RaZor Service Manual
Contents
1. or 8 good quality adjustable wrenches for hose connections 10 or 15 good quality adjustable wrenches for the Cap and Body 1st Stage Annual Service Kit p n 345 1001 Clean Shop Rags LTI Christo Lube 111 p n 347 0111 or Dow Corning 111 Silicone Grease Service Video Tape for this regulator p n 347 0103 or Service CD ROM p n 347 0103C or DVD p n 347 0103D Intermediate Pressure Testing Gauge 4 2 DISASSEMBLY OF THE RaZor FIRST STAGE FOR OVERHAUL To view all of the parts used in the RaZor 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 CAREFULLY bleed ALL of the air from the cylinder that the RaZor 1st stage is installed in by opening the Valve 25 and depressing the Purge Button on the 2nd stage until the reading on the submersible pres sure gauge is between 50 and 100 psi Use the 6 adjustable wrench to carefully turn the Burst Plug 11 counter clockwise just until you hear the final pressure being relieved Do not remove the Burst Plug 11 at this time Remove a low pressure port plug to insure that all cylinder pressure is relieved as the cylinder warms back up The purpose of this exercise is to loosen the Burst Disc 12 for later removal 4 2 2 Use or 8 adjustable wrenches to disconnect all hoses from the first stage Pull back the hose protec tor from th2. 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 resis tance 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 discard 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 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 2
3. 4 4 29 Use a wrench to snug the Cap 2 onto the body with 1 5 ft lbs 1 4 7 Nm of torque 12 zeago 4 5 SET UP AND TESTING THE FIRST STAGE Note The RaZor regulator has an unbalanced piston 1st stage Intermediate pressure will begin in the higher end of the range with high tank pressures and drop as the tank pressure decreases with use For this reason the RaZor s intermediate pressure must be tested and set at the highest inlet cylinder pressure that the regulator is going to see during use This is usually 3000 3500 psi 207 241 bar 4 5 1 Install the normal hoses fittings and all but one LP Port Plug into the ports of the 1st stage 4 5 2 In the remaining open port install an intermediate pressure gauge Make sure at least one of the ports has a functioning 2nd stage installed or that the intermediate pressure gauge has an Over Pressure Relief Valve 4 5 3 Turn the Valve Handwheel 25 on the RaZor clockwise to the OFF position 4 5 4 Slowly while observing proper safe filling procedures fill the cylinder using either the 341 FA10 CL Yoke Fill Adapter supplied with every RaZor or the 330 6048 AA Filling Whip and Valve Assembly Remember that for proper set up the cylinder must be filled to the full rated pressure Disconnect the filling whip or adapter when finished 4 5 5 Listen carefully for any leaks Immerse the RaZor in water if leaks are suspected but not confirmed If leaks are found correct the problem causing the l
4. 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 Before installing new O rings into the regulator lightly lubri cate the O rings with LTI Christo Lube 111 for enriched air regulators or Dow Corning 111 silicone grease 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 grease 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 2 Use the Stem 21 to turn the Plug Assembly 20 clockwise in the valve port in the Body 4 until it bottoms 4 4 3 Install a new lubricated O ring 18 onto the valve Bonnet Nut 23 4 4 4 Install a new lubricated Teflon Seal 22 into the Bonnet Nut 23 4 4 5 Install the Stem 21 into the Bonnet Nut 23 4 4 6 With the Stem 21 slightly protruding from the Bonnet Nut insert the Stem s tang into the slot of the Plug Assembly 20 Turn the Bonnet Nut Clock wise to screw it into the Body 14 NOTE While screw ing the Bonnet Nut into the body periodically twist the Stem and the Plug Assembly to be sure that they are properly engaged Tightening the Bonnet Nut down without the tang of the stem engaged in the Plug Assembly can damage the tang on the Stem Tighten the Bonnet Nut 23 to 2 3 ft lb 8 4 Nm of torque
5. zea gt SYSTEMS INC Regulator Valve Service Manual For Zeagle RaZor 1st and Envoy 2nd Stage Scuba Regulators and Filler Whip Manual p n 347 3005 Copyright 2007 ITEM PART 1 2 3 4 5 6 T 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 175 1630 341 FB02 CL 160 0022 N7 341 FB04 CD 160 0008 N7 341 FB06 GA 341 FB07 VH 341 FB08 SA 341 0127 CD 160 0011 N7 341 FB16 CD 341 FB15 ZA 341 FB14 ZA 341 FB09 CL 341 0139 BA 341 FB11 AA 160 0214 N9 160 0012 N9 341 0128 CD 341 FB24 CA 341 FB25 CD 341 FB26 GA 341 FB27 CD 341 FB28 GA 341 FB29 CL 341 FB30 VH 341 FB31 CD 341 FB17 VH 341 FB18 CD 160 0004 L9 341 FB21 CD 160 0013 N9 341 FB23 SA 341 FA10 CL 160 0014 N9 RaZor 1st Stage Parts DESCRIPTION Label Cap regulator O ring large end of piston Piston O ring small end of piston Seat for piston Spring main Shim LP Port Plug includes O ring O ring for LP hose amp port plugs Burst Plug Burst Disc Gasket copper Body Conical Filter Dip Tube Assembly O ring for neck of cylinder O ring for QD Fitting Bonnet Nut amp HP Port Plug HP Port Plug includes O ring Plug Assembly Stem Seal Bonnet Nut Washer Handwheel Spring for Handwheel Nut Spring for check valve Plug check valve O ring on check valve Quick Disconnect male O ring for Cap Cap fill F
6. 8 during the entire overhaul 8 2 5 If your filler valve has a Threaded Handwheel Fitting remove the filler handwheel 1 from the Swivel Assembly 5 with a wrench 32 zeze 8 2 6 Remove the spool 3 from the swivel assembly 5 Remove the O rings 2 4 from the spool using a sharp pin or pick to pierce the O ring and flip it off of the spool Take care not to scratch the O ring sealing surface on the spool as you remove the O rings 8 2 If itis in good shape the swivel assembly 5 can be left in the body If it is going to be changed remove it from the valve body 8 at this time 8 2 8 Use expanding Cir Clip pliers to remove the Cir Clip 6 from the body 8 2 9 Remove the purge collar 7 from the body Place a mark on the bottom edge of the collar to remind you which way the collar will go back on during assembly 8 2 10 Remove and discard the nylon purge valve 11 8 2 11 Turn the handwheel 18 halfway between fully opened and fully closed to position the valve plug assembly loosely 8 2 12 Use a 5 32 Allen wrench to remove the stem nut spring handwheel and nylon washer 20 19 18 17 from the valve stem 13 8 2 13 Use a small adjustable wrench to remove the bonnet nut 16 from the body 8 2 14 Remove the stem 13 from the bonnet nut 8 2 14 Remove and discard the Teflon washer 14 and the O ring 15 from the bonnet nut 16 8 2 15 Use the stem 13 to turn the valve plug assembly that you loosened i
7. 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 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 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 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 7 8 Brand new exhaust valves will
8. into the body 8 Go to step 8 4 15 8 4 14 If the threaded connection 1 2 3 4 5 is used put pipe sealant or Teflon tape onto the male threads of the swivel 5 and install it tightly into the body 8 Generously lubricate the spool with its O rings installed 2 3 4 and install it into the swivel 5 Thread the filler handwheel 1 into the swivel and tighten it snuggly with an adjustable wrench on the swivel s nut 8 4 15 Put pipe sealant or Teflon tape onto the male threads of the gauge 9 Use an adjustable wrench on the flats of the gauge to tighten it 8 4 16 Put pipe sealant or Teflon tape onto the male threads of the hose 10 Use two wrenches to tighten the hose into the body 8 4 17 If the filler whip is part of a fill station manifold put pipe sealant or Teflon tape onto the male threads of the hose and install it into the fill station manifold If the filler whip is used to fill the RaZor regulator from another scuba tank install the male threads of the hose into the yoke assembly for the filling whip 21 8 4 18 Pressurize and test the system for leaks Correct any leaks found 34 zeago 37150 Chancey Road Zephyrhills Florida 33541 U S A Zeagle Scuba the Zeagle symbol 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 Web Site www zeagle com E mail
9. 9 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 19 zeagie gt s 5 4 19 Install the O ring 9 over the external threaded end of the valve tube 21 5 4 20 Install the bushing 8 flat side facing the body over the external threaded end of the valve 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 se
10. lb 2 3 Nm NN OO A 2 2 Zeagle Scuba Regulator Model Numbers Model Description ED a a 350 2121 50 D DIN st stage with ZX 2nd Stage 30 Hose DIN to Yoke Converter 350 3110 Envoy Yoke 1st stage with Envoy 2nd Stage 30 Hose 350 3121 Envoy DIN 1st stage with Envoy 2nd Stage 30 Hose DIN to Yoke Converter 350 4110 DS V Yoke 1st stage with ZX 2nd Stage 30 Hose 350 4121 DS V DIN 1st stage with ZX 2nd Stage 30 Hose DIN to Yoke Converter 350 5210 Envoy Deluxe Yoke 1st stage with Envoy 2nd Stage 30 Hose 350 5221 Envoy Deluxe DIN 1st stage Envoy 2nd Stage 30 Hose DIN to Yoke Converter 350 6230 RaZor Valve Reg 1st stage with Envoy 2nd Stage 44 Hose 350 7210 ReZort Yoke 1st stage with Envoy 2nd Stage 30 Hose 350 7221 ReZort DIN 1st stage with Envoy 2nd Stage 30 Hose DIN to Yoke Converter 320 1110 2nd stage only ZX Octopus 2nd Stage with yellow cover 36 hose 320 1115 2nd stage only ZX 2nd Stage with gray cover 30 hose 320 3115 2nd stage only Envoy 2nd Stage with gray cover 30 hose 320 3110 2nd stage only Envoy Octopus 2nd Stage with yellow cover 36 hose 310 1110 l st stage only Flathead VI Yoke 310 1120 1st stage only Flathead VI DIN 310 2110 1st stage only 50 D swivel turret Yoke 310 2120 1st stage only 50 D swivel turret DIN 310 4110 l st stage only DS V non swivel Yoke 310 4120 1st stage
11. not contained in these kits must be inspected by the technician and changed if necessary Parts will be handled under war ranty 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 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 a
12. 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 the diaphragm 4 from the housing 10 If the cover is difficult to remove you can try several methods to loosen it Heat the 2nd stage body surrounding the Ring by running hot water from a tap over it When the plastic is hot it will expand and loosen the threads Rubber pads are available to use in the hand to loosen tight jar lids These pads will allow you to get a better grip on the Cover Ring 1 Zeagle sells a Cover Ring Removal Purge Cover Aligning Tool The part number is 347 1005 See photo 7 Note Tool may also be black plastic fl el oe ae oe ee Photo 7 i 347 1005 15 zeaute gt One side of the 347 1005 tool is used to engage the notches on the Cover Ring 1 Once the notches are engaged by the tool it is easy to turn the Cover Ring off of the Housing by turning the tool counter clockwise See photo 8 es 19 Tool to Remove the Cover Photo 8 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 valve 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
13. with your finger See photo 11 Note Depress the lever 19 while moving the seat with the wrench This prevents premature indentation and wear of the seal 22 1 8 Freeplay UP amp DOWD Ps gt Photo 11 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 20 zeagie 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 IF the regulator is to be used as an Octopus unit then turn the adjust knob plug 29 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 connec tion 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 the maximum pressure the regulator is going to be used with Install an intermediate pressure 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 slightl
14. 4 4 7 Lubricate with a small amount of grease and install the Teflon Washer 24 onto the Stem 24 4 4 8 Install the Handwheel 25 onto the stem 4 4 9 Install the Spring 26 into the Handwheel 10 zegsie gt 4 4 10 Install the valve Nut 27 onto the Stem 21 Use a 5 32 Allen wrench to tighten the Nut until the outer edge of the nut is flush with the top edge of the Handwheel 25 4 4 11 Position the Body 14 so that the port marked FILL is facing up Place the Spring 28 into the FILL port with the wide end of the spring facing down 4 4 12 Install the O ring 80 onto the check valve Plug 29 NOTE This O ring is quite stiff A technique for installing the O ring onto the Plug is to place the new O ring on a clean flat surface Grip the Plug with a pair of pliers Push the Plug stem into the hole of the O ring until the stem touches the flat surface See Photo 4 Push the O ring the rest of the way into place with the fingers Installing the Plug 29 into the O ring 30 The Kit O ring may be black Photo 4 4 4 13 Place the Plug and white O ring assembly into the Spring 28 with the O ring facing up 4 4 14 Install the O ring 18 onto the Quick Disconnect 31 over the threads that will screw into the Body 4 4 15 Install the O ring 32 onto the Quick Disconnect 31 over the threads that the Cap 33 will screw onto WARNING The QD Cap O ring 31 is just slightly larger than the typical HP Port O rin
15. 7 from the outside of the valve tube 21 16 zeEagie 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 turning counterclockwise at the same time The seat will usually 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 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 pla
16. Ball Tanks as well When items 1 2 3 4 and 5 are installed the Filler turns the handwheel item 1 on or off of the threads of the filling probe on the RaZor regulator to make the connection The male con nection on the Razor regulator is designed to work with either one of these filling connections IMPORTANT The 48 hose filling assembly can be used as a permanent filling station whip by disconnecting the Yoke Item 21 and then screwing the 1 4 male NPT end of the hose into the filling station plumbing 31 zeagle gt SYSTEMS INC 8 0 SERVICE PROCEDURES FOR THE ZEAGLE RaZor Filler Valve and Whip 8 0 1 Before you begin disassembly of the regulator test the Filler Whip and Hose for smoothness of opera tion and leakage Pre testing in this way will help the technician to pinpoint any specific problems requiring repair 8 0 2 The work area must be clean and well lighted with clean compressed air available to blow sand and dirt from parts You ll need a sturdy vise bolted to a secure workbench 8 1 TOOLS amp ITEMS REQUIRED FOR RaZor Filler Whip SERVICING 5 32 Allen wrench p n 347 0532 Cir Clip Pliers or 8 good quality adjustable wrenches for hose connections Annual Service Kit p n 345 1003 Clean Shop Rags LTI Christo Lube 111 p n 347 0111 or Dow Corning 111 Silicone Grease The Service Video for this Filler Valve is included in the RaZor Regulator Service Video VHS Tape
17. G POSSIBLE CAUSE RECOMMENDED ACTION Inlet filter clogged Replace the filter Air supply 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 23 zeago 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 ing it down with a vise or fingers to near solid height 350 where the on 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 regula tor 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 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 hiss
18. QUENCY FLUTTERING DURING INHALATION Above the surface only POSSIBLE CAUSE RECOMMENDED ACTION and other 2nd stage components diaphragm with another Move venturi lever 16 towards position until harmonic resonance stops O S OOOO Explain to the customer that this is not harmful to the regulator and does not happen underwater 25 zeagies 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 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 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 ultrasonic cleaning process for the rest of the parts 6 3 COMMONLY USED CLEANING SOL
19. Ring 2 342 0209 LG Purge Dome GRAY standard color 2 342 0209 LY Purge Dome YELLOW octopus color 2 342 0209 LK Purge Dome BLACK 3 342 0208 KA Diaphragm Cover 4 342 0207 AA Diaphragm 5 342 0225 KA Deflector 7 342 0221 CD Nut 8 342 0222 SA Bushing 9 160 0015 N7 O ring bushing to housing 10 342 0201 KA Housing 11 111 4002 Tie Wrap 2 needed 12 342 0216 MU Mouthpiece 13 342 0217 LA Exhaust Tee 14 342 0218 MA Exhaust Valve 15 160 0019 N7 O ring control lever to housing 16 342 0203 KA Venturi Control Lever 17 160 0010 N7 O ring for seat 18 342 0212 HB Seat orifice 19 342 0206 WH Lever 20 342 0228 UA Pin 21 342 0202 CD Valve Tube 22 342 0213 MB Seating Seal 23 342 0214 HA Piston 24 160 9532 N7 O ring for piston 25 342 0220 VH Spring 26 342 0215 HA Balancing Cylinder 27 160 0015 N7 O ring for valve tube 28 160 0011 N7 O ring for spring adjuster 29 342 0230 SA Spring Adjust Plug 30 165 1034 30 Hose Assembly other lengths available 31 160 0011 N7 O ring hose inlet end 32 342 0229 LA Hose Protector 33 160 0010 N7 O ring hose outlet end 34 342 0222 SA Plastic Bushing replaces Heat Sink 8 in some models 35 342 0230 SA 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 Service Kit Part for the 1st Stage is 345 1000 The 2nd Stage Se
20. UTIONS SOLUTION COMMENTS Hot Soapy water Preferable Good for plastic silicone and olated 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 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 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 26 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 trapp
21. all technical questions to Zeagle at tech zeagle com Phone 813 872 5568 Fax 813 782 5569 2002 2007 Zeagle Systems Inc Printed in USA The Part Number for this Manual is 347 3005 Rev A zeagig gt SYSTEMS INC
22. anual 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 blow 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 mouthpiece tie 11 with side cutting pliers Discard the old mouthpiece tie Examine the condition of the mouthpiece Pay particular attention to the area on top just behind where the old tie tightened This is a prime area for small holes to develop 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 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
23. at into the valve tube 5 4 24 Tighten the seat 18 clockwise with the Allen wrench It is important that the final adjustment leaves the lever with about 1 8 3 2 mm free movement at the end to allow for the natural 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 counter clockwise 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 3 2 mm free play when you move the tip of the lever with your finger See photo 9 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 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 1 8 3 2 mm free play when you move the tip of the lever
24. d Stage Model Serial Octopus Model Serial Part Installed Description of Part Warranty Item Y N 93435 1000 irst Stage Service Kit 949 2000 econo age oervice KI eee 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 29 zeagie gt SYSTEMS INC 7 4 2nd Stage O Rings included in Kit 345 2000 OO 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 30 zeagig gt 30 inch Regulator Hose Assembly includes the hose with both O rings and hose protector Item 30 SECOND STAGE REGULATOR 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 DESCRIPTION 1 342 0210 KA Cover
25. d Washer 24 from the Stem 21 4 2 7 Use the 6 adjustable wrench too loosen and remove the Bonnet Nut 23 Remove the Stem 21 from the Bonnet Nut and use it as a tool to turn the Plug Assembly 20 out of the body See Photo 1 Plug Assembly 20 removal using Stem 25 as a tool Photo 1 If the Valve was not turned 1 2 way between open and closed as described in step 4 2 6 you may need to install the Handwheel 25 temporarily back on the Stem to turn the Plug Assembly out with more force 4 2 8 Remove and discard the O ring 18 and Seal 22 from the Bonnet Nut 23 4 2 9 Unscrew the Burst Plug 11 that was previously loosened in step 4 2 1 Tip the tank and body so that the Burst Disc 12 and Gasket 13 fall out If the Gasket 13 does not fall out when the body is tipped you may need to pry it out with a soft brass pick Be EXTREMELY careful and do not scratch the surface under the gasket since a scratch on the body at the gasket area will create a leak The gasket can be reused once or twice If you are going to reuse it and it does not fall out easily leave it in place when the reg is cleaned Check that it is still in place during assembly 4 2 10 At this point all of the ports on the body should be empty 8 zeagies 4 2 11 Hold the cylinder with a firm strap band or mount it in a tank vise Use normal precautions so that the surface of the cylinder is not marred or damaged Use a good 10 or 15 adjustab
26. d of the Piston See Photo 5 4 4 23 Install the pre lubricated see 4 4 1 O rings 3 5 onto the piston Carefully guide the large end of the Piston into the Cap until it bottoms Use a gentle rocking motion of necessary to move the Piston into the Cap but do not cock it at too severe an angle since this may cause the Piston to gouge the sealing surface of the Cap 4 4 24 Support the Body 14 so that the Cap threaded end is facing up Use the same number of Shims 8 that were installed in the Spring Cavity when you took the RaZor apart If there was one Shim it goes on the Body side of the Spring 7 If there were two Shims install one at each end of the Spring 4 4 25 Install the Spring 7 on top of the Shim 4 4 26 Lubricate the threads on the Cap 2 with grease Bring the Cap with its Piston 4 installed over the Spring and Shim sitting in the cavity of the body and screw them together as far as you can by hand 4 4 27 Install the new O ring 35 from the Service Kit into the face of the Filling Adapter 35 4 4 28 Wipe a dab of grease on the first outward three male threads on the Regulator Install the Regulator into its Cylinder hand tight Mount the cylinder in a secure plastic band tool or tank vise that will not mar the finish on the cylinder Use a wrench on two wrench flats on the regulator that do not have Port Plugs or Hoses in them yet to tighten the regulator into the cylinder with 20 30 ft lbs 27 41 Nm of torque
27. e 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 Note Hose Protectors are easier to slide back from the 1st stage end of the hose if they are twisted and pulled when the hose is still installed in the 1st stage If a hose protector is particularly difficult to pull back try removing the hose and soaking the hose protector end in hot water to soften it up Temporarily reinstall the hose and try pulling and twisting the hose protector again 7 zeagig gt 4 2 3 With the Razor Valve Regulator still installed tightly in the cylinder AND ALL AIR BLED FROM THE CYLINDER use a 10 or 15 adjustable wrench to loosen not remove the Cap 2 from the Body 14 4 2 4 Use a 3 160 Allen wrench to remove all port plugs from the body Discard the port plug O rings 10 18 4 2 5 Use the 6 adjustable wrench to loosen and remove the male Quick Disconnect probe 31 from the body When removing probe be careful not to lose the Spring 28 or Check Valve Plug 29 Discard the Probe and Plug O rings 18 30 32 4 2 6 Turn the Valve Handwheel 25 so the Valve is about 1 2 way between open and closed Use a 5 32 Allen wrench to remove the Nut 27 from the Valve Remove the Spring 26 Handwheel 25 an
28. eaks before proceeding 4 5 6 Position the intermediate pressure gauge so the dial can be seen See Photo 6 Checking the Intermediate Pressure with a Gauge Photo 6 4 5 7 Turn the air on to the regulator section of the RaZor by SLOWLY turning the Handwheel 25 coun ter clockwise 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 160 psig 11 bar 4 5 8 If the pressure gauge continues to rise above 160 psig 11 bar turn the air supply off immediately and inspect the regulator to determine the cause 13 zeagie gt 4 5 9 Depress the 2nd stage purge cover fully then release it several times to clear particles from the regu lator 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 10 The pressure range for Zeagle RaZor Regulators at 3000 psi inlet pressure is 120 150 psi 8 3 10 3 bar Add Shims 8 in either side of the spring 7 to raise the intermediate pressure Remove Shims to lower the pressure The pressure increase per shim is not linear due to the rate of the spring so no specific increase per spring can be given Generally only add a shim if the intermediate pressu
29. ed 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 connec tion 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 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
30. ese instructions completely before you begin servicing the regulator or filling whip 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 For example if the serial number begins with A it is a DS V non swivel first stage e g A001324 E is a RaZor Valve Regulator first stage G is a ReZort first stage and F is a Flathead VI first stage For further information contact Zeagle 1 0 INTRODUCTION 1 0 1 The procedures in this manual apply to the Zeagle RaZor Valve Regulator the Envoy type 2nd stage that comes attached to it and the Filling Whip Refer to the exploded views as you read the service section of the manual The Item Numbers referred to in the service section are those seen in the corresponding exploded view A WARNING NEVER tighten the hose fitting to the first stage with more than 40 in Ibs 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
31. g Be very A careful using the O ring Chart to make sure you are selecting the proper O ring from the Service Kit Failure to install the proper O ring will result in premature O ring failure and leakage 4 4 16 Install the Quick Disconnect 31 into the FILL port over the Spring 28 and Plug 29 Tighten the QD Probe 31 to 2 3 ft lb 3 4 Nm 4 4 17 Install the Fill Cap 33 onto the QD Probe 31 hand tight 4 4 18 Hold the Body 14 so that the Burst Plug Port is facing up Drop the Burst Gasket 13 into the port first Bulge outwards if it is used Drop the Burst Disc 12 on top of the gasket If the Gasket or Disc do not fall properly in place use something soft like a plastic toothpick to push them into place 4 4 18 Install the Burst Plug 11 over the Burst Disc Tighten the Burst Plug to 50 55 in Ib 5 6 6 2 Nm 11 _zeagie gt 4 4 19 Install the Filter 15 into the tank thread end of the body with the narrow end first Install the Dip Tube Assembly 16 over the Filter Tighten the Dip Tube with 2 3 ft lb 3 4 Nm of torque 4 4 20 Install the O ring 17 onto the thread end of the body 4 4 21 Use the fingertip to spread a film of grease on the inside of the Cap 2 where the large O ring 3 slides Installing the Seat 6 into the Piston 4 Photo 5 4 4 22 Place the piston Seat 6 on a clean flat surface and press the Piston 4 stem straight over the seat until the new seat is installed into the en
32. gs down and curves leans to the right See Photo 9 Work the lever into the valve tube one foot at a time so the lever legs are spread outwards as little as possible Photo 9 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 10 18 Zeamles Photo 10 ell 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 10 the J shaped foot has been highlighted with black marker so you can see the J clearly The piston is normally all white 5 4 10 Insert the shuttle valve assembly as shown in Photo 10 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 seating seal Wiggle the lever to get this past the tabs When the J shaped feet get to the lever tabs they will lift the lever inwards as you push the assembly in 5 4 11 Install a new well lubricated O ring 28 onto the spring adjuster plug 29
33. ic 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 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 ha
34. illing Adpater O ring for face of filling adapter 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 1001 The 2nd Stage Service Kit Part for the Envoy 2nd stage used with the RaZor is 345 2000 RaZor Reg Valve Assembly Model 310 6230 Zeanle SYSTEMS INC 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 the RaZor 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 Tips 7 0 Warranty and Maintenance Information 1 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 th
35. ing does not stop the seat 18 needs adjusting or the seal 22 needs replacing B CREEPING INTERMEDIATE PRESSURE POSSIBLE CAUSE RECOMMENDED ACTION Damaged or worn 1st stage seat 6 Replace seat Nick in sealing surface of Body Orifice 14 Replace Body or Buff out Scratch ee eee Seat 6 has not taken shape of Orifice yet Let the Regulator sit with the pressure on for Pa few minutes and measure pressure again C HISSING FROM SECOND STAGE but intermediate pressure is OK POSSIBLE CAUSE RECOMMENDED ACTION Worn O ring 24 on piston 23 Worn O ring 17 on seat 18 24 zeagie gt C WET BREATHING POSSIBLE CAUSE RECOMMENDED ACTION diaphragm Replace if holes found by holding up to a light Worn venturi lever O rings 15 27 Replace O rings 15 27 saing suraose Replace ventuilever 16 sealing surfaces Replace venturi lever 16 feaingeufaces Repiace housing sealing surfaces Replace housing Improper clearing techniques by diver Instruct diver on clearing techniques 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 Remove the main spring 7 flip it over and other 1st stage components and re install Replace spring or other components until resonance stops E LOW FRE
36. 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 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 2 zeagie gt 7 1 3 Fill out the Zeagle Service Order Parts Request form PRINT CLEARLY If you use ser vice 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 plast
37. le wrench to grip the wrench flats on the RaZor body tightly You can also use an HP Port Wrench Apply a counter clockwise force to remove the RaZor from the cylinder See Photo 2 Removing the RaZor from the Cylinder Photo 2 4 2 12 Remove the valve thread O ring 17 from the RaZor and discard it 4 2 13 Use a 6 adjustable wrench to remove the Dip Tube 16 from the Body 14 Remove and discard the Filter 15 from the Body 4 2 14 Remove the Cap 2 from the Body 14 It should be hand tight from step 4 2 3 Remove any Spacer s 8 the Spring 7 and the Piston 4 from the Cap Remove and discard the O rings 3 5 from the piston Whenever possible try to remove the O rings by pinching them with the fingers and rolling them out of the groove WARNING If a sharp pick is used to remove the O rings it should be made from soft brass not A steel ANY scratches left in the groove when removing O rings will cause leaks bubbling out of the Cap ambient pressure ports and the piston will have to be replaced to stop these leaks 4 2 13 Remove the Seat 6 from the Piston 4 by pushing it out with a 1 16 drill bit Place one end of the drill bit on a flat hard surface Lower the large end of the Piston over the drill bit until the flat end of the drill bit rests against the back side of the Seat Push the Piston firmly down straight on the drill bit until the seat is pushed out of the piston Discard the old Seat see Pho
38. ll other parts of the second stage for signs of deterioration Replace those parts too where necessary 17 zeagie 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 Before installing new O rings into the regulator lightly lubricate the O rings with Dow Corning 111 Silicone Grease or 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 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 left Turn the valve tube until you can see the hole where the air exits the valve tube indicated by the arrow in photo The lever is inserted so that it han
39. n step 8 2 11 completely out of the body Discard the plug assembly 8 2 16 Put all metal parts except the gauge 9 that need cleaning into an ultra sonic cleaner Refer to section 6 2 for cleaning recommendations Rinse the parts in fresh water and blow them dry for inspection 8 3 INSPECTION OF THE FILLER VALVE FOR OVERHAUL 8 3 1 If the filler valve was passing air even when the handwheel was firmly shut look closely at the cone shaped orifice where the valve plug assembly was removed from If any significant nicks are seen on the sealing surface of the orifice then the body 8 will have to be replaced 8 3 2 Inspect the entire length of the filler hose for nicks cuts bubbles blisters under the surface of the outer plastic layer Pay particular attention to the area at the metal crimping ferrules at each end as this is where hoses tend to fail first Replace the hose if any defects are seen 8 4 ASSEMBLY OF THE FILLER VALVE AFTER INSPECTION 8 4 1 Open the service parts kit 345 1003 8 4 2 Lubricate the threads lightly and install the new valve plug assembly into the body Use the stem 13 to turn the valve plug assembly until it reaches the bottom of the threads 33 Zeagle gt 8 4 3 Lightly lubricate the O ring 15 and install it on the bonnet nut 16 8 4 4 Lightly lubricate the Teflon washer 13 and install it onto the stem 13 8 4 5 Install the stem 13 into the bonnet nut 16 8 4 6 Install the bonnet nut and stem as
40. ny of the parts listed in this manual is your current parts and price list from Zeagle 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 Service Videos in various formats VHS CD DVD etc are also available 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 RaZor AIR PLOW sesesxseccsuntetiasincainaiantes 33 cu ft 935 liters min 1 atmosphere INHALATION RESISTANCE 0 9 2 0 2 3 5 08 cm w c 1 atmosphere EXHALATION RESISTANCE 0 6 1 52 cm w c max 1 atm RECOMMENDED LUBRICANT LTI Christo Lube 111 A FIRST STAGE REGULATOR VALVE COMBINATION TYPE Tank Valve with Unbalanced Flow by Pis
41. on 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 30 hose model assembly number 320 3115 and as an advanced octopus unit yellow 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 number can be seen by curling back the mouthpiece and looking at the end of the mouth tube 5 1 TOOLS REQUIRED or suggested FOR SECOND STAGE SERVICING Two good quality 6 or 8 15 or 20 cm adjustable wrenches Side cutting pliers Cover Ring Removal and Purge Dome Alignment Tool p n 347 1005 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 Dow Corning Compound 111 Silicone Grease or LTI Christo Lube 111 p n 347 0111 Service Video Tape for this regulator p n 347 0103 or Service CD ROM p n 347 0103C or DVD p n 347 0103D 14 zeagie gt 5 2 DISASSEMBLY OF THE SECOND STAGE WARNING NEVER tighten the hose fitting to the first stage with more than 40 in Ibs 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 m
42. only DS V non swivel DIN 310 3210 1st stage only Envoy Yoke 310 3220 1st stage only Envoy DIN 310 5210 l st stage only ReZort Yoke 310 5220 1st stage only ReZort DIN 310 6230 1st stage only RaZor Tank Valve Regulator Combination 330 0001 DIN to Yoke Converter allows a DIN equipped regulator to be mounted on a Yoke Valve with no tools 5 Zeagle gt s 3 0 1st Stage O Rings included in Kit 345 1001 for RaZor Valve Regulator Model 310 6230 160 0214 N9 17 to seal base to cylinder 160 0022 N 7 3 for large end of piston 4 160 0014 N9 35 for Filling Adapter 35 160 0013 N9Q 32 for QD cap 2 160 0012 N9 18 for bonnet nut 23 QD probe 31 160 0011 N7 10 for LP ports 9 O CC 160 0008 N7 5 for small end of piston 4 160 0004 L9 30 white urethane for check valve 29 O 6 zeagle gt 4 0 SERVICE PROCEDURES FOR THE ZEAGLE RaZor Valve Regulator Combination 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 RaZor 1st STAGE SERVICING 5 32 Allen wrench p n 347 0532 3 16 Allen wrench p n 347 0316 1 16 drill bit
43. oval Alignment Tool p n 347 1005 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 new mouthpiece tie 11 from the service kit Position the tie lock on the side of the mouth piece Tighten the tie securely and cut off the excess 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 21 zeagie gt 5 7 TESTING OF THE SECOND STAGE A INHALATION EFFORT 5 1 With air pressure applied turn the spring adjust plug 29 fully counter clockwise Move the venturi lever to the position Depress and release the purge dome A large 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 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 spring adjust plug turned fully counter clockwise then one full turn in
44. p n 347 0103 or Service CD ROM p n 347 0103C or DVD p n 347 0103D 8 2 DISASSEMBLY OF THE FILLER VALVE FOR OVERHAUL To view all of the parts used in the RaZor first stage look at the page before this one in this manual The bracketed numbers in the text refer to the corresponding circled item numbers on the exploded view draw ing NOTE Your Filler Valve may be equipped with the Screw on threaded connection 1 2 3 4 5 or the High Pressure Quick Disconnect 22 Adjust your service procedure accordingly 8 2 1 Inspect the filler hose 10 carefully Look for any cracks cuts or severe abrasions Replace if neces sary 8 2 2 Use two wrenches or a vise and wrench to remove the valve assembly from the hose Unless it is damaged or leaking leave the Nylon Washer 23 in the Valve Body 8 during the entire overhaul 8 2 3 Position the valve assembly in a vise clamping it by the body Remove the gauge 9 from the valve body with a 6 or 8 adjustable wrench 8 2 4 If your filler valve has a Quick Disconnect Fitting 22 remove it from the valve body with a wrench It is not practical to remove or replace the small ball bearings from the QD fitting If they are worn or missing the entire QD Fitting 22 is replaced The O ring in the end of the QD Fitting is removed by piercing it with a pin and flipping it out Discard the O ring Go to step 8 2 8 below Unless it is damaged or leaking leave the Nylon Washer 23 in the Valve Body
45. re when the cylinder pressure is 3000 psi is below 120 8 3 bar Adding just one shim under these conditions will not push the intermediate pressure above the maximum 160 pressure Do not aim for a specific pressure within the range just add or remove shims to get the pressure within the range The optimal intermediate pressure for Zeagle RaZor regulators is 130 psi 10 bar but any setting between 120 and 160 psi 8 3 11 bar at 3000 psi 207 bar inlet pressure will provide good stable performance 4 5 11 After reaching the proper pressure setting push the purge cover on the second stage again several 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 12 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 shooting Section 6 1 of this manual Note Never set the output pressure of the first stage above 160 psig 11 bar 5 0 ENVOY SECOND STAGE SERVICE PROCEDURES The RaZor regulator comes equipped with a Zeagle Envoy 2nd stage Procedures covered in this manual secti
46. rvice Kit Part is 345 2000 30 ze agi g gt SYSTEMS INC ITEM PART OONDABRWDNDN RaZor Filling Whip Parts DESCRIPTION Filling Whip Assembly 331 FA01 CD Filler Handwheel 160 0003 N9 O Ring for Swivel includes 331 FA03 CD Spool spud 160 0003 N9 O Ring for Swivel 48 Hose with Yoke 330 6048 AA 331 FA05 AA Swivel Assembly eas Cir Clip See the Service Procedure 331 FA07 CD Purge Collar Beginning on page 32 331 FA08 CD Body 331 FA09 AA Gauge 5000 psi 165 1063 Hose 48 5000 psi with 1 4 Male NPT ends 331 FA11 SA Purge Valve 341 FB24 CA Valve Plug Assembly 341 FB25 CD Stem 341 FB26 GA Teflon Washer 160 0012 N9 O Ring for bonnet nut An asterisk next to the Item Number 341 FB27 CD Bonnet Nut a o Aeon A ion cher means that part is included in the Standard 341 FB29 CL Handwheel for Valve Service Kit The Service Kit Part for the oh lees e menennicey Filling Whip Assembly is 345 1002 341 FB31 CD Stem Nut 330 6014 AA Yoke Assembly for Filling Whip 331 FA12 WA Quick Disconnect female 331 FA35 SA Washer Nylon Optional Quick Disconnect Fitting replaces items 1 to 5 Item 22 is an optional Quick Disconnect method for using this filling whip When this QD Fitting is used the operator pulls back the collar on the QD fitting to make and release the connection similar to a BC Inflator Hose connection Item 22 is often used to fill Paint
47. sembly into the body Take care to engage the stem s tang into the slot in the plug assembly 12 as the bonnet nut is tightened Failure to engage the stem tang into the slot can cause the tang to break as the bonnet nut is tightened 8 4 7 Tighten the bonnet nut 16 snuggly with 1 2 ft lbs 2 3 Nm of torque 8 4 8 Place the original nylon washer handwheel spring and stem nut 17 18 19 20 onto the stem 13 8 4 9 Tighten the stem nut into the handwheel until the outer edge of the stem nut is even with the edge of the handwheel 8 4 10 Insert the nylon purge valve 11 into the body pointed end first 8 4 11 Install the purge collar over the body and purge valve Note the mark you put on the edge of the collar as per step 8 2 9 so that the purge collar is installed the right way around 8 4 12 Use Cir Clip pliers to install the Cir Clip 6 into its groove on the body A NOTE ON TEFLON TAPE If using Teflon tape always take special care not to get tape on the first out side thread Any tape that gets on this thread or on the inner face of the thread body will be cut off when the thread is tightened Loose tape will then probably get tangled in the internal valving causing leaks 8 4 13 If the stainless steel Quick Disconnect fitting 22 is used on your filler valve Install the new face seal O ring from the kit into the QD fitting Put pipe sealant or Teflon tape on the male threads of the QD fitting Tighten the QD fitting 22
48. sometimes adhere slightly to the case causing a slight increase in exhalation effort This condition will disappear with use 22 zeagies C LEAK TEST 5 9 Disconnect the air supply Purge the regulator of all positive air pressure 5 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 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 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 TROUBLESHOOTIN
49. stic 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 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 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 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 a
50. to 3 Photo 3 4 3 Cleaning and Inspection of the 1st 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 effectiveness lf 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 all O ring grooves for scratches or wear If the regulator was leaking air because of scratch es or wear replace the parts If some corrosion deposits persist carefully wipe them away with a plastic scrubbing cloth or plastic or wooden dowel Blow any resulting dust out of the regulator parts 4 3 4 Closely examine the sealing cones orifices in the Body 14 where the valve Plug Assembly 20 and where the Seat 6 of the Piston 4 seal 4 4 PRELIMINARY ASSEMBLY OF THE FIRST STAGE 4 4 1 To determine the identity of each O ring in the Service Kit remove them from the bag and use
51. ton Regulator Combined WEET aea 1 54 Ib 69 kg INTERSTAGE PRESSURE 120 140 psi 8 3 9 7 bar 3000 psi inlet 207 bar LOW PRESSURE PORTS 4 3 8 24 UNF HIGH PRESSURE PORTS 1 7 16 20 UNF FILL PORTS ooann 1 7 16 20 UNF WAC ES FRU acnceecetentocesecectnceccce Body CDA 360 Brass O rings Buna N Seat Advanced Polymer FIPE serce hee sneiceeenec see ons Downstream valve balanced diaphragm Diver Adjustable Dive Pre Dive Venturi Lever and Technician Externally Adjustable Resistance Control Knob WE IOR Erani 4 Ib 18 kg w o hose HOSE LENGTH 008 48 in 1 23 m as equipped on Rapid Diver BCD MATERIALS ooien Cover Flexible Thermoplastic Case Rigid Thermoplastic Poppet Seat Advanced Elastomer O rings Buna N Diaphragm Elastomeric Polymer Exhaust Valve Thermoplastic Elastomer Mouthpiece Silicone 4 zeagie gt 2 1 Torque Specifications Description Item RaZor into Tank Cap 2 Valve Bonnet Nut 23 Burst Plug 11 Dip Tube 16 HP Balance Plug 35 QD Fill Probe 31 Port Plugs 9 19 Hose inlet end 30 Hose outlet end 30 2nd Stage Nut 7 Torque 20 30 ft lbs 27 41 Nm 2 3 ft lb 3 4 Nm 2 3 ft lb 8 4 Nm 50 55 in Ib 5 6 6 2 Nm 2 3 ft lb 3 4 Nm 2 3 ft lb 8 4 Nm with 1 4 Allen wrench 2 3 ft lb 3 4 Nm 2 3 ft lb 3 4 Nm with 5 32 Allen wrench 2 3 ft lb 8 4 Nm 2 3 ft lb 3 4 Nm 1 2 ft
52. ve 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 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 28 zeagie gt 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 for ANY Warranty Servicin 37150 Chancey Rd Zephyrhills FL 33541 813 782 5568 Fax 813 782 5569 www zeagle com d l les You MUST contact Zeagle for an RA SYSTEMS INC 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 1st Stage Model Serial 2n
53. y loose against the L shaped foot of the shuttle valve assembly See Photo 9 There should be about 1 8 3 2 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 The diaphragm cover 3 is the best tool to align the diaphragm into the body 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 If the Zeagle Z logo is not straight it can be easily aligned using one side of the Cover Ring Rem
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