Oceanic AIR XS Operating instructions

© 2002 Design 1998
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AIRXSALTERNATEINFLATOR
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TROUBLE SHOOTING - REGULATOR
SYMPTOM POSSIBLECAUSE TREATMENT
* Free flow or leakage present. 1.Excessive lever(47) height.
2.Excessive intermediate pressure
from first stage.
3.Lever arm(47) bent.
4.Debris trapped under front
cover(44).
5.Damaged or worn poppet seat(21).
6.Damaged orifice(20).
7.Locking nut(38) overtightened onto
poppet(22) shaft.
8.Washer(46) bent or distorted.
9.Spring(23) weakened or worn.
10.Orifice(20) incorrectly adjusted.
1.Adjust orifice and locking nut to
arrive at correct springload tension
and lever height. (Refer to tuning
section.)
2.Refer to first stage troubleshooting
chart.
3.Replace with new.
4.Disassemble and clean or replace
with new as needed.
5.Replace with new.
6.Replace with new.
7.Loosen to correct springload
tension and lever height. (Refer to
tuning section.)
8.Replace washer, spacer, and
locking nut with new.
9.Replace with new.
10.Turn in clockwise to adjust. (Refer
to tuning section.)
* Excessive inhalation resistance. 1.Locking nut(38) overtightened onto
poppet(22) shaft, causing excessive
spring tension.
2.Locking nut(38) insufficiently
tightened onto poppet(22) shaft,
causing lever slack.
3.Lever arm(47) bent.
4.Orifice(20) incorrectly adjusted.
5.Insufficient intermediate pressure
from first stage.
1.Loosen to correct springload and
lever height. (Refer to tuning
section.)
2.Tighten to correct springload and
lever height. (Refer to tuning
section.)
3.Replace with new.
4.Adjust to correct contact. (Refer to
tuning section.)
5.Refer to first stage troubleshooting
chart.
1.Tear in mouthpiece(49).
2.Exhaust valve diaphragm(41)
distorted or damaged.
3.Demand diaphragm(43) distorted or
damaged.
4.Front cover retainer ring(45) not
sufficiently tight on housing.
5.Cracked or damaged housing(24).
* Water entering second stage. 1.Replace with new.
2.Replace with new.
3.Replace with new.
4.Tighten until secure.
5.Replace with new.
* Little or no airflow when purge
button is depressed.
* Rattle heard inside second
stage. 1.Lever(47) slack present.
2. Debris trapped inside hous-
ing(24).
1.Lever slack present.
2.Lever arm(47) bent.
3.Orifice(20) incorrectly adjusted.
1.Tighten locking nut onto poppet
shaft. (Refer to tuning section.)
2. Disassemble and clean or replace
with new as needed.
1.Tighten locking nut onto poppet
shaft. (Refer to tuning section.)
2.Replace with new.
3.Adjust orifice to correct contact.
(Refer to tuning section.)

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TROUBLE SHOOTING - INFLATOR
SYMPTOM POSSIBLECAUSE TREATMENT
* Air leakage detected from
beneath the oral button(51). 1.Oral button shaft o-ring(54) is
damaged or worn.
2.Oral button(51) shaft is damaged or
worn.
3.Internal damage to o-ring seating
surface inside the housing(24).
4.Oral button spring(52) is weakened.
* Air leakage detected from
beneath the oral valve disk(37).
* Air leakage detected from
beneath the exhaust valve
guard cap(42).
* Air leakage detected from the
valve housing(32).
1.Oral button locking nut(38) is loose.
2.Oral valve disk(37) is damaged or
worn.
3.Oral valve seat(36) is damaged or
worn.
4.Debris trapped between oral valve
seat(36) and oral valve disk(37).
5. Oral valve seat(36) is loose.
6. Oral valve seat gasket(35) is
damaged or worn.
1.Exhaust valve(41) is distorted or
damaged.
2. Exhaust valve(41) stem in not
sufficiently trimmed.
3. Exhaust valve frame(40) is loose.
4. Exhaust valve gasket(39) is
damaged or worn.
1.Valve housing outer o-ring(34)
damaged or worn.
1.Tighten locking nut(38) onto the
oral button shaft(51).
2.Replace with new.
3.Replace with new.
4.Disassemble and clean or replace
with new as needed.
5. Tighten sufficiently into the hous-
ing.
6. Replace with new.
1.Replace with new.
2.Replace with new.
3.Replace with new.
4.Replace with new.
1.Replace with new.
2. Trim exhaust valve stem.
3. Tighten sufficiently into the
housing.
4. Replace with new.
1.Replace with new.
1.Exhaust valve(3) is distorted or
damaged.
2. Exhaust valve(3) stem is not
sufficiently trimmed.
3. Exhaust valve frame(4) is loose.
4. Exhaust valve spring(5) is weak-
ened.
5. Gasket/Poppet assembly(6) is
damaged or worn.
6. Internal damage to seating surface
inside the upper housing assem-
bly(7).
1.Replace with new.
2. Trim exhaust valve stem.
3. Tighten sufficiently into the
housing.
4. Replace with new.
5. Replace with new.
6. Replace with new.
1.Schraeder valve(31) is worn or
damaged.
2. Valve housing inner o-ring(33) is
worn or damaged.
1.Replace with new.
2. Replace with new.
* Inflatorisautoinflating.
1.Upper gasket seal(57) damaged or
worn.
1.Replace with new.* Air leakage detected from
beneath the button slide(25).
1.Replace with new.* Air leakage detected from
beneaththe upperhousing
assembly(7).
* Air leakage detected from
beneaththe upperhousing
guard cap(1).
1.Buttton boot(27) damaged or worn.

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REMOVING THE AIRWAY FROM THE BC
1. Using a Retaining Nut Tool, turn the nut portion of the upper
housingassembly(7)counterclockwisetoloosenandremovethe
airway assembly from the BC upper valve retainer. (Fig. 1)
2. Removeanddiscardtheuppergasketseal(57). DONOTreuse.
3. Clean and inspect the upper housing retainer on the BC for any
signs of cracking or distortion, especially around the threads.
UPPER INFLATOR DISASSEMBLY & SERVICE
1. Clean and inspect the upper housing nut(7) for any signs of
crackingor distortion,especially aroundthe threads.
2. Remove the upper housing guard cap(1) by turning counter
clockwise by hand. Remove the color ring(2).
3. Remove the exhaust valve frame(4) with exhaust valve(3) by
turning counter clockwise. (Fig 2) Remove and discard the
exhaust valve. DO NOT reuse.
4. Remove the exhaust valve spring(5) and poppet assembly(6).
Discard the poppet assembly and DO NOT reuse.
5. Examine the spring(5), checking for any signs of distortion or
corrosion. Replace with new if found.
6. Cleanandexaminetheoverallconditionofallpartstobereused,
checking for any signs of stress cracks, decay or corrosion.
Replace with new if found.
7. Clean and examine the condition of the exhaust valve gasket
seatingsurfaceinsidetheupperhousing(7)foranynicks,scoring,
or other signs of damage. Replace with new if found.
8. Secure the upper housing with one hand and alternately pull the
pull-dump ball(12) and lower inflator assembly straight down
several times. The exhaust valve arm(9) will pivot outward
indicatingthattherapidexhaustcablesaresecurelyintactandof
thecorrect length.
9. Inspecttheentirelengthofthecorrugatedairwayhoses(11/15)for
any signs of decay or damage that may result in future leakage.
Replace with new if found.
NOTE: Step10isonlynecessaryifthecomponentsreferenced
inprevious steps7-9requirereplacement.
10. Toremovethecorrugatedhoses(11/15)andrapidexhaust cables(9/
14):
Fig. 1
Fig. 2

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a. Being careful to avoid damaging the corrugated airway
hose(11), snip thetie wrap(10) that holdsthe hose ontothe
upper housing(7) and gently pull it off and away from the
housing.
b. Usinga1/16"driftpinpunch,lightlytaptherapidexhaustarm
pin(8)outofthehousing. Removetherapidexhaustarmwith
cable(9)fromtheupperhousing(7).
c. Beingcarefultoavoiddamaging thecorrugatedairway
hose(11\15), snip the tie wraps(10) that hold the hoses onto
the pull ball(12) and gently pull it off and away from the ball.
d. Using a 1/16" drift pin punch, lightly tap the cable pin(13)
partially out of the pull ball(12) far enough to remove the
cables(9/14).
e. Beingcarefultoavoiddamagingthecorrugatedairwayhose(15),
snip the tie wrap(10) that holds the hose onto the lower
inflator housing(24) and gently pull it off and away from the
housing.
f. Using a 1/16" drift pin punch, lightly tap the cable pin(13)
partiallyoutofthehousing(24)farenoughtoremovethecable.
UPPER INFLATOR REASSEMBLY
NOTE: Layeachoftherapidexhaustcables(9/14)alongside
each of the corrugated airway hoses(11/15) to ensure the
correctlengthofeach.
1. Toreplacetherapidexhaustcables(9/14)andcorrugatedairway
hoses(11/15)ontotheupperhousing(7)andpullball(12):
a. Inspect both ends of the rapid exhaust arm with cable(9) to
ensure the crimps are securely intact.
b. Whileholdingtheupperhousing(7)withtheairwayhoseinlet
openingatthetop,inserttherapidexhaustarmpin(8)partially
into one of the pin holes in the side of the inlet.
c. Holdingtherapidexhaustarmwithcable(9)bythecrimp,lower
thearmintotheinletopening. Insertthepin(8)throughthearm
and into the pin hole in the opposite side of the inlet. (Fig. 2)
d. Exercising care not to allow the pin to fall out, slide the
corrugatedairwayhose(11)over the cableandontotheinlet
openingoftheupperhousing(7)sothatthehosemoldlinesare
facingthe3 and9o'clockpositions. (Fig. 3). Ensurethatthe
ridge of the housing is seated securely inside the recessed
grooveofthehose(11).
Fig. 3
Fig. 2

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Fig. 4
e. Fastenaplastictie-wrap(10)aroundthegrooveofairwaytube.
Tightenthetie-wrapwiththelocktabpositionedatthesideof
upper housing assembly. Snip off the excess.
f. Holdthepullball(12)sothatthecablepinholeportionoftheball
isdown(Fig.4). Inserttherapidexhaustcablepin(13)partially
intothe pinhole inthe sideof the pullball(12). Lay theupper
inflatorassemblyflatwiththeretainingnutfacingdownandpull
thecrimpedloopoftherapidexhaustcabletauttoensureitis
nottwisted. Placethecrimpedloopoverthepin(13)insidethe
pullball(12).
g. Press the corrugated hose(15) onto the barrel of the pull
ball(12) so that the hose mold lines are facing the 3 and 9
o'clock positions. Fasten a plastic tie-wrap(10) around the
grooveof the airwaytube. Tightenthe tie-wrapwiththe lock
tab positioned at the side of the pull ball assembly. Snip off
the excess.
h. Placeoneofthecrimpedloopsofthelowerexhaustcable(14)
overthepin(13)insidethepullball(12)andpushthepingently
through until it is seated flush inside the opposite wall of the
pull ball.
i. Exercising carenot to allowthe pin tofallout, slidethelower
corrugatedairwayhose(15)overthecableandontothelower
inletopeningofthepullball(12)sothatthehosemoldlinesare
facingthe 3and 9 o'clockpositions. Ensure thattheridge of
thepullballisseatedsecurely inside therecessedgrooveof
thehose(15).
j. Fastenaplastictie-wrap(10)aroundthegrooveofairwaytube.
Tightenthetie-wrapwiththelocktabpositionedatthesideof
upper housing assembly. Snip off the excess.
k. Lay the lower inflator assembly flat on its side with the front
cover(44)facingupandinsertthecablepin(13)throughthepin
hole,halfwayintothebarrelofthecorrugatedhoseopening.
NOTE: Donotperformthefollowingstepifthelowerinflator
unit is also being serviced.
l. Lay the upper inflator assembly flat with the retaining nut
facing down and pull the crimped loop of the lower exhaust
cable(14) taut to ensure it is not twisted. Place the crimped
loop over the pin inside the lower housing and push the pin
gentlythrough until it is seated flush inside the oppositewall
of the housing.
NOTE: Position the lower housing so the quick disconnect
valvestemis on the same side of the corrugated hoseas the
inflator hose keeper on the upper housing.
j. Pressthecorrugated hose(15) ontothebarrel ofthelower

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housing so that the mold lines are facing the 3 and 9 o'clock
positions. Fastenaplastictie-wrap(10)aroundthegrooveof
airwaytube. Tightenthetie-wrapwiththelocktabpositioned
at the side of lower housing assembly. Snip off the excess.
2. Installanewexhaust valve(3)bygentlypulling thestemthrough
thecenteroftheexhaustvalveframe(4)untiltheflangeofthestem
is completely seated on the opposite side.
WARNING: Trimtheexcesslengthofthestembeforeassem-
blingtheframeontotheupperhousing. Failuretodosocould
result in severe leakage. (Fig. 5)
3. Install the exhaust valve poppet assembly(6) into the upper
housing(7) with the gasket resting on the seating rim in the
housing.
4. Settheexhaustvalvespring(5)ontopofthepoppetassembly(6),
outside the alignment tabs. (Fig. 6)
5. Presstheexhaustvalveframe(4)withexhaustvalve(3)downover
thespring(5)andthreadclockwiseintotheupperhousing(7)until
secure. DO NOT overtighten.
NOTE: Lift the exhaust valve(3) up and visually inspect to
ensurethatthespring(5)isinstalledcorrectlyanddidnotslip
off the mounting tabs during installation.
6. Install the color ring(2) over the threads of the valve frame(4).
7. Installtheupperhousingcap(1)ontothevalveframe(4),threading
clockwise until secure. DO NOT overtighten.
LOWER (POWER) INFLATOR
DISASSEMBLY & SERVICE
NOTE: Oceanicrecommendsthatallgaskets,nonmetalfilters
ando-rings,bothstaticanddynamic,thatareremovedduring
disassembly of the Lower Inflator should be discarded and
replacedwithnew.
1. Beingcarefultoavoiddamagingthecorrugatedairwayhose(15),
snipthetiewrap(10) whichholdsthehoseonto the lowerinflator
housing(24)andgentlypullitoffandawayfromthehousingifithas
notbeenpreviouslyremoved.
2. Usinga1/16"driftpinpunch,lightlytapthecablepin(13)partially
out of the housing(24) far enough to remove the cable.
3. Beingcarefultoavoiddamagingthemouthpiece(49),snipthetie
wrap(50)that holdsthemouthpiece ontothelower inflatorhous-
ing(24) and gently pull it off and away from the housing. Inspect
themouthpiecetoensurethatitissuppleandfreeofanytearsor
corrosion.
Fig. 5
Fig. 6

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Fig. 8
4. Toremovethecoloredbuttonslide(25)useasmallscrewdriverto
gentlyprythesidesoftheslide,onesideatatime,awayfromthe
housing.(Fig.7).
NOTE: Useonlyenoughpressureliftingthesidesofthebutton
slidetoreleasethefourslideretainingtabsfromthehousing.
5. Removetheslidespring(26)andinspectforanysignsofcorrosion.
Discard if found and DO NOT reuse.
6. Removethe frontcover retainingring(45) byturning ina counter
clockwisedirectiontoexposethefrontcover(44),usingauniversal
front cover tool if necessary, and remove the front cover(44).
7. Grasp the diaphragm(43) by the raised edges of the center, and
gently lift out with a slight upward twist to remove. Inspect the
diaphragmto ensure itissupple andfreeof any tears,corrosion,
or other distortion. Discard if found.
8. Depressandholdtheleverarm(47)toremovetheinletcoupling(17)
inacounterclockwisedirection,usingan11/16"openendwrench.
(Fig. 8). Remove the adjustable orifice(20) from the inlet cou-
pling(17) by turning counter clockwise by hand. Remove and
discard orifice o-rings(19) and Do Not attempt to reuse.
CAUTION: Theorificecone(20)willnowbeexposed,andmust
behandledwithcaretopreventdamagetoits'delicateseating
surface.
NOTE: The orifice cone(20) may remain in the housing(24)
oncetheinletcoupling(17)isremoved. Inthiscase,pullthe
orificeconestraightupwithslow,steadyforce. DONOTrock
back and forth to remove.
9. Pressthevalvehousing(32)outofthelowerinflatorhousing(24)by
pushingfirmlyinwardontherubbercoveredbuttonboot(27). (Fig.
9).
10. Carefully peel the button boot(27) off the valve housing(32) and
removethepushpin(28).
11. Remove the filter tube retainer o-ring(30) and the filter tube(29)
fromthebarrelofthevalvehousing(32). Examineforanysignsof
distortion or corrosion. Discard if found.
12. Carefullyremovethe valvehousinginner o-ring(33)and outer o-
ring(34)bysqueezingandgraspingthemwiththefingers. Discard
andDONOTreuse.
NOTE: DONOTuseadentalpickorothermetalinstrumentto
remove the o-rings. Doing so could damage the seating
surfacesoftheinflatorvalve.
Fig. 9
Fig. 7

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Fig. 11
Fig. 10
13. InsertaSchraedervalvetoolintotheendofthevalvehousing(32)
and remove the Schraeder valve(31) by turning the tool counter
clockwise with slight inward pressure. Discard and DO NOT
reuse.
14. Usinga1/4"openendwrenchtoholdthelockingnut(38)secure,
turnthepoppet(22)outofthenutinacounterclockwisedirection,
using an Air XS poppet installation tool. (Fig. 10).
NOTE: To avoid a sudden ejection as they are disengaged,
continuouslyapplya slightamountofinwardpressurewhile
turning the poppet out of the locking nut.
15. Carefully remove the poppet(22), spring(23), washer(46), lever
arm(47), spacer(48), and locking nut(38) from the housing(24).
Discardthewasherandlockingnut,andDONOTattempttoreuse.
16. Examine the spacer(48) for deterioration. Discard if found.
Examinetheleverarm(47) and comparewithnewtoensurethat
itisnotbentordistortedinanyway. Discardifdistortionisfound.
17. Examinethepoppetspring(23)withamagnifierandcomparewith
new to ensure correct tension and length. Discard if found to be
weakenedorcorroded.
18. Removethe poppetseat(21)fromthepoppet(22)withtheuseof
a brass o-ring tool. Discard and DO NOT attempt to reuse.
19. Using the Air XS multi-tool (side A), remove the exhaust valve
cover(42)byturningthetoolcounterclockwisewithslightinward
pressure.
20. Using the Air XS multi-tool (side B), remove the exhaust valve
frame(40) with exhaust valve(41) by turning the tool counter
clockwise with slight inward pressure. (Fig. 11). Discard the
exhaust valve and DO NOT attempt to reuse.
21. Removetheexhaustvalve gasket(39) thatmaybefound seated
either on the underside of the exhaust valve frame(40) or inside
the housing(24). Discard and DO NOT attempt to reuse.
CAUTION: DONOTuseadentalpickorothermetalinstrument
to remove the exhaust valve gasket(39). Doing so could
damagetheseatingsurfacesoftheexhaust valveretaineror
housing.
22. Depress and hold the oral button(51) secure in the housing(24).
Removetheoral buttonlockingnut(38)by turningina counter
clockwisedirectionusinga1/4"nutdriver. Discardthelockingnut
and DO NOT attempt to reuse.
23. While applying slight outward pressure, turn the oral button(51)
counterclockwisetoremove. Removetheoralbuttonspring(52),
washer(53), and oral valve disk(37) from inside the housing.
Discard the oral valve disk(37) and DO NOT attempt to reuse.

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Fig. 12
24. UsingtheAirXSmulti-tool(sideC),removetheoralvalveseat(36)
byturningthetoolcounterclockwisewithslightinwardpressure.
Removethevalveseatgasket(35)thatmaybefoundseatedeither
on the underside of the oral valve seat(36) or inside the hous-
ing(24). Discardthevalveseatgasket(35)andDO NOT attempt
to reuse.
CAUTION: DONOTuseadentalpickorothermetalinstrument
toremovethevalveseatgasket(35). Doingsocoulddamage
theseatingsurfacesoftheoralvalveseat(36).
25. Cleanandexaminetheoverallconditionofallpartstobereused,
checking for any signs of stress cracks, decay or corrosion.
Lower (Power) Inflator Reassembly
NOTE: Priortoreassembly,itisnecessarytoinspectallparts,
bothnewandthosebeingreusedtoensurethateverypartand
componenthasbeenthoroughlycleaned.
WARNING: UseonlygenuineOceanicparts,subassemblies,
and components whenever assembling Oceanic products.
DO NOT attempt to substitute an Oceanic part with another
manufacturer's,regardlessofanysimilarityinshape,sizeor
appearance. Doing so may render the product unsafe, and
could result in serious injury or death of the user.
1. Lightlylubricateand installa newvalveseat gasket(35)onto the
stepped side of the oral valve seat(36).
2. Place the oral valve seat(36) onto the Air XS multi-tool (side C).
Lower the housing(24) onto the Air XS multi-tool with oral valve
seatseatfacingup. Turn the toolclockwiseintothehousing(24)
until secure. (Fig. 12). DO NOT overtighten.
3. Apply a light film of lubricant to each end of the oral button
spring(52)andplaceoverthethreadedendoftheoralbutton(51).
Placetheoralbuttonspringwasher(53)overthethreadsoftheoral
buttonshaftand onto thespring(52). Lightlylubricateand install
the oral button shaft o-ring(54) over the shaft and onto the
washer(53).
4. Ensuringthatthenotchesoftheoralbutton(51)arealignedwiththe
housing(24),presstheoralbuttoncompletelyintothehousingso
that the threaded end of the button is clearly visible.
5. Whilecontinuingto depresstheoral button(51), installanew oral
valvedisk(37)ontotheend of theoralbuttonshaftwiththemetal
insert facing up.
6. Turnanewlockingnut(38)clockwiseontotheoralbuttonthreads
with your fingertips until threading is started.

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7. While continuing to depress the oral button(51), turn the locking
nut(38) clockwise with a 1/4" nut driver until secure.
CAUTION: While depressing the oral button(51) slightly so
that the oral valve disk(37) is held away from the oral valve
seat(36), attempt to turn the oral valve disk with your index
finger. Ifyouareabletoturntheoralvalvedisk,itisimportant
thatthelockingnut(38)betightenedfurther. Failuretodoso
could result in severe leakage.
8. Installanewexhaustvalve(41)bygentlypullingthestemthrough
the center of the exhaust valve frame(40) until the flange of the
stem is completely seated on the opposite side.
WARNING:Trimtheexcesslengthofthestembeforeassem-
blingtheframeintothehousing. Failuretodosocouldresult
insevereleakage.
9. Lightlylubricateand installanew exhaustvalve gasket(39) onto
the stepped side of the exhaust valve frame(40).
10. Placetheexhaustvalveframe(40)withexhaustvalveandgasket
ontotheAirXSmulti-tool(sideB). Lowerthehousing(24)ontothe
AirXSmulti-toolwithexhaustvalveframefacingup. Turnthetool
clockwiseintothehousing(24)untilsecure. DONOTovertighten.
11. Installtheexhaustvalvecover(42)intothehousing(24),threading
clockwise by hand until secure. DO NOT overtighten.
12. Installanewpoppetseat(21)intothepoppet(22),withthesidethat
isperfectlysmoothfacingout. Ensurethatitiscompletelyseated,
flush with the inner rim of the poppet. DO NOT use adhesive.
13. Apply a light film of lubricant to each end of the spring(23) and
placeontothepoppet(22). Fitthepoppetintotheprongedendof
the Air XS poppet installation tool and insert the poppet shaft
completelythroughtheinlettubeofthehousing,compressingthe
springuntilthe threaded portionoftheshaft iscompletelyvisible
insidethehousing. Holdinpositionbygraspingthetoolwith the
fingers and the outer rim of the housing with the thumb.
14. Placethewasher(46)overthethreadsofthepoppet(22)andonto
the shaft. Place the spacer(48) onto the poppet shaft. Turn the
locking nut(38) clockwise onto the poppet threads with your
fingertips until threading is started.
15. Invertthehousing(24)sothatthepoppetinstallationtoolisfacing
up. Whilecontinuingtocompressthespring,placetheforksofthe
leverarm(47)overthepoppetshaft,betweenthewasher(46)and
spacer(48). (Fig.13).
16. Usinga1/4"openendwrenchtoholdthelockingnut(38)secure,
turnthe poppet(22) clockwise with the Air XS poppet installation
tooluntilthefirstindexmark(minimumadjustment)ofthepoppet
tool is aligned flush with the inlet opening of the housing(24).
(Fig.14).
Fig. 13
Fig. 14
MinimumAdjustment MaximumAdjustment