Oceanic GT-3 User Manual
REGULATORS
GT-3 SECOND STAGE
OCEANIC
GT-3
SERVICE
PROCEDURE
®
This GT-3 Product Service Procedure conveys a list of components and service
procedures that reflect the GT-3 as it was configured at the time of this writing (2/19/05).
Doc. 12-2804-r01 (2/19/05)
© 2002 Design, 2005
PG-1
OCEANIC® Product Service Guide
REGULATORS
GT-3 SECOND STAGE
CONTENTS
TROUBLESHOOTING .................................................................................................................................................................2
DISASSEMBLY PROCEDURE ....................................................................................................................................................3
REASSEMBLY PROCEDURE .....................................................................................................................................................7
FINAL TUNING AND TESTING ...................................................................................................................................................8
PARTS LIST AND EXPLODED VIEW DIAGRAM ..................................................................................................................... 11
GENERAL PROCEDURES
REFER TO ...............................................................................................................................................................DOC. 12-2202
SPECIFICATIONS
Torques
P/N 4330 Inlet Coupling 100 to 120 in-lbs
P/N 4787.2 Adjust Knob Screw 4 to 5 in-lbs
P/N 6332 Packing Nut 11 to 13 in-lbs
LP Hose 50 to 60 in-lbs
Opening Effort (IP = 140 psi)
1. Leak with Adjustment Knob turned fully out (clockwise).
2. No leak with Adjustment Knob turned in (counter clockwise)
1-1/2 turns.
3. Minimum effort with no leak = 1.2 inches of H2O or less.
TOOLS REQUIRED
Standard Tools
Inch pounds Torque Wrench
1/4" Open End Wrench
3/4” Crows Foot Wrench
11/16” Crows Foot Wrench
Standard Screwdriver - small
Cotton Swab
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 40.9510 In-line Adjustment Tool
P/N 40.9520 O-ring Tool Kit
P/N 40.9650 Universal Front Cover Tool
© 2002 Design, 2005
PG-2
Doc. 12-2804-r01 (2/19/05)
OCEANIC® Product Service Guide
REGULATORS
GT-3 SECOND STAGE
TROUBLE SHOOTING
SYMPTOM POSSIBLE CAUSE TREATMENT
* Free flow or leakage present.
ADJUSTMENT KNOB (33)
turned in.
* Excessive inhalation resis-
tance. ADJUSTMENT KNOB
(33) turned out.
* Rattle heard inside Second
Stage.
1. LEVER ARM (17) bent.
2. Excessive intermediate pressure.
3. Damaged or worn POPPET SEAT
(14).
4. Damaged ORIFICE (11).
5. LOCK NUT (20) overtightened onto
POPPET (15) shaft.
6. WASHER (18) bent or distorted.
7. ORIFICE (11) incorrectly adjusted.
8. POPPET SPRING (16) worn or
weakened, or incorrect part.
9. INLET COUPLING (12) not sufficiently
tightened into HOUSING (4) Inlet
Tube.
10. Trapped debris.
1. LOCK NUT (20) overtightened onto
POPPET (15) Shaft, causing excessive
POPPET SPRING (16) tension.
2. LOCK NUT (20) insufficiently tightened
onto POPPET (15) Shaft, causing
LEVER ARM (17) slack.
3. LEVER ARM (17) bent.
4. ORIFICE (11) incorrectly adjusted.
5. Insufficient Intermediate Pressure from
First Stage.
1. Gravel or sand trapped inside
HOUSING (4).
2. LEVER ARM (17) slack present.
1. Replace with new.
2. Refer to First Stage Troubleshooting
Chart.
3. Replace with new.
4. Replace with new.
5. Replace with new and readjust.
(Refer to tuning section.)
6. Replace WASHER (18), SPACER
(19), and LOCK NUT (20) with new.
7. Turn in clockwise to adjust. (Refer
to tuning section.)
8. Replace with new.
9. Follow correct procedure given in
Reassembly Section to tighten.
10. Remove and clean.
1. Replace with new and readjust.
(Refer to Tuning Section.)
2. Tighten to correct Spring load and
Lever height. (Refer to Tuning
Section.)
3. Replace with new.
4. Adjust to correct contact. (Refer to
Tuning Section.)
5. Refer to First Stage Troubleshooting
Chart.
1. Remove and clean.
2. Tighten LOCK NUT (20) onto
POPPET (15) Shaft. (Refer to
Tuning Section.)
* Little or no airflow when Purge
Button is depressed.
* ADJUSTMENT KNOB (33)
difficult to turn.
* Water entering Second Stage.
© 2002 Design, 2005
1. FRONT COVER (2) not sufficiently
tightened into HOUSING (4).
2. LEVER ARM (17) slack present.
3. ORIFICE (11) incorrectly adjusted.
1. Debris or corrosion present on
ADJUSTMENT SHAFT (29).
2. Debris present inside ADJUSTMENT
KNOB (33).
3. Debris or corrosion present on
ADJUSTMENT SPRING (27).
1. Tear in MOUTHPIECE (8).
2. EXHAUST VALVE (6) distorted or
damaged.
3. DIAPHRAGM (3) distorted or damaged.
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 (7) loose or
missing.
PG-3
1. Tighten COVER RING (1) until
secure.
2. Tighten LOCK NUT (20) onto
POPPET (15) Shaft. (Refer to
Tuning Section.)
3. Adjust ORIFICE (11) to correct
contact. (Refer to Tuning Section.)
1. Disassemble and clean.
2. Flush out or disassemble if
necessary to clean.
3. Disassemble to clean or replace
with new if necessary.
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.
Doc. 12-2804-r01 (2/19/05)
OCEANIC® Product Service Guide
REGULATORS
GT-3 SECOND STAGE
DISASSEMBLY PROCEDURE
NOTE: Be sure to perform the steps outlined in the Initial
Inspection Procedures (Doc. 12-2202) prior to disassembling 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 (7) that holds the MOUTHPIECE (8), and
remove the MOUTHPIECE. Inspect the condition of the MOUTHPIECE to ensure that it is supple and free of any tears or
corrosion. Discard if found.
2. Remove the Hose from the Second Stage, using an 11/16" open
end wrench, while holding the Hex portion of the INLET COUPLING (12) secure with a 3/4" open end wrench.
3. Remove the COVER RING (1) using a universal Front Cover tool
if necessary, and remove the FRONT COVER (2) to expose the
DIAPHRAGM (3).
Fig. 1
4. Grasp the DIAPHRAGM (3) by the Raised Edges of the Center,
and lift with a slight upward twist to remove. Inspect the
DIAPHRAGM to ensure it is supple and free of any tears,
corrosion, or other distortion. Discard if found.
5. Depress and hold the LEVER ARM (17) to remove the INLET
COUPLING (12) in a counter clockwise direction, using a 3/4"
open end wrench (Fig. 1).
6. Remove the COUPLING O-RING (13) from the INLET COUPLING (12) and inspect for any signs of decay. Discard if found.
7. Using a narrow slotted blade screwdriver, remove the ORIFICE
(11) by turning it counter clockwise inside the INLET COUPLING
(12). When it has disengaged completely from the threads,
press it out with the use of a cotton swab (Fig. 2).
Use caution to avoid nicking or scratching the delicate Knife
Edge of the ORIFICE as this is done.
Remove and discard the ORIFICE O-RING (10). 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.
Fig. 2
Fig. 3
8. While holding the POPPET (15) secure with the Poppet Tool,
loosen the LOCK NUT (20) by turning it counterclockwise using
a Modified 1/4" Open End Wrench (Fig. 3).
9. Using the Poppet Tool, push the POPPET (15) inward in the Inlet
Tube of the HOUSING (4), compressing the POPPET SPRING
(16), and carefully remove the LEVER ARM (17) (Fig. 4).
© 2002 Design, 2005
PG-4
Fig. 4
Doc. 12-2804-r01 (2/19/05)
OCEANIC® Product Service Guide
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