XS Scuba PN RG100 Installation and operating manual

Service & Repair Manual
SERVICE AND REPAIR MANUAL
SPIRIT REGULATOR
PN RG100
Revised - 02/11

Spirit Regulator
2
Spirit Regulator Service and Repair Manual
Contents
Section 1 - Introduction
Warnings, Cautions, & Notes ................................................................................................................ 3
Scheduled Service................................................................................................................................. 3
EAN/ Nitrox Service............................................................................................................................... 3
Facility Requirements............................................................................................................................ 4
Specialty Tools....................................................................................................................................... 5
Section 2 - Preliminary Inspection
External Inspection................................................................................................................................ 6
Immersion / Leak Test ........................................................................................................................... 6
Intermediate Pressure Test.................................................................................................................... 7
Section 3 - Disassembly Procedures
General Guidelines................................................................................................................................ 8
First Stage Disassembly........................................................................................................................ 9
Second Stage Disassembly................................................................................................................. 12
Section 4 - Reassembly Procedures
General Guidelines.............................................................................................................................. 15
First Stage Reassembly ...................................................................................................................... 16
Second Stage Reassembly ................................................................................................................. 19
Secton 5 - Final Testing Procedures
First Stage Intermediate Pressure Test ............................................................................................... 22
Second Stage Adjustment and Flow Test ............................................................................................ 23
Subjective Breathing Test .................................................................................................................... 24
Flowbench Testing (optional)............................................................................................................... 25
External Leak Test ............................................................................................................................... 25
Troubleshooting Guide
First Stage ........................................................................................................................................... 26
Second Stage...................................................................................................................................... 27
Schematic & Parts Lists
Spirit First Stage.................................................................................................................................. 28
Spirit Second Stage............................................................................................................................. 29

Service & Repair Manual
3Copyright ©2011 XS Scuba
This manual provides factory prescribed procedures for the correct service and repair of the
Spirit™ regulator, including the rst 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 received 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, & 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 CAUTION indicates any situation or technique that will result in potential damage to the prod-
uct, or render the product unsafe if instructions are not followed correctly.
A 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 infrequent use.
NOTE: A unit that receives heavy or frequent 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 service, whether it is a routine overhaul or a repair of a specic 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.
CAUTION: It is important to avoid using, testing, or otherwise pressurizing a dedicated
EAN regulator with standard compressed air, which contains hydrocarbon contaminants.
Introduction
1
SECTION

Spirit Regulator
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Spirit Regulator Service and Repair Manual
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 airlls 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:
❏Ultrasonic Cleaner – Select the right size model that can keep
up with the volume 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 rst 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.
It is designed specically for the professional dive store service
bench, and will prevent damage that can easily be caused by a
conventional vise.
❏Magnication Lamp – Strong lighting and magnication are
essential requirements for performing a thorough parts inspec-
tion - especially when locating the source of a small leak.
❏Quality Wrenches & Sockets – When working with brass
parts, it is especially critical to use the correct size wrench
and to ensure that it ts 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 specied, in order to avoid overtightening or
undertightening a part. This is especially important for smaller
parts and ttings, 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 specic
range.
"Jaws" Gripmaster Vise
Ultrasonic Cleaner

Service & Repair Manual
5Copyright ©2011 XS Scuba
Specialty Tools
For the nest tools, xtures, and supplies that are designed and manufactured specically 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 efciently
- and done right.
Illustrations courtesy of Peter Wolfinger.
Galion, OH 44833
Phone: [phone]
www.scubatools.com
Required Tools/ Lubricant
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
Hakko Side Cuts, 5" PN #16-020-500
Snap Ring Pliers
11/16" Open End Wrench
3/4" Open End Wrench
[phone]
Breaker Bar # 20-157-500
PETER BUILT
1" - SIX POINT
3/8"
Drive
I” Yo ke Nut Socket #20-155-500
Custom (narrow diameter)
3/8" x 3" Drive Extension #20-156-500
100
200
80
60
40
20 180
160
120
IP RANGE
125-150 PSI
PSI
PETER BUILT
"Quality in the making"
[phone]
USE NO OIL
140
25
50
150
125
100
75
175
200
225
250
275
300
0
IP RANGE
125-150 PSI
PSI
USE NO OIL
PETER BUILT CO.
"Quality in the making"
[phone]
260 3.5 x 60
260 2.0 x 50
Select Tool Kit (5 pcs) # 11-090-500
Poppet Align/ Orifice Preset Tool, #20-785-400
Intermediate Pressure
Te st Gauge, #20-510-100
Snap Ring Pliers # 10-101-500
O-ring Tool Set #10-102-100
No. 4 Hook Spanner, #20-404-200
Dual Drive In-Line Adjusting Tool # 20-500-200 Second Stage Rim Clamp #20-790-200
M
Piston Installation Bullet

Spirit Regulator
6
Spirit Regulator Service and Repair Manual
Preliminary Inspection
External Inspection
1. Closely examine the conical lter to check for any signs
that contaminants have entered the system, including sea
water, rust, or aluminum oxide.
NOTE: A green discoloration of the lter 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
the cylinder.
2. Slide back the hose protectors, if present, to visually
inspect the condition of the hoses, especially at their t-
tings.
3. Closely examine the nish of the rst stage to check for
any chips, scratches, or other damage that exposes the
brass beneath the nish.
CAUTION:Do not clean any parts that show damage
to their nish inside an ultrasonic cleaner.
4. Closely examine all parts of the rst 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 rst stage to a cylinder that
is lled 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 rst stage in
fresh water to check further for any signs of air leakage,
especially at the ttings 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-
2
SECTION

Service & Repair Manual
7Copyright ©2011 XS Scuba
forming the next procedure.
Intermediate Pressure Test
NOTE: It is not necessary to perform this test unless
a problem has been reported that requires diagnostic
troubleshooting and repair. When performing routine
overhaul service, proceed directly to the following
section, Disassembly.
1. Connect a calibrated intermediate pressure test gauge
to the regulator, either with a quick-disconnect inator
hose or with the female tting 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 rst 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 rst 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
uctuating back and forth.
4. If the intermediate pressure creeps up or otherwise uc-
tuates after cycling the regulator, wait for it to stabilize (if
possible) before making a nal note of the intermediate
pressure.
NOTE: Correct intermediate pressure for the rst
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 perform any disassembly.
▼After completing the Preliminary Inspection, proceed
to Section 3 – Disassembly

Spirit Regulator
8
Spirit Regulator Service and Repair Manual
Disassembly Procedures
General Guidelines
▼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
nish. DO NOT attempt to perform the service unless all
of the required tools and parts are available.
▼ All o-rings are classied 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 identied by its reference
number shown on the drawing the rst 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
shown to the customer, however, to ensure their con-
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.
3
SECTION

Service & Repair Manual
9Copyright ©2011 XS Scuba
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 rst 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 inator hose with a 2" (or other size
required) open end wrench. Remove all remaining port
plugs(13&15) with a ®" (4mm) hex key.
2. Remove and inspect the O-rings(12&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 rst stage secure throughout the
next procedure. This ensures the best protection
against slippage and accidental damage to soft
metal parts. If an ordinary bench vise will be used,
the rst 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 rst 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 rst stage in the op-
posite position, so that the yoke or DIN adapter faces
straight up.
Fig. 1 – Loosening the Piston Cap

Spirit Regulator
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Spirit Regulator Service and Repair Manual
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 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,
use an adjustable wrench or an open end wrench
that does not t completely over the ats 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.
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 lter(6), and
remove the O-ring(7) with a brass O-ring tool. Discard
the lter 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 lter retainer(3b), andturn it
counter-clockwise to loosen and remove (see Fig. 4).
Remove and discard both O-rings(3a&3c).
b. Lift the handwheel(3f) off the lter housing(3g), and
closely inspect the condition of the threads to ensure it
is free of any burrs or other damage that could prevent
proper threading.
c. Apply a m" open-end or box wrench to the lter hous-
ing, and loosen it counter-clockwise with steady force
to remove from the rst stage body. Remove and dis-
card the lter(3d) and both O-rings(3e).
Fig. 3 – Removal of Filter Retaining Ring
Fig. 4 – Removal of DIN Retainer
Fig. 2 – Loosening the Yoke Retainer