XS Scuba Inspire Regulator, Service Manual

Page 1: ...1 www XSscuba com XS Scuba Inspire Regulator Service Manual Inspire Regulator Service Manual Covers Inspire Regulator and Inspire Octopus ...

Page 2: ...mbols WARNING indicates a procedure or situation that may result in serious injury or death if instructions are not followed correctly 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 NOTE is used to emphasize important points tips or reminders Cleaning Procedures 19 Preparing an...

Page 3: ...factory mandated torque values using a calibrated torque wrench To do otherwise could lead to damage or failure of the product 8 Unless otherwise instructed the following is assumed a When instructed to remove unscrew or loosen a threaded part turn the part counterclockwise The manual abbreviates counterclockwise with CCW b When instructed to install screw in or tighten a threaded part turn the pa...

Page 4: ...rd the medium or interstage pressure Record the value and whether it stabilizes or creeps 5 Pressurize the regulator and submerge in a tub of water Are there any leaks If so document where the leaks are coming from 6 Purge the regulator Is the purge strong or weak Is there free flow or leaking after purging 7 If an adjustment knob or venturi deflector lever is present check if they move freely 8 A...

Page 5: ...ch Round Surface Loosen and tighten diaphragm clamp TL136 Multi Purpose Tool Remove and install parts TL117 Regulator Cover Removal Tool Remove and install front cover n a Side cutters Removes mouthpiece tie wrap n a Circlip Pliers Removing Installing Circlip TL121 Inline Adjuster w Gauge Measures MP and adjusts 2nd stage n a Torque Wrench with Crows Feet and Hex Key Adapters For applying proper t...

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Page 10: ...6 20 UNF end of the TL122 Regulator Support Handle Vise Mounting Tool into the HP port Be sure to fully engage the threads NOTE It will be necessary to use a bench mounted vise to hold the first stage securely throughout the next procedures The first stage must be mounted outside of the vise by use of the TL122 Support Handle Vise Mounting Tool installed into the HP port 5 Securely mount the tool ...

Page 11: ...ome in through the backside of the yoke retainer 7 and push out the filter 5 and its associated o ring 6 v Remove the o ring 8 from the underside of the yoke retainer 7 B Inspire with DIN connector Reference exploded diagram with DIN version i Remove the handwheel retainer 2 using a 6 mm hex key ii Remove the handwheel 6 dust cap 9 and saddle 10 iii Remove the two o rings 1 3 found on each side of...

Page 12: ... regulator in the vise so that the turret 21 and turret bolt 28 are facing up B Using a 6 mm hex key remove the turret bolt as sembly 28 8 Remove the turret 21 A Remove the thrust washer 26 B Remove the turret 21 by pulling straight up on it C Remove the underlying o ring 20 9 Separate turret bolt assembly 28 A Separate the HP seat 22 and valve spring 23 from turret bolt 28 B Remove the two outer ...

Page 13: ... 18 and remove it CCW B Lift out spring seat 15 12 Remove diaphragm washer 14 A Using a strong o ring pick get underneath the clear diaphragm washer 14 and lift it out 13 Remove the diaphragm 13 CAUTION The diaphragm 13 makes an airtight seal by resting on a critically machined surface on the main body 11 While removing the diaphragm do not scratch the main body 11 or it may need to be replaced A ...

Page 14: ...aphragm washer 10 and the inhalation diaphragm 9 Carefully inspect the diaphragm for small tears or holes If found in good condition it may be reused 3 Remove the Mouthpiece 3 A With a pair of side cutters carefully cut the tie wrap 2 and discard Be careful not to let side cut ters nick the mouthpiece 3 B Remove the mouthpiece 3 Inspect the mouth piece for holes or tears especially around the seal...

Page 15: ...old it in place by turning the adjustment knob 26 CCW until it comes to a soft stop CAUTION Applying too much pressure to the adjustment knob 26 can result in bending the retaining pin 18 thus making it difficult to remove and causing replacement B While pressing the lever 19 all the way down carefully slide the entire valve assembly 17 out of the main housing 1 by pushing on the inlet side of the...

Page 16: ... retaining pin 18 If the retaining pin 18 does not fall out on its own you may push it out with the TL136 Multi Purpose Tool ii Turn the adjusting knob 26 CCW until it is free iii Remove and discard its associated o ring 25 D Separate the poppet assembly from the valve housing 17 i The poppet assembly comprised of the balance chamber 24 spring 23 and poppet 21 are removed at this time Grab the lev...

Page 17: ...move the crown orifice from the air barrel A Use the back end of the TL136 Multi Pur pose tool to push the orifice 13 out of the valve housing 17 If it doesn t move it is possible that it may still have some thread engagement see step 7a iv Remove the o ring 14 from the crown orifice 13 8 Separate the Poppet Assembly A Separate the balance chamber 24 the spring 23 and the poppet 21 B Disassemble t...

Page 18: ...ww XSscuba com XS Scuba Inspire Regulator Service Manual ii Again using a fingernail remove the low pressure seat 20 from the front of the poppet 21 This completes the Inspire 2nd Stage Disassembly 8B 8B 8B ...

Page 19: ...er the inside of the hose s Doing so may cause a breakdown of the inner hose lining which can lead to obstruction of the air passage way Preparing and Inspecting Parts Nitrox Preparation If you are preparing the regulator to place back into nitrox service O2 not to exceed 40 you should use powderless latex or nitrile gloves to keep finger oils off of the clean parts O rings All O rings should be r...

Page 20: ...emoves corrosion and mineral build up from metallic parts Household grade Oakite31 diluted with water Use in sonic cleaner to clean metal parts Oakite Products Inc 50 Valley Road Berkeley Heights NJ 07922 www chemetallna com Christo lube MCG 111 o ring dressing XS Scuba 4040 W Chandler Ave Santa Ana CA 92704 866 977 2822 www XSscuba com Tribolube 71 o ring dressing Aerospace Lubricants 1600 George...

Page 21: ...it the diaphragm 13 into the under cut groove of the main body 11 Work the edges with your finger to make certain that is fully seated in the under cut 4 Install the diaphragm washer 14 on top of the diaphragm 13 It too should fit in the under cut recess 5 Place the spring seat 15 in the center of the diaphragm 13 with the perimeter tabs facing up 6 Drop a main spring washer 16 on to the spring se...

Page 22: ...e turret bolt Use the TL136 multi tool to seat it evenly NOTE This is a dynamic o ring 24 The stem of the HP seat moves through the center of it with each breath Therefore lubricate it generously making certain to get lubricant on the inner wall of the o ring B Install o rings 25 28 on to the turret bolt C Install spring 23 and HP seat 22 12 Install turret 21 and turret bolt 28 assembly A Turn the...

Page 23: ... 10 in lbs 10 Nm F Remove the regulator body from the vise 13 Install the connector assembly A Inspire with yoke connection i Insert a non lubricated o ring 6 into the top of the yoke retainer 7 ii Insert filter 5 narrow end first into the top of the yoke retainer 7 It should nest in the o ring 6 iii Using circlip pliers secure filter with the circlip 4 Install circlip 4 with flat side facing up M...

Page 24: ... it will go vii Mount the body back into the vise viii Using the 19 mm socket TL123 with an extension attached to a ft lb torque wrench apply a torque to the retainer of 24 ft lbs 1 Nm ix Install the yoke knob B Inspire with DIN connection Refer to the DIN version exploded parts diagram i Add the replacement o ring 8 to the bottom of the DIN housing 7 ii While holding the DIN housing 7 upside down...

Page 25: ...threads facing upwards 6 vii Insert unlubricated filter o ring 5 into the DIN housing 7 Make sure that it lays flat viii Insert filter 4 pointed end first into the DIN housing 7 ix Install the two o rings 1 3 on either side of the handwheel retainer 2 x Thread the handwheel retainer 2 by hand into the DIN housing 7 xi Using a 6 mm hex key adapter apply a torque to the handwheel retainer 2 of 90 10...

Page 26: ... 31 on to male end of MP hose B Install MP hose into its respective port Using a torque wrench and a 9 16 crow s foot torque the hose to 40 in lbs 4 5Nm C Slide the hose protector back into position This concludes Inspire First Stage Reassembly Adjusting and Testing 1 Checking medium pressure A Attach the TL121 Inline Adjuster with Gauge to the end of the MP hose Attach a proper functioning 2nd st...

Page 27: ...o a MP port G Let the unit sit under pressure for 5 minutes The medium pressure should remain fairly stable It is common to see the pressure creep by a few psi The standard of acceptability for medium pressure creep is up to 5 psi over a 5 minute period If the medium pressure creeps more than 5 psi over a 5 minute period this indicates that there is a leak Refer to the Troubleshooting Table locate...

Page 28: ...poppet 21 with its two o rings 22 should be seated inside the balancing chamber 24 E Set aside for the next completed assembly NOTE The latest lp seat is the one that is orange in color This is the one found in the service kit Please discard previous versions that are colors other than orange 3 Prepare Adjusting Knob 26 A Install o ring 25 into groove on the adjusting knob 26 Set aside for the nex...

Page 29: ...e lp seat 20 past the lever feet and allow the L shaped sockets to engage When the L shaped features on the poppet 21 engage the lever feet they will lift the lever 19 upwards as you push the assembly in D Install the adjusting knob 26 i Insert adjusting knob 26 o ring side first just behind the poppet assembly into the valve housing 17 The lever 19 should now have spring tension on it ii Turn the...

Page 30: ...gh Guide it up slowly B Confirm that the lever feet are between the molded tabs on the box bottom CAUTION Confirm that the lever feet are between the molded tabs on the box bottom This retains the lever feet so that they don t back out of the valve housing C Install the valve housing o ring 6 on to the threaded end of the valve housing 17 D Install the bushing 7 on to the threaded end of the valve...

Page 31: ...row end of the valve housing B Using the Regulator In Line Adjusting Tool TL121 or a 3 16 hex key press the crown orifice in as far as it will travel Turn it CW two complete revolutions This is the preset position Center Line Top Edge of Lever Arm 8 Adjusting Lever Height A Thread the TL121 Tool onto the air inlet end of the valve housing B Connect a medium pressure hose 135 to 145 psi to the inle...

Page 32: ...m the crown orifice Failure to perform this step can cause changes to the regulator s adjustment 9 Continuation of Assembly A Install the diaphragm 9 i Position the diaphragm 9 into the main housing 1 Use the back of the TL136 Multi Purpose Tool to work the edges of the diaphragm into place B Install the thrust washer 10 over the top of the diaphragm 9 C Install the front purge cover 11 i Place th...

Page 33: ...to a container of water with the mouthpiece up Keep the diaphragm perfectly horizontal Place your ear close to the mouthpiece You should hear the demand valve open indicated by hissing air when the diaphragm is approximately 1 inch deep If not be sure that the adjustment knob is turned all the way out 3 Vacuum Test A Do not pressurize the regulator in this step B Plug the mouthpiece C Immerse the ...

Page 34: ...Depress the purge button to ensure an adequate volume of air needed to clear the regulator passes through the mouthpiece C Inhale slowly but deeply through the mouthpiece A properly serviced and adjusted regulator should deliver air without excessive effort or resistance It should not flutter shudder or stutter D Afterward there should be no freeflow hissing or leaking E Exhalation should be smoot...

Page 35: ...le but too high Main spring force is too strong Turn the adjustment screw 19 CCW Restricted Air Flow Hard inhalation throughout entire system Cylinder valve not opened all the way Open valve all the way Check supply pressure Cylinder valve requires service Get valve serviced Conical filter is wholly or partially contaminated Service entire regulator including filter replacement Visually inspect cy...

Page 36: ...fice CCW until the lever is up against the back of the diaphragm Lever 19 bent Replace lever Excessive breathing resistance Adjusting knob 26 in too far Back out adjusting knob 26 Lever 19 is bent Replace lever MP too low Make sure that MP is between 130 and 145 psi 9 10 bar Lever too low Back out crown orifice CCW until the lever is up against the back of the diaphragm Breathes wet or water enter...

Page 37: ... 150 psi 9 10 bar 5 0 SCFM 142 L min minimum flow rate Leak Test Inlet 3000 psi 207 bar No leaks allowed Test Bench Specifications Part Description Key Item Torque RP450 08 Retaining Nut Valve Housing 30 in lbs 3 4 Nm RP550 30 Regulator MP Hose 40 in lbs 4 5 Nm Second Stage Torque Specifications Part Description Key Item Torque RP500 28 Turret Bolt 90 in lbs 10 10 Nm RP500 07 Yoke Retainer 7 24 ft...

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