Spirit Regulator Service Manual
Contents
1. M Poppet Align Orifice Preset Tool 20 785 400 Piston Installation Bullet Intermediate Pressure Test Gauge 20 510 100 Dual Drive In Line Adjusting Tool 20 500 200 Second Stage Rim Clamp 20 790 200 Required Tools Lubricant Illustrations courtesy of Peter Wolfinger 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 Set PN 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 Lube PN MS150 P Hakko Side Cuts 5 PN 16 020 500 Galion OH 44833 Phone 419 468 2212 Snap Ring Pliers www scubatools com 11 16 Open End Wrench 3 4 Open End Wrench Copyright 2011 XS Scuba Spirit Regulator MS scusa Preliminary Inspection Z m LU Su 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 dis coloration 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 e cylinder 2 Slide back the hose protectors if present to visually inspect the2. first place it in hot 120 150 F water for 2 3 minutes and allow it to soften 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 Fig 11 Orifice Inspection 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 de cayed pull the exhaust valve straight out of the housing and discard it k 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 v 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 Spirit Regulator Service and Repair Manual W X scusa Service amp Repair Manual d Reassembly Procedures seetion General Guidelines v Refer to the schematic parts list that highlights automatic replacement parts which should be discarded and replaced with new during reassembly Thes
3. 8 00 0 50 3 00 35 00 0 50 2 00 0 50 2 00 0 50 eege RP100 22 RP100 23 Collar Piston Cap 90008 OF COERGE 09 6 RP250 06 RP250 07 RP250 08 RP250 08S RP250 09 RP250 10 RP200 19 RP250 12 RP250 13 RP250 14 RP250 15 Poppet LP Seat Air Barrel Brass Air Barrel Titanium Lever Pad Adjustable Orifice O ring Housing Body Retaining Clip Diaphragm Thrust Washer ALILIA RP250 11 RP250 22 RP250 23 RP250 24 RP200 19 LP30 RP200 29 RP250 25 RP250 26 No Bump Tie Strap 0 50 Exhaust Valve 2 50 Mouthpiece 3 50 Exhaust Tee 6 00 O ring 0 50 LP Hose 30 12 00 O ring 0 50 Hose Protector 2 00 Hose Cover 2 00 DI Copyright 2011 XS Scuba
4. Filter Retainer 6 00 RP200 17 O ring RP200 38 Filter RP200 29 O ring RP100 29 Handwheel RP100 30 DIN Retainer RP200 29 O ring GIS DIN Adapter Part RK7 Includes Service Kit Dealer 3 50 E Spirit Regulator Service and Repair Manual EN Service amp Repair Manual SCUBA Schematic amp Parts List Spirit First Stage Second Stage Service Kit Includes BIBER First Stage Service Kit Includes HEA EE SPIRIT XS SCUBA Part RK2 Dealer 7 00 SPIRIT XS SCUBA Part RK3 Dealer 6 00 Dealer Part Description Dealer Part RP250 28 Plug RP250 16 Front Cover 5 00 RP250 02 RP250 17 Retaining Ring 15 00 RP250 03 RP250 18 Lever 4 00 RP250 04 RP200 12 O ring 0 50 RP250 05 RP250 20 Inlet Fitting 2 00 Part Description Dealer Part Description Description Dealer RP200 01 RP200 02 RP100 17 RP100 18 RP100 19 RP100 20 RP100 21 Yoke Screw Decal 1 00 Yoke Screw 8 00 RP200 03 Dust Cap w String amp O ring 3 00 RP100 04 Yoke 20 00 RP200 05 Retaining Clip 1 00 HP Spring HP Seat O ring O ring Balance Shuttle Cap LP Spring O ring O ring Piston 66 8G S65 ONFDOOSSO RP200 06 RP200 07 RP 100 08 RP200 29 RP100 10 RP100 11 RP200 31 RP200 32 RP200 17 RP200 16 RP100 16 Filter O ring Yoke Retainer O ring Saddle Main Body O ring LP Port Plug O ring HP Port Plug Spring Washer 1 50 0 50
5. barrel See Fig 31 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 32 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 33 Lay the diaphragm 14 inside the housing directly over the lever with its raised surface facing up and then the thrust washer 15 Fit the front cover 16 inside the housing so that it seats directly over the diaphragm Turn it as needed to align the logo horizontally level See Fig 34 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 tight en the retaining ring until snug with the other Be careful to avoid over tightening Install the mouthpiece 23 onto the housing correctly ori ented 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 st
6. condition of the hoses especially at their fit tings 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 A 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 per Spirit Regulator Service and Repair Manual D X scusa Service amp Repair Manual forming the next procedure Intermediate Pressure Test NOTE It is not necessary to perform this test unless a problem has been reported that reguires diagnostic troubleshooting and repair When performing routine overhaul service proceed directl
7. off the filter housing 3g and closely inspect the condition of the threads to ensure it is free of any burrs or other damage that could prevent Fig 4 Removal of DIN Retainer proper threading c Apply a m open end or box wrench to the filter hous ing and loosen it counter clockwise with steady force to remove from the first stage body Remove and dis card the filter 3d and both O rings 3e Spirit Regulator Service and Repair Manual K X scusa Service amp Repair Manual 8 Remove the saddle 10 and check for any signs of dam age Set it aside to be reused if none are found 9 Remove the first stage from the vise While holding the first stage body secure with one hand unscrew the piston cap pre loosened in Step 4 counter clockwise with the other Lift the piston cap with the piston 21 straight up and off the first stage body and spring 17 Remove the collar 22 and discard or set it aside to be reused de pending on its condition 10 Pull the piston straight out of the piston cap being care ful to avoid rocking or twisting it in order to prevent metal against metal contact Remove and discard both dynam ic O rings 19 amp 20 11 To remove the high pressure seat 18 from the end of the piston shaft carefully insert a slim rod through the head and shaft of the piston Firmly press the rod against the underside of the seat to press it out of the piston shaft see Fig 5 Discard the seat and do not atte
8. on opposite ends and turn the socket counter clockwise 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 de scribed above DO NOT under any circumstances Fig 2 Loosening the Yoke Retainer 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 b Turn the yoke screw counter clockwise to remove and set aside the breaker bar and socket c Unscrew the yoke retainer counter clockwise to re move from the body along with the yoke d Remove the main seal O ring 9 from the yoke retain er Discard the O ring and do not reuse regardless of its condition Fig 3 Removal of Filter Retaining Ring 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 with a brass O ring tool Discard the filter and O ring and do not reuse these parts regardless of their condition 7 Disassembly of the DIN Connector a Apply a 4 hex key to the filter retainer 3b andturn it counter clockwise to loosen and remove see Fig 4 Remove and discard both O rings 3a amp 3c b Lift the handwheel 3f
9. shown to the customer however to ensure their confi dence and satisfaction that complete overhaul service has been performed Inspect all reusable parts as directed either during or im mediately following the disassembly procedures When in doubt compare the part with one that is new to best determine its condition Spirit Regulator Service and Repair Manual D X scusa Service amp 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 b 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 13 amp 15 with a 4mm hex key 2 Remove and inspect the O rings 12 amp 14 on these items to determine their condition and discard them if any signs of decay are found 3 Loosen the yoke screw 2 as needed to remove the dust cap 4 from the yoke 3 NOTE It will be necessary to use a bench mounted vise to hold the first stage secure throughout the next procedure This ensures the best protection against s
10. the DIN Connector a Install both O rings 3e and filter 3d into the filter housing 3g b Mate the filter housing into the inlet port of the first stage body and turn clockwise by hand until snug Apply a torque wrench with a m deep socket to tight en the filter housing to a torque measurement of 17 foot lbs 1 See Fig 15 D Copyright 2011 XS Scuba Spirit Regulator SCUBA c Fit the handwheel 3f over the filter housing with the male threaded side facing up d Install both O rings 3c amp 3a onto the filter retainer 3b Mate the filter retainer into the filter housing and turn clockwise by hand until snug Apply a torque wrench with 4 hex key socket to tighten the filter retainer to a torque measurement of 130 inch Ibs 10 13 Resecure the first stage inside the Gripmaster Vise so that the piston cap faces straight up 14 Fit the 4 Hook Spanner Peter Built PN 20 404 200 over the piston cap 23 to engage the pin with one of the bore holes and hold the tool securely engaged While holding the tool securely engaged turn the piston cap clockwise only until it has reached the extent of its thread engagement and do not tighten beyond snug 15 Loosen the vise to remove the first stage and remove the vise mounting tool 16 Lubricate and install the O rings 12 amp 14 onto all Fig 15 Torguing DIN Housing hoses and port plugs Install the LP hoses and port plugs 13 amp 15 into their respective port
11. with no signs of creeping or fluctuation If the in termediate pressure is not within the specified range or if it fails to lock up with no creep refer to the Troubleshoot ing Guide 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 35 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 inch lbs 4 Ensure that all the first stage ports are sealed and con nect the first stage with a filtered gas supply of 2 500 3 000 psi Slowly open the valve to pressurize the regu lator Listen to verify that a leak can be heard from the second stage valve and proceed to step 6 Fig 35 Inline Adjustment Tool w IP Gauge a If airflow cannot be heard it will be necessary to initiate a slight leak between the orifi
12. Initially connect the first stage to a supply of 300 psi fil tered test gas and slowly open the supply valve to pres surize 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 A to rise above 200 psi immediately shut the test gas supply valve Refer directly to the Troubleshooting guide and remedy as needed before proceedino 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 Spirit Regulator Service and Repair Manual EN X scusa Service amp Repair Manual 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 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 Guide 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
13. age proceed to Section 5 Final Testing Fig 31 Installing Orifice Fig 32 Preliminary Adjustment of Orifice Preset Depth 480 490 m ME Fig 33 Using the Orifice Pre Set Tool Fig 34 Proper Logo Alignment DI Copyright 2011 XS Scuba Spirit Regulator MS scuBA Z O H O n N 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 de pending on the connection of the test gauge CAUTION To provide a safety relief valve in the A event that intermediate pressure exceeds 155 170 psi ensure that a fully assembled and properly ad justed 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
14. ages Cylinder valve requires service Filter is clogged Low intermediate pressure Low intermediate pressure Piston cap is loose Main valve spring is damaged Incorrect number of spring washers High intermediate pressure HP seat damaged or worn Piston O rings damaged or worn Piston is damaged First stage body damaged internally Incorrect number of spring washers Leakage from beneath yoke 1 Yoke retainer O ring damaged or worn TREATMENT Fully open valve turn back 1 4 turn Check fill pressure Connect to a different cylinder 3 Replace filter with new See below Tighten piston cap Replace spring and spring washers With new spring only Install up to a total of three washers Replace HP seat Replace O rings Replace orifice Replace body Remove washers Replace O ring CAUTION All repairs must be performed with a complete overhaul service unless A 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 Spirit Regulator Service and Repair Manual EN MS scusa service amp Repair Manual Troubleshooting Guide SYMPTOM Freeflow or leakage Adjustment knob turned in Excessive Inhalation Resistance or Hesitation Adjustment kn
15. ce and poppet Press the knurled knob inward to engage the slotted drive of the Inline Adjustment Tool with the head of DI Copyright 2011 XS Scuba Spirit Regulator X scuBA 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 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 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 When the second stage is properly adjusted with no leaks or lever slack depressurize and purge the system to dis connect the LP hose 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 Ibs 5 Subjective Breathing Test 1 v While the regulator is c
16. ceived 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 amp Notes Pay special attention to information provided in Warnings Cautions and Notes that are ac companied by one of these symbols A WARNING indicates a procedure or situation that may result in serious injury or death if instruc tions are not followed correctly A A CAUTION indicates any situation or technigue that will result in potential damage to the prod uct or render the product unsafe if instructions are not followed correctly AV NOTE is used to emphasize important points tips and reminders Scheduled Service Because the Spirit 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 infreguent use NOTE A unit that receives heavy or freguent 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 Spirit User s Guide When performing serv
17. d Stage Disassemb ly Fig 6 HP Cone Inspection m Copyright 2011 XS Scuba Spirit Regulator MS scuBA 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 instru ments such as dental picks can easily damage the sealing surface of a softer brass part causing irrepa rable 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 an n open end wrench apply a 17mm open end wrench to the fitting of the LP hose Turn the hose fitting counter clockwise to loosen and remove 3 Using a plastic or brass O ring tool carefully remove the O ring 25 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 i i lacement of the LP hose 4 Using an n open end wrench turn the inlet fitting coun ter clockwise to loosen from the second stage hous ing 12 and unscrew it completely by hand to remove 5 Snip the plastic tie strap 21 that holds the mouth piece 23 and gently pull the mouthpiece off the second stage housing 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 discomf
18. e 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 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 lt 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 inspec tion especially when locating the source of a small leak Quality Wrenches amp 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 cus tomer 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
19. e parts are provided in the Annual Service Kit V Before performing any reassembly it is important to individu ally 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 v ifthe 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 oll Vv Prior to dressing inspect all O rings with magnification to en sure they are supple clean and completely free of any scoring or decay that would impair proper sealing vw 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 tempera ture conditions It is also non reactive to oxygen and is ap proved for use with EAN Nitrox CAUTION Silicone grease is not compatible with oxygen enriched air and must be strictly avoided when servic ing 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 v Dress all O rings with a visible film of Christo Lube but avoid applying excessive amounts a
20. econd 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 recom mended 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 Trouble shooting Guide v 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 depres surize 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 Spirit regulator DI Copyright 2011 XS Scuba Spirit Regulator SCUBA Troubleshooting Guide First Stage SYMPTOM POSSIBLE CAUSE Excessive inhalation resistance 1 Cylinder valve partially opened from both second st
21. facing up insert one leg of the lever 18 into one hole so that it engages with the poppet see Fig 26 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 27 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 28 8 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 page EEN 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 29 S 9 Apply a light coat of lubricant to both ends of the poppet ge spring 4 and place the spring inside the air barrel over M Eesen the small end of the poppet 7 fe TEEN 10 Insert the small end of the shuttle cap 3 into the end of the poppet spring A Fig 28 Poppet Ali
22. gnment Preset Tool 11 Install the O ring 2 onto the housing plug 1 Mate the housing plug directly over the shuttle cap and screw the plug clockwise by hand to engage the threads of the air barrel Apply a c hex key to tighten only until snug DO NOT OVERTIGHTEN 12 Install the retaining clip 13 over the groove of the hous ing plug inside the housing so that it snaps securely into place See Fig 30 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 Spirit Regulator Service and Repair Manual EN Fig 29 Valve Assembly Completely Installed X scusa Service amp Repair Manual CAUTION Be careful to avoid overtightening the inlet fitting which can crack the wall of the second 15 16 17 18 19 20 stage housing requiring its replacement Install the O ring 11 onto the head of the adjustable ori fice 10 and carefully insert the orifice into the inlet of the air barrel with 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
23. he groove See Fig 7 Apply a c hex key to turn the housing plug counter clockwise until loosened and remove it from the housing Carefully remove the O ring 2 with a plastic tool and discard Closely xamine the condition of the housing plug especially around the threads and O ring seating groove Discard if any dam age is found that may cause leakage or set it aside to be reused While holding the lever 18 lightly depressed press the inlet end to slide the entire valve assembly out of the other end of the second stage housing see Fig 8 Remove and discard the inlet fitting O ring 19 Turn the air barrel over to allow the balance shuttle cap 3 and LP spring 4 to drop out see Fig 9 Inspect the spring closely with a magnifier to check for any signs of corrosion Discard it if corrosion is found and do not reuse 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 Turn the air barrel over to allow the poppet 6 to drop out Using fingernails or a plastic tool carefully remove the LP seat 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 Remove the white lever pad 9 from the air barrel Discard and do not reuse While holding the ai
24. ice 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 a Copyright 2011 XS Scuba Spirit Regulator SCUBA Ultrasonic Cleaner 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 com modity 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 I Ultrasonic Cleaner Select the right size model that can keep up with the volum
25. 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 Spirit Regulator Service and Repair Manual D X scusa Service amp 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 se lection of the most innovative specialty tools found anywhere to help you get the job done efficiently and done right Breaker Bar 20 157 500 PETER BUILT CO 419 468 2212 LNIOd XIS wh TIME Esa I Yoke Nut Socket 20 155 500 Select Tool Kit 5 pcs 11 090 500 260 2 0 x 50 dc CHROM VAN Fe MADE IN W GERMANY 260 3 5 x 60 j ho CHROM VAN MADE IN W GERMANY C O ring Tool Set 10 102 100 Custom narrow diameter 3 8 x 3 Drive Extension 20 156 500 No 4 Hook Spanner 20 404 200 Snap Ring Pliers 4 10 101 500
26. ine 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 21 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 cor rectly the lever pad should rest flush against the flange with both tabs securely seated See Fig 22 CAUTION Do not stretch the legs of the lever pad Fig 24 Correct Poppet Orientation or attempt to install it if damage has occurred 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 23 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 24 Fig 25 Poppet Correctly Installed i Copyright 2011 XS Scuba Spirit Regulator SCUBA 7 Closely examine both holes where the lever pad is in Stalled to ensure that the ears of the poppet are prop erly aligned as shown see Fig 25 While holding the air barrel with the flat cut
27. ise become unseated or damaged and metal on metal contact could cause damage to the piston or the piston cap 4 Fit the collar 22 over the open end of the piston cap so that it seats flush aginst the shoulder 5 Over the support post inside the intermediate pressure chamber of the first stage body install the same color thickness and number of spring isolators 16 that were disassembled from the high pressure chamber CAUTION Unless the spring has been replaced with new it is very important to reinstall the same number and color combination of spring isolators as the original quantity that was removed during the disassembly procedure No more than two spring isolators may be used between the spring and the body and no more than one spring isolator may be used between the spring and the piston 6 Apply a light film of lubricant to both ends of the high pressure spring 17 and place the spring down over the support post inside the high pressure cavity of the body Fig 16 Swivel Retainer w O rings Spirit Regulator Service and Repair Manual e MS scusa Service amp Repair Manual T 10 Fig 13 Installing Piston Cap Fig 14 Torquing Yoke Retainer 11 Place the remaining spring isolator directly over the top of the spring Hold the body secure with the open intermediate pressure end facing straight up and position the piston cap over the body so that the piston shaft is aligned thro
28. lippage 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 inside the Gripmaster Vise so that the piston cap 23 faces straight up and the yoke screw faces down Fit the 4 Hook Spanner Peter Built PN 20 404 200 onto the piston cap to mate the pin inside one of the bore holes see Fig 1 While holding the tool securely engaged turn the piston cap counter clockwise to loosen no more than 4 turn 90 degrees so that it can later be removed by hand Do not loosen it further than 4 turn at this time 5 Loosen the vise and resecure the first stage in the op posite position so that the yoke or DIN adapter faces straight up Fig 1 Loosening the Piston Cap a Copyright 2011 XS Scuba Spirit Regulator SCUBA 6 Disassembly of the Yoke Connector a Loosen the yoke screw several turns counter clock wise Place a 1 Yoke Retainer Socket Peter Built PN 20 156 500 inside the yoke and over the hex fea tures of the yoke retainer 8 Pass a Breaker Bar PN 20 157 500 through the yoke and tighten the yoke screw lightly snug over the dimpled feature see Fig 2 Then grasp the breaker bar with both hands
29. m ke dl a M scuBA SERVICE AND REPAIR MANUAL SPIRIT REGULATOR PN RG100 Revised 02 11 Spirit Regulator MS scuBA Contents Section 1 Introduction Warnings Cautions Se NOIES EE 3 Scheduled Ee 3 EAN INURE OX OVC e 3 PAC IES CCU IPG ING S essre anen EE EEE OEE NNE E EEEE E 4 SPECA TOO EE 5 Section 2 Preliminary Inspection ECT IS DS O EE 6 Immersion Leak Test W 6 intermediate Pressure TeS EEN T Section 3 Disassembly Procedures ELTER Ee e E 8 EST lade DISASSE un Le EE 9 S cond Stage RI le 12 Section 4 Reassembly Procedures General E Me in EE 15 FIP SE IAG eG FREGS ue 16 SECONG Stage En e 19 Secton 5 Final Testing Procedures First Stage Intermediate Pressure Test 22 second Stage Adjustment and Flow Test 23 eler ill e RE 24 FIOW DENIC Testing eeler NEE 25 Eeler TOSE rre E E E E E 25 Troubleshooting Guide lege e E A E E E E E EE aero asie oeekc0s ne 26 ON Te 27 Schematic amp Parts Lists SPERIE et 28 SPIO CONA E Let 29 Spirit Regulator Service and Repair Manual D XS scusa Service amp Repair Manual Introduction Z SS O LU Su This manual provides factory prescribed procedures for the correct service and repair of the Spirit regulator including the first and second stage It is not intended to be used as an in structional manual for untrained personnel The procedures outlined within this manual are to be performed only by personnel who have re
30. mpt to re use 12 Remove the high pressure valve spring and spring isola tors 16 from the body Inspect the spring isolators 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 XI with no signs of permanent corrosion or damage Fig 5 Removal of HP Seat CAUTION If damage is found or if the intermediate pressure was measured lower than 135PSI during preliminary inspection replace the spring DO NOT attempt to raise the intermediate pressure by adding spring isolators to compensate for a damaged spring 13 Under strong lighting closely inspect the inner bore and all sealing surfaces of the first stage body with a magni fier including the intermediate and high pressure ports and especially the machined orifice cone see Fig 6 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 nec essary to discard the first stage body and replace it with new Do not attempt to polish the sealing surface of the orifice cone v After completing the disassembly of the first stage proceed to the following procedure Secon
31. ob turned out Insufficient airflow when purge button is depressed Water entering second stage Second Stage POSSIBLE CAUSE Excessive intermediate pressure Damaged or worn LP seat Damaged orifice sealing surface Damaged orifice O ring Orifice incorrectly adjusted Poppet spring damaged 7 Lever pad is damaged or incorrectly installed Insufficent intermediate pressure Orifice incorrectly adjusted Lever is damaged Lever is slack or orifice incorrectly adjusted Lever is bent Exhaust valve worn or damaged 2 Mouthpiece worn or damaged Adjustment knob or O ring damaged reassemble as required TREATMENT Refer to first stage troubleshooting Replace with new Replace with new Replace with new Reset to preliminary setting and readjust Replace with new Replace with new Refer to first stage troubleshooting Reset to preliminary setting and readjust Replace with new Reset to preliminary settings and readjust Replace with new Replace with new 2 Replace with new Disassemble and inspect replace or incorrectly installed or worn EI Copyright 2011 XS Scuba Spirit Regulator MS scuBA Schematic amp Parts List Spirit First Stage EXPLODED VIEW eS gt 300 BAR DIN Adapter F Part Description Dealer XS e SC U BA E RP100 Complete DIN Adapter 25 00 RP200 37 O ring 0 50 II Eau UI RP100 25
32. onnected 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 Slowly turn the adjustment knob clockwise to verify that the airflow stops between 2 1 turn Turn the adjustment knob completely in clockwise to maximum opening effort and depress the purge to en sure that an adequate volume of air flows through the mouthpiece sufficient to clear the second stage 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 ef fort 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 Spirit Regulator Service and Repair Manual EI X scusa Service amp Repair Manual Guide on pages 26 27 Flowbench Testing optional The Subjective Breathing Test combined with the Inter mediate 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 5 column inches H O External Leak Test After first stage reassembly and final adjustment of the s
33. ort 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 damage If any damage is found dis card the cover and replace with new 8 Lift out the diaphragm 14 and thrust washer 15 from the Spirit Regulator Service and Repair Manual me X scusa Service amp Repair Manual Fig 7 Removal of Retaining Clip Fig 8 Removal of Valve Assembly 13 Fig 9 Removal of LP Spring 15 16 10 11 12 14 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 Using a small flat blade screwdriver rotate the metal retain ing clip 13 over the groove of the housing plug 1 inside the second stage housing until the notch in the center faces up Place the tip of a 2mm flat blade screwdriver inside this notch and gently lift the clip off t
34. r 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 to remove the orifice without damaging its polished sealing surface i Copyright 2011 XS Scuba Spirit Regulator MS scuBA 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 seal ing edge of the orifice Gently press out the orifice See Fig 10 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 the orifice head Discard the O ring and do not reuse 19 Closely examine the orifice with the use of a magnifier a checking for any scratches or other damage to the seal Fig 10 Removal of Adjustable Orifice ing edge and the groove that holds the O ring see Fig 11 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 de flector
35. rm any disassembly v After completing the Preliminary Inspection proceed to Section 3 Disassembly Di Copyright 2011 XS Scuba Spirit Regulator MS scuBA Z SS O LU Su Disassembly Procedures General Guidelines M 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
36. s in the first stage Apply a calibrated torque wrench with 4mm 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 v After completing the reassembly of the first stage pro ceed to the following procedure Second Stage Reas sembly Spirit Regulator Service and Repair Manual i SCUBA Service amp Repair Manual Second Stage Reassembly WARNING DO NOT attempt to use any other manu facturer s part as a substitute for any XS Scuba part regardless of any similarity in shape size or appear ance 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 hous ing 12 by gently pulling the stem through the hole in the center of the sealing area until the barb has passed through and is securely 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 Fit the exhaust deflector 24 over the top ridge of the sec ond stage housing so that the two corners are securely seated and then stretch the lower portion down until it snaps securely into place Fig 22 Air Barrel Orientation 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 exam
37. s 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 rub ber parts v Use all replacement parts provided in the XS Scuba Authorized Dealer parts kit e Copyright 2011 XS Scuba Spirit Regulator SCUBA First Stage Reassembly WARNING DO NOT attempt to use any other manu facturer s part as a substitute for any XS Scuba part regardless of any similarity in shape size or appear ance Doing so may render the product unsafe and could result in serious injury or death 1 Generously lubricate and install the piston head O ring 20 onto the head of the piston 21 and install the piston shaft O ring 19 onto the piston shaft 2 Install the high pressure seat 18 into the end of the pis ton shaft and check to ensure it is seated flush with no visible protrusion see Fig 12 Fig 12 HP Seat Installation 3 Set the piston cap 23 on a flat surface with the open end facing up Place the head of the piston inside the cap so that it rests perfectly level above the threads and then gently press the piston straight down into place until it is fully seated CAUTION Be careful to prevent the piston from becoming cocked at an angle as the head travels past the threads of the piston cap The O ring could otherw
38. ugh the center of the spring Mate the piston cap onto the body and firmly press downward while turning it clockwise to engage the threads see Fig 13 Continue turning by hand until snug Fit the saddle 10 onto the high pressure inlet end of the first stage Secure the first stage inside the Gripmaster Vise with the high pressure end facing straight up 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 retain ing ring 5 to identify which side is flat and which side is slightly 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 rings remain prop erly seated insert the threaded end of the yoke re tainer through the bottom of the yoke 3 and mate the yoke retainer into the inlet port of the first stage body Turn the retainer clockwise by hand until snug d Apply a torque wrench with the 1 Yoke Nut Socket PN 20 155 500 and 3 x a Socket Drive Extension PN 20 156 500 Tighten the yoke retainer to a mea surement of 24 foot lbs 1 See Fig 14 e Install the dust cap 4 onto the yoke and mate the yoke screw 2 into the yoke Turn the screw one to two revolutions clockwise to engage the threads 12 Reassembly of
39. y to the following section Disassembly 1 Connect a calibrated intermediate pressure test gauge to the regulator either with a guick 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 ad justed 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 Ifthe intermediate pressure creeps up or otherwise fluc tuates 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 at tempting to perfo
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