EOS PNEUMATICALLY BALANCED SECOND STAGE

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1 EOS SERVICE PROCEDURE R02 (10/3/10) EOS PNEUMATICALLYBALANCED SECONDSTAGE PRODUCTSERVICEPROCEDURE ThisServiceProcedureconveysalistofcomponentsandproceduresthatreflecttheEOSsecondstageasitwasconfigured atthetimeofthiswriting(10/3/10). SUPPORT:TOLL FREE: FAX:

2 CONTENTS TROUBLESHOOTING...3 DISASSEMBLYPROCEDURE...4 REASSEMBLYPROCEDURE..7 FINALADJUSTMENTANDTESTING PARTSLISTANDEXPLODEDVIEW.. 15 GENERALPROCEDURES REFERTOGENERALSERVICEPROCEDURE..DOC.NO r02 SPECIFICATIONS Torques Terminology PN Screw 3to4in lbs IPIntermediatePressure. PN7099 Packingnut 11to13in lbs IWCInchesWaterColumn(inhalationeffort). PN LPHose 50to60in lbs LeakLowvolumereleaseofair,audible&detectableinwater. PN7038 AdjustmentTube16 17in lbs FreeFlowHighflowrate,stopswhenairstreamisobstructed. PN7039 ValveHousingNut25 27in lbsoverpurgehighflowratewillnotstopwhenairstreamis obstructed. 1.NoleakwithAdjustmentKnobturnedfullyoutcounterclockwise. 2.InhalationEffortnottoexceed1.2IWC. 3.NofreeflowallowedwhenVenturiSwitchsetnegative(switchforward). 4.FreeflowallowedwhenVenturiSwitchsetpositive(switchback). 4.Nooverpurgeallowed. TOOLSREQUIRED StandardTools SpecialtyTools InchPoundsTorqueWrench OceanicapprovedHalocarbonBasedLubricant(See 5/8 OpenEndWrench GeneralProcedure Doc for approved list) 11/16 OpenEndWrench 3/32 HexKey PN IPGauge 5/8 Socket PN O RingToolSet 3/32 HexDriver PN AdapterIPGaugetoLPQD 5/8 Socket 5/16 HexDriver 13/16 OpenEndWrench 5/64 PinPunch AdjustableCrowsFootWrench SmallFlatBladeScrewdriver CottonSwab WoodenorPlasticDowel MagnifyingLight MagnehelicGauge SUPPORT:TOLL FREE: FAX: service@oceanicusa.com 2

3 TROUBLESHOOTING EOS SERVICE PROCEDURE R02 (10/3/10) SYMPTOM POSSIBLECAUSE TREATMENT Freefloworleakpresentwith AdjustmentKnob(20)turnedfully outcounterclockwise. Excessiveinhalationeffortwith AdjustmentKnob(20)turnedfully outcounterclockwise. Rattlenoiseheardinsidesecond stage. Littleornoairflowwhenpurgeis depressed. AdjustmentKnob(20)difficultto turn. Waterenteringsecondstage. 1. DemandLever(28)bent. 2. Excessiveintermediatepressure. 3. DamagedorwornPoppetSeat(30). 4. DamagedOrifice(26). 5. Orifice(26)incorrectlyadjusted. 6. LPHose(39)nottightenedontoValve Housing(27or44)inlettube. 7. Trappedsandordebris. 8. Scoreinsidesealingsurfaceof AdjustmentTube(11). 9. WeakordamagedPoppetSpring(15). 1. DemandLever(28)bent. 2. Orifice(26)incorrectlyadjusted. 3. InsufficientIntermediatePressurefrom 1 st stage. 1. GravelorsandtrappedinsideHousing (6). 2. ExcessiveDemandLever(28)slack. 1. FrontCoverRing(1)nottightened correctly. 2. ExcessiveDemandLever(28)slack. 3. Orifice(26)incorrectlyadjusted. 1. Debrisorcorrosionpresenton AdjustmentShaft(17). 2. DebrispresentinsideAdjustmentKnob (20). 3. SpringFollower(16)damagedorcross threaded. 4. PoppetSpring(15)damagedor corrosionpresent. 1. HoleortearinMouthpiece(8). 2. ExhaustValve(9)damagedor deformed. 3. Diaphragm(5)damagedordeformed. 4. DebristrappedbeneathExhaustValve (9)orDiaphragm(5). 5. FrontCoverRing(1)nottightenedonto Housing(6). 6. DamagedVenturiSwitchO ring(34). 7. CrackedordamagedHousing(6). 8. MouthpieceTieWraplooseormissing. 1. ReplaceDemandLever(28). 2. ReadjustIPof1 st stageto specification. 3. ReplacePoppetSeat(30). 4. ReplaceOrifice(26). 5. ReadjustOrifice(26)(refertoFinal Adjustmentsection). 6. TorqueLPHose(39)to specification. 7. Removesandordebrisandclean. 8. ReplaceAdjustmentTube(11). 9. ReplaceAdjustmentSpring(15). 1. ReplaceDemandLever(28). 2. ReadjustOrifice(26)(refertoFinal Adjustmentsection). 3. ReadjustIPof1 st stageto specification. 1. Removeandclean. 2. ReadjustOrifice(26)(refertoFinal Adjustmentsection). 1. TightenFrontCoverRing(1)until secure. 2. ReadjustOrifice(26)(refertoFinal Adjustmentsection). 3. ReadjustOrifice(26)(refertoFinal Adjustmentsection). 1. Disassembleandclean. 2. Flushoutordisassembletoclean. 3. ReplaceSpringFollower(16). 4. CleanorreplacePoppetSpring (15). 1. ReplaceMouthpiece(8). 2. ReplaceExhaustValve(9). 3. ReplaceDiaphragm(5). 4. Removeandclean. 5. Tightenuntilsecure. 6. RemoveVenturiSwitch(35)and replaceo ring(34). 7. ReplaceHousing(6). 8. Tightenorreplace. SUPPORT:TOLL FREE: FAX: service@oceanicusa.com 3

4 EOS SERVICE PROCEDURE R02 (10/3/10) DISASSEMBLYPROCEDURE NOTE: Be sure to perform the steps outlined in the General Service Procedure (Doc. No r02) prior to disassembling the Eos second stage. Review the Troubleshooting section on page 3 to better understand which internalpartsmayneedreplacing,andtobetteradvisethecustomeroftheservicerequired. 1. CarefullysniptheTieWrap(7)(scheduleA)ontheMouthpiece(8);removeMouthpiece(8)andinspectforholes, tearsordeformation.discardifanyfound. 2. RemovetheLPHose(39)fromtheValveHousing(27or44)usinganadjustablewrench;removetheO ring(37)and SwivelWasher(24ONLYUSEDONSWIVELVER.2)withabrasspick(O ringtoolkit )fromthevalvehousing (27or44)anddiscard(scheduleA);DONOTREUSE.(Fig.1) NOTE:ThewasherlocatedinsidetheLPHosebehindtheswivelballisnotserviceableandisNOTtoberemoved. 3. RemovetheCoverRing(1)andTopCover(2)byturningcounterclockwise. 4. RemovetheDiaphragmRetainingRing(3)byunscrewingitcounterclockwise. 5. RemovetheDiaphragmWasher(4)andDiaphragm(5)bygraspingtheraisededgesofthecenterandliftwithaslight upwardtwisttoremove.holduptothelightandinspectforholes,tearsordeformation;discardifanyfound. 6. TurntheAdjustmentKnob(23)outcompletelycounterclockwise.RemovetheAdjustmentKnobScrew(22)witha 3/32 hexkeyandremovetheadjustmentknob(23)fromtheadjustmentshaft(17). 7. RemovethePackingNut(20)fromtheAdjustmentTube(11)witha5/8 openendwrenchturningclockwise(fig.2); thenutisleft handthreaded.becarefulnottolosethethrustwasher(19). Fig.1 Fig.2 Fig.3 NOTE:TheAdjustmentShaft(17)subassemblyisunderspringloadandmaypopoutwhenthePackingNut(20)is removed;becarefulnottoloseanycomponentsduringdisassembly. 8. RemovetheThrustWasher(19)fromtheAdjustmentShaft(17);ifmissing,itmaybeinsidethePackingNut(20). 9. GrasptheAdjustmentShaft(17)withyourfingersandpullstraightoutfromtheAdjustmentTube(11).(Fig.3). 10. RemovethePoppetSpring(15)andBalanceShaft(14).IftheBalanceShaft(14)doesnotcomeout,gentlytapthe AdjustmentTube(11)intoyourhandtoremoveit(Fig.4).ExaminetheBalanceShaft(14)andcompareittoanew onetoinsurethatitisnotbentordeformed;discardifdamaged. 11. RemovetheO ring(18)fromtheadjustmentshaft(17)andinspectforanysignsofdamage;discardiffound. SUPPORT:TOLL FREE: FAX: service@oceanicusa.com 4

5 NOTE:DonotremovetheSpringFollower(16)fromtheAdjustmentShaft(17)unlessitisdamagedandneeds replacing,ordebrisneedstoberemovedtocleanit.inthiscase,removebyturningthespringfollower(16) clockwisewhileholdingtheadjustmentshaft(17)inyourotherhand.notethatthethreadislefthanded. 12. ThePoppetSpring(15)isscheduleA,discardanddonotreuse.(Fig.5). Fig.4 Fig.5 Fig RemovetheValveHousingNut(36)witha13/16 openendwrenchbyturningcounterclockwise(fig.6). 14. CarefullypushtheValveHousing/AdjustmentTubeAssemblyoutthroughtheHousing(6),beingcarefulnotto damagethedemandlever(28)andsetaside(fig.7). 15. RemovetheRatchetDetent(41)andO ring(42)withasmallflatbladescrewdriver;discardanddonotreuse (schedulea)(fig.8). 16. SlidetheVenturiTubeSwitch(35)offtheAdjustmentTube(11).RemovetheVenturiTubeSwitchO ring(34)by pinchingtheo ringandrollingoff(fig.9);inspectforanydamageanddiscardiffound. Fig.7 Fig.8 Fig RemovetheAdjustmentTube(11)fromtheValveHousing(27or44)byholdingthesquareflatsoftheValve Housing(27or44)withan11/16 openendwrenchandinserta5/16 hexdriverintotheadjustmenttube(11)and turnclockwise;thethreadislefthanded(fig.10). 18. RemovetheAdjustmentTubeO ring(12)bysqueezingwithyourfingersandexaminefordamage;discardifany found. 19. RemovetheBalanceShaftO ring(13)locatedinsidethesmallopeningendoftheadjustmenttube(11)bypressing itoutwitha5/64 pinpunch.discardtheo ring(13)(schedulea)anddonotreuse.(fig.11). 20. ExaminetheDemandLever(28)toinsurethatitisnotbentordeformed.IftheDemandLever(28)isdeformed, removebypullingoutwardononelegoftheleverwithyourfingersuntilitisremovedfromtheholeinthesideofthe ValveHousing(27or44);repeatwiththeotherside. SUPPORT:TOLL FREE: FAX:

6 NOTE:ItisnotnecessarytoremovetheDemandLever(28)unlessitisdamaged.TheValveHousing(27or44)maybe cleanedwiththedemandlever(28)attached. 21. RemovetheValveHousingO ring(29)bysqueezingitwithyourfingers.examinetheo ring(29)fordamage;discard iffound. 22. IfthePoppet(31)didnotcomeoutwiththeremovaloftheAdjustmentTube(11),pushthepoppetoutthroughthe ValveHousing(27or44)withcottonswab(Fig.12). Fig.10 Fig.11 Fig RemovethePoppetSeat(30)withyourfingersanddiscard(scheduleA);DONOTREUSE(Fig.13). 24. RemovethePoppetO rings(32,33)bysqueezingthemwithyourfingersandworkingthemovertheendofthe Poppet(31)(Fig.14).DONOTuseadentalpickoranytooltoremovethem.DiscardtheO rings(32,33)(schedulea) anddonotreuse. 25. Usinganarrowflatbladescrewdriver,carefullyremovetheOrifice(26)byturningitcounterclockwiseintheValve Housing(27or44)untilthethreadsdisengage.Oncethethreadsarefullydisengaged,pressouttheOrifice(26)with acottonswab.(fig.15)removetheorificeo ring(25)anddiscard(schedulea);donotreuse. Fig.13 Fig.14 Fig.15 NOTE:WhenremovingtheOrifice(26),becarefulnottodamageornicktheknifeedgesealingsurface;doingsowill resultinaleakuponreassemblyrequiringitsreplacement.examinetheknifeedgewithamagnifiedlightsourcefor anynicksordents;discardifanyfound. 26. RemovetheExhaustCover(10)bygraspingtheuppercornerandpullingdownward(Fig.16). 27. ExaminetheoverallconditionoftheHousing(6)andExhaustCover(10)toinsuretherearenostressfracturesor deformation.insurethatallthreadingonthehousing(6)isingoodconditionandfreefromsandordebris.discard eitherifanydamageisfound. 28. ExaminetheExhaustValve(9)withasoftprobetoinsurethatitisresilientandnoholesortearsarepresent;discard ifanyfound.inspectthesealingsurfaceundertheexhaustvalve(9)onthehousing(6)toinsurethereisnodebrisor damage. SUPPORT:TOLL FREE: FAX:

7 EOS SERVICE PROCEDURE R02 (10/3/10) NOTE: It is not necessary to remove the Exhaust Valve (9) if it is in good condition; the Housing (6) may be cleaned without removing it. REASSEMBLY PROCEDURE NOTE: Prior to Reassembly, it is important to inspect all parts, both new and those being reused, for defects and damage. Inspect to insure that all o rings are clean and supple, and all parts and components have been thoroughly cleaned and dried in accordance to the General Service Procedure (Doc. No r02). Inspect all critical sealing surfaces for scratches or imperfections. WARNING: Use only genuine Oceanic parts, subassemblies and components whenever assembling Oceanic products. DO NOT substitute any Oceanic part with a part from another manufacturer, regardless of any similarity in shape, size or appearance. Doing so may render the product unsafe, and could result in serious injury or death. 1. If it was removed, install a new Exhaust Valve (9) into the Housing (6) by gently pulling the valve stem through the Housing (6) with a hemostat or needle nose pliers, insuring that the retaining nipple is pulled inside the Housing (6) and properly seated. Installation may be aided with the use of soapy water. (Fig. 17). Fig. 16 Fig. 17 Fig. 18 WARNING: DO NOT use Christo Lube or any other lubricant on the Exhaust Valve ( ) to install; doing so may result in the Exhaust Valve ( ) slipping from the Housing ( ) rendering the product unsafe, and could lead to serious injury or death. 2. Reinstall Exhaust Cover (10) by engaging the top corners of the Housing (6) first, then pressing downward until bottom lip of the Exhaust Cover (10) snaps over the lower ledge of the housing. If necessary, the Exhaust Cover (10) can be heated in water to 140 degrees F. to make it more pliable. 3. Install a new Ratchet Detent O ring (42) onto the Ratchet Detent (41) (Fig. 18). 4. Install the Ratchet Detent (41) into the Housing (6) by press fitting into the slot near the large housing opening with your fingers (Fig 19). Fig. 19 Fig. 20 SUPPORT: TOLL FREE: FAX: service@oceanicusa.com Fig. 21 7

8 5. LubricateandcarefullyworktheValveHousingO ring(29)ontotheplasticportionofthevalvehousing()tube untilseatedintothegroove. 6. IftheDemandLever(28)wasremoved,reinstallbyholdingtheValveHousing(27or44)withthesmallflatmolded ontotheplasticpartofthehousingtubefacingupwards.carefullyinsertonelegofthedemandlever(28)without excessivelybendingitintothesquarebroachedholeononesideofthevalvehousing(27or44)tube(fig.20);pull theoppositelegofthedemandlever(28)outwardsandinserttheendintothesquarebroachedholeinthe oppositesideofthevalvehousing(27or44)tube.thedemandlever(28)shouldnowrestontheflatmoldedon topofthehousingtube;thiswillinsurethatthesquareaspiratorholeononesideofthetubewillfacethe mouthpieceopeninginsidethehousing(6). 7. LightlylubricateandinstalltheAdjustmentTubeO ring(12)ontothenarrowgrooveinthemiddleofthe AdjustmentTube(11)(Fig.21). 8. LightlylubricateandinstallanewBalanceShaftO ring(13)intothesmallopeningoftheadjustmenttube(11)by pressingitintoplacewiththenarrowendofthepoppet(31)shaft.removethepoppet(31)shaftandlookintothe smallopeningoftheadjustmenttube(11);youshouldbeabletoseeclearthrough.ifnot,removeo ringand reinstalluntilcorrectlyseated. 9. InspectandinstallanewPoppetSeat(30)ontothePoppet(31),largeflatendfacingoutuntilitisfullyseatedand flushwiththeedgeofthepoppet(31)(fig.22).examinetheholeinthecenterofthepoppetseat(30)toinsurethat itisclearandnotplugged.donotuseanyadhesiveorlubricant. Fig.22 Fig.23 Fig LightlylubricateandinstallbothPoppetO rings(32,33)intothenarrowgroovesoftheshaftofthepoppet(31)(fig. 23). 11. InsertthePoppet(31)seatendfirstintotheroundopeningoftheValveHousing(27or44),pressingitintoplace withacottonswab(fig.23);thedemandlever(28)shouldpopupmomentarily.makesurethesideofthepoppet with4 fins facedownwardtoinsurethatthepoppetengagesthelegsofthedemandlever(28). NOTE:WheninstallingthePoppet(31)intotheValveHousing(27or44),itmustbeorientatedwiththesideofthe Poppet(31)having4finsfacingdown;thesidewith2finsfacingup(Fig.25). Fig.25 Fig.26 Fig.27 SUPPORT:TOLL FREE: FAX:

9 CAUTION:FailuretoalignthecomponentspreciselyasdescribedmaypreventthePoppet(31)fromengagingthelegs ofthedemandlever(28)renderingtheunitinoperable. 12. InstalltheAdjustmentTube(11)ontotheValveHousing(27or44)byscrewingitoncounterclockwise;thethread islefthanded.inserta5/16 hexdriverattachedtoacalibratedtorquewrenchintotheadjustmenttube(11)and torquecounterclockwiseto16 17in/lbswhileholdingthesquareendoftheValveHousing(27or44)withan 11/16 openendwrench(fig.26). 13. InserttheValveHousing/AdjustmentTubeAssemblythroughtheroundholeoftheHousing(6)whiledepressing thedemandlever(28)(fig.27)andpushuntilfullyseated;thesquarebroachofthevalvehousing(27or44)will engagethesquareholeofthehousing(6)andthedemandlever(28)willfaceupwards(fig.28). 14. InstalltheValveHousingNut(36)ontotheValveHousing(27or44)byturningclockwisewithanadjustablecrows footwrenchattachedtoacalibratedtorquewrenchandtorqueto25 27in/lbs(Fig29). Fig.28 Fig.29 Fig InstalltheVenturiTubeSwitchO ring(34)onthegrooveoftheventuriswitch(fig.30). 16. WhileholdingtheHousing(6)facingup,installtheVenturiTubeSwitch(35)ontotheAdjustmentTube(11)and intothehousing(6)(fig.31). 17. ThecomponentsoftheAdjustmentShaft(17)assemblymustbefirstassembledpriortoinstallationintothe AdjustmentTube(11).LightlylubricateandinstalltheAdjustmentShaftO ring(18)ontothegrooveonthe AdjustmentShaft(17). 18. Ifremoved,installtheSpringFollower(16)flatsidefirstontotheAdjustmentShaft(17),screwingbyhandcounter clockwiseuntilitstops;donottightenwithawrenchoranytool.insurethatyoudonotcrossthreadduring assembly. 19. PlacetheAdjustmentShaft(17)subassemblylargesidedownonalevelflatsurfacewiththepointedendfacingup. LightlylubricatebothendsofthePoppetSpring(15)andplaceontotheAdjustmentShaft(17)withoneendofthe springseatedintotherecessinthefaceofthespringfollower(16).placethebalanceshaft(14)largesidefirst centeredontothepoppetspring(15)(fig.32). Fig.31 Fig.32 Fig.33 SUPPORT:TOLL FREE: FAX:

10 EOS SERVICE PROCEDURE R02 (10/3/10) 20. While holding the Housing (6) with the Adjustment Tube (11) opening facing down, carefully lower onto the Adjustment Shaft (17) assembly (Fig. 33). 21. Install the Thrust Washer (19) onto the end of the Adjustment Shaft (17); place the Packing Nut (20) large opening first over the Adjustment Shaft (17) and thread counter clockwise onto the Adjustment Tube (11); the thread is left handed. 22. Tighten the Packing Nut (20) by turning counter clockwise with a 5/8 socket attached to a calibrated torque wrench and torque to in/lbs. (Fig. 34). Fig. 34 Fig. 35 Fig. 36 CAUTION: Over tightening the Packing Nut (20) may result in the failure of the fastener rendering it unusable, requiring its replacement. 23. Install the Adjustment Knob/Cover (21, 23) onto the Adjustment Shaft (17). Insert the Adjustment Knob Screw (22) and tighten clockwise; attach a 3/32 hex driver to a calibrated torque wrench and torque to 3 4 in/lbs. (Fig. 35). 24. Carefully examine the knife sealing edge of the Orifice (26) for nicks or imperfections. Lightly lubricate and install a new Orifice O ring (25) onto the groove of the Orifice (26). Insert the Orifice (26) into the Valve Housing (27 or 44) knife edge first (Fig. 36). CAUTION: Be careful to protect the knife edge sealing surface of the Orifice (26) during installation. 25. Using a narrow flat blade screwdriver, engage the slotted head of the Orifice (26) and slowly turn in clockwise into the Valve Housing (27 or 44) until the knife edge of the Orifice (26) barely makes contact with the Poppet Seat (30). This will be indicated by the slight drop of the Demand Lever (28); when this occurs depress the Demand Lever (28) and slightly turn the Orifice (26) out counter clockwise, bringing the Demand Lever (28) upright. CAUTION: Continuing to turn the Orifice (26) inward any further may result in damage to the Poppet Seat (30), requiring its replacement. Fig. 37 Fig. 38 SUPPORT: TOLL FREE: FAX: service@oceanicusa.com Fig

11 26. InstalltheDiaphragm(5)intotheHousing(6)withtheraisedcenterfacingupandthesmoothstrikeplatefacingthe DemandLever(28).ExaminetheraisedliportheDiaphragm(5)edgetoinsureitisfullyseatedintothegrooveat thebaseofthethreadsofthehousing(6).(fig.37). 27. InstalltheDiaphragmWasher(4)ontopoftheDiaphragm(5)makingsureitlaysflat(Fig.38). 28. ThreadtheDiaphragmRetainer(3)clockwiseuntilsnug;torqueto11 12in/lbs(Fig.39). 29. InstalltheFrontCover(2)intotheFrontCoverRing(1);noticethattheFrontCover(2)hastwosmalltabs,oneon eachsidethatfitintotherectangularslotsinthethreadedportionofthefrontcoverring(1)(fig.40).checkthat thelogosarecorrectlyoriented(fig41). Fig.40 Fig InstalltheFrontCover/RingAssemblyintothehousingbyturningclockwiseuntilfullyseatedandsecure.Logo shouldbealignedalongthecenterlineofthehousing(6).donotcrossthreadwhileinstalling.donotovertighten. NOTE:Forstep31,ONLYUSESwivelWasher(24)withValveHousing(27,SwivelVersion1).ForSwivelVersion2 followeverythingexceptinstallationofsaidswivelwasher(24).seeexplodedviewdiagramforafurther detailedviewofbothversions. 31. LightlylubricatetheSwivelWasher(24)andinstallintotheopeningoftheValveHousing(27or44)flatsidein, concavesidefacingout(fig.42).lightlylubricateandinserttheswivelo ring(37)nexttotheswivelwasher(24) (Fig.43). Fig.42 Fig.43 SUPPORT:TOLL FREE: FAX:

12 FINALADJUSTMENTANDTESTING EOS SERVICE PROCEDURE R02 (10/3/10) NOTE:AdjustmentandtestingoftheEossecondstageisdonewithaninletIntermediatePressureof140psi(+/ 3 psi)andsupplypressureof3000psi. 1. ConnectthesecondstageLPSwivelHose(39)toaLPPortofaproperlyadjustedfirststage;connectaLPQDInflator HosetoanotherLPport.Installportplugstosealalltheotherportsofthefirststage. 2. Connectthefirststagetoapuresupplyairsourceof3000psi(207BAR).ConnectacalibratedIntermediatePressure GaugetotheLPQDInflatorhose(makesurethatthereisanoverpressurereliefdeviceconnectedtotheIPGaugeto relievepressureinexcessof175psi).slowlyopenthesupplyvalvetopressurizetheregulator,purgingthesecond stageseveraltimestocyclethefirststagetostabilizetheip(fig.44).checktheipgaugetoinsurethatthe intermediatepressureis140psi(+/ 3psi). NOTE:IftheIntermediatePressureisotherthanrecommended,readjustthefirststageIPtospecification.Ifnecessary, refertothetroubleshootingsectionofthefirststagetodeterminepossiblecauseandresolution. Fig.44 Fig PriortoAdjustingthesecondstage,checkthefollowingitems:TheFrontCover/CoverRing(1,2)ontightandsecure; theadjustmentknob/cover(21,23)isturnedoutfullycounterclockwiseuntilstopped;theventuritubeswitch(35) issetnegative(switchlevertowardsmouthpiecetube);themouthpiecehasbeenremoved. CAUTION:ToavoidcuttingthePoppetSeat(30)withtheknifeedgeoftheOrifice(26),alwaysdepresstheFront Cover(2)whileadjustingtheOrifice(26);failuretodosowillresultindamagingthePoppetSeat(30),requiringits replacement. 4. LeverHeightAdjustment:Ifavailable,attachanInlineAdjustmentToolbetweenthesecondstageandtheLPSwivel Hose()toadjusttheleverheight(Fig.45).Pressurizetheregulatorandlistentodeterminethatnoairflowis present;ifnonepresent,engagetheslottedheadoftheorifice(26)withtheinlineadjustmenttoolandturnthe Orifice(26)counterclockwiseinsmallincrementswhiledepressingtheFrontCover(2)untilaslightleakispresent. NowturntheInlineAdjustmentToolclockwiseuntiltheleakjuststops,thenturninanadditional1/12turnmore. MakesuretodepresstheFrontCover(2)whileturningtheOrifice(26)topreventdamagingthePoppetSeat(30).If aleakwaspresentuponinitialpressurization,turntheinlineadjustmenttoolclockwiseinsmallincrementsuntilthe leakjuststops,thenturninanadditional1/12turnmore. 5. IfnoInlineAdjustmentToolisavailable,fullydepressurizetheregulatorandremovetheLPSwivelHose(39)fromthe secondstage.useanarrowflatbladescrewdriverandadjusttheorifice(26)asoutlinedisstep4above. NOTE:TurningtheOrifice(26)clockwiseinfurtherthannecessarytostopairflowwillresultinexcessiveDemand Lever(28)slackandexcessivespringtension,preventingpeakperformance. 6. Afterattainingcorrectleverheight,installtheLPSwivelHose(39)byattachinganadjustablecrowsfootwrenchtoa calibratedtorquewrenchandturningclockwise;torqueto50 60in/lbs(Fig.46). SUPPORT:TOLL FREE: FAX: service@oceanicusa.com 12

13 7. Pressurizetheregulatoragainandlistenforleaksorairflow;noneshouldbepresent.Ifaleakispresent,repeatsteps 3through5. 8. HoldthesecondstagewiththeFrontCover(2)facingdownwards;gentlyshakeupanddown,listeningforanyrattle soundindicatingexcessiveleverslack.ifarattlesoundisfound,readjusttheorifice(26)asoutlinedinsteps4and5. 9. InhalationEffortTestwithMagnehelicGauge&IPGauge:Attachthecorrectlyadjustedsecondstagetoa *MagnehelicGaugeviathemouthpieceadapter;slowlyinhaleonthemouthpiecewhilewatchingtheIPGauge.The momenttheneedleoftheipgaugemovesleftfrom140psiindicatingtheprecisemomentthefirststagehas opened,lookatthemagnehelicgaugeandrecordtheinhalationeffortinincheswatercolumn(iwc);thisisalso referredtoascrackingeffort.inhalationeffortisnottoexceed1.2iwc. *(MagnehelicisaregisteredtrademarkofDwyerInstruments). Fig InhalationEffortTestwithFlowmeter:Attachthecorrectlyadjustedsecondstagetoaflowmeterthatisconnected toamagnehelicgaugeviathemouthpieceadapter(fig.47).initiateairflowthroughtheflowmeterwiththeneedle valvewhilewatchingtheipgauge.themomenttheipgaugeneedlemovesleftfrom140psiindicatingtheprecise momentthefirststagehasopened,lookatthemagnehelicgaugeandrecordtheinhalationeffortiniwc.inhalation effortisnottoexceed1.2iwc. NOTE:Iftheinhalationeffortisgreaterorlessthanspecification,refertotheTroubleshootingsectiononpage3to determinethepossiblecauseandresolution. Fig DepressurizeandremovethesecondstagefromtheMagnehelicGauge.AttachacleanMouthpiece(8)tothe mouthpiecetubeandsecurewithatiewrap(7). SUPPORT:TOLL FREE: FAX:

14 12. Installtheprotectorcaponthefirststageyokeretainerandtightendownwiththeyokescrew.Makingsurethatall otherportsonthefirststagearesealedclose,lightlyinhaleonthesecondstagetodeterminevacuumintegrity;you shouldnotbeabletodrawairthroughthesecondstage.ifyoucan,refertothetroubleshootingsectiononpage3 todeterminethepossiblecauseandresolution. 13. Checkallfittingstoinsurenonearelooseandarecorrectlytorquedbeforereturningtheregulatortothecustomer. SUPPORT:TOLL FREE: FAX:

15 SERVICEPARTSKITS P/N DESCRIPTION NOTES KIT,SVC,EOS2NDSTG,SWIV DOCUMENTS P/N DESCRIPTION NOTES PROCEDURE,SVC,EOS PROCEDURE,ADMINISTRATION PROCEDURE,REGULATOR GENERAL SUPPORT:TOLL FREE: FAX:

16 COMMENTS NUMBERBOX NOTICE ORINGS NLA,NA NS DPL EOS SERVICE PROCEDURE R02 (10/3/10) NumbersinboxesrepresentScheduleAParts,includedinServiceKit Thisdocumentforidentificationandpartsorderingonly Unlessspecificallylisted,O ringsareonlyofferedin12packstominimizecosts NoLongerAvailable;NotAvailable NotShown SeeDealerPriceList EOSSECONDSTAGE DIA. CAT. P/N DESCRIPTION NOTES 1 c A COVERRING,TOP,EOS,ASSY 2 c COVER,TOP,EOS 3 c 7046 RING,RETAINING,DIAPHRAGM 4 b 7045 WASHER,DIAPHRAGM 5 b 5236 DIAPHRAGM,DEMAND 6 c HOUSING,EOS,NEO 7 a WRAP,TIE,51/2",BK 8 b MOUTHPIECE,ORTHO,GY 9 b 6326 VALVE,EXHAUST 10 c COVER,EXHAUST,EOS,NEO 11 c 7038 TUBE,ADJUSTMENT 12 b O RING,*ORDER2.014K(12PK)* b 2.014K O RING,(12PK) 13 a 5473 ORING.070X b 5468 SHAFT,BALANCE 15 a 7822 SPRING,POPPET 16 c 5475 FOLLOWER,SPRING 17 c 7040 SHAFT,ADJUSTMENT 18 b O RING*ORDER2.107K(12PK)* b 2.107K O RING(12PK) SUPPORT:TOLL FREE: FAX: service@oceanicusa.com 16

17 19 b 5054 WASHER,THRUST 20 c 7099 NUT,PACKING 21 c KNOB,ADJUSTMENT 22 c SCREW,SOCKETHEAD 24 a 6959 WASHER,HOSE,LPSWIVEL ONLYforSWIVELVERSION1 25 a O RING*ORDER2.010K(12PK)* a 2.010K O RING(12PK) 26 b 6621 ORIFICE,ADJ,MOLDED 27 c 7041 VALVEHOUSING,W/INSERT SWIVELVERSION1 28 c 5463 LEVER,DEMAND 29 b O RING,*ORDER2.017K(12PK)* b 2.017K O RING(12PK) 30 a 5465 SEAT,POPPET 31 b 5464 POPPET 32 a 5474 O RING,.091X a 5474 O RING,.091X b O RING,*ORDER2.018K(12PK)* b 2.018K O RING,(12PK) 35 c 7044 SWITCH,VENTURITUBE,EOS 36 c 7039 NUT,VALVEHOUSING 37 a 6968 ORING,2.014VITON90DUR 38 b 6948 PROTECTOR,HOSE,SWIVEL SWIVELVERSION1 39 b HOSE,SWIVEL,EOSASSY30"BK 40 b O RING*ORDER3.903K(12PK)* b 3.903K O RING(12PK) 41 a 7051 RATCHETDETENT 42 a O RING,*ORDER2.003K(12PK)* a 2.003K O RING(12PK) 43 c TBD PROTECTOR,HOSE SWIVELVERSION2 44 c 7894 VALVEHOUSING,W/INSERT SWIVELVERSION2 SUPPORT:TOLL FREE: FAX: service@oceanicusa.com 17