flanges in the body that form a flat ledge for the lever support. Keep this positioning in mi...

  • Page 18

    15 6.1.19 use a 3/16” allen wrench to remove the seat (14) from the lever support (22). Carefully remove the o-ring (15) from the seat taking care not to scratch the o-ring groove in the process. (see photo 15) 6.1.20 carefully remove the o-rings (17) from the qd tube (16) (see photo 16) photo 16 ph...

  • Page 19

    16 6.1.20 use a sharp pick to pierce and remove the seal (13) from the poppet (12). (see photo 17) 6.1.21 do not disassemble the lever support assembly beyond this point! (see photo 18) to make the technician’s job much easier, it is important to avoid processes that are very time consuming, but do ...

  • Page 20

    6.2 cleaning and inspecting the octo-z 6.2.1 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. ! Warning ! Do not use vinegar or other acid solutions on the plast...

  • Page 21

    7.0 preliminary assembly of the octo-z 7.0.1 ensure that all parts are clean. To determine the identity of each o-ring in the octo-z service kit, remove them from the bag and use the o-ring identification chart by printing out page 5 of this manual. After printing the o-ring identification page, lay...

  • Page 22

    7.0.3 install new lubricated o-rings(17), onto the qd tube (16) and then screw the qd tube into the lever support (22). Screw the two sections together until they are hand tight. This positioning will allow the as- sembly to slide properly into the body (25). (see photo 22) 7.0.4 insert the lever/qd...

  • Page 23

    7.0.5 install the cir-clip back into the proper groove on the qd tube (16) using a flat bladed screwdriver. There are two groove on the qd tube, the cir-clip must be installed into the groove farthest from the tip of the qd fitting. (see photo 23) 7.0.6 install the qd plug (7) onto the qd fitting. U...

  • Page 24

    7.0.7 before installing the oval deflate button (3) into the body, it is important to understand that the shaft on the button assembly is not in the middle of the button. That means that sometimes the button will not fit properly into the hole in the body. Photo 25 on the left shows the button insta...

  • Page 25

    7.0.9 install the washer (28) and the spring (26) on top of the o-ring. (see photo 28) 7.0.10 install the oval button assembly (3) properly oriented into the proper opening in the body (25). Hold the button, spring, washer and o-ring in place with one finger. Insert the selector valve (36) into the ...

  • Page 26

    7.0.11 use the finger on one hand to fully depress the oval button (3) so that the button’s stem passes through the center of the selector valve (36) and the selector valve is pushed firmly against the exhaust opening. Use the other hand to place the new self locking nut (37) over the stem’s threads...

  • Page 27

    7.0.13 the exhaust valve (40) does not have to be removed from the exhaust valve support (39) unless an inspection of the valve shows tears or if the valve does not return to the closed position quickly when flip- ping it from edge to edge. If the valve is found defective, it would be replaced at th...

  • Page 28

    7.0.15 install the exhaust valve assembly into the exhaust opening of the body (25). Position the exhaust valve assembly with the nipple facing into the body. (see photo 34) 7.0.16 when the exhaust valve assembly touches the flat gasket (38) at the bottom of the exhaust open- ing, flip the exhaust v...

  • Page 29

    7.0.17 install the exhaust valve grate (41) on top of the exhaust valve assembly. When you feel the ex- haust valve grate touch the exhaust valve assembly underneath, turn the exhaust valve grate about 1/4 more turn clockwise. (see photo 36) 7.0.18 install the new o-ring (30) from the service kit in...

  • Page 30

    7.0.19 install the two new o-rings (6) onto the stem of the inflate button (4). Insert the inflate button and spring (5) into the proper opening in the body (25). (see photo 38) 7.0.20 use the finger on one hand to fully depress the round button (4). Use the other hand to place the sealing nut (29) ...

  • Page 31

    7.0.21 use a flat bladed screwdriver to tighten the sealing nut onto the stem threads. Stop tightening the nut as soon as you feel it bottom on the threads. (see photo 40) 7.0.22 install the inflate cover (32) into the opening and use a flat bladed screwdriver or coin to tighten it. The threads of t...

  • Page 32

    7.0.23 when you look into the open end of the octo-z at this point, you may notice that the nipple from the exhaust valve (40) is bent and touching the selector valve (36) as it is depressed. This is normal. Do not cut the end of the nipple! If you do, the stub of the nipple will stick strait up, an...

  • Page 33

    Note : attach the octo-z inflator hose to a properly adjusted first stage that it is going to be used with, mount- ed on an air tank filled to between 2700 and 3500 psi. Install an intermediate pressure gauge into one of the low-pressure ports. Never tighten the inflator hose to the 1st stage with m...

  • Page 34

    7.2.3 if when the pressurized qd hose is connected to the octo-z air is leaking from the lever assembly area, then the seat (14) needs to be rotated clockwise, to close the gap between the orifice in the seat and the seal (13) at the end of the poppet (12). 7.2.4 if when the octo-z is pressurized no...

  • Page 35

    7.2.9 press the purge cover (34) firmly over the diaphragm (35) with a rocking motion. Push the cover inwards from the left and right as well as the top and bottom. You will hear as clicking sound as the cover moves down into position. When you do not hear anymore clicking sounds, the cover is in pl...

  • Page 36

    7.2.11 install the mouthpiece onto the mouthtube on the body. Install and tighten the plastic tie (24) that came in the service kit. Cut off any excess tab sticking out of the tie with side cutting pliers. (see photo 48) 8.0.0 testing the octo-z after rebuilding after completed the bi-annual overhau...

  • Page 37

    34 refer to section 7.2 of this manual for the octo-z and also look at the 1st stage regulator’s service manual for the set up of the 1st stage. The spring (23) can be conditioned to a higher thrust. This is done by stretching it slightly with your fingers. Note: this will raise the cracking effort ...

  • Page 38

    35 e. Wet breathing: possible cause recommended action f. High frequency humming or buzzing during inhalation (1st stage issue): possible cause recommended action remove the main spring flip it over and re-install. Replace spring or other components until resonance stops. Harmonic resonance between ...

  • Page 39

    36 10.2 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. 11.0 pre-dive checks: 11.0.1 check the hoses and ...

  • Page 40

    11.0.2 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 sourc...

  • Page 41

    38 13.1.3 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 par...

  • Page 42

    I 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...

  • Page 43

    37150 chancey road zephyrhills, florida 33541 u. S. A. Zeagle scuba, the zeagle symbol, octo-z, razor, rezort, zx, envoy, 50d, ds-v 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 w...