POSEIDON Xstream Series User manual

XSTREAM
SERVICE MANUAL V2.9

1. CONTENTS
!
SERviCE maNual - xSTREam
Table of contents
1. Safety regulations 2
2. Introduction 3
"#$%&'()* +
,-$.&/-*0#'1233%* 4
,56237)*8)-1*90$38(0389*90-*0#'1233%* 4
:6;$3.-6-'9)* 4
Product upgrades 5
Information about Xstream Upgrade kit 4826 5
Information about Xstream 1st stage covers. 5
Information about Xstream Upgrade to cover with adjustment screw. 5
Recommendations 5
EN 144-3 5
Article number on o-rings 5
3. Determination of required service 6
4. Tools and tool order form 7
5. Spare parts & service kits 8
,-/3'1*)9#(-)* <
=&$)9*)9#(-*239936*638'9-1* >
=&$)9*)9#(-*>?* !?
,-$.&/-%&9)* !!
Xstream Upgrade Kit 11
Xstream EN 144-3 upgrade kits 11
O-ring conversion table 12
6. Service 13
@&)#))-6275* !+
Xstream first stage 13
Xstream second stage 18
:');-/9&3')* A?
B7-#'&'(* A!
Xstream Deep/Dive Cleaning 21
Xstream Deco/Duration Cleaning for Oxygen Use 21
The cleanroom area and work environment requirements 22
Preparations and Pre-cleaning 22
Cleaning 22
Rinsing and drying in the cleanroom 23
Verification 23
C))-6275* A+
Xstream first stage 23
Xstream second stage 29
7. Final inspection 32
,-99&'(D*E&'#7*&');-/9&3'* +A
Method for regulators cleaned for oxygen use 32
Method for all other regulators 33
8. Technical data 35
F3$G8-*9#27-* +H
I$318/9*1#9#* +H
B3'.-$)&3'*9#27-)* +J
I-$E3$6#'/-* +K
Work of breathing 37
Breathing curve 37
9. Oxygen statement 39
10. Updates 39
APPENDIX A 40
=CLMFNO)* 4?
APPENDIX B 41
=8'1#6-'9#7*3P5(-'*$&)%)*/36;$-0-')&3'* 4!
The O4 concept 41
APPENDIX C 42
Q36-'/7#98$-*$-(87#93$*;-$E3$6#'/-* 4A
1st stage regulator performance 42
APPENDIX D 43
B7-#'$336*#'1*3P5(-'*/7-#'&'(*$-G8&$-6-'9* 4+
Check list 43

1. SaFETY REGulaTiONS
2
SERviCEmaNual - xSTREam
1. Safety regulations
F0-*&')9$8/9&3')*&'*90&)*0#'1233%*68)9*2-*E3773R-1*&'*1-9#&7*)9-;*25*)9-;S*Q-(7&(-'/-*/#'*/#8)-*)-$&38)*&'T8$5*3$*
-.-'*1-#90S*
Special warnings are marked with this symbol
U)9$-#6*@-/3*#'1*U)9$-#6*@8$#9&3'*6#'8E#/98$-1*;$&3$*93*A?!HV?!V?!D*#$-*1-)&('-1*93*2-*8)-1*R&90*(#))-)*90#9*
0#)*-7-.#9-1*3P5(-'*/3'9-'9S*F0&)*$-G8&$-)*);-/&#7*;$3/-18$-)*R0&7-*)-$.&/&'(W*93*/7-#'*90-*$-(87#93$*#'1*93*%--;*&9*
/7-#'S*Q-(7&(#'/-*93*E3773R*90-*&')9$8/9&3')*(&.-'*&'*90&)*6#'8#7*&'9$318/-)*#*$&)%*E3$*90-*/8)936-$*3E*0#.&'(*#*E&$-*
R0&/0* &'* 98$'* /#'* /#8)-* )-$&38)* &'T8$5* 3$* -.-'* 1-#90S* ,-$.&/&'(* 90-* #23.-V6-'9&3'-1* $-(87#93$)D* )0#77* #7R#5)* 2-*
/3'18/9-1*&'*#*/7-#'*-'.&$3'6-'9*8)&'(*/7-#'*9337)D*#)*1-)/$&2-1*&'*)-/9&3'*J*#'1*&'*C;;-'1&P*XS
F3* -'0#'/-* )#E-95* 18$&'(* )-$.&/&'(D* 90-* $-(87#93$)* U)9$-#6* @-/3* #'1* U)9$-#6* @8$#9&3'* )0#77* 2-* 9-)9-1* 8)&'(*
/7-#'*#&$*#//3$1&'(*93*);-/&E&/#9&3'*&'*<S*F0-$-*&)*'3*'--1*93*9-)9*$-(87#93$)*&'*90-*)-$.&/&'(*-'.&$3'6-'9*8)&'(*(#))-)*
R&90*Y*A!Z*3P5(-'S
*********,9#$9&'(*R&90*)-$&#7*'862-$*!H????!*U)9$-#6*@--;*&)*6#'8E#/98$-1*93*2-*Q&9$3P*[-#1*389*3E*90-*23PS*F0&)*6-#')*
90#9*#77*'&9$&7*3V$&'()*0#.-*2--'*$-;7#/-1*R&90*\I@Q*#'1]3$*^&93'*3V$&'()*#'1*3'75*3P5(-'*/36;#9&27-*782$&/#'9)*0#.-*
2--'*8)-1*18$&'(*6#'8E#/98$&'(S*:E*90-*Q&9$3P*[-#15*)9#98)*&)*93*2-*6#&'9#&'-1*#E9-$*)-$.&/&'(D*3'75*)-$.&/-*%&9*6#$%-1*
R&90*\CQ4?*#'1*3P5(-'*/36;#9&27-*782$&/#'9*6#5*2-*8)-1S*
* ,-$.&/&'(* 68)9* 3'75* 2-* /#$$&-1* 389* 25* ;-$)3')* R03* 0#.-* 2--'* 9$#&'-1* #'1* /-$9&E&-1* 25* I3)-&13'S* ,-$.&/&'(*
U)9$-#6*@-/3*#'1*U)9$-#6*@8$#9&3'*$-G8&$-)*#'*#11&9&3'#7*/-$9&E&/#9&3'*#)*_I`,\:@`Q*`Uab\Q*F\BcQ:B:CQd
`'75*I`,\:@`Q*3$&(&'#7*;#$9)*6#5*2-*8)-1*E3$*)-$.&/&'(S*e0-$-*)9#9-1D*I`,\:@`Q*3$&(&'#7*9337)*68)9*2-*8)-1S

2. iNTRODuCTiON
3
SERviCE maNual - xSTREam
2. Introduction
"#$%&'()
This manual contains servicing and repair instructions and product information for the Poseidon Xstream regulator series. The
different Xstream regulator models are most clearly identifed by their color. There is always a possibility that the customer has
altered the colors himself, why it is important always to check the permanently marked article number as part of the identification
of the product. The pictures below show where to find the article and serial number:
4790-BK / 002-10 Xstream Deep / Xstream Deep (4+1)
4791-BK / 001-47 / 0100-000 Xstream Deep90 / Xstream Deep90 (5+2) / Xstream Deep Mk3
4790-GN/ 002-13 /4882-GN Xstream Duration/Xstream Duration(4+1)/Xstream Duration EN 144-3
4790-WE/ 002-16 /4882-WE Xstream Deco/Xstream Deco (4+1)/Xstream Deco EN 144-3
4791-GY Xstream Dive90
4792-YW Xstream Dive Octopus
0110-002 - Xstream Oxygen
(Only sold with MkVI EU)
4791-GN/ 001-87 /4881-GN / 0100-001 / 0100-007 Xstream Duration90/Xstream Duration90(5+2)/
Xstream Duration90 Mk3 / Xstream Duration90 Mk3 EN 144-3

2. iNTRODuCTiON
4
SERviCE maNual - xSTREam
• CE 0120 Meets or exceeds requirements in EU Directive 89/686/EEC, Personal Protective Equipment.
Manufacturing assessment carried out by notified body SGS Yarsley, ID no. 0120.
• 0100-000 Model identification
• E.g 200001 or 1200001 Serial number, 6 or 7 digit, first or first two digits denotes year of manufacture. 2 = 2002 /
12 = 2012
• WP 300bar Working pressure 300 bar
• Oxygen Approved for use with 99.95% oxygen
• Nitrox 50% Approved for use with maximum 50% oxygen
• Nitrox Ready Approved for use with EAN40 max
,-$.&/-*0#'1233%
This servicing handbook is available for download at the Poseidon Extranet at http://extranet.poseidon.se. Make sure you have
the latest issue before undertaking any servicing. The handbook is available in English only.
Further assistance can be reached between 8:00 am to 4:30 pm (GMT+1) at Poseidon Diving Systems:
Phone: [phone] ask for “technical assistance”
Fax: [phone]
e-mail: [email protected]
,56237)*8)-1*90$38(0389*90-*0#'1233%
Icon Description Other information
[-63.-*371*;#$9S*@-)9$35*#'1*(&.-*2#/%*93*
/8)936-$

[-;7#/-*R&90*'-R*;#$9
^&)8#775*&');-/9
1I3)-&13'*($-#)-*f!D*#$9&/7-*'3*<H!H
RI3)-&13'*($-#)-*f[D*#$9&/7-*'3*<H!J
e#$'&'(S*Q-(7&(-'/-*/#'*/#8)-*)-$&38)*&'T8$5*3$*
-.-'*1-#90S
:6;$3.-6-'9)
Poseidon has made several improvements, all introduced 2003 starting with serial number 310001.
Starting in 2006, all Xstream 1st stages are equipped with an adjustment screw cover. Older versions with no adjustment screws
should be upgraded.
Startingin2009,allXstream90modelrststagesareequippedwithabuiltinoverpressurevalve.
Starting 2015-01-01, all Xstream Deep 1st stages/regulators are Nitrox ready out of the box.

2. iNTRODuCTiON
5
SERviCE maNual - xSTREam
Product upgrades
Regulators with serial numbers less than 310001 are subject to a mandatory update programme. To obtain updated replacement
parts, order the kit 4826 and submit to Poseidon the serial number of the regulator by sending an email to service@poseidon.
com with the serialnumber and date of service clearly marked.
Regulators fulfilling this criteria shall have the following parts replaced on its first service:
• 4560 replaced by 4760 Seat holder. Seats on regulators numbered after 310001 are
different and will not fit older seat holders.
• 4577replacedby4777Lowerpin-guide.Theparthasbeenchangedtowithstanda
greater torque.
• 4562replacedby4762Uppercentrepiece.Theparthasbeenchangedtocorrespond
to the change of 4577
• 4581Washer.Theparthasbeenchangedtoeaseassemblythroughamoreprecisefit.
• 0015-012(4423)O-ring
• 4563Pin bushing 1.stage Xstream
Information about Xstream Upgrade kit 4826
4760 Seat holder and 4581 Washer are not critical parts to replace, however old seat holders will not fit new seats and is therefore
includedintheUpdatekitXstreamataspecialprice.4777Lowerpin-guideand4762Uppercentrepieceshouldbereplaced
and is therefore included in the kit at no cost.
Information about Xstream 1st stage covers.
During 2006, we began manufacturing Xstream DEEP, DEEP90, DURATION, DURATION90 and DECO 1st stages with chrome
colored 1st stage covers with an adjustment screw. Starting january 2007, all Xstream 1st stages, regardless of model/version,
will have a chrome colored 1st stage cover with an adjustment screw.
Information about Xstream Upgrade to cover with adjustment screw.
Any Xstream 1st stages that don’t have a cover with an adjustment screw should be upgraded with a cover that has an
adjustment screw. This upgrade is not mandatory but recommended.
The upgrade is made using the ”Xstream Adjustable kit” (4767-KIT) that contains the following parts:
• 1x4767-CEXstreamcover
• 1x4798-CHAdjustmentscrew
• 1x4763Adjustmentspring
• 1x4764Seatspring
All these parts must be replaced when upgrading the 1st stage!
Recommendations
For regulators with serial numbers less than 310001 we recommend to offer the customer to replace the old type valve housing
nuttotheimprovedversionwitharticlenumber4547.Thiswillsignificantlyreducetheinhalationeffort.Howeverifthecustomer
choses to keep his old valve housing nut it is perfectly safe to do so.
EN 144-3
Xstream Deco, Xstream Duration and Xstream Duration90 are available also in EN 144-3 configurations, i.e., regulators which
comply with the new EN 144-3 standard. See page 3 for correct article numbers.
Older Xstream models can be upgraded to comply with the same standard using an EN 144-3 upgrade kit. See Spare Parts lists
on page 13 for details.
Article number on o-rings
In this revision of the service manual, all o-ring article number have been updated to match the current article number system
used by Poseidon. A conversion list between the old and new o-ring article numbers can be found on page 14.
Nitrox ready (EAN40)
Xstream Deep regulators with serial number 1500001 and later are Nitrox ready from the manufacturer. A special EAN40 ser-
vice kit for the Xstream Deep 1st stage (article number 0009-016) and a EAN40 service kit for the Xstream Deep / Jetstream
2nd stage (article number 0009-017) has been introduced.

3. DETERmiNaTiON OF REQuiRED SERviCE
J
SERviCE maNual - xSTREam
+S*@-9-$6&'#9&3'*3E*$-G8&$-1*)-$.&/-
TobecoveredbythePoseidonLifetimeWarrantyprogram,allXstreamregulatorsmustbeservicedatleastonceevery24
months.
It’s recommended that the Xstream regulator is service once every 24 months or once every 100 dives, which ever comes
first.
The serviced regulator must also be registered on the Poseidon website (http://extranet.poseidon.com).
It is always acceptable to do a service or cleaning up, on customers request.
It’srecommendedthatlowpressurehosesarereplacedonceeveryfour(4)yearstoavoidLPhosefailuiresduetowearand
tare.
If water has entered a first stage (or suspiciion there of), the first stage shoudl be disassembled, cleaned and dried before
diving with it again. Water inside a 1st stage can cause corrosion or damage that has a negative effect on the functionality of
the 1st stage.
Xstream Deep 1st stages and regulators with serialnumber 1500001 or higher comes Nitrox Ready out of the box. To maintain
this status, the EAN40 service kits must be used and only oxygen compatible lubricants applied. Testing and adjusting must
be made using gas filtered in accordance with the EAN standard.
Xstream Deep 90 1st stages and regulators with serial numbers lower than 1500001 can be serviced to reach Nitrox Ready
level if the following actions are taken:
• All 1st stage components made out of metal are washed in an ultra sonic cleaner, using the Poseidon Fine clean Ultra
liquid, for a time period of 10 - 15 minutes.
• The EAN40 service kits (0009-016 and 0009-017) are used for the 1st and 2nd stage.
• Only Poseidon oxygen compatible lubricant (part number 8515) is used
• Gas filtered according to the EAN standard is used for testing/adjusting.

4. TOOlS
7
SERviCE maNual - xSTREam
4. Tools
To service Poseidon regulators there is a number of tools required. Some of the tools are special tools for Xstream and Poseidon
and some tools are standard tools available in most hardware stores. Below you will find a list of all tools needed, with a
description of what it is used for. Note that tools intended to be used for Nitrox approved and O2 clean equipment should be
kept separate to avoid contamination.
Item Description
Xstream
Picture
2297 O-ring remover Used to remove o-rings. o
Open end wrench 6, 13-23 mm Various open end wrenches in millimeters are essential or assembly and
dissassembly of various things. o
3460 Regulator test Used to check or finally adjust the regulator.
o
Ultra Sonic Cleaner Used to clean all regulators. Mandatory for Xstream Deco and Duration.
o
3773 Torque wrench set Used to set the torque on various parts of the regulator.
o
Allen key 2,5 mm, 4mm, 5 mm,
6 mm
Used to unscrew blindplugs and to adjust IP on Xstream. o
2706 Allen key 1,5 mm Used to untighten and tighten the locking screw on Jetstream and Xstream
valve tube and stopscrews on most first stages. o
3605 Combination tool 1 Used to to screw and unscrew various parts on the Xstream second stages.
o
3606 Combination tool 2 Used to to screw and unscrew various parts on the first stage and second
stages. o
2705 Adjusting tool Used to adjust the cracking pressure on Xstream second stages.
o
4591 17 mm torque wrench Used to untighten and tighten the connection stem on Xstream first stages.
o
Item Description
Xstream
Picture
Articles of consumption
8515 Oxygen grease #1 Only approved oxygen grease when lubricating
oxygen critical parts on the high pressure side.
Approved for 300 bar 60oC.
o
8516 Regulator grease Used for lubrication of air version regulators.
o
4835 Poseidon fine clean ultra 5 litre o

5. SPaRE PaRTS & SERviCE KiTS
<
SERviCE maNual - xSTREam
4670-BK Second stage Xstream Deep 4670-GN Second stage Xstream Duration 4670-WE 4670-GY 4670-YW
Second stage Xstream Deco Second stage Xstream Dive Second stage Xstream Octopus
HS*,;#$-*;#$9)*g*)-$.&/-*%&9) ,-/3'1*)9#(-)
Item # Description
4536 Diaphragm cover
4533 Diaphragm silicone
4538-BK
4538-WE
4538-GN
4538-YW
4538-GY
Cover Xstream 2nd stage (Deep)
Cover Xstream 2nd stage (Deco)
Cover Xstream 2nd stage (Duration)
Cover Xstream 2nd stage (Octopus)
Cover Xstream 2nd stage (Dive)
4539 Sticker Poseidon Xstream
4531 Checkvalve
4537-BK Housing
0011-278 O-ring Xstream 2nd st., viton
0010-025 O-ring
2857 LP-valvehousing
3440 Valve insert
0013-009 O-ring 2nd stage Xstream, EPDM
4547 Valve housing nut, Xstream
2787 Rubber plate
2875 Stop screw
1167 Lockingstrap
4532 Mouthpiece AIR
0013-351 O-ring 2nd stage Xstream, EPDM
4534 Valve tube Xstream
0013-001 O-ring 2nd stage Xstream, EPDM
4545 Servo-valve Xstream
0120-000 Second stage Xstream Deep 0120-001 Second stage Xstream Duration 0120-002 0120-003
Second stage Xstream Deco Second stage Xstream Octopus

5. SPaRE PaRTS & SERviCE KiTS
>
SERviCE maNual - xSTREam
Item # Description
0012-028
0011-037
4807-59
O-ring (Deep)
O-ring, viton (Deco/Duration)
O-ring, viton (*/**)
4571
4871
Conn. stem 1.stage Xstream
Conn. stem 1.stage Xstream (*/**)
4572 Cup type filter Xstream
4581 Stainl. washer 1.stage Xstream
4576-BK
4576-WE
4576-GN
4876-GN
4876-WE
Wheel G5/8” Xstream, black
Wheel G5/8” Xstream, white
Wheel G5/8” Xstream, green
Wheel Xstream, green (*)
Wheel Xstream, white (**)
4774 Housing1.stageXstream
4555 Spring for ball Xstream
4556 Ball 1.stage Xstream
0015-059
0016-036
O-ring (Deep)
O-ring, viton (Deco/Duration)
4758 Zytel valve seat Xstream
4760 Valve seat holder Xstream
4764 Valve seat spring Xstream
4777 LowerpinguideXstream
4563 Pin bushing 1.stage Xstream
0015-012 O-ring
4762 Upper pin guide Xstream
4559 Actuating pin, Xstream
4564 Roll.diaphragm 1.stage Xstream
4565 Pressure plate 1.stage Xstream
4763 Adjust. spring 1.stage Xstream
4570-BK
4570-WE
4570-GN
Barrier 1.stage Xstream black
Barrier 1.stage Xstream white
Barrier 1.stage Xstream green
4767-BK
4767-CE
Cover Xstream 1st stage, black
Cover Xstream 1st stage, chrome
4568 Screw cover M3x10 Xstream, 3
pcs
4798-BK
4798-CE
Adjustment screw, black
Adjustment screw, chrome
2680 Blindscrew UNF7/16
0012-132
0011-277
O-ring (Deep/Dive)
O-ring, viton (Deco/Duration)
2679 Blindscrew UNF3/8, 2 pcs
0010-353
0013-164
O-ring (Deep/Dive)
O-ring, EPDM (Deco/Duration)
=&$)9*)9#(-*239936*638'9-1
* 4884-GN Xstream Duration EN 144-3
** 4884-WE Xstream Deco EN 144-3
4780-BK 1st stage G 5/8” Xstream DEEP 002-09 1st stage G 5/8” Xstream DEEP (4+1) 4780-GN 1st stage G 5/8” Xstream DURATION 002-12 1st stage G 5/8” Xstream DURATION (4+1) 4780-WE 4884-GN 4884-WE
1st stage G 5/8” Xstream DECO 1st stage Xstream DURATION EN 144-3 1st stage Xstream DECO EN 144-3
002-15 1st stage G 5/8” Xstream DECO (4+1)