5.5 SET- UP OF THE SECOND STAGE
For the following adjustments, the cover and diaphragm must be removed.
5.5.1 Turn the spring adjust knob plug (29) out counter-clockwise all the way. IF the regulator is to be used
as an Octopus unit, then turn the adjust knob plug (29) back in clockwise one turn.
5.5.2 Install the new O-rings (31,33) onto the hose assembly (30). Install the hose between a serviced first
stage and the second stage, tighten snugly. Use two wrenches to tighten the second stage hose connec-
tion.
Note
: Attach the second stage to the overhauled and properly adjusted first stage that it is going to be used
with, mounted on an air tank filled to the maximum pressure the regulator is going to be used with. Install an
intermediate pressure gauge into one of the low-pressure ports.
5.5.3 Carefully turn the air on. After adjusting the second stage as outlined in assembly step 5.4.24 in this
manual, the lever (19) should be should be slightly loose against the “L” shaped foot of the shuttle valve
assembly. See Photo # 9. There should be about 1/8” (3.2 mm) of free play at the end of the lever. There
should be no air leaking from the second stage with proper intermediate pressure applied to the hose. If
there is air leaking from anywhere on the second stage, correct the problem before going further. The best
test to check for the slightest leaks is to immerse the second stage (with no cover or diaphragm installed)
under pressure in water and look for bubbles indicating a leak. Correct the problem if leaks are found. See
Troubleshooting section 6.1 for help.
5.5.4 Work the lever up and down a few times while the regulator is pressurized. Each time the lever is
released, no air hissing should be heard.
5.6 FINAL ASSEMBLY OF THE SECOND STAGE
5.6.1 Install the diaphragm (4) into the housing (10) so that it sits evenly on the ledge.
5.6.2 Install the diaphragm cover (3) over the diaphragm. The diaphragm cover (3) is the best tool to align the
diaphragm into the body. Push the cover firmly over the diaphragm so the diaphragm is seated properly.
5.6.3 Install the purge dome (2) into the cover ring (1).
5.6.4 Screw the purge dome and cover ring into housing. Adjust the purge dome in the cover ring so that
the Zeagle logo sits properly when the cover ring is tightened firmly hand tight. If the Zeagle “Z” logo is not
straight, it can be easily aligned using one side of the Cover Ring Removal/Alignment Tool p/n 347-1005.
5.6.5 Install the mouthpiece (12). Be sure to position the mouthpiece so that the overbite where the top teeth
fit, is on the top.
5.6.6 Install the new mouthpiece tie (11) from the service kit. Position the tie lock on the side of the mouth-
piece. Tighten the tie securely and cut off the excess.
! WARNING !
NEVER
tighten the hose with more than 40 in. lbs. (4.5 Nm) of torque. The inlet hose fitting can be
weakened by over tightening.
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