Oceanic ZX Manual

REGULATORS
ZX SECOND STAGE
©2002 Design, 2005
PG-1
OCEANIC
®
Product Service Guide
Doc. 12-2808-r01 (2/19/05)
ZX
SERVICE
PROCEDURE
This ZX Service Procedure conveys a list of components and service procedures that
reflect the ZX as it was configured at the time of this writing (2/19/05).
OCEANIC
®

REGULATORS
ZX SECOND STAGE
©2002 Design, 2005
PG-2
OCEANIC
®
Product Service Guide
Doc. 12-2808-r01 (2/19/05)
CONTENTS
TROUBLESHOOTING .................................................................................................................................................................3
DISASSEMBLY PROCEDURE ....................................................................................................................................................4
REASSEMBLY PROCEDURE .....................................................................................................................................................7
TUNING AND TESTING ............................................................................................................................................................. 11
PARTS LIST AND EXPLODED VIEW DIAGRAM .....................................................................................................................13
SPECIFICATIONS
REGULATOR GENERAL PROCEDURES
REFER TO ...............................................................................................................................................................DOC. 12-2202
TOOLS REQUIRED
Torques
P/N 4787.2 Screws 3 to 4 in-lbs
P/N 6332 Packing Nut 11 to 13 in-lbs
LP Hose 50 to 60 in-lbs
Standard Tools
Inch pounds Torque Wrench
5/8” Open End Wrench
11/16” Open End Wrench
3/4” Open End Wrench
3/32" Hex Key
Standard Small Blade Screwdriver
1" Deep Wall Socket
Cotton Swab
Opening Effort (IP = 140 psi, Vane set negative)
1. Leak with Adjustment Knob turned fully out (clockwise).
2. No leak with Adjustment Knob turned in 1 turn (counter clockwise).
3. Minimum Effort with no leak = 1.2 inches of H2O, or less.
Specialty Tools
P/N 40.2302 Christo-Lube MCG111 - 2 oz
P/N 40.3362 Poppet Tool
P/N 40.9315 Intermediate Pressure Gauge
P/N 40.9520 O-ring Tool Kit
P/N 40.9650 Universal Front Cover Tool

REGULATORS
ZX SECOND STAGE
©2002 Design, 2005
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OCEANIC
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Product Service Guide
Doc. 12-2808-r01 (2/19/05)
TROUBLE SHOOTING
SYMPTOM POSSIBLE CAUSE TREATMENT
* Free flow or leakage present,
with ADJUSTMENT KNOB (11)
turned in.
1. Replace with new.
2. Refer to First Stage Troubleshooting
Chart.
3. Replace with new.
4. Replace with new.
5. Turn in clockwise to adjust. (Refer
to Tuning Section.)
6. Follow correct procedure given in
Reassembly Section to tighten.
7. Remove and clean.
* Water entering Second Stage.
* ADJUSTMENT KNOB (11)
difficult to turn.
* Little or no airflow when Purge
Button is depressed.
* Rattle heard inside Second
Stage.
* Excessive inhalation resis-
tance, with ADJUSTMENT
KNOB (11) turned out.
1. Tear in MOUTHPIECE (8).
2. EXHAUST VALVE (6) distorted or
damaged.
3. DIAPHRAGM (3) distorted or dam-
aged.
4. Debris trapped beneath EXHAUST
VALVE (6).
5. FRONT COVER (2) insufficiently
tightened onto HOUSING (4).
6. Cracked or damaged HOUSING (4).
7. Mouthpiece TIE WRAP (35) too loose
or missing.
1. Debris or corrosion present on
ADJUSTMENT SHAFT (15).
2. Debris present inside ADJUSTMENT
KNOB (11).
3. Debris or corrosion present on or
inside ADJUSTMENT SPRING (17).
1. FRONT COVER (2) not sufficiently
tightened into HOUSING (4).
2. DEMAND LEVER (27) slack present.
3. ORIFICE (31) incorrectly adjusted.
1. Gravel or sand trapped inside
HOUSING (4).
2. DEMAND LEVER (27) slack present.
1. DEMAND LEVER (27) bent.
2. ORIFICE (31) incorrectly adjusted.
3. Insufficient Intermediate Pressure from
First Stage.
1. DEMAND LEVER (27) bent.
2. Excessive intermediate pressure.
3. Damaged or worn POPPET SEAT
(25).
4. Damaged ORIFICE (31).
5. ORIFICE (31) incorrectly adjusted.
6. LP HOSE ASSEMBLY (34) not
sufficiently tightened onto VALVE
HOUSING (26) Inlet Tube.
7. Trapped debris.
1. Replace with new.
2. Replace with new.
3. Replace with new.
4. Remove and clean.
5. Tighten until secure and properly
aligned.
6. Replace with new.
7. Tighten or install.
1. Disassemble and clean.
2. Flush out or disassemble if
necessary to clean.
3. Disassemble to clean or replace
with new as needed.
1. Tighten COVER RING (1) until
secure.
2. POPPET (24) not inserted properly.
Follow correct procedure given in
Reassembly Section.
3. Adjust ORIFICE (31) to correct
contact. (Refer to tuning section.)
1. Remove and clean.
2. POPPET (24) not inserted properly.
Follow correct procedure given in
Reassembly Section.
1. Replace with new.
2. Adjust to correct contact. (Refer to
Tuning Section.)
3. Refer to First Stage Troubleshooting
Chart.

REGULATORS
ZX SECOND STAGE
©2002 Design, 2005
PG-4
OCEANIC
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Product Service Guide
Doc. 12-2808-r01 (2/19/05)
Fig. 1
DISASSEMBLY PROCEDURE
NOTE: Be sure to perform the steps outlined in the Initial
Inspection Procedures (Doc. 12-2202) prior to Disassem-
bling 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 (35) that holds the MOUTHPIECE (8),
remove the MOUTHPIECE, and inspect the condition of it to
ensurethatitissuppleandfreeofanytearsorcorrosion. Discard
if found.
2. While holding the HOUSING (4) secure, remove the LP HOSE
(34) using an 11/16" open end wrench (Fig. 1). Remove the LP
HOSE SWIVEL PACKING WASHER (33) (Fig. 2).
NOTE: The Washer located inside the LP HOSE behind the
Swivel Ball is not serviceable and is NOT to be removed.
3. Remove the COVER RING (1) and FRONT COVER (2) by
turning the RING counter clockwise. Use a Front Cover Tool if
necessary. Separate the FRONT COVER and COVER RING.
4. Grasp the DIAPHRAGM (3) by the Raised Edges of the center,
andliftwithaslightupwardtwisttoremoveit. Inspectittoensure
that it is supple and free of any tears or distortion. Discard if
found.
5. Turn the ADJUSTMENT KNOB (11) out completely, counter
clockwise. Remove the ADJUSTMENT KNOB SCREW (10)
usinga3/32"hexkey andslidetheADJUSTMENTKNOBoffthe
ADJUSTMENT SHAFT (15).
6. Remove the PACKING NUT (12) by turning it counter clockwise
using a 5/8" open end wrench.
7. Remove the THRUST WASHER (13) from the ADJUSTMENT
SHAFT (15).
8. Grasp the ADJUSTMENT SHAFT (15) and pull it straight out of
the ADJUSTMENT TUBE (20) (Fig. 3).
9. RemovetheADJUSTMENTSPRING(17)andBALANCESHAFT
(18). If the BALANCE SHAFT does not come out, gently tap the
ADJUSTMENT TUBE (20) in your hand to remove it.
Examine the BALANCE SHAFT and compare it with a new one
to ensure that it is not bent or distorted in any way. Discard it if
distortion is found.
10. RemovetheSTEMO-RING(14)fromtheADJUSTMENTSHAFT
(15) and inspect it for any signs of decay. Discard it if found. Fig. 3
Fig. 2

REGULATORS
ZX SECOND STAGE
©2002 Design, 2005
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OCEANIC
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Product Service Guide
Doc. 12-2808-r01 (2/19/05)
Fig. 5
Fig. 8
NOTE: Removal of the SPRING FOLLOWER (16) from the
ADJUSTMENT SHAFT (15) should not be necessary unless
itisbroken orneeds tobereplaced. Inthiscase removeit by
holding the ADJUSTMENT SHAFT in one hand and turning
the SPRING FOLLOWER clockwise with your other hand.
Note that the Thread is left handed.
11. Examine the ADJUSTMENT SPRING (17) with a magnifier and
compare it with a new one to ensure correct tension and length.
Discard it if found to be distorted, weakened, or corroded.
12. Remove the ADJUSTMENT TUBE RETAINER (9) by grasping
the Top with your fingers and lifting it straight up and off the
ADJUSTMENT TUBE (Fig. 4)
13. RemovetheADJUSTMENTTUBE/SHAFTAssembly(20/15)by
grasping the Threaded portion with your fingers and pulling it
straight out of the VALVE HOUSING (26) (Fig. 5).
The DEMAND LEVER (27) will drop as the Assembly is with-
drawn.
14. If the POPPET (24) does not come out, tip the HOUSING to one
side and gently tap it in your hand to remove the POPPET.
15. RemovethePOPPETSEAT(25)fromthePOPPET(24)withthe
use of a dental pick. Discard and DO NOT attempt to reuse it.
16. RemovethePOPPETO-RINGS(22/23)bysqueezingthemwith
yourfingersand working themover the End ofthe POPPET (24)
(Fig. 6). DO NOT use tools to remove them. Discard the O-
RINGS and DO NOT attempt to reuse them.
17. Remove the ADJUSTMENT TUBE O-RING (19) from the AD-
JUSTMENT TUBE (20) and inspect it for any signs of decay.
Discard it if found.
18. Remove the BALANCE SHAFT O-RING (21) located inside the
ADJUSTMENT TUBE (20) by pressing it out with a wooden
dowel or dull punch (Fig. 7). Discard the O-RING and DO NOT
attempt to reuse it.
19. Usingawoodendowel,presstheVALVEHOUSING(26)straight
through the HOUSING (4) and out through the Adjustment
Assembly opening in the opposite side (Fig. 8).
20. Examine the DEMAND LEVER (27) to ensure that it is not bent
or distorted in any way. If distortion is found and it is necessary
to remove the DEMAND LEVER, proceed as follows:
Usingyour fingers,pressoutwardononeProng oftheDEMAND
LEVER to disengage it from the VALVE HOUSING (26), repeat
to disengage the other Prong, and lift the DEMAND LEVER up
and off the VALVE HOUSING.
Fig. 6
Fig. 7
Fig. 4

REGULATORS
ZX SECOND STAGE
©2002 Design, 2005
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21. RemovetheVALVEHOUSINGO-RING(28)bysqueezingitwith
yourfingersandworkingitoverthemoldedportionoftheVALVE
HOUSING, not over the Threads. Inspect the O-RING for signs
of decay or distortion. Discard it if found.
22. Using a narrow slotted blade screwdriver, remove the ORIFICE
(31)byturning it counter clockwiseinsidetheVALVEHOUSING
(26). When it has disengaged completely from the Threads,
press it out with the use of a cotton swab (Fig. 9).
A. Use caution to avoid nicking or scratching the delicate Knife
Edge of the ORIFICE as this is done.
B. Remove ORIFICE O-RING (32) and inspect it for signs of
decay or distortion. Discard it if found..
C. Inspect the ORIFICE carefully with the use of a magnifier to
ensure that it is perfectly free of any scoring or nicks. If found,
discard and DO NOT attempt to reuse it.
23. Usinga3/32"hexkey,removetheEXHAUSTCOVERSCREWS
(7).
24. Once the EXHAUST COVER (5) is disengaged from the lower
Alignment Tab, remove it from the HOUSING (4).
25. Inspect the overall condition of the HOUSING (4), and the
EXHAUST COVER (5) to ensure they are free of any stress
cracks or other distortions. Ensure that all Threading on the
HOUSINGisingoodcondition. Discardeitherifanydistortionor
damage is found.
26. Using a soft probe, inspect the condition of the EXHAUST
VALVE (6) to ensure that it is supple and free of any tears or
corrosion, and that it seals completely around the Seating
Surface of the HOUSING (4).
NOTE: If the EXHAUST VALVE is in good condition, it is not
necessary to remove it. The HOUSING may be cleaned with
the EXHAUST VALVE attached.
27. If the EXHAUST VALVE (6) requires replacement, remove it by
grasping it at the Flange and pulling it straight out, snipping the
Retainer Stem if necessary. Discard it.
28. Inspect the VENTURI SWITCH (30) for smooth even operation,
ensuring there is no resistance throughout its range of move-
ment. Inspect for signs of trapped debris .
NOTE: If the VENTURI SWITCH is in good condition, it is not
necessary to remove it. The HOUSING (4) may be cleaned
with the VENTURI SWITCH attached.
29. To remove the VENTURI SWITCH (30), grasp it by the Adjust-
ment Tab and pull it straight out of the HOUSING (4) (Fig. 10).
Fig. 9
Fig. 10

REGULATORS
ZX SECOND STAGE
©2002 Design, 2005
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Product Service Guide
Doc. 12-2808-r01 (2/19/05)
30. Remove the VENTURI SWITCH O-RING (29) and inspect it for
signs of decay or distortion. Discard it if found.
31. Closely examine the VENTURI SWITCH (30) for signs of distor-
tion, cracks, corrosion, or other damage. Discard it if 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-ringsare cleanandsupple,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. If removed, install a new EXHAUST VALVE (6) into the HOUS-
ING (4) by gently pulling the Retainer Stem through the HOUS-
ING until the Retaining Flange is inside the HOUSING and
properly seated.
2. ReplacetheEXHAUSTCOVER(5)ontotheExhaustTeeportion
of the HOUSING (4) by engaging the lower Alignment Tab (Fig.
11), then securing it to the HOUSING with the EXHAUST
COVERSCREWS(7). TurntheSCREWSclockwisetoatorque
of 5 to 6 in-lbs.
3. To replace the VENTURI SWITCH (30), if removed:
A. Lightly lubricate and install the VENTURI SWITCH O-RING
(29) onto the VENTURI SWITCH, ensuring that it is properly
seated in the Groove.
B. InserttheVENTURI SWITCH straight into theHOUSING (4),
aligned so that the Adjustment Stop Post will be seated in the
Adjustment Groove located on the HOUSING and small round
End will be guided into the hole on the opposite side of the
Mouthpiece opening (Fig. 12).
C. Turn the VENTURI SWITCH back and forth through its
complete range of motion ensuring smooth movement without
any restriction.
4. To remove the VALVE HOUSING (26):
A. Lightly lubricate and install the VALVE HOUSING O-RING
(28) into the Groove of the VALVE HOUSING. Work it over the
molded Tube, DO NOT roll it over the Threads. Fig. 12
Fig. 11

REGULATORS
ZX SECOND STAGE
©2002 Design, 2005
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Product Service Guide
Doc. 12-2808-r01 (2/19/05)
B. While holding both ends of the VALVE HOUSING secure,
press the Prongs of the DEMAND LEVER (27) down over the
Tube of the VALVE HOUSING.
C. Using care not to bend the Prongs of the DEMAND LEVER
pressone ofthem outwardand pullit upandinto theopening on
the side of the VALVE HOUSING. Repeat for the other Prong.
D. Insert the VALVE HOUSING, Threaded End first, through
the Adjustment Assembly opening of the HOUSING (4).
E. Position the VALVE HOUSING with the Square hole in the
molded Tube pointing toward the VENTURI SWITCH (30) and
the squared Demand Lever Recess of the Tube facing up (Fig.
13).
F. Using a wooden dowel, press the Threaded end of the
VALVEHOUSING completely into the octagonal openingof the
HOUSING ensuring that the VALVE HOUSING O-RING (28)
does not get pinched and enters the opening.
5. Lightly lubricate and install new POPPET O-RINGS (22/23) into
the two inner Grooves of the Shaft of the POPPET (24).
6. Inserta new POPPET SEAT(25)intothePOPPET(24) withthe
larger flat head end facing out. Ensure that it is completely
seated, flush with the Rim of the POPPET. DO NOT use
adhesive.
7. The components of the Adjustment Assembly (Fig. 14) are first
assembled prior to installing them together into the VALVE
HOUSING. Proceed closely as follows:
A. LubricateandinstalltheADJUSTMENTTUBEO-RING (19)
into the Groove toward the Threaded end of the ADJUSTMENT
TUBE (20).
B. Lubricate and install a new BALANCE SHAFT O-RING (21)
into the small opening End of the ADJUSTMENT TUBE (20).
C. LubricateandinstalltheSTEMO-RING(14)intotheGroove
of the ADJUSTMENT SHAFT (15).
D. If removed, install the SPRING FOLLOWER (16) onto the
ADJUSTMENT SHAFT (15). Screw it on counter clockwise, flat
side first. DO NOT tighten with a wrench.
E. Holding the ADJUSTMENT TUBE with the larger Threaded
end facing up, insert the BALANCE SHAFT (18) Shaft end first
down into the TUBE.
F. VerylightlylubricatebothendsoftheADJUSTMENTSPRING
(17) and insert it down into the TUBE.
Fig. 13
Fig. 14

REGULATORS
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©2002 Design, 2005
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G. Place the ADJUSTMENT SHAFT (15) with SPRING FOL-
LOWER (16) down over the ADJUSTMENT SPRING (17) (Fig.
15).
H. Install the THRUST WASHER (13) onto the ADJUSTMENT
SHAFT(15),thenslidethePACKINGNUT (12) over the SHAFT
andthreaditclockwiseontotheADJUSTMENTTUBE(20)afew
turns. DO NOT tighten the PACKING NUT at this time.
I. Insert the O-ring end of the POPPET (24) into the Small
opening end of the ADJUSTMENT TUBE (20).
NOTE: When the Adjustment Assembly is installed into the
VALVE HOUSING, it must be oriented with the Tabs of the
ADJUSTMENTTUBE atthe3and9o'clockpositionsandthe
side of the POPPET having 4 Tabs facing down and the side
with 2 Tabs facing up (Fig. 16).
CAUTION: Failuretoalignthecomponentsasdescribedwill
prevent the POPPET from engaging with the Prongs of the
DEMAND LEVER rendering the unit inoperable.
8. Insert the Adjustment Assembly, POPPET End first, straight
through side opening of the HOUSING (4) and into the VALVE
HOUSING (26). The DEMAND LEVER (27) will pop upright.
9. Whileexertingslightinwardpressure ontheAdjustmentAssem-
bly, insert the ADJUSTMENT TUBE RETAINER (9) down into
the Groove of the ADJUSTMENT TUBE (20) (Fig. 17).
10. Release inward pressure on the Adjustment Assembly and
tighten the PACKING NUT (12) by turning it clockwise until
secure. Check that the DEMAND LEVER (27) is in the up
position and operates without restriction and that the ADJUST-
MENT KNOB RETAINER (9) is properly oriented and secure.
11. Tighten the PACKING NUT (12) by turning it clockwise with a 5/
8" open end wrench to a torque of 11 to 13 in/lbs.
CAUTION: DO NOT over tighten! Doing so will damage the
HOUSING or other parts, requiring their replacement.
12. Install the ADJUSTMENT KNOB (11) over the ADJUSTMENT
SHAFT(15) andPACKINGNUT(12). Insertthe ADJUSTMENT
KNOBSCREW(10)andtightenwitha3/32"hexkeytoa torque
of 3 to 4 in/lbs.
13. LightlylubricateandinstallanewORIFICEO-RING(32)intothe
Groove of the ORIFICE (31). Lubricate the Threads of the
ORIFICEwithaverythinfilmoflubricantandinserttheORIFICE
into the Inlet of the VALVE HOUSING (26) with the Knife Edge
facing in (Fig. 18).
CAUTION: Usecaretoprotectthe delicate Knife Edge of the
ORIFICE as this is done.
Fig. 17
Fig. 15
Fig. 16
Fig. 18

REGULATORS
ZX SECOND STAGE
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14. Using a narrow shafted, slotted blade screwdriver, slowly turn
theORIFICE(31)clockwiseintotheVALVEHOUSING(26)until
theKnifeEdgeisbarelycontactingthePOPPETSEAT(25). This
is indicated by the DEMAND LEVER (27) beginning to drop. As
soon as it does, stop turning the ORIFICE and turn it slightly
counter clockwise to bring it upright.
CAUTION: ContinuingtoturntheORIFICEinanyfurther will
cause damage to the POPPET SEAT, requiring its replace-
ment.
15. Place the DIAPHRAGM (3) inside the HOUSING (4) with the
raisedCenterfacingup,andensurethatitseatsflushattheBase
of the inner Threads of the HOUSING.
16. Place the COVER RING (1) on the FRONT COVER (2) and
thread it clockwise into the HOUSING (4), taking care to ensure
that it is correctly seated in the Threads. Hand tighten until
secure and ensure the FRONT COVER is properly aligned, with
the logo right side up (Fig. 19). Use the Front Cover Tool, if
necessary. DO NOT over tighten.
17. SecuretheMOUTHPIECE(8)ontotheHOUSING(4)withanew
TIE WRAP (35), positioning the Locking Tab of the TIE WRAP
towards the LP Hose.
NOTE: Oceanic's patented Orthodontic Mouthpieces are
designedtoaccommodatethenaturaloverbiteofthehuman
jaw. Ensure that it is properly positioned.
18. Lubricate the LP HOSE SWIVEL PACKING WASHER (33) and
insert it in the Inlet Coupling.
19. InstalltheLPHOSEASSEMBLY(34)ontotheInletoftheVALVE
HOUSING (26), and tighten to a torque of 50 to 60 in/lbs with
an 11/16" open end wrench, while holding the Second Stage
secure.
TUNING AND TESTING
FIRST STAGE TESTING
1. PerformtheLeakDetectionTestspecifiedintheInitialInspection
Procedure (Doc. No. 12-2202).
NOTE: RefertotheTroubleShootingSectionforthespecific
FirstStagetodeterminethepossiblecause andtreatmentof
any air leaks that may be found.
2. Connect the Second Stage LP Hose 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.
Fig. 19

REGULATORS
ZX SECOND STAGE
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3. Connect a recently calibrated Low Pressure Test Gauge to the
additional Low Pressure Hose, and connect the First Stage to a
pure air source of 3,000 PSI (20 BAR).
4. SlowlyopenthevalvetopressurizetheRegulatorAssemblyand
check the Test Gauge to ensure that the Intermediate Pressure
is set as recommended in the Specifications for the First Stage
being used.
NOTE: Ifthe Intermediate Pressure isfound to be otherthan
recommended, refer to that specific Regulator First Stage's
Trouble Shooting Section to determine possible cause and
treatment.
TUNING
1. Prior to Tuning the Second Stage, check the following items:
A. The FRONT COVER (2) is secure and properly aligned.
B. The ADJUSTMENT KNOB (11) is turned counter clockwise
1 turn from fully open (or out, counter clockwise).
C. The MOUTHPIECE (8) has been cleaned and disinfected
with warm, soapy water.
2. Pressurize the Regulator Assembly with a pure air source of
3,000 PSI (20 BAR) and listen to determine that no air flow is
present.
3. If air flow is present, purge the Regulator Assembly of air and
remove the LP HOSE from the Inlet Coupling of the Second
Stage.
4. Using a narrow shafted, slotted blade screwdriver, turn the
ORIFICE (31) clockwise into the VALVE HOUSING (26) a small
fraction of a turn.
NOTE: TurningtheORIFICE(32)infurtherthannecessaryto
stop air flow will result in DEMAND LEVER slack and exces-
sive Spring load tension, prohibiting peak performance.
CAUTION: To avoid cutting the POPPET SEAT (25) with the
Knife Edge of the ORIFICE (32), depress the Purge Button
while turning the ORIFICE in or out.
5. InstalltheLPHOSEASSEMBLY(34)ontotheInletoftheVALVE
HOUSING (26), and tighten to a torque of 50 to 60 in/lbs with
an 11/16" open end wrench, while holding the Second Stage
secure.
6. Pressurize the Regulator Assembly again with a pure air source
of 3,000 PSI (20 BAR) and listen to determine that no air flow is
present.

REGULATORS
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7. If air flow is present, repeat steps 3 through 6.
8. HoldtheSecondStagewiththeMOUTHPIECE(8)facingdirectly
down, and gently shake it up and down. Listen carefully for any
rattle that may be present, indicating DEMAND LEVER (27)
slack.
9. If a rattle is heard in the Second Stage, proceed as follows:
A. Remove the COVER RING (1), FRONT COVER (2), and
DIAPHRAGM (3) to gain access to the Valve Assembly.
B. Purge the Regulator Assembly of air.
C. IftheDEMANDLEVER(27)hasdropped,itwillbenecessary
to remove and properly install the Adjustment Assembly into the
VALVE HOUSING following the associated steps of the Disas-
sembly and Reassembly Procedures.
10. ReplacetheDIAPHRAGM(3),FRONTCOVER(2),andCOVER
RING (1), if removed, and pressurize the Regulator again with a
pure air source of 3,000 PSI (20 BAR). Determine the range of
adjustment by performing the following procedure:
A. Turn the ADJUSTMENT KNOB (11) completely out (counter
clockwise). A slight to moderate air flow should be present.
B. Turn the ADJUSTMENT KNOB completely in (clockwise)
and fully depress the Purge Button. This should initiate a slight
air flow.
NOTE: If air flow is greater or less than specified for each
adjustment, refer to the Trouble Shooting Section on page 3
to determine the possible cause and treatment.
11. Purge the Regulator of air, remove the In-Line Adjustment Tool
and connect the LP Hose directly onto the Inlet Coupling of the
VALVEHOUSING(26), using awrenchas prescribed instep 20
of the Reassembly Procedure.
12. Pressurize the Regulator Assembly again with a pure air source
of3,000PSI(20BAR). ReturntheADJUSTMENTKNOB(11)to
its mid range position. Inhale lightly through the MOUTHPIECE
(8) to determine that air flows easily and smoothly without any
hesitation or lag.
NOTE: If hesitation or lag is detected, refer to the Trouble
ShootingSection on page 3todetermine the possible cause
and treatment.
13. Cleananddisinfectthe MOUTHPIECE (8) inwarm,soapywater
before returning the Second Stage to the customer.

REGULATORS
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Product Service Guide
Doc. 12-2808-r01 (2/19/05)
1c 6981.23 RING, FRONT COVER
2c 6980.07 COVER, FRONT (BK)
3b 6979 DIAPHRAGM
4c 6975.07 HOUSING (BK/GY)
5c 6977.07 COVER, EXHAUST (BK)
6b 6326 VALVE, EXHAUST (BK)
7c 4787.2 SCREW, EXHAUST COVER (2)
8b 4485.07 MOUTHPIECE (BK)
9c 5466 RETAINER, ADJUSTMENT TUBE
10c 4787.2 SCREW, ADJUSTMENT KNOB (BK)
11c 6971 KNOB, ADJUSTMENT
12c 6332 NUT, PACKING
13b 5054 WASHER, THRUST
14b 2.107 O-RING, STEM
15c 6685 SHAFT, ADJUSTMENT
16c 5475 FOLLOWER, SPRING
17c 5467 SPRING, ADJUSTMENT
18c 5468 SHAFT, BALANCE
19b 2.016 O-RING, ADJUSTMENT TUBE
20c 5455 TUBE, ADJUSTMENT
Dia.
No. Part # Description
1
Dia.
No. Part # Description
21a 5473 O-RING, BALANCE SHAFT
22a 5474 O-RING, POPPET OUTER
23a 5474 O-RING, POPPET INNER
24c 6982 POPPET
25a 5465 SEAT, POPPET
26c 6983 HOUSING, VALVE
27c 5463 LEVER, DEMAND
28b 2.016 O-RING, VALVE HOUSING
29b 2.008 O-RING, VENTURI SWITCH
30c 6989 SWITCH, VENTURI
31c 6621 ORIFICE
32b 2.010 O-RING, ORIFICE
33c 6959 WASHER, LP HOSE SWIVEL PACKING
34c 40.2120.030 ASSEMBLY, LP HOSE (30") (BK)
35a 1978.07 WRAP, TIE (BK)
N/S 40.6161 KIT, SERVICE PARTS (includes all Bold items)
23
9
5
6
31
34
32
33
8
36
4
27 7
7
29 30
26 24 21 19 17 15 13
25 22
23 20 18 16 14
12 11
10
28
(2) O-RINGS