Oceanic SLIMLINE 2 OCTO Manual

REGULATORS
SLIMLINE 2 OCTO SECOND STAGE
©2002 Design, 2005
PG-1
OCEANIC®Product Service Guide
Doc. 12-2809-r01 (2/19/05)
SLIMLINE 2 OCTO
SERVICE
PROCEDURE
ThisSlimLine2ServiceProcedureconveysalistofcomponentsandserviceprocedures
that reflect the SlimLine 2 as it was configured at the time of this writing (2/19/05).
OCEANIC
®

REGULATORS
SLIMLINE 2 OCTO SECOND STAGE
©2002 Design, 2005
PG-2
OCEANIC®Product Service Guide
Doc. 12-2809-r01 (2/19/05)
CONTENTS
TROUBLESHOOTING .................................................................................................................................................................3
DISASSEMBLY PROCEDURE ....................................................................................................................................................4
REASSEMBLY PROCEDURE .....................................................................................................................................................5
FINAL TUNING AND TESTING ...................................................................................................................................................7
PARTS LIST AND EXPLODED VIEW DIAGRAM .....................................................................................................................10
SPECIFICATIONS
Torques
P/N 4330 Coupling 100 to 120 in-lbs
LP Hose 50 to 60 in-lbs
GENERAL PROCEDURES
REFER TO ...............................................................................................................................................................DOC. 12-2202
TOOLS REQUIRED
Standard Tools
Inch pounds Torque Wrench
3/4” Crows Foot Wrench
11/16” Crows Foot Wrench
Standard Screwdriver - small
3/32" Allen Key
1/4” Open End Wrench
Cotton Swab (Q-Tip)
Soft Jawed Vise
Specialty Tools
P/N 40.2302 Christo-Lube MCG111 - 2 oz
P/N 40.3367 Poppet Tool
P/N 40.9315 Intermediate Pressure Gauge
P/N 40.9510 In-line Adjustment Tool
P/N 40.9520 O-ring Tool Kit
P/N 40.9650 Universal Front Cover Tool
Opening Effort (IP = 144 psi)
Preferred Set-up 1.5 to 2.0 inches of H2O
Acceptable 1.5 to 2.2 inches of H2O

REGULATORS
SLIMLINE 2 OCTO SECOND STAGE
©2002 Design, 2005
PG-3
OCEANIC®Product Service Guide
Doc. 12-2809-r01 (2/19/05)
TROUBLE SHOOTING
SYMPTOM POSSIBLE CAUSE TREATMENT
* Free flow or leakage present. 1.Excessive LEVER ARM (9) height.
2.Excessive Intermediate Pressure
from First Stage.
3.LEVER ARM (9) bent.
4.Purge Button stuck down.
5.Damaged or worn POPPET SEAT
(5).
6.Damaged ORIFICE (2).
7.LOCK NUT (12) overtightened onto
Shaft of POPPET (6).
8.WASHER (10) bent or distorted.
9.POPPET SPRING (7) weakened,
worn, or incorrect part.
10.ORIFICE (2) incorrectly adjusted.
1.Adjust ORIFICE (2) and LOCK
NUT (12) to arrive at correct
spring load tension and LEVER
ARM (9) height. (Refer to Tuning
Section.)
2.Refer to First Stage Trouble-
shooting Chart.
3.Replace with new.
4.Disassemble and clean or replace
with new.
5.Replace with new.
6.Replace with new.
7.Loosen to correct spring load
tension and LEVER ARM (9)
height. (Refer to Tuning Section.)
8.Replace WASHER (10), SPACER
(11), and LOCK NUT (12) with
new.
9.Replace with new.
10.Turn in clockwise to adjust.
(Refer to Tuning Section.)
1.Tear in MOUTHPIECE (18)
2.EXHAUST VALVE (14) distorted or
damaged.
3.DIAPHRAGM (15) distorted or
damaged.
4.FRONT COVER (17) not sufficiently
tightened onto HOUSING (8).
5.Cracked or damaged HOUSING (8).
6.Mouthpiece TIE WRAP (19) loose
or missing.
1.Replace with new.
2.Replace with new.
3.Replace with new.
4.Tighten until secure.
5.Replace with new.
6.Tighten or install.
* Water entering Second Stage.
* Little or no air flow when Purge
Button is depressed. 1.LEVER ARM (9) slack present.
2.LEVER ARM (9) bent.
3.ORIFICE (2) incorrectly adjusted.
1.Tighten LOCK NUT (12) onto Shaft
of POPPET (6). (Refer to Tuning
Section.)
2.Replace with new.
3.Adjust ORIFICE (2) to correct
contact. (Refer to Tuning Section.)
* Rattle heard inside Second
Stage. 1.LEVER ARM (9) slack present. 1.Tighten LOCK NUT (12) onto Shaft of POPPET (6). (Refer to
Tuning Section.)
* Excessive inhalation resis-
tance. 1.LOCK NUT (12) overtightened onto
Shaft of POPPET (6), causing
excessive Spring tension.
2.LOCK NUT (12) insufficiently
tightened onto Shaft of POPPET
(6), causing LEVER ARM (9) slack.
3.LEVER ARM (9) bent.
4.ORIFICE (2) incorrectly adjusted.
5.Insufficient Intermediate Pressure
from First Stage.
1.Loosen to correct spring load and
LEVER ARM (9) height. (Refer to
Tuning Section.)
2.Tighten to correct spring load and
LEVER ARM (9) height. (Refer to
Tuning Section.)
3.Replace with new.
4.Adjust to correct contact. (Refer to
Tuning Section.)
5.Refer to First Stage Troubleshooting
Chart.

REGULATORS
SLIMLINE 2 OCTO SECOND STAGE
©2002 Design, 2005
PG-4
OCEANIC®Product Service Guide
Doc. 12-2809-r01 (2/19/05)
Fig. 1
Fig. 3
DISASSEMBLY PROCEDURE
NOTE: Be sure to perform the steps outlined in the Initial
Inspection Procedures Doc 12-2022 prior to disassembling
the Regulator. Review the Troubleshooting Section to gain
a better idea of which internal Parts may be worn, and to
better advise your customer of the service that is needed.
1. Snip the TIE WRAP (19) that holds the MOUTHPIECE (18), and
remove the MOUTHPIECE. Inspect the condition of the MOUTH-
PIECE to ensure that it is supple and free of any tears or corrosion.
Discard if found.
2. RemovetheLPHOSE(20)fromtheSecondStage,usingan11/16"
open end wrench, while holding the Hex portion of the INLET
COUPLING (3) secure with a 3/4" open end wrench.
3. To expose the DIAPHRAGM (17), remove the FRONT COVER
RING (15) and FRONT COVER (16) by turning it off counter
clockwise using a Front Cover Tool if necessary.
4. GrasptheDIAPHRAGM(17)bytheraisedEdgesoftheCenter,and
gently lift out with a slight upward twist to remove (Fig. 1). Inspect
the DIAPHRAGM to ensure it is supple and free of any tears,
corrosion, or other distortion. Discard if found.
5. RemovetheINLETCOUPLING(3)inacounterclockwisedirection,
using a 3/4" open end wrench, while hold ing the LEVER ARM (9)
depressed (Fig. 2).
6. Remove and inspect the COUPLING O-RING (4) for any signs of
decay. Discard if found.
7. Using a narrow slotted blade screwdriver, remove the ORIFICE (2)
by turning it counter clockwise inside the INLET COUPLING (3).
When it has disengaged completely from the Threads, press it out
with the use of a cotton swab. Use caution to avoid nicking or
scratching the Knife Edge of the ORIFICE as this is done. Remove
and discard the ORIFICE O-RING (1). Inspect the ORIFICE
carefullywiththeuse of a magnifier to ensurethatitis perfectly free
of any scoring or nicks. If found, discard and DO NOT attempt to
reuse.
8. UsingaPoppet Tool,turnthePOPPET(6)outofthe LOCKNUT(12)
inacounterclockwise directionwhile holdingthe LOCKNUT secure
with a 1/4" Open End Wrench (Fig. 3). To avoid a sudden ejection
as they are disengaged, continuously apply slight inward pressure
with the Poppet Tool while turning the POPPET out.
9. CarefullyremovethePOPPET(6),POPPETSPRING(7),WASHER
(10), LEVER ARM (9), SPACER (11), and LOCK NUT (12) from the
HOUSING(8). DiscardtheWASHERandLOCKNUT,andDONOT
attempt to reuse them.
10. Examine the SPACER (11) for deterioration. Discard if found.
11. Examine the LEVER ARM (9) and compare with new to ensure that
it is not bent or distorted in any way. Discard if distortion is found.
Fig. 2

REGULATORS
SLIMLINE 2 OCTO SECOND STAGE
©2002 Design, 2005
PG-5
OCEANIC®Product Service Guide
Doc. 12-2809-r01 (2/19/05)
12. Examine the POPPET SPRING (7) with a magnifier and compare it
withanewonetoensurecorrecttensionandlength. Discardiffound
to be weakened or corroded.
13. Remove the POPPET SEAT (5) from the POPPET (6) with the use
of an O-ring Tool (Fig. 4). Discard, and DO NOT reuse it.
14. Using a soft probe, inspect the condition of the EXHAUST VALVE
(14)toensureitissuppleandfreeofanytearsorcorrosion,andthat
itsealscompletelyaroundtheSeatingSurfaceoftheHOUSING(8).
Examine the EXHAUST GRILL (13) to ensure that it is securely
fastened onto the HOUSING.
NOTE: Provided that the EXHAUST VALVE (14) is in good
condition and the EXHAUST GRILL (15) is intact, further
Disassembly is not necessary. The HOUSING (8) may be
cleanedwiththesepartsassembled,asanAssembly. (Refer
to the Cleaning Section.)
15. If further Disassembly is needed to replace the EXHAUST VALVE
(14) or EXHAUST GRILL (13), the GRILL may be removed by
insertingthebladeofasmallscrewdriverintotheTabSlotsoneach
side of the GRILL. Slight inward and upward pressure will disen-
gage the Tabs (Fig. 5).
16. The EXHAUST VALVE (14) may now be removed by grasping it at
the Flange and pulling straight out, snipping off the Retainer Stem
if necessary. Discard and DO NOT reuse.
17. Inspecttheoverallcondition of the HOUSING (8) toensureitis free
of any stress cracks or other distortions, and that the Threads are
in good condition. Discard if distortion or bad Threads are found.
REASSEMBLY PROCEDURE
NOTE: Prior to Reassembly, it is necessary to inspect all
Parts, both new and those that are being reused. Check to
ensurethatO-ringsarecleanandsupple,andthateveryPart
and Component has been thoroughly cleaned and dried.
WARNING: Use only genuine Oceanic Parts, Subassem-
blies,andComponentswheneverAssemblingOceanicprod-
ucts. DO NOT attempt to substitute an Oceanic Part with
anothermanufacturer’s,regardlessofanysimilarityinshape,
size, or appearance. Doing so may render the product
unsafe,andcouldresultinseriousinjuryordeathoftheuser.
1. ReplacetheEXHAUSTVALVE(14),ifremovedfromtheHOUSING
(8) by gently pulling the Retainer Stem through the HOUSING until
the Flange is inside the HOUSING and properly seated (Fig. 6).
2. If removed, replace the EXHAUST GRILL (13) into the Exhaust
portion of the HOUSING (8) by aligning the Tabs with the Tab Slots
in the HOUSING and snapping it into place with your fingers.
3. PlacethePOPPETSEAT(5)intothePOPPET(6),withthesidethat
is perfectly smooth facing out. Ensure that it is completely seated,
flush with the inner rim of the poppet. DO NOT use adhesive.
Fig. 4
Fig. 6
Fig. 5

REGULATORS
SLIMLINE 2 OCTO SECOND STAGE
©2002 Design, 2005
PG-6
OCEANIC®Product Service Guide
Doc. 12-2809-r01 (2/19/05)
4. Apply a light film of lubricant to each end of the POPPET SPRING
(7) and place onto the POPPET (6). Fit the POPPET into the
ProngedendofthePoppetToolandinserttheShaftofthePOPPET
completelythroughtheInletTubeoftheHOUSING(8)compressing
the SPRING until the Threaded portion of the Shaft is completely
visible inside the HOUSING. Hold in position by grasping the Tool
with your fingers and the Outer Rim of the HOUSING with your
thumb (Fig. 7).
5. ExaminebothsidesoftheWASHER(10)tonotethatonesurface
is slightly rounded at the edge and smooth, while the other has
aslightlyupturnedLiparound itsoutercircumference. Place the
WASHER over the Threads of the POPPET (6) and onto the
Shaft, with the Smooth Side facing up. Place the SPACER (11)
onto the POPPET Shaft. Thread the LOCK NUT (12) clockwise
onto the POPPET Threads with your fingertips.
6. Place the Forks of the LEVER ARM (9) over the POPPET Shaft
betweentheWASHER(10)andtheSPACER(11)(Fig.9). Relax
the POPPET (6) and watch to ensure that the LEVER ARM
stands upright.
7. Usingthe1/4"openendwrenchtohold theLOCKNUT(12)secure,
turn the POPPET (6) with the Poppet Tool until 3 threads are
showing beyond the outer surface of the LOCK NUT (Fig. 10).
Remove the tools, and depress the LEVER ARM (9) repeatedly to
ensure smooth movement.
CAUTION: Itisveryimportantthat3ThreadsofthePOPPET's
ShaftareadjustedoutsidetheLOCKNUTbeforeproceeding
further. The LEVER ARM may otherwise become caught on
the end of the POPPET's Shaft, resulting in free flow.
8. LubricateandinstalltheCOUPLINGO-RING(4)ontotheINLET
COUPLING(3). Install the COUPLINGinto the InletTube of the
HOUSING (8) with the Smaller Opening facing in. Turn clock-
wise using a 3/4" open end wrench to a torque of 110 in/lbs.
9. LubricateandinstalltheORIFICEO-RING(1)ontotheORIFICE(2).
Lubricate the Threads of the ORIFICE with a very light film of
lubricant, and insert the ORIFICE into the INLET COUPLING (3)
with the Knife Edge facing in (Fig. 11).
CAUTION: Be careful to protect the delicate Knife Edge as
this is done.
Fig. 7
Fig. 9
Fig. 11
Fig. 8
Fig. 10

REGULATORS
SLIMLINE 2 OCTO SECOND STAGE
©2002 Design, 2005
PG-7
OCEANIC®Product Service Guide
Doc. 12-2809-r01 (2/19/05)
10. Using a narrow shafted, slotted blade screwdriver, gently turn
the ORIFICE (2) clockwise into the INLET COUPLING (3) until
the Knife Edge is barely contacting the POPPET SEAT (5). DO
NOTcontinueto turn theORIFICEanyfurtherbeyondthispoint,
which will cause the LEVER ARM (9) to drop. Doing so will also
damage the ORIFICE Seat requiring its replacement.
NOTE: For best sensitivity of touch during step 10, place
yourfingergentlyontheLOCKNUT(12)whileslowlytruning
theORIFICE(2). Assoonascontactismade,youwillfeelthe
LOCK NUT begin to turn. Hold the screwdriver by the shaft
rather than by the handle.
11. Place the DIAPHRAGM (15) inside the HOUSING (8) with the
Raised Center facing up, and ensure that it seats flush at the Base
of the Inner Threads (Fig. 12).
12. PlacetheFRONT COVER(17)ontothe HOUSING (8)ontop of the
DIAPHRAGM (15), taking care to ensure that it is correctly seated.
13. Place the FRONT COVER RING (16) down over the FRONT
COVER (17) and hand tighten clockwise until secure and in proper
alignment, attained when the Oceanic logo faces the MOUTH-
PIECE (18) (Fig. 13). Use the Front Cover Tool, if necessary. DO
NOT overtighten.
14. Secure the MOUTHPIECE (18) onto the HOUSING (8) with a TIE
WRAP (19), positioning the Locking Tab of the TIE WRAP towards
the LP HOSE (20).
15. Replace and lubricate the O-ring located inside the Second Stage
Coupling End of the LP HOSE (20). Install the HOSE onto the
Second Stage, and tighten to a torque of 55 in/lbs with an 11/16"
open end wrench, while holding the Hex portion of the INLET
COUPLING (3) secure with either a 3/4" open end wrench.
FINAL TUNING AND TESTING
FIRST STAGE TESTING
1. Perform the Leak detection Test specified in the Initial Inspection
procedure.
NOTE: Refer to the Trouble Shooting section to determine
thepossiblecauseandtreatmentofanyairleaksthatmaybe
found.
2. ConnecttheSlimLine 2 Second StageLPHOSE to a Low Pressure
Port of the First Stage. Ensure that all other Ports are sealed with
Port Plugs, with the exception of an additional Low Pressure Quick
Disconnect Hose.
3. Connecta recentlycalibratedIntermediatePressureTestGaugeto
the additional Low Pressure Hose, and connect the First Stage to a
pure air source of 3,000 PSI (200 BAR).
Fig. 12
Fig. 13

REGULATORS
SLIMLINE 2 OCTO SECOND STAGE
©2002 Design, 2005
PG-8
OCEANIC®Product Service Guide
Doc. 12-2809-r01 (2/19/05)
4. SlowlyopenthevalvetopressurizetheRegulator,andcheckthe
Test Gauge to ensure that the Intermediate Pressure is set as
recommended in the Specifications for the First Stage used.
NOTE: Ifthe Intermediate Pressureisfound to beotherthan
recommended, refer to that Regulator's Trouble Shooting
Section to determine possible cause and treatment.
TUNING
1. Prior to Tuning the SlimLine 2 Second Stage, check the following
items:
A. 3 Threads on the Shaft of the POPPET should be visible
inside the HOUSING extending past the outer end of the LOCK
NUT.
CAUTION: It is very important that 3 threads of the Shaft of
the POPPET are adjusted outside the LOCK NUT before
proceedingfurther. TheLEVERARMmayotherwisebecome
caught on the End of the POPPET's Shaft, resulting in an
uncontrolled free flow.
B. The FRONT COVER RING should be tightened securely and
the FRONT COVER properly aligned on the HOUSING.
C. Connect an In-Line Adjustment Tool between the LP HOSE
and INLET COUPLING.
D. The MOUTHPIECE should be cleaned and disinfected with
warm, soapy water.
2. Pressurize the Regulator Assembly with a pure air source of 3,000
PSI(200BAR),andlistentodeterminethataslightairflowisinitially
present. If necessary to initiate this air flow, turn the ORIFICE
slightly out (counter clockwise) using the In-Line Adjustment tool.
NOTE: While pressurized, the slotted blade of the In-Line
Tool will be held away from the ORIFICE, and will therefore
need to be pushed inward and held while turning it in either
direction. Locate the slotted head of the ORIFICE by touch
before attempting any adjustment.
3. Use the In-Line Tool to turn the ORIFICE clockwise with very small
fractions of a turn, just until air flow is no longer present, and pause
to listen carefully for air flow or leakage after each adjustment.
NOTE: Turning the ORIFICE further than necessary to stop
airflowwillresultinLEVERARMslackandexcessivespring
load tension, impairing proper performance.
CAUTION: Avoid cutting the POPPET SEAT with the Knife
Edge of the ORIFICE by depressing the Purge Button while
turning the ORIFICE in or out.

REGULATORS
SLIMLINE 2 OCTO SECOND STAGE
©2002 Design, 2005
PG-9
OCEANIC®Product Service Guide
Doc. 12-2809-r01 (2/19/05)
4. Hold the Second Stage with the MOUTHPIECE facing directly
down,andgentlyshakeitupanddown. Listencarefullyforanyrattle
that may be present, indicating LEVER ARM slack. If LEVER ARM
slack is present, perform the following procedure:
A. Remove the FRONT COVER RING, FRONT COVER, and
DIAPHRAGM to gain access to the Valve Assembly.
B. Purge the Regulator Assembly of air.
C. Depress the LEVER ARM and hold it down to remove the
INLETCOUPLINGfromtheHOUSING(withLPHOSEandIn-line
Adjustment Tool still attached), using a 3/4" open end wrench.
NOTE: The Cone of the ORIFICE will now be exposed,
protruding out through the INLET COUPLING, and must be
protected to prevent damage to its delicate Seating Surface.
D. Use the 1/4" open-end wrench to turn the LOCK NUT
clockwise 1/8 turn, while using the Poppet Tool to hold the
POPPET secure. Use the correct method given in step 8 of the
Reassembly Procedure to replace the INLET COUPLING after
each adjustment, and again determine whether LEVER ARM
slack is eliminated.
NOTE: Avoid tightening the LOCK NUT any further than is
necessary to eliminate LEVER ARM slack. It may be neces-
sary to repeat step D several times to arrive at the correct
setting.
CAUTION: Be careful to avoid over adjusting! If air flow
returns,replacetheLOCKNUTandPOPPETSEATwithnew,
and start over after rereading the above procedures.
5. Purge the Regulator Assembly of air to remove the In-Line Adjust-
ment Tool and connect the LP HOSE directly onto the INLET
COUPLING, using two wrenches as prescribed in the Reassembly
Procedure.
6. Reinstall the DIAPHRAGM, FRONT COVER, and FRONT COVER
RING,and pressurize theRegulatorAssembly againwitha pureair
sourceof 3,000 PSI (200 BAR). Inhale lightly through the MOUTH-
PIECE. Air should flow easily and smoothly, without any hesitation
or lag.
NOTE: If hesitation or lag is detected, refer to the Trouble-
shooting Section to determine possible cause and treat-
ment.
7. CleananddisinfecttheMOUTHPIECEinwarm,soapywaterbefore
returning the Regulator to the customer.

REGULATORS
SLIMLINE 2 OCTO SECOND STAGE
©2002 Design, 2005
PG-10
OCEANIC®Product Service Guide
Doc. 12-2809-r01 (2/19/05)
1a 2.010 O-RING, ORIFICE
2c 6621 ORIFICE
3c 4330 COUPLING, INLET
4b 3.906 O-RING, COUPLING
5a 4340 SEAT, POPPET
6c 4333 POPPET
7b 5074 SPRING, POPPET
8c 6787 HOUSING
9c 6786 ARM, LEVER
10a 5117 WASHER
11b 4335 SPACER
12a 4336 NUT, LOCK
13c 6789 GRILL, EXHAUST
14b 6326 VALVE, EXHAUST
15b 6380 DIAPHRAGM
16c 6553 RING, FRONT COVER
17c 6554.18.1 COVER, FRONT
18c 6651.07 MOUTHPIECE
19a 1978.07 WRAP, TIE
20c 40.2118.039 ASSEMBLY, LP HOSE
16932.039 HOSE, MAXFLO (39" YL)
21c 6325.07 PROTECTOR, HOSE
N/S 2.010 O-RING, LP HOSE (SECOND STAGE END)
N/S 3.903 O-RING, LP HOSE (FIRST STAGE END)
N/S 40.6162 KIT, SERVICE PARTS (includes all Bold items)
Dia.
No. Part # Description Dia. No. Part # Description
20
21
7
5
16
4
2
3
17
13
8
14
11
9
10
16
15
12
19
18