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EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) EOS PNEUMATICALLY BALANCED SECOND STAGE PRODUCT SERVICE PROCEDURE This Service Procedure conveys a list of components and procedures that reflect the EOS second stage as it was configured at the time of this writing (10/3/10). SUPPORT: TOLL‐FREE: 800‐435‐3483 | FAX: 510‐569‐5404 | EMAIL: service@oceanicusa.com...
EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) CONTENTS TROUBLESHOOTING………………………………………………………………………………………………………………………………….………………………..3 DISASSEMBLY PROCEDURE…………………………………………….………………………………………………………………………………….……………….4 REASSEMBLY PROCEDURE…………………………………………………………………………………………………………………………………………………..7 FINAL ADJUSTMENT AND TESTING………………………………………………………..…………………………………………………………….…………...11 PARTS LIST AND EXPLODED VIEW…………………………………………………………………………………………………………………………………..…15 GENERAL PROCEDURES REFER TO GENERAL SERVICE PROCEDURE……………………………………………………………………………………….….DOC. NO. 12‐2202‐r02 ______________________________________________________________________________________________________ SPECIFICATIONS Torques Terminology PN 4787.2 Screw 3 to 4 in‐lbs IP Intermediate Pressure. PN 7099 Packing nut 11 to 13 in‐lbs IWC Inches Water Column (inhalation effort). PN 40.2122.030 LP Hose ...
EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE TREATMENT Demand Lever (28) bent. Replace Demand Lever (28). Excessive intermediate pressure. Readjust IP of 1 stage to Damaged or worn Poppet Seat (30). specification. Damaged Orifice (26). Replace Poppet Seat (30). Free flow or leak present with Orifice (26) incorrectly adjusted. Replace Orifice (26). Adjustment Knob (20) turned fully LP Hose (39) not tightened onto Valve Readjust Orifice (26) (refer to Final out counterclockwise. Housing (27 or 44) inlet tube. Adjustment section). Trapped sand or debris. Torque LP Hose (39) to Score inside sealing surface of specification. Adjustment Tube (11). Remove sand or debris and clean. ...
EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) DISASSEMBLY PROCEDURE NOTE: Be sure to perform the steps outlined in the General Service Procedure (Doc. No. 12‐2202‐r02) prior to disassembling the Eos second stage. Review the Troubleshooting section on page 3 to better understand which internal parts may need replacing, and to better advise the customer of the service required. Carefully snip the Tie Wrap (7) (schedule A) on the Mouthpiece (8); remove Mouthpiece (8) and inspect for holes, tears or deformation. Discard if any found. ...
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EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) NOTE: Do not remove the Spring Follower (16) from the Adjustment Shaft (17) unless it is damaged and needs replacing, or debris needs to be removed to clean it. In this case, remove by turning the Spring Follower (16) clockwise while holding the Adjustment Shaft (17) in your other hand. Note that the thread is left handed. 12. The Poppet Spring (15) is schedule A, discard and do not reuse. (Fig. 5). Fig. 4 Fig. 5 Fig. 6 13. Remove the Valve Housing Nut (36) with a 13/16” open end wrench by turning counter clockwise (Fig. 6). 14. Carefully push the Valve Housing/Adjustment Tube Assembly out through the Housing (6), being careful not to damage the Demand Lever (28) and set aside (Fig. 7). 15. Remove the Ratchet Detent (41) and O‐ring (42) with a small flat blade screwdriver; discard and DO NOT REUSE (schedule A) (Fig. 8). 16. Slide the Venturi Tube Switch (35) off the Adjustment Tube (11). Remove the Venturi Tube Switch O‐ring (34) by pinching the o‐ring and rolling off (Fig. 9); inspect for any damage and discard if found. Fig. 7 ...
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EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) NOTE: It is not necessary to remove the Demand Lever (28) unless it is damaged. The Valve Housing (27 or 44) may be cleaned with the Demand Lever (28) attached. 21. Remove the Valve Housing O‐ring (29) by squeezing it with your fingers. Examine the O‐ring (29) for damage; discard if found. 22. If the Poppet (31) did not come out with the removal of the Adjustment Tube (11), push the poppet out through the Valve Housing (27 or 44) with cotton swab (Fig. 12). Fig. 10 Fig. 11 Fig. 12 Remove the Poppet Seat (30) with your fingers and discard (schedule A); DO NOT REUSE (Fig. 13). 24. Remove the Poppet O‐rings (32, 33) by squeezing them with your fingers and working them over the end of the Poppet (31) (Fig. 14). DO NOT use a dental pick or any tool to remove them. Discard the O‐rings (32, 33) (schedule A) and DO NOT REUSE. 25. Using a narrow flat blade screwdriver, carefully remove the Orifice (26) by turning it counter clockwise in the Valve Housing (27 or 44) until the threads disengage. Once the threads are fully disengaged, press out the Orifice (26) with a cotton swab. (Fig. 15) Remove the Orifice O‐ring (25) and discard (schedule A); DO NOT REUSE. Fig. 13 ...
EOS SERVICE PROCEDURE 12-2810-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. 12‐2202‐r02). Inspect all critical sealing ...
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EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) Lubricate and carefully work the Valve Housing O‐ring (29) onto the plastic portion of the Valve Housing ( ) tube until seated into the groove. If the Demand Lever (28) was removed, reinstall by holding the Valve Housing (27 or 44) with the small flat molded onto the plastic part of the housing tube facing upwards. Carefully insert one leg of the Demand Lever (28) without excessively bending it into the square broached hole on one side of the Valve Housing (27 or 44) tube (Fig. 20); pull the opposite leg of the Demand Lever (28) outwards and insert the end into the square broached hole in the opposite side of the Valve Housing (27 or 44) tube. The Demand Lever (28) should now rest on the flat molded on top of the housing tube; this will insure that the square aspirator hole on one side of the tube will face the mouthpiece opening inside the Housing (6). Lightly lubricate and install the Adjustment Tube O‐ring (12) onto the narrow groove in the middle of the Adjustment Tube (11) (Fig. 21). Lightly lubricate and install a new Balance Shaft O‐ring (13) into the small opening of the Adjustment Tube (11) by pressing it into place with the narrow end of the Poppet (31) shaft. Remove the Poppet (31) shaft and look into the small opening of the Adjustment Tube (11); you should be able to see clear through. If not, remove o‐ring and reinstall until correctly seated. Inspect and install a new Poppet Seat (30) onto the Poppet (31), large flat end facing out until it is fully seated and flush with the edge of the Poppet (31) (Fig. 22). Examine the hole in the center of the Poppet Seat (30) to insure that it is clear and not plugged. Do not use any adhesive or lubricant. Fig. 22 Fig. 23 Fig. 24 10. Lightly lubricate and install both Poppet O‐rings (32, 33) into the narrow grooves of the shaft of the Poppet (31) (Fig. 23). ...
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EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) CAUTION: Failure to align the components precisely as described may prevent the Poppet (31) from engaging the legs of the Demand Lever (28) rendering the unit inoperable. 12. Install the Adjustment Tube (11) onto the Valve Housing (27 or 44) by screwing it on counter clockwise; the thread is left handed. Insert a 5/16” hex driver attached to a calibrated torque wrench into the Adjustment Tube (11) and torque counter clockwise to 16‐17 in/lbs while holding the square end of the Valve Housing (27 or 44) with an 11/16” open end wrench (Fig. 26). 13. Insert the Valve Housing/Adjustment Tube Assembly through the round hole of the Housing (6) while depressing the Demand Lever (28) (Fig. 27) and push until fully seated; the square broach of the Valve Housing (27 or 44) will engage the square hole of the Housing (6) and the Demand Lever (28) will face upwards (Fig. 28). 14. Install the Valve Housing Nut (36) onto the Valve Housing (27 or 44) by turning clockwise with an adjustable crows foot wrench attached to a calibrated torque wrench and torque to 25‐27 in/lbs (Fig 29). Fig. 28 Fig. 29 Fig. 30 15. Install the Venturi Tube Switch O‐ring (34) on the groove of the Venturi Switch (Fig. 30). 16. While holding the Housing (6) facing up, install the Venturi Tube Switch (35) onto the Adjustment Tube (11) and into the Housing (6) (Fig. 31). 17. The components of the Adjustment Shaft (17) assembly must be first assembled prior to installation into the Adjustment Tube (11). Lightly lubricate and install the Adjustment Shaft O‐ring (18) onto the groove on the Adjustment Shaft (17). ...
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EOS SERVICE PROCEDURE 12-2810-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 11‐13 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. ...
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EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) 26. Install the Diaphragm (5) into the Housing (6) with the raised center facing up and the smooth strike plate facing the Demand Lever (28). Examine the raised lip or the Diaphragm (5) edge to insure it is fully seated into the groove at the base of the threads of the Housing (6). (Fig. 37). 27. Install the Diaphragm Washer (4) on top of the Diaphragm (5) making sure it lays flat (Fig. 38). 28. Thread the Diaphragm Retainer (3) clockwise until snug; torque to 11‐12 in/lbs (Fig. 39). 29. Install the Front Cover (2) into the Front Cover Ring (1); notice that the Front Cover (2) has two small tabs, one on each side that fit into the rectangular slots in the threaded portion of the Front Cover Ring (1) (Fig. 40). Check that the logos are correctly oriented (Fig 41). Fig. 40 Fig. 41 30. Install the Front Cover /Ring Assembly into the housing by turning clockwise until fully seated and secure. Logo should be aligned along the centerline of the Housing (6). Do not cross thread while installing. Do not over tighten. NOTE: For step 31, ONLY USE Swivel Washer (24) with Valve Housing (27, Swivel Version 1). For Swivel Version 2 follow everything except installation of said Swivel Washer (24). See Exploded View Diagram for a further detailed view of both versions. 31. Lightly lubricate the Swivel Washer (24) and install into the opening of the Valve Housing (27 or 44) flat side in, concave side facing out (Fig. 42). Lightly lubricate and insert the Swivel O‐ring (37) next to the Swivel Washer (24) ...
EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) FINAL ADJUSTMENT AND TESTING NOTE: Adjustment and testing of the Eos second stage is done with an inlet Intermediate Pressure of 140 psi (+/‐ 3 psi) and supply pressure of 3000 psi. Connect the second stage LP Swivel Hose (39) to a LP Port of a properly adjusted first stage; connect a LP QD Inflator Hose to another LP port. Install port plugs to seal all the other ports of the first stage. Connect the first stage to a pure supply air source of 3000 psi (207 BAR). Connect a calibrated Intermediate Pressure Gauge to the LP QD Inflator hose (make sure that there is an overpressure relief device connected to the IP Gauge to relieve pressure in excess of 175 psi). Slowly open the supply valve to pressurize the regulator, purging the second stage several times to cycle the first stage to stabilize the IP (Fig. 44). Check the IP Gauge to insure that the intermediate pressure is 140 psi (+/‐ 3 psi). NOTE: If the Intermediate Pressure is other than recommended, readjust the first stage IP to specification. If necessary, refer to the Trouble Shooting section of the first stage to determine possible cause and resolution. Fig. 44 Fig. 45 Prior to Adjusting the second stage, check the following items: The Front Cover/Cover Ring (1, 2) on tight and secure; the Adjustment Knob/Cover (21, 23) is turned out fully counter clockwise until stopped; the Venturi Tube Switch (35) is set negative (switch lever towards mouthpiece tube); the mouthpiece has been removed. CAUTION: To avoid cutting the Poppet Seat (30) with the knife edge of the Orifice (26), always depress the Front Cover (2) while adjusting the Orifice (26); failure to do so will result in damaging the Poppet Seat (30), requiring its replacement. Lever Height Adjustment: If available, attach an Inline Adjustment Tool between the second stage and the LP Swivel Hose ( ) to adjust the lever height (Fig. 45). Pressurize the regulator and listen to determine that no air flow is present; if none present, engage the slotted head of the Orifice (26) with the Inline Adjustment Tool and turn the Orifice (26) counterclockwise in small increments while depressing the Front Cover (2) until a slight leak is present. ...
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EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) Pressurize the regulator again and listen for leaks or air flow; none should be present. If a leak is present, repeat steps 3 through 5. Hold the second stage with the Front Cover (2) facing downwards; gently shake up and down, listening for any rattle sound indicating excessive lever slack. If a rattle sound is found, readjust the Orifice (26) as outlined in steps 4 and 5. Inhalation Effort Test with Magnehelic Gauge & IP Gauge: Attach the correctly adjusted second stage to a *Magnehelic Gauge via the mouthpiece adapter; slowly inhale on the mouthpiece while watching the IP Gauge. The moment the needle of the IP Gauge moves left from 140 psi indicating the precise moment the first stage has opened, look at the Magnehelic Gauge and record the Inhalation Effort in Inches Water Column (IWC); this is also referred to as Cracking Effort. Inhalation Effort is not to exceed 1.2 IWC. *(Magnehelic is a registered trademark of Dwyer Instruments). Fig. 46 10. Inhalation Effort Test with Flowmeter: Attach the correctly adjusted second stage to a flow meter that is connected to a Magnehelic Gauge via the mouthpiece adapter (Fig. 47). Initiate airflow through the flow meter with the needle valve while watching the IP Gauge. The moment the IP Gauge needle moves left from 140 psi indicating the precise moment the first stage has opened, look at the Magnehelic Gauge and record the Inhalation Effort in IWC. Inhalation effort is not to exceed 1.2 IWC. NOTE: If the inhalation effort is greater or less than specification, refer to the Trouble shooting section on page 3 to determine the possible cause and resolution. ...
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EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) 12. Install the protector cap on the first stage yoke retainer and tighten down with the yoke screw. Making sure that all other ports on the first stage are sealed close, lightly inhale on the second stage to determine vacuum integrity; you should not be able to draw air through the second stage. If you can, refer to the Trouble Shooting section on page 3 to determine the possible cause and resolution. 13. Check all fittings to insure none are loose and are correctly torqued before returning the regulator to the customer. SUPPORT: TOLL‐FREE: 800‐435‐3483 | FAX: 510‐569‐5404 | EMAIL: service@oceanicusa.com...
EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) SERVICE PARTS KITS P/N DESCRIPTION NOTES 40.6166 KIT, SVC, EOS 2ND STG, SWIV DOCUMENTS P/N DESCRIPTION NOTES 1 2.2210 PROCEDURE, SVC, EOS www.OceanicNet.com (FREE) 1 2.2201 PROCEDURE, ADMINISTRATION www.OceanicNet.com (FREE) PROCEDURE, REGULATOR 1 2.2202 www.OceanicNet.com (FREE) GENERAL SUPPORT: TOLL‐FREE: 800‐435‐3483 | FAX: 510‐569‐5404 | EMAIL: service@oceanicusa.com...
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EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) COMMENTS N UMBER BOX Numbers in boxes represent Schedule A Parts, included in Service Kit N OTICE This document for identification and parts ordering only O RINGS Unless specifically listed, O‐rings are only offered in 12 packs to minimize costs N LA, NA No Longer Available; Not Available N S Not Shown D PL See Dealer Price List EOS SECOND STAGE DIA. CAT. P/N DESCRIPTION NOTES 1 c ...
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EOS SERVICE PROCEDURE 12-2810-R02 (10/3/10) 19 b 5054 WASHER, THRUST 20 c 7099 NUT, PACKING 21 c 7105.07 KNOB, ADJUSTMENT 22 c 4787.2 SCREW, SOCKETHEAD 24 a 6959 WASHER, HOSE, LP SWIVEL ONLY for SWIVEL VERSION 1 25 a 2.010 O‐RING *ORDER 2.010K (12 PK)* a 2.010K O‐RING (12 PK) ...