1. The Forum Rules have undergone some minor changes and updates.  Please take the time to read them; it will only take a couple of minutes of your time. By doing so, you lessen the chance of incurring the wrath of the moderation team or making yourself look foolish to other members.

    90% of users posting adverts in the Sales forums need to be reminded to read the rules as their posts are wrong.  This is unnecessarily time-consuming and will no longer happen - if your advert doesn't follow the Sales Rules it will be deleted and you'll have to start all over again.

    To close this box once you've read it (and the Rules), click on the X in the top right-hand corner.

    Thank you.

    AGF Staff



    Dismiss Notice
  2. A reminder of one of the Forum Rules:

    'Behaviour

    Do not make inappropriate or offensive posts - including threats, harassment, swearing, prejudice, defamation, deliberate insults or name-calling, other negative remarks about this forum, its moderators and administrators or your fellow members. Even if this is just your own personal opinion, RESPECT YOUR FELLOW MEMBERS.'

    There have been changes made to our censoring software in an attempt to help with this growing problem.

    Click the X in the top-right-hand corner to dismiss this notice.
    Dismiss Notice
  3. Dear members,

    Our membership (like our country) consists of people from all walks of life; different in far more ways than can be listed here and each with a different view based on their experience of life - regardless of their colour, religion or cultural heritage. Every single person in the UK has been born of mixed race – we are a multi-coloured and multi-cultural country.

    As many of you are aware there are a handful of individuals amongst this membership that persist in making provocative, inflammatory, racist and otherwise offensive comments. This has been happening across the forum to a certain degree but is most especially prevalent in the Adult section.

    The moderation team has tried to stay on top of this, however unfortunately because of the ‘offensive’ nature of much of its content we don’t monitor the Adult section quite as much as perhaps we should. As a result much of this behaviour has gone unnoticed unless it has been reported to us. While the team always intended to take a "light touch" approach to the Adult section it would seem that some people aren’t quite adult enough to be left unmonitored after all.

    This behaviour is, and always has been against Forum Rules as well as the specific stipulations of the Adults forum and it will no longer be tolerated. We feel it's time to draw a line in the sand and as such from this point onward offenders will receive an immediate and permanent ban from the forum.

    In order for us to achieve our goal of restoring the forum to the friendly and tolerant place it once was, we ask that ALL members be mindful of the content they post and help us to stop unacceptable behaviour by using the 'Report' tool at the bottom of any offending post - the results of which can be seen only by Admin/Moderators.

    You should all receive a copy of this message by PM. 

    To close this message box, click on the 'X' in the top-right-hand corner.

    Dismiss Notice
  4. Hotmail block emails from us entering your inbox. Unless you can setup a safe sender you will not get activation emails from the forum. Please use an alternative provider or complain to Hotmail.
    Hotmail addresses include.

    @Hotmail.co.uk @Hotmail.com @outlook.com @Live.com
    Dismiss Notice
  5. Postings on Politics, Religion & Controversial Off-Topic Material

    The majority of users do not want to read about these subjects and people have left the forum as a result of it – this is after all an 'Airgun' Forum. It’s all very well to say they don’t have to read it if they don't want to, but as most of us use the ‘New Posts’ button there is no easy way to avoid it.

    All AGF staff members are in favour of people being able to discuss what they want, but we have to draw the line somewhere if it is upsetting other users. We don’t want to read about these topics either.

    IMPORTANT- The discussion of politics and religion is no longer allowed anywhere on the forum (including the Adult section).  The only exception is if it's airgun related - they must be put in the Airgun Related Politics section..

    We will not tolerate bullying or personal attacks, racism or any other offensive 'isms'. we will remove these topics from the forum, we will not give you an area where you can abuse each other. We will not hesitate to ban offenders.

    To clear this text box, click on the 'X' in the top right-hand corner.

    Dismiss Notice

Zbroia Kozak/hortitsia Leak Diagnosis And Fix (pic Heavy)

Discussion in 'Technical' started by RichieRich, Apr 20, 2019.

  1. RichieRich

    RichieRich Ping!

    Messages:
    5,331
    Likes Received:
    3,395
    Location:
    County Durham
    Howdy all!

    To save you the time, wits, and the ball-ache, I am writing this little guide on how to find the leak on your Zbroia Kozak. This may well apply to the Hortitsia, however, i have not seen one of these so i can only advise approaching with caution.

    Please only attempt this if you are comfortable working on your rifle, and please bear in mind, any work you undertake yourself may void your warranty. Neither myself or the Airgun Forum are responsible for any damage you may cause to your rifle, or injury to yourself.

    Safety Warning: Compressed Air can kill or injure. Please take extreme caution when working on a PCP rifle, and ensure it is fully discharged of all air before proceeding to disassemble a cylinder shown later in this guide.

    You will need:
    Silicone Grease (Most dive shops sell this)
    Sink full of cold water
    Replacement O-Rings (I bought these)
    Small allen key
    Phillips screwdriver (PH1 size if you are using a screwdriver with removable bits)
    KStKc.png


    Finding the leak

    To start the procedure, first unscrew the cylinder from your rifle, taking care not to knock the valve stem on the way out. Then remove the filler protective cap to expose the filler hole and gauge.

    Cylinder.jpg

    Next, we will use water to test where the leak is coming from. In my email from Zbroia, they advise putting the cylinder in water to see where it leaks, so this is perfectly safe to do. Just ensure you are able to dry the cylinder surfaces and fill area thoroughly afterwards.

    Step 1:
    Dip the firing valve end in first. If you have bubbles emerging here, Get in touch with the RFD you bought it from. As the Regulator is at this end of the cylinder, it would be best for the RFD to get this sorted for you under warranty.

    Step 2:
    If you are able to, dip the regulator breather hole, which is on the side of the cylinder around 3 inches from the firing valve. (you may require a bath to do this, no not a wash :rolleyes:). If you have bubbles emerging repeatedly from here, it requires a trip to the RFD for repair as it may need a full stripdown and pressure setting again. You could use the opportunity to replace the regulator for a Huma/Lane, which is covered in this guide HERE.

    Step 3:
    Dip the filling end of the cylinder into the water. Here, there is 3 places that Air can emerge from in the pic shown below.

    A: Gauge leak. Possible oring failure/incorrect size (see this post), and contact your RFD.
    B: Valve block/cylinder leak. Oring failure or debris on sealing surface.
    C: Fill valve oring. Requires replacement.

    Filling.jpg

    If you are not comfortable fixing your leak, you can finish here, and notify your RFD where the leak is coming from. This should hopefully help expedite the repair process now they know what to fix for you.
    Here ends your quest!



    If you wish to progress further and repair yourself....
    Firstly, make sure you have the required items at the top of this post. The remainder of this guide only covers the filler valve block repair.

    To start off, Dry-fire your rifle until the cylinder is empty. Then unscrew it from your rifle.
    Press the firing valve stem sideways (silver rod sticking out, see below) to release any remaining air inside. (Its quite important you do not do this with a full cylinder. Just google Compressed Air Injury to see why this is a bad idea)
    Firing.jpg

    At this point, you can unscrew the fill valve block by hand. If it is not moving, you can use your spare fill probe to gain a better grip on the valve block to unscrew it from the cylinder.

    Once removed, place the cylinder to one side, and clean any grease/crap/debris from the valve block.


    TO FIX LEAK B
    Remove the oring (arrowed in pic below) from the valve block, taking care not to scratch or gouge the block surface.
    Clean the surface and apply a small bead of silicone grease in the oring groove. Then install and grease the oring. For refitting, see section below "Fitting the valve block" as another step is required.
    Valve Block Complete.jpg


    TO FIX LEAK C

    Step 1:
    Using the allen key, place it into one of the 4 holes shown, and proceed to unscrew the silver cap. Underneath this, is a gauze filter, which needs removing.
    Fill 1.jpg


    Step 2:
    Note the depth of the second cap. Unscrew the second silver cap, noting the recess in the middle. Both caps have this and need to face each other on re-assembly.
    Fill 2.jpg

    Step 3:
    Using the phillips screwdriver, unscrew the filler valve from the block and set the screw aside.
    Fill 3.jpg

    Step 4:
    Clean the valve sealing surface thoroughly and inspect for debris or damage. You can for good measure, insert your fill probe and connect to your tank to give the block a quick blast of air to dislodge any debris that may be inside the block before the valve.
    Fill 4.jpg

    Step 5:
    Clean the screw thoroughly and ensure there is no debris on the angled section of the screw head. apply a dab of silicone grease to this surface, then install a new oring onto the screw. Grease the oring, then install back into the valve block. Take care not to overtighten the screw, just needs to be nipped tight.
    Fill 5.jpg

    Step 6:
    Re-install the caps and filter in reverse steps 2 then 1, ensuring the outer cap is flush with the end of the valve block. For refitting, see below, as another step is required.


    REFITTING THE VALVE BLOCK

    Step 1:
    Clean the inner threads of the cylinder, and the flat sealing surface inside at the end of the thread. You may need 2 or three attempts to ensure this surface is debris free.

    Step 2:
    Apply a coating of silicone grease to the sealing surface inside the cylinder. Also apply very lightly to the cylinder thread.

    Step 3:
    Insert the valve block and screw in until the filler hole gap ring reaches the edge of the cylinder. At this point you can re-insert the cylinder into the rifle. Once re-inserted, you can let your OCD take over and screw the valve block in the remainder of the way allowing the gauge to be the correct orientation. Make sure at this point that your fill probe can be inserted, otherwise, unscrew until it has sufficient clearance.
    Valve 1.jpg Valve 2.jpg

    Step 4:
    Fill your cylinder VERY SLOWLY to full pressure. This is just a precaution to ensure that your new oring will not overheat from a fast fill from empty.

    Step 5:
    Once filled, remove the cylinder from the rifle and follow the "Finding the leak" process at the beginning of this guide again to make sure there is no further leaks and you have resolved the issue. Thoroughly dry the cylinder and pop the valve protective cap back on. Re-insert the cylinder into the rifle.

    THATS IT! YOU ARE DONE!

    Please note, that while your cylinder begins to settle from it's fill from empty, it is normal to see a slight drop in pressure. Just top it back up again after it has settled for a few hours.
     
    Last edited: Aug 12, 2019
    32:1, sagalout, rathunter and 24 others like this.
  2. billy.whizz

    billy.whizz Posting Addict

    Messages:
    1,342
    Likes Received:
    1,356
    Location:
    Cornwall
    Richierich, thank you for taking the time and trouble too help out the guys o the forum who have problems with leaks . its guys like you who make this forum what it is.enjoy your new leak free rifle.
     
    RichieRich and Marky-Boy like this.
  3. Jukebox

    Jukebox Better to burn out...than to fade away.

    Messages:
    5,063
    Likes Received:
    9,326
    Location:
    Cannock
    Bravo sir.....absolutely awesome write up that even a Wally like me could follow.
    Love this forum and its members :thumb:
     
    billy.whizz, RichieRich and Marky-Boy like this.
  4. topcat666

    topcat666 Engaging Member

    Messages:
    152
    Likes Received:
    144
    Location:
    Durham
    Impressed by the time and effort put in to the subject by the OP.
    Many thanks.
     
    billy.whizz and RichieRich like this.
  5. RichieRich

    RichieRich Ping!

    Messages:
    5,331
    Likes Received:
    3,395
    Location:
    County Durham
    No worries Chaps. Happy to help out others in their endeavour for leak free shooting :)
     
    billy.whizz likes this.
  6. TR158

    TR158 Keyboard Hero

    Messages:
    2,122
    Likes Received:
    3,661
    Location:
    London
    You sir, for today at least, are the top of all top chaps!

    .
     
    billy.whizz and RichieRich like this.
  7. Herbie87

    Herbie87 Keyboard Hero

    Messages:
    2,257
    Likes Received:
    5,436
    Location:
    Cambridgeshire
    Great guide, has helped diagnose my leak - thankfully its the easier of them all to fix!
     
    billy.whizz likes this.
  8. billy.whizz

    billy.whizz Posting Addict

    Messages:
    1,342
    Likes Received:
    1,356
    Location:
    Cornwall
    would you like too share what it was causing the leak?. and what you did too fix it?
     
  9. Herbie87

    Herbie87 Keyboard Hero

    Messages:
    2,257
    Likes Received:
    5,436
    Location:
    Cambridgeshire
    After dipping the filler end of the cylinder into water, I had a steady flow of bubbles from the main fill valve joint (Marked as "B" on Richie's guide). Seal kit ordered and all being well, just the one o ring to replace!
     
    RichieRich likes this.
  10. billy.whizz

    billy.whizz Posting Addict

    Messages:
    1,342
    Likes Received:
    1,356
    Location:
    Cornwall
    Great im pleased the guide was of use too you and you can fix it easily.:)
     
    Herbie87 likes this.
  11. RichieRich

    RichieRich Ping!

    Messages:
    5,331
    Likes Received:
    3,395
    Location:
    County Durham
    Another happy customer :D
     
    Jukebox, Herbie87 and billy.whizz like this.
  12. Herbie87

    Herbie87 Keyboard Hero

    Messages:
    2,257
    Likes Received:
    5,436
    Location:
    Cambridgeshire
    Absolutely, you're a credit to the forum :up:
     
    RichieRich and Jukebox like this.
  13. RichieRich

    RichieRich Ping!

    Messages:
    5,331
    Likes Received:
    3,395
    Location:
    County Durham
    :oops:
     
    Jukebox and billy.whizz like this.
  14. billy.whizz

    billy.whizz Posting Addict

    Messages:
    1,342
    Likes Received:
    1,356
    Location:
    Cornwall
    Worthy praise for KING of the C.O.C.K.S ?
     
    Jukebox likes this.
  15. Seranoser

    Seranoser Zs.D

    Messages:
    10
    Likes Received:
    7
    Good morning. I became a happy/unhappy Kozak owner a weak ago. There are more positive things about the rifle than negative. I guess the problems relate to poor quality control, mentality...
    Why I’m seeking your advice because unfortunately I’ve noticed a slight, not more than 20 bar pressure drop in the cylinder. Is it going to settle in time or it’s a sign of a leak?
     
  16. billy.whizz

    billy.whizz Posting Addict

    Messages:
    1,342
    Likes Received:
    1,356
    Location:
    Cornwall
    good morning Seranoser, im glad your happy with your new kozak. it looks like you have a air leak form the cylinder. if you follow richierichs guide it will show you how too check for a leak and how too fix it. if you feel that fixing it yourself is not for you then report it back too the rfd you bought the rifle from and get it checked /fixed. the guide that rich has put together makes it really easy too sort the leak problems. I wish you all the best with your problem and hope its resolved soon. on a lighter note welcome too the C.O.C.K.S. AS A NEW MEMBER.:thumb:
     
    TR158 and Seranoser like this.
  17. Seranoser

    Seranoser Zs.D

    Messages:
    10
    Likes Received:
    7
    Thank you billy.whizz I was hoping that loosing this amount of air is not significant and will settle after a time, but it looks like the o ring problem has not been sorted yet by the manufacturer. I’ve seen RichieRich’s ‘recipe’, but not confident enough to do it, so it’s going to be the RFD to sort the problem out...
     
    TR158 likes this.
  18. billy.whizz

    billy.whizz Posting Addict

    Messages:
    1,342
    Likes Received:
    1,356
    Location:
    Cornwall
    Seranoser. the guage on the kozak is not the best ,read accurate,it tends too move with temperature,so be sure that its deff going down ! and not just a change in temp that making it fluctuate. im sure you could manage too unscrew the cylinder?? if you can do that then dip the cylinder end in a pot of water and it will show bubbles if its leaking.at least then you can be sure its leaking or not. where abouts are you ?/ someone may be near you who can help you do this?
     
    TR158 likes this.
  19. Seranoser

    Seranoser Zs.D

    Messages:
    10
    Likes Received:
    7
    I can do the test. Is there any recommended cylinder pressure to do the water test?
     
    Simonsays likes this.
  20. RichieRich

    RichieRich Ping!

    Messages:
    5,331
    Likes Received:
    3,395
    Location:
    County Durham
    Morning!

    Fill it to the highest you can get from your dive bottle. The cylinder on the gun can take a 300bar fill. This should make a leak more apparent and easy to spot.
     
    TR158 and billy.whizz like this.

Share This Page

  1. This site uses cookies to help personalise content, tailor your experience and to keep you logged in if you register.
    By continuing to use this site, you are consenting to our use of cookies.
    Dismiss Notice