XS_Scuba_seaair_manual

XS_Scuba_seaair_manual
SERVICE AND REPAIR MANUAL
SEAAIR REGULATOR
PN RG200
Service & Repair Manual
Revised - 02/11
SeaAir Regulator
Contents
Section 1 - Introduction
Warnings, Cautions, & Notes.................................................................................................................................................3
Scheduled Service....................................................................................................................................................................3
EAN/ Nitrox Service...............................................................................................................................................................3
Facility Requirements.............................................................................................................................................................4
Specialty Tools.........................................................................................................................................................................5
Section 2 - Preliminary Inspection
External Inspection.................................................................................................................................................................6
Immersion / Leak Test............................................................................................................................................................6
Intermediate Pressure Test.....................................................................................................................................................7
Section 3 - Disassembly Procedures
General Guidelines..................................................................................................................................................................8
First Stage Disassembly..........................................................................................................................................................9
Second Stage Disassembly....................................................................................................................................................13
Section 4 - Reassembly Procedures
General Guidelines................................................................................................................................................................16
First Stage Reassembly..........................................................................................................................................................17
Second Stage Reassembly.....................................................................................................................................................21
Section 5 - Final Testing Procedures
First Stage Intermediate Pressure Test................................................................................................................................24
Second Stage Adjustment and Flow Test............................................................................................................................25
Subjective Breathing Test......................................................................................................................................................26
Flowbench Testing (optional)..............................................................................................................................................27
External Leak Test.................................................................................................................................................................27
Troubleshooting Guide - First Stage...........................................................................28
Troubleshooting Guide - Second Stage..................................................................29
Schematics & Parts Lists
SeaAir First Stage...................................................................................................................................................................30
SeaAir Second Stage..............................................................................................................................................................31
SeaAir Regulator Service and Repair Manual
2
Service & Repair Manual
SECTION
1
Introduction
This manual provides factory prescribed procedures for the correct service and repair of the SeaAir
regulator, including the first and second stage. It is not intended to be used as an instructional manual for
untrained personnel. The procedures outlined within this manual are to be performed only by personnel
who have received factory authorized training through a repair seminar that has been directly sponsored
by XS Scuba.
If you do not completely understand all of the procedures outlined in this manual, contact XS Scuba
to speak directly with a Technical Advisor before proceeding any further.
Warnings, Cautions, & Notes
Pay special attention to information provided in Warnings, Cautions, and Notes that are accompanied
by one of these symbols:
A WARNING indicates a procedure or situation that may result in serious injury or death if instructions are not
followed correctly.
A CAUTION indicates any situation or technique that will result in potential damage to the product, or render
the product unsafe if instructions are not followed correctly.
A NOTE is used to emphasize important points, tips, and reminders.
Scheduled Service
Because the SeaAir regulator is considered to be a life-supporting product, it is extremely critical that it
receives service according to the procedures outlined in this manual on a regularly scheduled basis; at least
once a year with normal or infrequent use.
NOTE: A unit that receives heavy or frequent use, such as in rental, instruction, or commercial applications, should be serviced at least twice each year - or more often - depending on the conditions
of use and the manner in which it is maintained. (Refer to the care and maintenance procedures
outlined in the SeaAir User's Guide.)
When performing service, whether it is a routine overhaul or a repair of a specific problem, it is important to understand how the regulator is designed and how it operates. If you have any questions, please
consult your XS Scuba representative.
EAN/ Nitrox Service
Newly manufactured XS Scuba regulators are assembled and packaged to be compatible with oxygen
enriched air (EAN/ Nitrox), not to exceed 40% oxygen content. If the regulator is going to be used for this
application, however, it must be dedicated and clearly labled as such, in order to prevent any crossover use
with standard compressed air. Refer to the instructions provided in the XS Scuba Authorized
Service Document, titled - Regulator Parts Cleaning Procedures.
CAUTION: It is important to avoid using, testing, or otherwise pressurizing a dedicated EAN
regulator with standard compressed air, which contains hydrocarbon contaminants.
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Copyright ©2011 XS Scuba
SeaAir Regulator
Facility Requirements
As an Authorized XS Scuba Dealer, your customers expect you to
provide top-notch overhaul service, both before and after the sale. Next to
airfills and gas blending, it is the single most important commodity your
store can provide.
The service department is therefore the most important part of your
store. It should be clean and well lighted, and stocked with a complete inventory of parts and all the specialty tools you will need to get the job done
right. As a minimum requirement, your service facility should be equipped
with the following items:
❏ Ultrasonic Cleaner – Select the right size model that can keep up with
the volume of equipment that your store services. A built in timer and
heater will help control the cleaning time and temperature of the solution, since most solutions work best when heated.
Ultrasonic Cleaner
❏ Bench Mounted Vise – A vise is sometimes needed to hold the regulator secure – especially when removing the first stage yoke retainer.
Special care must be taken, however, to avoid damage that can result
from improper use of this tool. Be sure to follow the instructions provided in this manual.
NOTE: XS Scuba especially endorses and recommends the Jaws
Gripmaster Bench Vise, available from Peter Built Co. It is designed
specifically for the professional dive store service bench, and will prevent damage that can easily be caused by a conventional vise.
❏ Magnification Lamp – Strong lighting and magnification are essential
requirements for performing a thorough parts inspection - especially
when locating the source of a small leak.
"Jaws" Gripmaster Vise
❏ Quality Wrenches & Sockets – When working with brass parts, it is
especially critical to use the correct size wrench and to ensure that it
fits properly over the part. The use of an adjustable wrench is very
likely to cause damage to your customer's equipment, and should be
strictly avoided at all times.
❏ Calibrated Inch-Pound and Foot-Pound Torque Wrenches –
It is important to follow the manufacturer's torque values whenever they
are specified, in order to avoid overtightening or undertightening a part.
This is especially important for smaller parts and fittings, when overtightening can easily damage the part. Torque wrenches that can be
set for both inch-pound and foot-pound measurements tend to be less
accurate than wrenches that are designed to measure torque within a
specific range.
SeaAir Regulator Service and Repair Manual
4
Service & Repair Manual
Specialty Tools
For the finest tools, fixtures, and supplies that are designed and manufactured specifically for servicing
SCUBA equipment, we recommend one source for all your service facility’s needs.
Peter Built Co., in Galion, Ohio, is dedicated to serving the diving industry, and offers a wide selection of
the most innovative specialty tools found anywhere to help you get the job done efficiently - and done right.
1" - SIX POINT
Breaker Bar # 20-157-500
PETER BUILT
3/8"
Drive
(419) 468-2212
260 2.0 x 50
260 3.5 x 60
O-ring Tool Set #10-102-100
100
60
75
150
100
175
120
125
80
200
IP RANGE
125-150 PSI
140
225
IP RANGE
125-150 PSI
50
250
PSI
180
275
PSI
25
20
Piston Installation Bullet
M
160
40
Poppet Align/ Orifice Preset Tool, #20-785-400
Snap Ring Pliers # 10-101-500
Select Tool Kit (5 pcs) # 11-090-500
No. 4 Hook Spanner, #20-404-200
Custom (narrow diameter)
3/8" x 3" Drive Extension #20-156-500
I” Yoke Nut Socket #20-155-500
USE NO OIL
USE NO OIL
0
300
200
PETER BUILT
PETERinBUILT
CO.
"Quality
the making"
"Quality
in the making"
(419) 468-2212
(419) 468-2212
Dual Drive In-Line Adjusting Tool # 20-500-200
Intermediate Pressure
Test Gauge, #20-510-100
Second Stage Rim Clamp #20-790-200
Required Tools/ Lubricant
No. 4 Hook Spanner Wrench
PN #20-404-200
Dual Drive Adjusting Tool PN #20-500-200
Tech Driver IPG
PN #20-165-111
O-ring Tool SetPN#10-125-400
1/4" Slotted Screwdriver
PN #11-465-500
1/4" Nut Driver
PN #11-168-500
Small (.02) Blade Screwdriver
PN #11-133-500
Cristo LubePN #MS150
Hakko Side Cuts, 5"
PN #16-020-500
Snap Ring Pliers
11/16" Open End Wrench
3/4" Open End Wrench
Illustrations courtesy of Peter Wolfinger.
Galion, OH 44833
Phone: 419-468-2212
www.scubatools.com
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SECTION
SeaAir Regulator
2
Preliminary Inspection
External Inspection
1. Closely examine the conical filter to check for any signs that
contaminants have entered the system, including sea water, rust,
or aluminum oxide.
NOTE: A green discoloration of the filter indicates that
moisture has entered the regulator, and internal corrosion has
possibly occurred. Other types of discoloration may indicate
that the regulator has been used with a corroded cylinder.
Advise the customer of this, and the possible need to obtain
service for the cylinder.
2. Slide back the hose protectors, if present, to visually inspect the
condition of the hoses, especially at their fittings.
3. Closely examine the finish of the first stage to check for any
chips, scratches, or other damage that exposes the brass beneath
the finish.
CAUTION: Do not clean any parts that show damage to their
finish inside an ultrasonic cleaner.
4. Closely examine all parts of the first stage for any other signs of
external corrosion.
Immersion / Leak Test
1. Check to ensure that the regulator is fully assembled and connected to a second stage, and that there are no open ports or
hoses. Connect the first stage to a cylinder that is filled with
3,000 psi, and open the cylinder valve to pressurize the regulator.
2. If leakage cannot be heard, or if the source of leakage detected
audibly is not obvious, immerse the first stage in fresh water to
check further for any signs of air leakage, especially at the fittings of hoses.
3. Note the source of any leakage found and refer to
the Troubleshooting Guide to determine its possible cause.
4. Close the cylinder valve and depress the second stage purge
button to depressurize the regulator before performing the next
procedure.
Intermediate Pressure Test
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Service & Repair Manual
NOTE: It is not necessary to perform this test unless a problem has been reported that requires diagnostic troubleshooting and repair. When performing routine overhaul service,
proceed directly to the following section, Disassembly.
1. Connect a calibrated intermediate pressure test gauge to the
regulator, either with a quick-disconnect inflator hose or with
the female fitting of a second stage LP hose, depending on the
connection of the test gauge.
CAUTION: To provide a safety relief valve in the event that
intermediate pressure exceeds 155-170 psi, ensure that a fully
assembled and properly adjusted second stage is connected
to the first stage before pressurizing. Failure to relieve intermediate pressure that exceeds 400 psi may result in damage
or rupture of the test gauge or LP hose, and could cause
serious personal injury.
2. Slowly open the supply valve to pressurize the first stage. Closely monitor the IP test gauge to determine whether the intermediate pressure rises above 145 psi.
3. Note the intermediate pressure indicated by the test gauge, and
purge the second stage several times to determine whether
lockup is achieved without creeping or fluctuating back and
forth.
4. If the intermediate pressure creeps up or otherwise fluctuates
after cycling the regulator, wait for it to stabilize (if possible)
before making a final note of the intermediate pressure.
NOTE: Correct intermediate pressure for the first stage is
140 (±5) psi, with an inlet pressure between 2,500 - 3,000 psi.
5. Close the supply valve and depress the second stage purge button to depressurize the system before attempting to perform any
disassembly.
▼ After completing the Preliminary Inspection, proceed
to Section 3 – Disassembly
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SECTION
SeaAir Regulator
3
Disassembly Procedures
General Guidelines
▼ Prior to performing any disassembly, check to ensure that the
service facility is well equipped with all the tools and parts needed to perform a complete service from start to finish. DO NOT
attempt to perform the service unless all of the required tools
and parts are available.
▼ All o-rings are classified as being either dynamic or static.
Dynamic o-rings are those which sustain friction and movement, as they are either mounted directly onto a moving part,
or create a seal against a moving part. Static o-rings simply
create a seal between two non-moving parts, and are therefore
less subject to wear than dynamic o-rings. After passing close
inspection, static
O-rings may sometimes be reused, although this is not necessarily recommended. Dynamic O-rings must be automatically
discarded and replaced with every service, regardless of age or
appearance.
▼ Refer to the schematic and parts list while performing these
procedures. Each part is identified by its reference number
shown on the drawing the first time it is referred to in the procedure.
▼ Do not attempt to reuse parts that are designated to be automatically discarded and replaced with the parts provided in the
overhaul parts kit. These parts should be shown to the customer, however, to ensure their confidence and satisfaction that
complete overhaul service has been performed.
▼ Inspect all reusable parts as directed, either during or immediately following the disassembly procedures. When in doubt,
compare the part with one that is new to best determine its
condition.
SeaAir Regulator Service and Repair Manual
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Service & Repair Manual
First Stage Disassembly
CAUTION: Whenever possible, use only plastic or brass O-ring
tools for removing O-rings in order to prevent damage to the sealing
surface. Steel instruments, such as dental picks, can easily damage the sealing surface of a softer brass part, causing irreparable
leakage and requiring the part to be replaced with new.
1. Before disassembling the first stage, remove the low pressure
second stage hose with a 15mm open end wrench, the high
pressure hose with a s" open end wrench, and the low pressure
inflator hose with a 2" (or other size required) open end wrench.
Remove all remaining port plugs(17&32) with a x" hex key.
2. Remove and inspect the O-rings(16&31) on these items to determine their condition, and discard them if any signs of decay
are found.
3. Remove the dust cap(3) from the yoke(4).
NOTE: It will be necessary to use a bench mounted vise to
hold the first stage secure throughout this procedure. This
ensures the best protection against slippage and accidental
damage to soft metal parts. If an ordinary bench vise will be
used, the first stage must be mounted outside the vise with
the use of a vise mounting tool fastened into the high pressure
port. To ensure the best available protection against
damage, XS Scuba specifically recommends the
Gripmaster Vise, available from Peter Built Co.
4. Secure the first stage in a vise as described above, with the yoke
and yoke screw(2) facing up (See Fig. 1).
Fig. 1 – Correct vise mounting
5. Disassembly of the Yoke Connector
a. Loosen the yoke screw several turns counter-clockwise.
Place a 1" Yoke Retainer Socket (available from Peter Built
Co.) inside the yoke and over the hex features of the yoke
retainer(8). Pass a Breaker Bar (available from Peter Built
Co.) through the yoke, and tighten the yoke screw clockwise until it is lightly snug over the dimpled feature of the
breaker bar (see Fig. 2). Then, grasp the breaker bar with
both hands on opposite ends and turn the socket counterclockwise with steady force to loosen the yoke retainer. Do
not use impact.
CAUTION: The socket and breaker bar combination provide
the best insurance against damage while removing the yoke
retainer, using the procedure described above. DO NOT, un-
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Fig. 2 – Yoke Retainer Removal
Copyright ©2011 XS Scuba
SeaAir Regulator
der any circumstances, use an adjustable wrench or an open
end wrench that does not fit completely over the flats on both
sides. Doing so may result in permanent damage to the yoke
retainer, requiring its replacement.
Fig. 3 – Removal of Filter Retaining Ring
b. Turn the yoke screw counter-clockwise to remove it from
the yoke, and set aside the breaker bar and socket.
c. Unscrew the yoke retainer counter-clockwise to remove
from the body, along with the yoke and saddle(10).
d. Remove the main seal O-ring(9) from the yoke retainer.
Discard the O-ring and do not reuse, regardless of its condition.
e. While holding the yoke retainer secure, apply a pair of Snap
Ring Pliers to remove the retaining ring(5) from the yoke
retainer (see Fig. 3). Tap out the filter(6), and remove the
O-ring(7) inside with a brass O-ring tool. Discard the filter
and O-ring, and do not reuse either part regardless of their
condition.
6. Disassembly of the DIN Connector
Fig. 4 – Removal of DIN Retainer
a. Secure the first stage in the vise with the DIN connector facing straight up. (See Fig. 4.)
b. Apply a 4" hex key to the DIN retainer(4f), and turn it
counter-clockwise to loosen and remove from the body,
along with the handwheel(4a) and saddle(4d).
c. Remove the DIN retainer from the handwheel, and then remove and discard: the filter(4g) and both O-rings(4e&4h).
Do not attempt to reuse these parts.
c. Closely inspect the condition of the DIN retainer and
handwheel to ensure that the threads are free of any burrs or
other damage. If thread damage is found that could impair
a proper connection, it is important to replace the part with
new.
d. Inspect the condition of the thrust washer(4b), spacer(4c),
and saddle, and replace if needed.
7. Resecure the first stage in the vise with the body(18) positioned
vertical, and the LP swivel facing down.
8. Apply a 4" hex key to the HP seat retainer(11) and turn it counter-clockwise to loosen and remove (see Fig. 5). Remove and
discard the O-ring(12).
Fig. 5 – Removal of HP Seat Retainer
9. Using a brass O-ring tool, carefully lift out the O-ring(14) inside
the HP chamber (see Fig. 6). Be careful to avoid touching the
exposed seating edge of the piston shaft. Discard the O-ring,
regardless of its condition.
10. While holding the HP seat retainer secure with a cloth covering
SeaAir Regulator Service and Repair Manual
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Service & Repair Manual
the HP seat, apply a short blast of low pressure air through the
small hole to dislodge the HP seat(13). (See Fig. 7.) Discard the
seat, and do not reuse.
11. Resecure the first stage in the vise with the body positioned
vertical, and the LP swivel facing up.
12. Apply a spanner wrench to one of the larger bore holds of the
piston cap(25), and hold it securely seated to turn the cap counter-clockwise to loosen it from the first stage body. (See Fig. 8.)
Turn the piston cap further by hand to loosen and remove, until
it can be carefully lifted straight off the body, along with the
piston(22).
Fig. 6 – Removal of HP Static Oring
13. Gently remove the piston from the piston cap, and then remove
and discard the piston head O-ring(23). Set the piston aside
with the shaft facing up, to be kept isolated from other metal
parts or work surfaces that might damage the polished seating
edge.
14. Remove the high pressure valve spring(21) and spring isolator(20) from the body. Inspect the spring isolator for any signs
of damage or distortion, and discard if any is found. Closely
inspect the spring with a magnifier to check for any signs of
damage or corrosion that has permeated the wall of the metal.
Set the spring aside to be reused if it is determined to be in
satisfactory condition with no signs of permanent corrosion or
damage.
CAUTION: If damage is found, or if the intermediate pressure was measured lower than 135PSI during preliminary
inspection, replace the spring with new. DO NOT attempt to
boost the intermediate pressure by adding spring isolators
unless a new spring has first been installed.
Fig. 7 – Removal of HP Seat
NOTE: If corrosion is found on the spring, check for any
signs that moisture may have entered the first stage. If evidence of moisture is found inside the first stage, it is important
to inspect all parts that could provide a possible leak path,
either due to damage or improper assembly.
15. Remove the first stage from the vise, and remove the vise
mounting tool if one was used.
16. Using a brass O-ring tool, remove the small dynamic O-ring(19)
from the first stage body, being careful to avoid damaging the
sealing surface of the internal groove.
Fig. 8 – Loosening Piston Cap
17. To remove the large external O-ring(15), pinch it between
thumb and forefinger with one hand, and then apply an O-ring
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Copyright ©2011 XS Scuba
SeaAir Regulator
tool to remove it with the other.
18. Secure the swivel cap(30) in a vise, using either the "Jaws Gripmaster," or with a vise mounting tool installed in one of the LP
ports. Ensure that the piston cap is facing up.
19. Mate a c" (8mm) hex key through the open piston cap and
into the hex of the swivel retainer(24). (See. Fig. 9.) Turn the
swivel retainer counter-clockwise to loosen and remove, and
lift the piston cap off the swivel cap.
20. Remove the swivel retainer from the piston cap, along with the
swivel washer(27). Examine the condition of the washer, and
reuse or replace it as needed.
Fig. 9 – Removal of Swivel Retainer
21. Remove and discard both O-rings(27&28) from the swivel cap,
and automatically discard them regardless of their condition.
22. Using a smooth plastic or brass probe, remove the rubber collar(26) from the piston cap. Examine the ring to determine its
condition, and replace with new as needed.
23. Under strong lighting, closely inspect the inner bore and all
sealing surfaces of the first stage body with a magnifier, including the intermediate and high pressure ports, and the inlet
port. Check to ensure there are no scratches or other damage
that could contribute to leakage. If damage is found that is
determined to cause irreparable leakage, it will be necessary to
discard the first stage body and replace it with new.
▼ After completing the disassembly of the first stage,
proceed to the following procedure - Second Stage
Disassembly.
SeaAir Regulator Service and Repair Manual
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Service & Repair Manual
Second Stage Disassembly
CAUTION: Whenever possible, use only plastic or brass
O-ring tools for removing O-rings in order to prevent damage to the sealing surface. Steel instruments, such as dental
picks, can easily damage the sealing surface of a softer brass
part, causing irreparable leakage and requiring the part to be
replaced with new.
1. Slide back the hose cover to expose the connection of the LP
hose.
2. While holding the inlet fitting(20) secure with a n" open-end
wrench, apply another n" open-end wrench to the fitting of
the LP hose. Turn the fitting counter-clockwise to loosen and
remove.
3. Using a plastic or brass O-ring tool, carefully remove the O-ring
from the post inside the hose fitting.
CAUTION: When performing the above step, be very careful to avoid scratching the O-ring sealing surface. Doing so
may cause a permanent leak that will require the replacement
of the LP hose.
4. Using a n" open end wrench, turn the inlet fitting counterclockwise to loosen, and unscrew it completely by hand to
remove.
5. Snip the plastic tie-strap(21) that holds the mouthpiece(23), and
gently pull the mouthpiece off the second stage housing(12).
Inspect the mouthpiece to ensure that it is supple and free of
any tears or corrosion. If any damage is found that could result
in discomfort or leakage, discard the mouthpiece and do not
reuse.
6. While holding the second stage secure with one hand, firmly
grasp the retaining ring(17) with the other, and turn the ring
counter-clockwise to loosen and remove it, along with the diaphragm cover(16).
NOTE: If the retaining ring is difficult to loosen, XS Scuba
recommends using the Rim Clamp (P/N 20-790-200), available from Peter Built Co. Complete instructions are provided
with the tool.
7. Separate the diaphragm cover from the retaining ring, and
closely inspect the cover to ensure that it is perfectly round and
free of any distortion or other damage. If any damage is found,
discard the cover and replace with new.
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Copyright ©2011 XS Scuba
SeaAir Regulator
8. Lift out the diaphragm(14) and thrust washer(15) from the
second stage housing. Inspect the diaphragm to ensure that it is
supple and free of any pinholes, tears, corrosion, or other damage. If any damage is found, discard it and replace with new.
9. Using a small flat blade screwdriver, rotate the metal retaining
clip(13) over the groove of the adjustment knob(1) as needed so
that the notch in the center is visible. Place the tip of a 2mm flat
blade screwdriver inside this notch, and gently lift the clip off
the groove. (See Fig. 10.)
Fig. 10 – Removal of Retaining Clip
10. While holding the lever(18) lightly depressed, slide the entire
valve assembly out of the second stage housing, adjustment
knob first (see Fig. 11). Remove and discard the inlet fitting Oring(19).
11. Unscrew the adjustment knob counter-clockwise from the air
barrel(8), and carefully remove the O-ring(2) with a plastic tool.
12. Turn the air barrel over to allow the balance shuttle cap(3) and
LP spring(4) to drop out (see Fig. 12). Inspect the spring closely
with a magnifier to check for any signs of corrosion. Discard it
if corrosion is found, and do not reuse.
Fig. 11 – Removal of Valve Assembly
13. Gently remove the lever from the air barrel by lifting out one leg
first, and then the other. Be careful to avoid bending or stretching either leg.
14. Turn the air barrel over to allow the poppet(6) to drop out. Using fingernails or a plastic tool, carefully remove the LP seat(7)
and small O-ring(5). Discard both soft parts, and do not reuse. Closely inspect the poppet around all seating surfaces, and
compare it with new to ensure no damage is visible. If damage
is found, discard the poppet and replace with new.
15. Remove the white lever pad(9) from the air barrel. Discard, and
do not reuse.
Fig. 12 – Removal of Adjustment Knob
16. While holding the air barrel secure, apply a medium blade
screwdriver to the slotted head of the adjustable orifice(10), and
turn it counter-clockwise to disengage its threads.
NOTE: The orifice is O-ring sealed, and it will remain inside
the air barrel after it has been unthreaded. The following step
must be performed correctly in order to remove the orifice
without damaging its polished sealing surface.
17. When the orifice has been unthreaded from the air barrel, carefully insert a small wooden or plastic dowel through the opposite end of the valve body, directly over the sealing edge of the
orifice. Gently press out the orifice. (See Fig. 13.)
18. To avoid using a sharp tool that can damage the orifice, squeeze
the O-ring(11) between thumb and forefinger to remove it from
SeaAir Regulator Service and Repair Manual
14
Service & Repair Manual
the orifice head. Discard the O-ring and do not reuse.
19. Closely examine the orifice with the use of a magnifier, checking for any scratches or other damage to the sealing edge and
the groove that holds the O-ring (see Fig. 14). If any damage or
wear is found, discard the orifice and do not attempt to reuse. If
it is in reusable condition, set it aside on a soft surface to keep it
isolated from other metal parts.
20. Remove the exhaust deflector(24) from the second stage housing to expose the exhaust valve(22) for inspection.
NOTE: To facillitate the removal of the exhaust deflector,
first place it in hot (120°-150°F) water for 2-3 minutes and
allow it to soften.
Fig. 13 – Removal of Adjustable Orifice
21. Closely inspect the exhaust deflector to check for any signs of
damage that may have been caused by abuse or improper disassembly. If found, discard it and replace with new.
22. Closely inspect the condition of the exhaust valve to ensure that
it is evenly seated against the second stage housing on all sides,
and free of any tears, holes, or other signs of decay. Peel back
the lip on all sides to ensure it is supple and returns to its original position. If any wear or damage is detected, or if the material feels stiff or decayed, pull the exhaust valve straight out of
the housing and discard it.
NOTE: It is not necessary to remove the exhaust valve
diaphragm unless it shows signs of wear or decay upon inspection. Once the diaphragm is removed, however, it will be
permanently stretched and then must be replaced with new.
▼ After completing the disassembly of the first and
second stages, refer to the instructions provided in
the XS Scuba Authorized Service Document, titled Regulator Parts Cleaning Procedures.
15
Fig. 14 – Orifice Inspection
Copyright ©2011 XS Scuba
SECTION
SeaAir Regulator
4
Reassembly Procedures
General Guidelines
▼ Refer to the schematic parts list, that highlights automatic replacement parts
which should be discarded and replaced with new during reassembly. These
parts are provided in the Annual Service Kit.
▼ Before performing any reassembly, it is important to individually inspect all
parts, both new and those that are being reused, to ensure that each part
and component is perfectly clean and free of any dust, decay, or blemishes.
▼ If the regulator has been serviced for use with EAN/Nitrox, it is important to
don powderless latex gloves before handling any parts, including O-rings, in
order to avoid contaminating the parts with skin oil.
▼ Prior to dressing, inspect all O-rings with magnification to ensure they are
supple, clean, and completely free of any scoring or decay that would impair
proper sealing.
▼ XS Scuba recommends Christo-Lube® MCG-11 (PN MS150) to be used exclusively for the lubrication and dressing of O-rings and other internal parts.
Christo-Lube® provides superior lubrication to that of silicone grease, especially in high pressure (DIN) systems greater than 3,000 psi, and extreme
temperature conditions. It is also non-reactive to oxygen, and is approved for
use with EAN/Nitrox.
'
CAUTION: Silicone grease is not compatible with oxygen enriched
air, and must be strictly avoided when servicing a regulator that
will be used with EAN/ Nitrox. The entire regulator will otherwise
become contaminated, and rendered unsafe for use with any mixture
of oxygen enriched air.
▼ Dress all O-rings with a visible film of Christo-Lube, but avoid applying excessive amounts, as this may attract particulate matter that can cause accelerated wear or damage to the O-ring.
CAUTION: The use of aerosol spray or petroleum based lubricants
must be strictly avoided. The propellant gas or petroleum base may
attack or weaken plastic or rubber parts.
▼ Use all replacement parts provided in the XS Scuba Authorized Dealer parts
kit.
SeaAir Regulator Service and Repair Manual
16
Service & Repair Manual
First Stage Reassembly
WARNING: DO NOT attempt to use any other manufacturer's
part as a substitute for any XS Scuba part, regardless of
any similarity in shape, size, or appearance. Doing so may
render the product unsafe, and could result in serious injury
or death.
1. Lubricate and install the small dynamic O-ring(19) into the
first stage body(18), checking to ensure that it is seated properly
inside the groove.
2. Install the large external O-ring(15) onto the groove near the
end of the body.
3. Generously lubricate and install the large dynamic O-ring(23)
onto the head of the piston(22), and stand the piston on its
head.
4. Apply a light film of lubricant to both ends of the high pressure
spring(21), and place the spring over the shaft of the piston.
5. Lay the spring washer(20) over the top of the spring.
NOTE: If more than one washer was removed during disassembly, be sure to reassemble the first stage using the same
number of washers, unless the HP spring has been discarded
and replaced with new. Up to three washers may be used.
Fig. 15 – Piston w/ Installation Bullet
▼ If one is needed, install between the spring and body.
▼ If two are needed, install on opposite sides of spring.
▼ If three are needed, install one between the spring and body,
and two between the spring and piston.
6. Insert a piston installation bullet into the end of the piston shaft.
This will protect the small dynamic O-ring inside the body, and
also the polished sealing surface of the piston (see Fig. 15).
7. Gently lower the threaded end of the body over the piston shaft,
until the body is supported by the spring . While holding the
piston and body together, turn the body over to allow the piston
installation bullet to drop out of the opposite end, tapping it
loose if necessary (see Fig. 16). Stand the body on end, with the
piston head facing up.
Fig. 16 – Removal of Bullet
8. Lubricate and install the large O-ring(28) into the groove of the
swivel cap(30), and the smaller dynamic O-ring(28) onto the
swivel stem. (See Fig. 17.)
9. Mate the smaller end of the piston cap(25) over the stem of the
swivel cap, and press it downward so that it snaps securely into
place.
17
Fig. 17 – Swivel Retainer w/ O-rings
Copyright ©2011 XS Scuba
SeaAir Regulator
10. Install the swivel washer(27) over the shoulder of the swivel
stem, inside the piston cap, and ensure that it is seated securely
and evenly around the base.
11. Being careful to avoid disturbing the position of the swivel
washer, mate the threaded end of the swivel retainer(24)
through the piston cap and into the stem of the swivel cap. Turn
it clockwise to engage the threads, and tighten it until finger
snug.
12. Secure the swivel cap(30) in a vise, using either the "Jaws Gripmaster," or with a vise mounting tool installed in one of the LP
ports. Ensure that the piston cap is facing up.
13. Apply an inch-pounds torque wrench with c" (8mm) hex key to
tighten the swivel retainer to a torque measurement of 80 inchlbs, and remove the swivel assembly from the vise.
Fig. 18 – Assembly of Piston Cap w/ Body
14. Fit the large diameter end of the rubber collar(26) over the
swivel cap, and press it down until the smaller end seats into
place.
NOTE: If the first stage is going to be prepared for use in
severe conditions (cold or silty water), do not install the collar
at this time. Refer to the instructions provided at the end of
this procedure for installing the IceBreaker™ environmental
sealing collar.
15. Gently mate the piston cap straight down over the head of the
piston, and tighten the piston cap and body together by hand
until snug. (See Fig. 18.)
16. Lubricate and install the O-ring(12) onto the HP seat retainer, at
the base of the threads.
17. Install the high pressure seat(13) into the HP seat retainer(11)
with the concave dimple facing out. (See Fig. 19.)
Fig. 19 – HP Seat Installation
18. Lubricate and install the O-ring(14) inside the first stage body,
using a smooth probe if necessary to ensure that it is seated
evenly over the shoulder at the base of the high pressure chamber.
19. Mate the HP seat retainer into the first stage body, and turne
clockwise by hand until finger snug.
20. Secure the first stage vertically in a vise, with the LP swivel assembly facing down.
21. Apply an foot-pounds torque wrench with 4" hex key to tighten
the HP seat retainer to a torque measurement of 18 foot-lbs.
22. Resecure the first stage in the vise, turned over with the LP
swivel assembly and piston cap facing straight up.
SeaAir Regulator Service and Repair Manual
18
Service & Repair Manual
23. Apply a spanner wrench to one of the larger bore holes of the
piston cap(25), and hold it securely seated to tighten the cap
clockwise until snug. Do not overtighten. (See Fig. 20.)
24. Resecure the first stage in the vise, positioned horizontal, with
the inlet port facing up.
25. Reassembly of the Yoke Connector
a. Install the O-ring(7) into the yoke retainer(8), followed by
the conical filter(6). Closely examine the retaining clip(5)
to compare the difference of one side, which is flat, from the
other which is rounded. Using snap ring pliers, install the
retaining ring into the groove above the filter, with the flat
side facing out.
b. Lubricate and install the main seal O-ring(9) into the groove
in the bottom of the yoke retainer.
c. Being careful to ensure that the O-ring remains properly
seated, insert the threaded end of the yoke retainer through
the bottom of the yoke(4). While holding the saddle in
place together with the first stage body, mate the yoke
retainer into the inlet port of the body. Tighten the yoke
retainer clockwise by hand until finger snug.
d. Apply a torque wrench with the 1” Yoke Nut Socket and
3"xa" Socket Drive Extension (available from Peter Built
Co.). Tighten the yoke retainer to 24 foot-lbs (±1). (See Fig.
21.)
e. Install the dust cap(3) onto the yoke, and mate the yoke
screw(2) into the yoke. Turn the screw one to two revolutions clockwise to engage the threads.
Fig. 20 – Tightening Piston Cap
3/8” Drive Torque Wrench
3500 PSI
PETER BUILT
1" - SIX POINT
26. Reassembly of the DIN Connector
a. Mate the threaded end of the DIN retainer through the
threaded side of the handwheel.
b. While holding the retainer and handwheel together, fit
the thrust washer(4b), spacer(4c), and saddle(4d) over the
threaded end of the DIN retainer, in respective order.
Fig. 21 - Torquing Yoke Retainer
PETER B
(419) 468
c. Install the filter(4g) and both O-rings(4e&4h)into the DIN
retainer.
d. Mate the DIN retainer into the inlet port of the first stage
body, and turn clockwise by hand until snug. Apply a
torque wrench with a 4” hex key to tighten the DIN retainer
to a torque measurement of 24 foot-lbs (±1).
27. Loosen the vise to remove the first stage, and remove the vise
mounting tool if one was used.
19
Copyright ©2011 XS Scuba
SeaAir Regulator
28. Lubricate and install the O-rings(16&31) onto all hoses and
port plugs. Install the LP hoses and port plugs(17&32) into
their respective ports in the first stage. Apply a calibrated
torque wrench with x" hex key socket (or appropriate size crow
foot for hoses) to tighten the port plugs and hoses to a torque
measurement of 38 inch-lbs (±2).
IceBreaker™ Environmental Seal Instructions
WARNING: DO NOT install the IceBreaker™ environmental
sealing collar without first packing the ambient chamber with
silicone grease purchased directly from XS Scuba, according
to the following instructions. Failure to do will seriously affect the regulator's performance, and could result in serious
injury or death.
1. Using a narrow tipped oral syringe, slowly inject silicone grease
through the ports on all sides of the piston cap. Rotate among
opposing ports, and repeat as needed until the pressure forces
excess grease to exit the opposite sides, indicating that the
chamber is full.
2. After verifying that the chamber is complete filled with grease,
wipe the outer surface of the piston cap clean with a soft cloth.
3. Fit the larger end of the IceBreaker™ collar down over the top of
the swivel cap, until it is securely in place over the piston cap,
and the smaller end is seated in the groove just below the swivel
(see Fig. 22).
•
After completing the reassembly of the first stage,
proceed to the following procedure - Second Stage
Reassembly
Fig. 22 – IceBreaker Environmental Collar
SeaAir Regulator Service and Repair Manual
20
Service & Repair Manual
Second Stage Reassembly
WARNING: DO NOT attempt to use any other manufacturer's
part as a substitute for any XS Scuba part, regardless of
any similarity in shape, size, or appearance. Doing so may
render the product unsafe, and could result in serious injury
or death.
1. Install the exhaust valve(22) into the second stage housing(12)
by gently pulling the stem through the hole in the center of the
sealing area, until the barb has passed through and is seated
inside.
NOTE: Prior to installing the exhaust deflector(24), place it in
hot (120°-150°F) water for 2-3 minutes and allow it to soften.
Fig. 23 – Lever Pad Features
2. Fit the exhaust deflector(24) over the top ridge of the second
stage housing, so that the two corners are securely seated, and
then stretch the lower portion down until it snaps securely into
place.
CAUTION: Do not use a tool to install the exhaust deflector.
Doing so may cause serious damage to the seating flange,
requiring replacement of the housing.
3. Closely examine both sides of the white lever pad(9) to identify
that the mounting tabs on both legs are rounded on one side
and flat on the other. (See Fig. 23.) Hold the air barrel with the
flat cut facing down, and place the clip over the tube with the
rounded side facing toward the flange, so that one tab engages
in the hole next to it. Then, gently press the opposite leg into
place so the the other tab engages in the opposite hole. When
done correctly, the lever pad should rest flush against the flange,
with both tabs securely seated. (See Fig. 24.)
Fig. 24 – Air Barrel Orientation
Fig. 25 – Poppet Features
CAUTION: Do not stretch the legs of the lever pad, or attempt to install it if damage has occurred.
Fig. 26 – Correct Poppet Orientation
4. Insert the stem of the LP seat(7) into the large end of the poppet(6). DO NOT use adhesive.
5. Lubricate and install the small O-ring(5) over the groove on the
opposite end of the poppet, being careful to avoid stretching it
excessively. Closely examine the shape and features of the poppet. (See Fig. 25.)
6. While holding the air barrel with the flat cut facing straight up,
guide the poppet into the tube, LP seat first, with the ears facing
straight down. (See Fig. 26.)
7. Closely examine both holes where the lever pad is installed, to
ensure that the ears of the poppet are properly aligned as shown
21
Fig. 27 – Poppet Correctly Installed
Copyright ©2011 XS Scuba
SeaAir Regulator
(see Fig. 27). While holding the air barrel with the flat cut
facing up, insert one leg of the lever(18) into one hole, so that
it engages with the poppet (see Fig. 28). Being careful to avoid
stretching or bending the lever, rotate it over the air barrel until
the opposite leg engages with the opposite side. Check to ensure
that the lever is properly seated on both sides, securely engaging
the poppet ears. (See Fig. 29.)
Fig. 28 – Lever Installation
NOTE: To better control the orientation of the poppet inside the air barrel while the lever is being installed, XS Scuba recommends using the Poppet Align/
Orifice Preset Tool (P/N 20-785-400), available from
Peter Built Co. (See Fig. 30.)
8. Apply a light coat of lubricant to both ends of the poppet
spring(4), and place the spring inside the air barrel, over the
small end of the poppet.
9. Insert the small end of the shuttle cap(3) into the end of the
poppet spring.
Fig. 29 – Correct Lever Orientation
10. Install the O-ring(2) onto the adjustment knob(1). Mate the
adjustment knob directly over the shuttle cap, and screw the
knob clockwise onto the air barrel approximately 3-4 full turns.
11. While holding the second stage housing right side up with the
front facing you, slide the valve assembly into the opening in
the right side of the housing. Gently depress the lever, and then
slide the valve assembly through the opening on the inlet side.
Be careful to ensure that both lever arms fit squarely between
the two flanges inside the housing, and then slide fully in place
so that the lever pad is seated flush. (See Fig. 31.)
Fig. 30 – Poppet Alignment/ Preset Tool
12. Install the retaining clip(13) over the groove of the adjustment
knob inside the housing, so that it snaps securely into place.
(See Fig. 32.)
13. Install the O-ring(19) over the threaded inlet of the air barrel,
being careful to avoid stretching it or rolling over the threads.
Use a smooth instrument to ensure that it is seated at the base of
the threads, against the wall of the housing.
14. Mate the inlet fitting(20) over the threads of the air barrel, and
turn it clockwise by hand until finger snug. Apply a n" open end
wrench to tighten it further by exactly 8 turn.
CAUTION: Be careful to avoid overtightening the inlet fitting, which can crack the wall of the second stage housing,
requiring its replacement.
Fig. 31 – Valve Assembly Completely Installed
SeaAir Regulator Service and Repair Manual
15. Install the O-ring(11) onto the head of the adjustable orifice(12)
and carefully insert the orifice into the inlet of the air barrel with
22
Service & Repair Manual
the polished cone facing in. Using a small wooden or plastic
down, press the orifice in so that it rests against the threads
inside the air barrel. (See Fig. 33.)
16. Turn the adjustment knob counterclockwise until it stops.
17. Apply a medium blade screwdriver to the slotted head of the
orifice inside the air barrel, and turn it clockwise while closely
watching the lever. When the lever starts to drop, stop – do not
turn the orifice any further. This will indicate that the orifice
has made contact against the LP seat. (See Fig. 34.)
Fig. 32 – Installing Retaining Clip
NOTE: To pre-set the orifice at exactly the correct depth
inside the air barrel, XS Scuba recommends using the Poppet
Align/ Orifice Preset Tool (P/N 20-785-400), available from
Peter Built Co. Complete instructions are provided with the
tool. (See Fig. 35.)
18. Lay the diaphragm(14) inside the housing, directly over the
lever with its raised surface facing up, and then the thrust
washer(15).
19. Fit the front cover(16) inside the housing so that it seats directly
over the diaphragm. Turn it as needed to align the logo straight
between the inlet and adjustment knob. (See Fig. 36.)
Fig. 33 – Installing Orifice
20. Mate the retaining ring(17) over the front cover and into the
housing, and turn it clockwise to engage the threads. While
holding the front cover secure with one hand, tighten the
retaining ring until snug with the other. Be careful to avoid
over-tightening.
21. Install the mouthpiece(23) onto the housing, correctly
oriented with the top facing up. Fasten a tie-strap(21) over
the mouthpiece with the locking tab facing toward the inlet
coupling, and cinch it snug. Trim the excess material close to
the locking tab.
▼ After completing the reassembly of the second stage, proceed to Section 5 – Final Testing
Fig. 34 – Preliminary Adjustment of Orifice
Preset Depth
.480” - .490”
Fig. 35 – Using the Orifice Pre-Set Tool
Fig. 36 – Correct Orientation of Front Cover
23
Copyright ©2011 XS Scuba
SECTION
SeaAir Regulator
5
Final Testing Procedures
CAUTION: If the regulator will be used with EAN/ Nitrox, it is
important to pressurize and flow test the regulator using only
hydrocarbon-free gas. The regulator will otherwise become
contaminated with hydrocarbons if normal compressed air
is used. Industrial grade compressed Nitrogen is strongly
recommended as a lower cost alternative to EAN/ Nitrox for
the purposes of flow testing.
First Stage Intermediate Pressure Test
1. Connect a calibrated intermediate pressure test gauge to the
regulator, either with a quick-disconnect inflator hose or with
the female fitting of a second stage LP hose, depending on the
connection of the test gauge.
CAUTION: To provide a safety relief valve in the event that
intermediate pressure exceeds 155-170 psi, ensure that a fully
assembled and properly adjusted second stage is connected
to the first stage before pressurizing. Failure to relieve intermediate pressure that exceeds 400 psi may result in damage
or rupture of the test gauge or LP hose, and could cause
serious personal injury.
2. Initially connect the first stage to a supply of 300 psi filtered
test gas, and slowly open the supply valve to pressurize the first
stage. Closely monitor the IP test gauge to determine whether
the intermediate pressure rises above 145 psi.
CAUTION: If the intermediate pressure continues to rise
above 200 psi, immediately shut the test gas supply valve.
Refer directly to the Troubleshooting guide, and remedy as
needed before proceeding any further.
3. When the intermediate pressure has been determined to be 145
psi or less, close the supply valve and purge the second stage to
depressurize the system. Connect the first stage to a supply of
2,500 - 3,000 psi test gas.
NOTE: Correct intermediate pressure for the first stage is between 135-145 psi, with a supply pressure of 2,500 - 3000 psi.
SeaAir Regulator Service and Repair Manual
24
Service & Repair Manual
4. Open the supply valve again while monitoring the IP test gauge
to ensure that the intermediate pressure does not rise above 145
psi. If the intermediate pressure rises above 145 psi, immediately close the supply valve and purge the system. Refer to the
Troubleshooting section, and remedy as needed before proceeding.
5. Repeatedly purge the second-stage approximately 15-20 times
to cycle the regulator. Then, check the test gauge to determine
whether the intermediate pressure locks up consistently after
each cycle and remains stable at 140 (±5) psi, with no signs
of creeping or fluctuation. If the intermediate pressure is not
within the specified range, or if it fails to lock up with no creep,
refer to the Troubleshooting section to determine the cause of
the problem. Repeat this procedure after it is corrected.
Second Stage Adjustment and Flow Test
1. Connect the IP Test Gauge onto the inlet fitting of the Inline
Adjusting Tool, and mate the opposite fitting of the tool onto
the inlet fitting of the second stage. Pull back the knurled knob
to retract the slotted drive, and tighten the tool clockwise onto
the inlet fitting only until finger snug. (See Fig. 37.)
2. Mate the female fitting of the LP hose onto the male fitting of
the IP Test Gauge, and tighten the swivel nut clockwise until
finger snug.
3. Install the LP hose into an intermediate pressure port of the first
stage regulator after it has been verified to be properly serviced,
with a stable intermediate pressure of 140 (±5) psi . Apply a
torque wrench with 17mm crow-foot to tighten to 38 (±2) inchlbs.
4. Turn the adjustment knob fully out counter-clockwise.
5. Ensure that all the first stage ports are sealed, and connect the
first stage with a filtered gas supply of 2,500-3,000 psi. Slowly
open the valve to pressurize the regulator. Listen to verify that
a leak can be heard from the second stage valve, and proceed to
step 6.
Fig. 37 – Inline Adjustment Tool w/ IP Gauge
a. If airflow cannot be heard, it will be necessary to initiate a slight leak between the orifice and poppet. Press the
knurled knob inward to engage the slotted drive of the Inline Adjustment Tool with the head of the orifice inside the
inlet fitting. Then, turn the orifice slightly counter-clockwise while lightly depressing the purge cover to prevent
wear on the seat. Do not adjust any further than is needed
to establish a slight leak.
6. Hold the drive of the Inline Adjustment Tool engaged with the
orifice. While lightly depressing the purge cover, turn the orifice slightly clockwise a very small fraction of a turn. Pause after
25
Copyright ©2011 XS Scuba
SeaAir Regulator
each adjustment to listen, and be careful to avoid over-adjusting
beyond the point that the leak has stopped. When the leak has
stopped, purge the second stage again to ensure that it does not
return. Observe the IP Test Gauge while purging to verify that
it indicates a stable intermediate pressure after each cycle, with
no creep or fluctuation.
CAUTION: Over-adjustment of the orifice can cause excessive spring load in the second stage valve, and may impair
the regulator’s performance.
8. When the second stage is properly adjusted with no leaks or
lever slack, depressurize and purge the system to disconnect the
LP hose.
9. Reconnect the LP hose to the inlet coupling, and apply a torque
wrench with 17mm crow-foot to tighten the fitting to a torque
measurement of 55 inch-lbs (±5).
Subjective Breathing Test
1. While the regulator is connected to a cylinder containing 2,500
– 3,000 psi and pressurized, turn the second stage adjustment
knob completely out counterclockwise, and verify that a slight
leak of airflow is present.
2. Slowly turn the adjustment knob clockwise to verify that the
airflow stops between 2 -1 turn.
3. Turn the adjustment knob completely in clockwise to maximum
opening effort, and depress the purge to ensure that an adequate
volume of air flows through the mouthpiece, sufficient to clear
the second stage.
4. Turn the adjustment knob out counter-clockwise until a leak
can be heard, and then back just until the leak stops. Breathe
from the second stage.
•
A properly serviced and adjusted regulator should deliver air
upon deep inhalation without excessive inhalation effort, freeflow, or vibration. When exhaling, there should be no resistance
or sticking of the exhalation valve. If any of these problems occur, refer to the Troubleshooting Guide.
Flowbench Testing (optional)
The Subjective Breathing Test, combined with the Intermediate Pressure Test, will sufficiently verify the regulator's performance
in most circumstances. As an additional test, a Magnahelic flowbench can be used to verify the second stage opening effort, which
should not exceed 1.0 column inches H2O with the knob turned out
counter-clockwise, or 2.5 column inches H2O with the knob turned
completely in clockwise.
SeaAir Regulator Service and Repair Manual
26
Service & Repair Manual
External Leak Test
After first stage reassembly and final adjustment of the second
stage has been completed, submerge the entire regulator in a test
tank of clean water while pressurized with 2,500-3000 psi. Observe
any bubbles arising from the submerged regulator over a one minute
period. The recommended time is necessary due to slower bubble
formation that occurs in smaller leaks. Disassemble the regulator at
the source of the leak to check sealing surfaces, assembly sequence
and component positioning in order to correct the problem(s).
NOTE: The location of extremely small leaks can best be
detected by applying a soap solution to the leak area. Before
disassembling to correct any leaks, rinse the entire regulator
thoroughly with fresh water and blow out all residual moisture
with filtered, low-pressure (25 psi) test gas. Refer to the
Troubleshooting section.
▼ When the second stage has been adjusted and tested according to the prescribed procedures, close the cylinder valve completely, and purge the second stage to depressurize the system. Loosen the yoke screw to remove the first stage from the
cylinder, and seal the dust cap over the inlet fitting. Disinfect
the mouthpiece, and dry the regulator completely with a clean
towel. This completes the overhaul service procedures for the
SeaAir regulator.
27
Copyright ©2011 XS Scuba
SeaAir Regulator
Troubleshooting Guide
First Stage
SymptomPossible CauseTreatment
Excessive inhalation resistance 1. Cylinder valve partially opened.
1. Fully open valve, turn back 1/4 turn. Check fill pressure.
from both second stages
2. Cylinder valve requires service.
2. Connect to a different cylinder.
3. Filter is clogged.
3. Replace filter with new.
4. Low intermediate pressure.
Low intermediate pressure
1. Piston cap is loose.
1. Tighten piston cap.
2. Replace spring and spring washers.
2. Main valve spring is damaged.
4. See below.
3. Incorrect number of spring washers
3. (With new spring only:) Install up to a total of three washers.
High intermediate pressure
1. HP seat damaged or worn.
1. Replace HP seat.
2. Piston O-rings damaged or worn.
2. Replace O-rings.
3. Piston is damaged.
3. Replace orifice.
4. First stage body damaged internally.
4. Replace body.
Leakage from beneath yoke
5. Incorrect number of spring washers
5. Remove washers.
1. Yoke retainer O-ring damaged or worn.
1. Replace O-ring.
CAUTION: All repairs must be performed with a complete overhaul service, unless the problem is
detected immediately after a complete overhaul service has already been performed. Do not attempt
to perform partial service if the regulator shows any signs of use. For additional troubleshooting
assistance, contact your XS Scuba distributor.
SeaAir Regulator Service and Repair Manual
28
Service & Repair Manual
Troubleshooting Guide
Second Stage
SymptomPossible CauseTreatment
Freeflow or leakage
(Adjustment knob turned in)
1. Excessive intermediate pressure.
1. Refer to first stage troubleshooting
2. Damaged or worn LP seat.
2. Replace with new.
3. Damaged orifice sealing surface.
3. Replace with new.
4. Damaged orifice O-ring.
4. Replace with new.
5. Orifice incorrectly adjusted.
5. Reset to preliminary setting and readjust.
6. Poppet spring damaged.
7. Lever pad is damaged or incorrectly
installed.
6. Replace with new.
7. Replace with new.
Excessive Inhalation Resistance 1. Insufficent intermediate pressure.
1. Refer to first stage troubleshooting
or
Hesitation
2. Orifice incorrectly adjusted.
3. Reset to preliminary setting and (Adjustment knob turned out)
readjust.
3. Lever is damaged.
3. Replace with new.
Insufficient airflow when
1. Lever is slack, or orifice incorrectly adjusted. 1. Reset to preliminary settings and readjust.
purge button is depressed
2. Lever is bent.
2. Replace with new.
Water entering second stage
1. Exhaust valve worn or damaged.
1. Replace with new.
2. Mouthpiece worn or damaged.
2. Replace with new.
3. Adjustment knob or O-ring damaged,
3. Disassemble and inspect, replace or incorrectly installed, or worn. reassemble as required.
29
Copyright ©2011 XS Scuba
SeaAir Regulator
Schematic & Parts List
SeaAir First Stage
1
55
2
6
7
4
88
3
9
10
11
12
13
14
19
15
17
20
20
21
22
24
23
18
27
25
26
16
E X P LO D E D VI EW
300 BAR DIN Adapter
33
34
35
#
Part #
RP200
36
37
DIN Adapter
Service Kit
SeaAir Regulator Service and Repair Manual
38
39
Dealer
25.00
33
RP200-33
Handwheel
34
RP200-34
Washer
1.00
35
RP200-35
Spacer
2.00
36
RP200-36
O-ring
37
RP200-37
DIN Retainer
38
RP200-38
Filter
1.50
39
RP200-17
O-ring
0.50
Part # RK6
Dealer 2.50
30
Description
Complete DIN Adapter
15.00
0.50
Includes:
36 38 39
10.00
28
29
30
31
32
Service & Repair Manual
Schematic & Parts List
SeaAir Second Stage
56
52
54
57
66
59
58
65
53
67
51
55
68
64
42
43
45
44
48
47
46
49
60
50
62
41
40
63
61
Second Stage
Service Kit
First Stage
Service Kit
Includes:
Includes:
Part # RK3
Dealer 6.00
#
Part #
Description
# Part #
1
RP200-01
Yoke Screw Decal
1.00
17
RP100-17
2
RP200-02
Yoke Screw
8.00
18
RP100-18
3
RP200-03
Dust Cap w/ String & O-ring 3.00
19
4
RP100-04
Yoke
20.00
20
5
RP200-05
Retaining Clip
1.00
6
RP200-06
Filter
7
RP200-07
8
RP100-08
9
9
6
Part # RK2
Dealer 7.00
7
18 19 20
Description
Part #
41 44 46 48
50 58 60 64 66
Dealer
#
HP Spring
6.00
40
RP250-28
Plug
4.00
55
RP250-16
Front Cover
HP Seat
2.00
41
RP250-02
O-ring
0.50
56
RP250-17
Retaining Ring
RP100-19
O-ring
0.50
42
RP250-03
Balance Shuttle Cap
2.00
57
RP250-18
Lever
4.00
RP100-20
O-ring
0.50
43
RP250-04
LP Spring
2.00
58
RP200-12
O-ring
0.50
21
RP100-21
Piston
20.00
44
RP250-05
O-ring
0.50
59
RP250-20
Inlet Fitting
2.00
1.50
22
RP100-22
Collar
2.00
45
RP250-06
Poppet
5.00
60
RP250-11
“No Bump” Tie Strap 0.50
O-ring
0.50
23
RP100-23
Piston Cap
15.00
46
RP250-07
LP Seat
2.00
61
RP250-22
Exhaust Valve
2.50
Yoke Retainer
8.00
47
RP250-08
Air Barrel - Brass
16.00
62
RP250-23
Mouthpiece
3.50
RP200-29
O-ring
0.50
47
RP250-08S
Air Barrel - Titanium
35.00
63
RP250-24
Exhaust Tee
6.00
10
RP100-10
Saddle 3.00
48
RP250-09
Lever Pad
2.00
64
RP200-19
O-ring
11
RP100-11
Main Body
35.00
49
RP250-10
Adjustable Orifice
4.00
65
LP30
LP Hose - 30”
12
RP200-31
O-ring
0.50
50
RP200-19
O-ring
0.50
66
RP200-29
O-ring
13
RP200-32
LP Port Plug
2.00
51
RP250-12
Housing Body 10.00
67
RP250-25
Hose Protector6
2.00
14
RP200-17
O-ring
0.50
52
RP250-13
Retaining Clip
3.00
68
RP250-26
Hose Cover
15
RP200-16
HP Port Plug
2.00
53
RP250-14
Diaphragm
5.00
16
RP100-16
Spring Washer
0.50
54
RP250-15
Thrust Washer
1.00
11
Dealer
5
31
Description
Dealer
# Part #
Description
Dealer
5.00
15.00
0.50
12.00
0.50
2.00
Copyright ©2011 XS Scuba
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