XS Scuba Airwave Octopus Installation and operating manual

Service & Repair Manual
rev. 06/08
SERVICE AND REPAIR MANUAL
AIRWAVE OCTO
PN RG320

AirWave Octo
2
AirWave Octo 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
Section 4 - Reassembly Procedures
General Guidelines.............................................................................................................................. 12
Section 5 - Final Testing Procedures
First Stage Intermediate Pressure Test ............................................................................................... 16
Second Stage Adjustment and Flow Test ............................................................................................ 17
Subjective Breathing Test .................................................................................................................... 18
Flowbench Testing (optional)............................................................................................................... 19
External Leak Test ............................................................................................................................... 19
Troubleshooting Guide................................................................................................ 20
Schematic & Parts List............................................................................................ 21

Service & Repair Manual
3Copyright ©2008 XS Scuba
This manual provides factory prescribed procedures for the correct service and repair of the
AirWave™ second stage regulator. It is not intended to be used as an instructional 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 product, 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 AirWave™ 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 com-
mercial 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 AirWave 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 ques-
tions, 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

AirWave Octo
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AirWave Octo Service and Repair Manual
Facility Requirements
"Jaws" Gripmaster Vise
Ultrasonic Cleaner
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 solu-
tion, 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 inspection - 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 customer'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 over-
tightening 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.

Service & Repair Manual
5Copyright ©2008 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
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
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
O-ring Tool Set #10-102-100
Dual Drive In-Line Adjusting Tool # 20-500-200
Second Stage Rim Clamp #20-790-200
M

AirWave Octo
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AirWave Octo 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 filter indicates that
moisture has entered the regulator, and internal corro-
sion has possibly occurred. Other types of discoloration
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 finish 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-
forming the next procedure.
2
SECTION

Service & Repair Manual
7Copyright ©2008 XS Scuba
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 sec-
tion, 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 adjusted
second stage is connected to the first stage before
pressurizing. Failure to relieve intermediate pressure
that exceeds 400 psi may result in damage or rupture
of the test gauge or LP hose, and could cause serious
personal injury.
2. Slowly open the supply valve to pressurize the 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 first stage
is 140 (±5) psi, with an inlet pressure between 2,500
- 3,000 psi.
5. Close the supply valve and depress the second stage
purge button to depressurize the system before attempt-
ing to perform any disassembly.
▼After completing the Preliminary Inspection, proceed
to Section 3 – Disassembly

AirWave Octo
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AirWave Octo 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 ©2008 XS Scuba
Second Stage Disassembly
CAUTION: Whenever possible, use only plastic or
brass O-ring tools for removing O-rings in order to pre-
vent damage to the sealing surface. Steel instruments,
such as dental picks, can easily damage the sealing
surface of a softer brass part, causing irreparable leak-
age and requiring the part to be replaced with new.
1. Slide back the hose cover to expose the connection of the
LP hose.
2. While holding the inlet tting(7) secure with a n" open-
end wrench, apply a n" open-end wrench to the tting of
the LP hose. Turn the hose tting counter-clockwise to
loosen and remove.
3. Using a plastic or brass O-ring tool, carefully remove the
O-ring from the post inside the hose tting.
CAUTION: When performing the above step, be very
careful to avoid scratching the O-ring sealing surface.
Doing so may cause a permanent leak that will require
the replacement of the LP hose.
4. Using a n" open end wrench, turn the inlet tting counter-
clockwise to loosen, and unscrew it completely by hand to
remove. Closely examine the plastic threads and overall
condition of the inlet tting, and replace with new if any
damage is found.
5. Snip the plastic tie-strap(12) that holds the mouth-
piece(11), and gently pull the mouthpiece off the second
stage housing(13). Inspect the mouthpiece to ensure that
it is supple and free of any tears or corrosion. If any dam-
age is found that could result in discomfort or leakage,
discard the mouthpiece and do not reuse.
6. While holding the second stage secure with one hand,
rmly grasp the retaining ring(1) with the other, and turn
the ring counter-clockwise to loosen and remove it, along
with the diaphragm cover(2).
NOTE: If the retaining ring is difficult to loosen,
XS Scuba recommends using the Rim Clamp (P/N
20-790-200), available from Peter Built Co. Complete
instructions are provided with the tool.
7. Separate the diaphragm cover from the retaining ring,
and closely inspect the cover to ensure that it is perfectly
round and free of damage. If any damage is found, dis-
card the cover and replace with new.

AirWave Octo
10
AirWave Octo Service and Repair Manual
8. Lift out the diaphragm(4) and thrust washer(3) from the
second stage housing. Inspect the diaphragm to ensure
that it is supple and free of any pinholes, tears, corrosion,
or other damage. If any damage is found, discard it and
replace with new.
9. Using a small regular screwdriver, rotate the metal
retaining clip(5) over the groove of the venturi
deector(22) as needed so that the notch in the center
is visible. Place the tip of a 2mm at blade screwdriver
inside this notch, and gently lift the clip off the groove.
(See Fig. 1.)
10. Apply a medium blade screwdriver to the screw(24) in
the center of the venturi deector switch(23), and turn
it counter-clockwise to loosen and remove. Pull off the
deector switch and set it aside.
11. While holding the lever(6) lightly depressed, slide the
entire valve assembly out of the second stage housing,
venturi deector rst (see Fig. 2). Remove and discard
the inlet tting O-ring(8).
12. Unscrew the venturi deector counter-clockwise from the
air barrel(15), and carefully remove the O-ring(21) with a
plastic tool.
13. Turn the air barrel over to allow the balance shuttle
cap(20) and LP spring(19) to drop out (see Fig. 3).
Inspect the spring closely with a magnier to check for
any signs of corrosion. Discard it if corrosion is found,
and do not reuse.
14. Gently remove the lever from the air barrel by lifting out
one leg rst, and then the other. Be careful to avoid
bending or stretching either leg.
15. Turn the air barrel over to allow the poppet(17) to drop
out. Using ngernails or a plastic tool, carefully remove
the LP seat(16) and small O-ring(18). Discard both soft
parts, and do not reuse. Closely inspect the poppet
around all seating surfaces, and compare it with new to
ensure no damage is visible. If damage is found, discard
the poppet and replace with new.
16. Remove the white lever pad(14) from the air barrel.
Discard, and do not reuse.
17. While holding the air barrel secure, apply a medium
blade screwdriver to the slotted head of the adjustable
orice(9), and turn it counter-clockwise to disengage its
threads.
Fig. 1 – Removal of Retaining Clip
Fig. 3 – Removal of Venturi Deflector
Fig. 2 – Removal of Valve Assembly