Zeagle Octo-Z 320-7200YL Service Manual
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Zeagle Octo-Z 320-7200YL Service Manual

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IMPORTANT:
Read about the Octo-Z's
Bi-Annual
Visual Inspection / Service Schedule
Item 4.2 on Page 6
p/n 320-7200
Regulator Service Manual
For Zeagle Octo-Z Regulator/Inflator
Manual p/n 347-3020, Copyright 2008

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Summary of Contents for Zeagle Octo-Z 320-7200YL

  • Page 1 IMPORTANT: Read about the Octo-Z’s Bi-Annual Visual Inspection / Service Schedule Item 4.2 on Page 6 p/n 320-7200 Regulator Service Manual For Zeagle Octo-Z Regulator/Inflator Manual p/n 347-3020, Copyright 2008...
  • Page 2 This Service manual uses signal words recommended by the American National Standards Institute (see ANSI Z535.4) to designate levels of hazard seriousness. These signal words and their designations are as follows: DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.
  • Page 3 Octo-Z Parts Zeagle ITEM # PART # DESCRIPTION..Octo-Z Model: 320-7200YL (Yellow) 165-1127 Inflator HOSE Complete (27”) 342-7241 QD Fitting (attaches to any Scuba 2nd Stage Hose) Model: 320-7200BK (Black) 342-7216-AY Oval BUTTON (Yellow) 342-7216-AK Oval BUTTON (Black) 342-7226-AY Round BUTTON (Yellow)

  • Page 4: Table Of Contents

    Before You Begin ... Read these instructions completely before you begin servicing the regulator. These instructions are intended for people who have been AUTHORIZED by Zeagle to repair Zeagle Scuba equip- ment. If you are not so authorized - STOP.

  • Page 5: Introduction

    1.0.4 The best source for current part numbers for any of the parts listed in this manual is your current parts and price list from Zeagle. The best source for Service PROCEDURES though, is a SERVICE MANUAL like this one.

  • Page 6: Specifications

    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.

  • Page 7: Model Numbers

    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 320-7200BK Octo-Z, Regulator / Inflator Combination (color Black) 320-7200YL Octo-Z, Regulator / Inflator Combination (color Yellow) 310-1110 1st stage only, Flathead-VI Yoke 310-1120...
  • Page 8 O- Ring Identification Page (O-rings included in Kit # 345-7000) 160-2819-N7 (32) for stem of Inflate Valve (??) 160-4502-N7 (13) for stem of Deflate Valve 160-0010-N7 (3) for Orifice (Seat) (1) 160-0109-N7 (18) for Valve Tube (2) 160-0017-N7 (33) for Inflate Valve Cap (35) 160-0114-N7 (20) for Corrugate Hose Coupling (21) Print this page out, so you can lay the O-rings from Kit 345-7000 on the page for easy identification.

  • Page 9: Service Procedures For The Octo-Z

    SERVICE PROCEDURES FOR THE ZEAGLE Octo-Z 4.0.1 Before you begin disassembly of the Octo-Z, attach it to a 1st stage and test it for function and leaks . Pre-testing in this way will help the technician to pinpoint any specific problems requiring repair.

  • Page 10: Visual Inspection Procedures

    5.0.0 VISUAL INSPECTION PROCEDURE 5.0.1 Visually inspect the exterior of the Octo-Z and its inflator hose, looking for cracks, tears or defects in the materials that would negatively affect the function of the Octo-Z. If any are found that are not warranty related, inform the customer that the affected parts will have to be replaced.
  • Page 11 5.0.4 Replace the Purge Cover Assembly onto the Octo-Z. 5.0.5 Attach the Octo-Z to a BC using the Bx Coupling. 5.0.6 Orally inflate the BC with the Octo-Z by putting the mouthpiece in the mouth and exhaling while depressing the oval Deflate/Oral Inflate Button. Release the button between breaths. Check for smooth quiet action of the oval button.

  • Page 12: Disassembly Of The Octo-Z

    345-7000 Service Kit will replaced no matter their condition at no cost to the owner IF they are the original owner, bought it at an authorized Zeagle Dealer and have it serviced/ inspected annually. The 345-7000 Kit is not provided for the bi-annual Visual Inspections. If the...
  • Page 13 6.1.4 Use a slotted screwdriver to loosen and remove the Inflate Valve COVER (32) from the BODY (25). 6.1.5 Hold the round Inflate BUTTON in place with one finger, while loosening the Sealing NUT (29) with a slotted screwdriver (See Photo 5) Photo 5 6.1.6 When the NUT (29) is disengaged from the threads of the Inflate Shaft (4), remove the Inflate BUTTON assembly (4), and SPRING (5), from one side of the BODY (25) and the NUT (29) from the other side.
  • Page 14 6.1.8 Remove the Valve GRATE (41) from the BODY (25) by turning the GRATE counter-clockwise. 6.1.9 Temporarily flip the edges of the EXHAUST VALVE (40) to expose the legs of the Valve SUPPORT (39) underneath. Use your fingers or needle nosed pliers to turn the Valve SUPPORT counter-clockwise until it is out of the BODY (25).
  • Page 15 6.1.13 The Selector VALVE (36) is removed from the BODY (25) by passing it through the opening that usu- ally holds the Front Cover. (See Photo 9). For later reassembly, notice when you remove it that it is properly oriented when the silver imbedded washer is facing up. Photo 9 Photo 10 6.1.14...
  • Page 16 6.1.15 Use a flat bladed screwdriver to remove the Cir-Clip (8) that holds the QD Tube (16) in the BODY. (See Photo 11) Photo 11 6.1.16 To remove the QD Tube (16) assembly from the BODY (25), push the tip of the QD against a hard surface.
  • Page 17 6.1.17 While removing the QD Tube, look into the open end of the body and notice that the Lever (20) is indexed into its proper position by engaging the flat part of the Lever Support (22) with three raised flanges in the Body that form a flat ledge for the Lever Support.
  • Page 18 6.1.19 Use a 3/16” Allen Wrench to remove the Seat (14) from the Lever Support (22). Carefully remove the O-ring (15) from the Seat taking care not to scratch the O-ring groove in the process. (See Photo 15) Photo 15 6.1.20 Carefully remove the O-rings (17) from the QD Tube (16) (See Photo 16) Photo 16...
  • Page 19 6.1.20 Use a sharp pick to pierce and remove the Seal (13) from the Poppet (12). (See Photo 17) Photo 17 6.1.21 DO NOT DISASSEMBLE THE LEVER SUPPORT ASSEMBLY BEYOND THIS POINT! (See Photo 18) To make the technician’s job much easier, it is important to avoid processes that are Photo 18...

  • Page 20: Cleaning And Inspection Of The Octo-Z

    6.2 CLEANING AND INSPECTING THE Octo-Z 6.2.1 Rinse all plastic 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. ! WARNING ! DO NOT use vinegar or other acid solutions on the plastic parts since this will cause the plastic to become brittle!

  • Page 21: Preliminary Assembly Of The Octo-Z

    7.0 PRELIMINARY ASSEMBLY OF THE Octo-Z 7.0.1 Ensure that all parts are clean. To determine the identity of each O-ring in the Octo-Z Service Kit, remove them from the bag and use the O-ring Identification Chart by printing out page 5 of this manual. After Printing the O-ring Identification page, lay each O-ring over its corresponding picture on the page and read the description.
  • Page 22 7.0.3 Install new lubricated O-rings(17), onto the QD Tube (16) and then screw the QD Tube into the Lever Support (22). Screw the two sections together until they are hand tight. This positioning will allow the as- sembly to slide properly into the Body (25). (See Photo 22) Photo 22 7.0.4 Insert the Lever/QD Assembly into the body.
  • Page 23 7.0.5 Install the Cir-Clip back into the proper groove on the QD Tube (16) using a flat bladed screwdriver. There are two groove on the QD Tube, The Cir-Clip must be installed into the groove farthest from the tip of the QD fitting.
  • Page 24 7.0.7 Before installing the Oval Deflate Button (3) into the body, it is important to understand that the shaft on the button assembly is not in the middle of the button. That means that sometimes the button will not fit properly into the hole in the Body.
  • Page 25 7.0.9 Install the Washer (28) and the Spring (26) on top of the O-ring. (See Photo 28) Photo 28 7.0.10 Install the Oval Button Assembly (3) properly oriented into the proper opening in the Body (25). Hold the Button, Spring, Washer and O-ring in place with one finger. Insert the Selector Valve (36) into the Body through the front opening.
  • Page 26 7.0.11 Use the finger on one hand to fully depress the Oval Button (3) so that the Button’s Stem passes through the center of the Selector Valve (36) and the Selector Valve is pushed firmly against the Exhaust opening. Use the other hand to place the new self locking Nut (37) over the Stem’s threads (See Photo 30) Photo 30 7.0.12 Use the 1/4”...
  • Page 27 7.0.13 The Exhaust Valve (40) does not have to be removed from the exhaust Valve Support (39) unless an inspection of the valve shows tears or if the valve does not return to the closed position quickly when flip- ping it from edge to edge. If the Valve is found defective, it would be replaced at this time with a new one. (See Photo 32) Photo 32 7.0.14 Install the lightly lubricated Flat Gasket (38) into the exhaust opening.
  • Page 28 7.0.15 Install the Exhaust Valve Assembly into the exhaust opening of the Body (25). Position the Exhaust Valve Assembly with the nipple facing into the body. (See Photo 34) Photo 34 7.0.16 When the Exhaust Valve Assembly touches the Flat Gasket (38) at the bottom of the exhaust open- ing, flip the Exhaust Valve (40) out of the way and use your fingers to tighten the Exhaust Valve Assembly about another 1/4 turn (See Photo 35) Photo 35...
  • Page 29 7.0.17 Install the exhaust Valve Grate (41) on top of the Exhaust Valve Assembly. When you feel the ex- haust Valve Grate touch the Exhaust Valve Assembly underneath, turn the exhaust Valve Grate about 1/4 more turn clockwise. (See Photo 36) Photo 36 7.0.18 Install the new O-ring (30) from the Service Kit into the groove in the Body where the Inflate Cover (32) seals.
  • Page 30 7.0.19 Install the two new O-rings (6) onto the stem of the Inflate Button (4). Insert the Inflate Button and Spring (5) into the proper opening in the Body (25). (See Photo 38) Photo 38 7.0.20 Use the finger on one hand to fully depress the Round Button (4). Use the other hand to place the Sealing Nut (29) over the Stem’s threads (See Photo 39) Photo 39...
  • Page 31 7.0.21 Use a flat bladed screwdriver to tighten the Sealing Nut onto the Stem threads. Stop tightening the Nut as soon as you feel it bottom on the threads. (See Photo 40) Photo 40 7.0.22 Install the Inflate Cover (32) into the opening and use a flat bladed screwdriver or coin to tighten it. The threads of the Cap and Body are indexed so that after you feel the Cap meet the body, you can tighten it a little more to line the ribs in the Cap with the ribs in the Body (See Photo 41) Photo 41...

  • Page 32: Set-Up Of The Octo-Z

    7.0.23 When you look into the open end of the Octo-Z at this point, you may notice that the nipple from the Exhaust Valve (40) is bent and touching the Selector Valve (36) as it is depressed. This is normal. DO NOT CUT THE END OF THE NIPPLE! If you do, the stub of the Nipple will stick strait up, and then when you de- press the Oval Button and move the Selector Valve, you will feel a great deal of resistance.
  • Page 33 Note: Attach the Octo-Z Inflator Hose to a properly adjusted first stage that it is going to be used with, mount- ed on an air tank filled to between 2700 and 3500 psi. Install an intermediate pressure gauge into one of the low-pressure ports.
  • Page 34 7.2.3 If when the pressurized QD Hose is connected to the Octo-Z air is leaking from the Lever Assembly area, then the Seat (14) needs to be rotated Clockwise, to close the gap between the orifice in the Seat and the Seal (13) at the end of the Poppet (12).
  • Page 35 Photo 46 7.2.9 Press the Purge Cover (34) FIRMLY over the Diaphragm (35) with a rocking motion. Push the Cover inwards from the left and right as well as the top and bottom. You will hear as clicking sound as the Cover moves down into position.

  • Page 36: Testing Of The Octo-Z After Re-Building

    7.2.11 Install the Mouthpiece onto the mouthtube on the Body. Install and tighten the plastic Tie (24) that came in the Service Kit. Cut off any excess tab sticking out of the Tie with side cutting pliers. (See Photo 48) Photo 48 8.0.0 TESTING THE OCTO-Z AFTER REBUILDING After completed the bi-annual overhaul of the Octo-Z, the testing needed is the same as that performed dur-...
  • Page 37 B. LOW INHALATION EFFORT or AIR HISSING FROM LEVER SUPPORT ASSEMBLY: POSSIBLE CAUSE RECOMMENDED ACTION Refer to section 7.2 of this manual for the Octo-Z and also look at the 1st 1st or Octo-Z Stage Regulator’s Service Manual for the set up of the 1st Stage. Stage adjusted improperly 2nd stage...
  • Page 38 E. WET BREATHING: POSSIBLE CAUSE RECOMMENDED ACTION Diaphragm improperly installed or hole in Check position of diaphragm visually. diaphragm Replace if holes found by holding up to a light. Damaged or loose fitting exhaust valve Replace exhaust valve (40) Crack in housing (25) Replace housing Kinked Flat Gasket (38) Re-position or Replace Flat Gasket (38)

  • Page 39: Parts Cleaning Recommendations

    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. 11.0 PRE-DIVE CHECKS: 11.0.1 Check the hoses and hose connections for cuts, abrasions or other signs of damage...

  • Page 40: Warranty And Maintenance Information

    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...

  • Page 41: Scheduled Maintenance

    13.1.5 If a body or housing is replaced, the replacement parts may 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.

  • Page 42: Order Form (Sample)

    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.
  • Page 43 U. S. A. Zeagle Scuba, the Zeagle symbol, Octo-Z, 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.

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Octo-z 320-7200bk

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