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

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17. Remove the tool and depress the lever arm(47) repeatedly to
ensuresmoothmovement.
WARNING: It is very important that the poppet is adjusted
using the Oceanic poppet installation tool exactly as de-
scribed in step 16. The lever arm may otherwise become
caught on the end of the poppet shaft, resulting in an
uncontrolledfreefloworleakage.
18. Lightly lubricate the threads and o-ring of the Schraeder intake
valve(31) and insert it, operating pin end first into the valve
housing(32)while holdingthe threaded end. Usinga Schraeder
valvetool, tightenin a clockwisedirection toatorque of5 to6in-
lbs.
19. Lubricateandinstallthevalvehousinginnero-ring(33)andouter
o-ring(34) by sliding them over the smaller end of the valve
housing(32).
20. Installthefiltertube(29) ontothebarrelofthehousing(32) andthe
filter tube o-ring(30) onto the filter tube.
21. Holding the valve housing(32) vertically with the open end up,
insertthepushpin(28) into thetopopeningandinstallthe button
boot(27) over the pin onto the grooved end of the housing(32).
Push the rubber button boot several times to ensure that the
Schraedervalve(31)operatesfreely.
22. Withtheellipticalopeningfacingthequickdisconnectinlet,insert
the assembled valve housing, button(27) first, into the large
opening on the side of the lower inflator housing(24) and press
firmly into place. (Fig. 15).
NOTE:Visuallyverifycorrectpositioningofthevalvehousing
by looking into the quick disconnect inlet. The elliptical
opening should be centered in the housing(24) so that the
poppetseat(21)isclearlyvisible.
23. Lubricate and install the o-ring(18) onto the threaded end of the
inletcoupling(17).
24. Lubricateandinstallthreenewo-rings(19)ontotheorifice(20).
25. Lightlylubricateandinsertthethreadedendoftheorifice(20)into
thelargeropeningendoftheinletcoupling-valvestem(17). Turn
theorificeina clockwise directionbyhanduntilresistanceisfelt.
CAUTION: Becarefultoprotectthedelicateknifeedgeofthe
orifice as this is done.
26. Holding the housing(24) vertically with the quick disconnect
(smaller)andcorrugatedhose(larger)openingsontop,carefully
insert the orifice/coupling assembly into the smaller opening,
threading it clockwise. (Fig. 16). Using a 11/16" crow's foot
adaptor and torque wrench, tighten in a clockwise direction to a
torque of 100 to 120 in-lbs.
Fig. 15
Fig. 16

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Fig. 17
27. Inserta5/32"hexkeyintotheinletcoupling(17) opening. Gently
turn the orifice(20) clockwise into the coupling(17) until the knife
edge is barely contacting the poppet seat(21).
NOTE: DONOTcontinuetoturntheorificeanyfurtherbeyond
this point, which will possibly damage the poppet seat,
requiringits'replacement.
NOTE: Thisisanimportantpreliminarysettingfortheorifice.
Forbestsensitivityoftouch,placethetipofyourindexfinger
onthelockingnut(38).
28. Place the diaphragm(43) inside the housing(24) with the raised
center facing up, and ensure that it seats flush at the base of the
inner threads. Place the front cover(44) directly over the dia-
phragm,and ensurethat itseats flush andthat theOceanic logo
isproperlyaligned.
29. Whileholdingthefrontcover(44)securewithyourthumb,thread
thefrontcoverretainingring(45)ontothehousing(24),takingcare
to ensure that it is correctly seated on the threads. Hand tighten
until secure. DO NOT overtighten. (Fig. 17).
30. Securethemouthpiece(49)ontothehousing(24)withanallplastic,
noncorrosive tie wrap(50), positioning the locking tab of the tie
wrap towards the bottom of the housing. Snip off excess.
NOTE: Oceanic's patented Orthodontic Mouthpieces are
designedtoaccommodatethenaturaloverbiteofthehuman
jaw.
31. Holdingthelowerinflatorhousing(24)withthemouthpiecefacing
up,place the slide spring(26) over the rubber button boot(27) so
thatitrestsonthe housing(24). Usingmoderate force,lowerthe
buttonslide(25) down over the spring(26) and recessed sides of
thehousing(24)untilthefourslidetabssnapintoplace. (Fig.18)
32. Lay the lower inflator assembly flat on its side with the front
cover(44) facing up and insert the cable pin(13) through the pin
hole, half way into the barrel of the corrugated hose opening.
33. Lay the upper inflator assembly flat with the retaining nut facing
downandpullthecrimped loop oftherapidexhaustcabletautto
ensureitisnottwisted. Placethecrimpedloopoverthepininside
thelowerhousingandpushthepingentlythroughuntilitisseated
flush inside the opposite wall 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.
Fig. 18

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34. Pressthecorrugatedhose(15)ontothebarrelofthelowerhousing
so that the mold lines are facing the 3 and 9 o'clock positions.
Fasten a plastic tie-wrap(10) around the groove of airway tube.
Tightenthetie-wrapwiththelocktabpositionedatthesideoflower
housing assembly. Snip off the excess.
INSTALLING THE AIRWAY ONTO THE BC
WARNING: CertainOvationandOceanSportBCsdonothave
aloweroverpressurereliefvalve,andrely onthefunctionof
onethatisincludedintheOceanicintegratedairwayassem-
bly that was originally sold with the BC. DO NOT attempt to
attachanon-OceanicairwaytotheBC. Doing so may result
in permanent, unrepairable damage to the bladder, and
rendertheBCunsafe.
1. Placetheuppergasketseal(57)insidetheupperretaineroftheBC.
Holdtheairwayinthedesiredpositionandthreadtheretainingnut
of the upper housing assembly(7) clockwise onto the upper
retainer. UsingaRetainingNutTool,tightentheretainingnutuntil
completely secure. (Fig. 19)
CAUTION: DONOTovertighten.
FINAL TUNING & TESTING
TUNING
1. Prior to tuning the Air XS, check the following items:
a. ThepoppetassemblyhasbeeninitiallyadjustedusingtheAir
XS poppet installation tool as described in step 16 of Lower
InflatorReassembly.
CAUTION: Itisimportanttoensurethatthisinitialadjustment
wasmadeasdescribedbeforeproceedingfurther. Thelever
arm(47) may otherwise become caught on the end of the
poppet shaft, resulting in an uncontrolled free flow.
b. Thefrontcover(44)shouldbetightenedsecurelyandproperly
alignedonthehousing.
c. Themouthpieceshouldbecleanedanddisinfectedwithwarm,
soapywater.
d. The Air XS is attached to a recently calibrated first stage via
an Air XS low pressure quick disconnect hose.
Fig. 19

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2. Pressurize the regulator with a pure breathing gas source of
3,000PSI (206 BAR), and listen to determine that a slight airflow
isinitiallypresent. Ifnecessary,disconnectthequickdisconnect
hose and insert a 5/32" hex key into the inlet coupling. Turn the
orifice slightly out counter clockwise to initiate this airflow.
CAUTION: ToavoidcuttingtheLPseatwiththeknifeedgeof
theorifice,depressthepurgebuttonwhileturningtheorifice
in or out.
3. Usethe5/32"hexkeytoturntheorificeclockwisewithverysmall
fractionsofaturn,justuntilairflowisnolongerpresent,andpause
to listen carefully for airflow or leakage after each adjustment.
Whilecontinuingtodepressthe lever arm,usethe5/32"hexkey
to turn the orifice clockwise an additional 1/12 of a turn.
CAUTION: Turning the orifice further than described will
resultinexcessiveleverarmslackandexcessivespringload
tension,impairingproperperformance.
4. HoldtheAir XSwiththe frontcoverfacing directlyup,and gently
shake up and down. Listen for excessive rattle that may be
present, indicating lever slack. Some lever slack is considered
normalduetothecloseproximityofthesofturethanefrontcover
to the inhalation diaphragm. Eliminating this completely would
resultin anoversensitive secondstage, consideredundesirable
foranalternateairdevice. Ifexcessiveleverarmslackispresent,
performthefollowingprocedure:
a. Purgethe regulator ofair.
b. Removethefrontcoverretainer,frontcoveranddiaphragmto
gain access to the valve assembly.
c. Depress the lever arm and hold to remove the inlet coupling
fromthe housing,using an11/16" openend wrench.
CAUTION: Theorificeconewillnowbeexposed,protruding
throughtheinletcoupling,andmustbehandledwithcareto
preventdamagetoits'delicateseatingsurface.
d. Removethebuttonslideandspring. Pressthevalvehousing
out of the lower housing by pushing firmly inward on the rubber
coveredbutton.
e. Using a 1/4" open end or box wrench to hold the locking nut
secure,turntheAirXS poppetinstallationtoolclockwise1/8turn
to tighten the locking nut further onto the poppet shaft.
WARNING: DONOTattempttotightenthelockingnutbeyond
where the second index mark (maximum adjustment) of the
AirXSpoppetinstallation toolisflushwiththe inletopening
ofthehousing. Doingsomayrendertheproductunsafe,and
could result in serious injury or death of the user. (Fig. 20).
NOTE: Avoid tightening the locking nut any further than is
necessary to eliminate lever slack. It may be necessary to
repeat step E several times to arrive at the correct setting. Fig. 20
MinimumAdjustment MaximumAdjustment

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P/N 40.3367 Air XS Poppet Installation Tool
P/N 40.3362 Air XS Multi-Tool
P/N 40.9650 Universal Front Cover Tool
P/N 08.9500 Retaining Nut Tool
P/N 40.9519 Schraeder Valve Tool
P/N 40.9313 5/32" Allen Key
P/N 40.2300 VFC-23 Cleaner - Pint
P/N 40.2308 VFC-23 Cleaner - Gallon
P/N 40.2302 Christo-Lube MCG111 - 2 oz.
P/N 40.9520 O-ring Tool Kit
P/N 40.9412 1/16" Drift Pin Punch
P/N 40.9512 1/4" Open End/Box Wrench
Torques
P/N 810266 5 to 6 in-lbs
Schraeder Valve 56.5 to 67.8 Newton - cm
P/N 83365 100 to 120 in-lbs
Inlet Coupling 11.5 - 13.5 Newton - m
Opening Effort (IP = 144 psi / 10 BAR)
1.6 to 2.2 inches of H2O
3.8 to 5.6 cm of H2O
f. Usetheproceduredescribedinsteps26-29 ofLowerInflator
Reassembly to replace the inlet coupling after each adjust
ment,andagaindeterminewhetherexcessiveleverarmslack
is present.
CAUTION: Be careful to avoid over adjusting! If airflow
returns,replacethelockingnutandseatwithnew, and start
overafterrereadingtheaboveprocedures.
5. Replace the valve housing assembly, button slide and spring,
diaphragm, front cover, and front cover retainer if removed, and
pressurizetheregulatoragainwithapurebreathinggassourceof
3,000PSI (206 BAR). Inhale lightly through the mouthpiece to
performasubjectivebreathingtest ofairflowandcrackingeffort.
Airshouldfloweasilyandsmoothly,withoutanyhesitationorlag.
NOTE: If hesitation or lag is detected, refer to the Trouble
Shootingsectiontodeterminepossiblecauseandtreatment.
NOTE: Ifnotpreviouslyinstalled,attachtheairwayontothe
BC as described in Installing the Airway onto the BC before
proceedingfurther.
6. Attach the Air XS to a pure air source, via a quick disconnect LP
hose,andperform the GeneralAirLeakInspection as described
in Buoyancy Compensator General Procedures (Section 5.1) to
ensurethatleakageisnotpresentandtheinflation,deflation,over
pressure relief valve, and pull dump are functioning perfectly. If
leakage is found, refer to the Trouble Shooting section to deter-
mine possible cause and treatment.
7. WiththeBCfullyinflated,removethe Air XSfrontcoverretainer,
frontcoveranddiaphragmtoperformonefinalleakdetectiontest.
Thisis importantto ensurethat noleakage is foundbetween the
oral valve disk(37) and oral valve seat(36). If leakage is found,
refertotheTroubleShootingsectiontodeterminepossiblecause
andtreatment.
SPECIFICATIONS
SPECIALTYTOOLS

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56
55
n/s 08.9700 Annual Service Kit
(Includes all Bold items)
1c 819011 Cap - Upper Housing
2c 819013.01 Ring - Color (BL)
3a 4576 Valve - Exhaust
4c 819039 Frame - Exhaust Valve
5c 819041 Spring - Exhaust Valve
6a 819040.1 Gasket/Poppet Assembly
7c 819042.1 Upper Housing Assembly
8c 819014 Pin - Rapid Exhaust Cable
9c 819691.6 Cable - Rapid Exhaust (6")
819691.8 Cable - Rapid Exhaust (8")
819691.10 Cable - Rapid Exhaust (10")
10c 84408 (4) Tie Wrap - Corrugated Hose
11c 84946.10 Corrugated Hose - Upper (10")
12c 83284 Ball - Pull
13c 84948 (2) Pin - Pull Ball/Air XS
14c 83286.6 Cable - Lower (6")
83286.8 Cable - Lower (8")
83286.10 Cable - Lower (10")
15c 84946.6 Corrugated Hose - Lower (6")
84946.8 Corrugated Hose - Lower (8")
84946.10 Corrugated Hose - Lower (10")
16c 83292 Cap - Quick Disconnect
17c 83365 Coupling - Inlet
18b 3.906 O-ring - Inlet Coupling
19a 2.010 (3) O-ring - Orifice Shaft
20c 83364 Shaft - Orifice
21a 4340 Seat - Poppet
22c 4333 Poppet
23c 5074b Spring - Poppet
24c 83260 Housing
25c 83271.01 Slide - Button (BL)
26c 819030 Spring - Button Slide
27b 819017 Boot - Button
28c 819023 Pin - Push
29b 810236 Tube - Filter
30b 2.011 O-ring - Filter Retainer
31a 810266 Intake Valve - Schraeder
32c 83267 Housing - Valve
33b 2.013 O-ring - Valve Housing (Inner)
34b 2.014 O-ring - Valve Housing (Outer)
35a 83361 Gasket - Oral Valve Seat
36c 83291 Seat - Oral Valve
37a 83262 Disk - Oral Valve
38a 4336 (2) Nut - Locking
39a 83275 Gasket - Exhaust Valve
40c 83264 Frame - Exhaust Valve
41a 83263 Exhaust Valve
42c 83265 Cover - Exhaust Valve
43b 6380 Diaphragm - Demand
44c 86554.01 Front Cover - Blue
45c 86553 Ring - Front Cover Retaining
46a 5117 Washer
47c 83270 Arm - Lever
48b 4335 Spacer
49c 4485.07 Mouthpiece
50a 1978.07 Tie Wrap (Mouthpiece)
51c 83261.01 Button - Oral (BL)
52c 83266 Spring - Oral Button
53c 86403 Washer - Spring
54a 2.008 O-ring - Oral Button Shaft
55b 3.903 O-ring - QD Hose
56c 816172.26 Air XS QD Hose Assembly (26")
816172.30 Air XS QD Hose Assembly (30")
816172.34 Air XS QD Hose Assembly (34")
57a 819045 Seal - Upper Gasket
Dia.
No. Part # Description
13
14
10
15
10
16
17
23
18
19
20
21
22
10
11
10
8
7
9
23
4
5
6
1
12
19
19
13
26
25
27 41
40
39
37
36
35
34
33
32
31
30
29
28 42
38
43 44 45
38
48
47
46
54
49 50
53
52
51
57
24