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

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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
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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

Service & Repair Manual
11 Copyright ©2008 XS Scuba
Fig. 5 – Orifice Inspection
NOTE: The orifice is O-ring sealed, and it will remain
inside the air barrel after it has been unthreaded. The
following step must be performed to remove the orifice
without damaging its polished sealing surface.
18. When the orice has been unthreaded from the air barrel,
carefully insert a small wooden or plastic dowel through
the opposite end of the valve body, directly over the
sealing edge of the orice. Gently press out the orice.
(See Fig. 4.)
19. To avoid using a sharp tool that can damage the orice,
squeeze the O-ring(10) between thumb and forenger to
remove it from the orice head. Discard the O-ring and
do not reuse.
20. Closely examine the orice with the use of a magnier,
checking for any scratches or other damage to the
sealing edge and the groove that holds the O-ring (see
Fig. 5). If any damage or wear is found, discard the
orice and do not attempt to reuse. If it is in reusable
condition, set it aside on a soft surface to keep it isolated
from other metal parts.
21. Gently pull the exhaust deector(26) off from the second
stage housing to expose the exhaust valve(25) for
inspection.
22. Closely inspect the exhaust deector to check for any
signs of damage that may have been caused by abuse
or improper disassembly. If found, discard it and replace
with new,
23. Closely inspect the condition of the exhaust valve to
ensure that it is evenly seated against the second stage
housing on all sides, and free of any tears, holes, or
other signs of decay. Peel back the lip on all sides to
ensure it is supple and returns to its original position. If
any wear or damage is detected, or if the material feels
stiff or decayed, pull the exhaust valve straight out of the
housing and discard it.
NOTE: It is not necessary to remove the exhaust valve
diaphragm unless it shows signs of wear or decay upon
inspection. Once the diaphragm is removed, however,
it will be permanently stretched and then must be re-
placed with new.
▼After completing the disassembly of the rst and
second stages, refer to the instructions provided in
the XS Scuba Authorized Service Document, titled -
Regulator Parts Cleaning Procedures.
Fig. 4 – Removal of Adjustable Orifice

AirWave Octo
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AirWave Octo Service and Repair Manual
General Guidelines
▼Refer to the schematic parts list, that highlights automatic re-
placement parts which should be discarded and replaced with
new during reassembly. These parts are provided in the Annual
Service Kit.
▼Before performing any reassembly, it is important to individually
inspect all parts, both new and those that are being reused, to
ensure that each part and component is perfectly clean and free
of any dust, decay, or blemishes.
▼ If the regulator has been serviced for use with EAN/Nitrox, it is
important to don powderless latex gloves before handling any
parts, including O-rings, in order to avoid contaminating the
parts with skin oil.
▼ Prior to dressing, inspect all O-rings with magnication to ensure
they are supple, clean, and completely free of any scoring or
decay that would impair proper sealing.
▼ XS Scuba recommends Christo-Lube® MCG-11 (PN MS150)
to be used exclusively for the lubrication and dressing of O-
rings and other internal parts. Christo-Lube® provides superior
lubrication to that of silicone grease, especially in high pressure
(DIN) systems greater than 3,000 psi, and extreme temperature
conditions. It is also non-reactive to oxygen, and is approved for
use with EAN/Nitrox.
CAUTION: Silicone grease is not compatible with oxygen
enriched air, and must be strictly avoided when servicing a
regulator that will be used with EAN/ Nitrox. The entire regula-
tor will otherwise become contaminated, and rendered unsafe
for use with any mixture of oxygen enriched air.
▼ Dress all O-rings with a visible lm of Christo-Lube, but avoid
applying excessive amounts, as this may attract particulate mat-
ter that can cause accelerated wear or damage to the
O-ring.
CAUTION: The use of aerosol spray or petroleum based
lubricants must be strictly avoided. The propellant gas or pe-
troleum base may attack or weaken plastic or rubber parts.
▼Use all replacement parts provided in the XS Scuba Authorized
Dealer parts kit.
Reassembly Procedures
4
SECTION

Service & Repair Manual
13 Copyright ©2008 XS Scuba
Second Stage Reassembly
WARNING: DO NOT attempt to use any other manu-
facturer's part as a substitute for any XS Scuba part,
regardless of any similarity in shape, size, or appear-
ance. Doing so may render the product unsafe, and
could result in serious injury or death.
1. Install the exhaust valve(25), if it was removed, into the
second stage housing(13) by gently pulling the stem
through the hole in the center of the sealing area, until the
barb has passed through and is securely seated against
the opposite side.
2. Mate two seating tabs on one side of the exhaust deec-
tor(26) into two slots inside the inner groove of the sec-
ond stage housing, and then press the opposite side until
it snaps securely into place.
3. Closely examine both sides of the white lever pad(14) to
identify that the mounting tabs on both legs are rounded
on one side and at on the other. (See Fig. 6.) Hold
the air barrel with the at cut facing up, and place the
clip over the tube with the rounded side facing toward
the ange, so that one tab engages in the hole next to it.
Then, gently press the opposite leg into place so the the
other tab engages in the opposite hole. When done cor-
rectly, the lever pad should rest ush against the ange,
with both tabs securely seated. (See Fig. 7.)
CAUTION: Do not stretch the legs of the plastic retain-
ing clip, or attempt to install it if damage or breakage
has occurred.
4. Insert the stem of the LP seat(16) into the large end of the
poppet(17). DO NOT use adhesive.
5. Lubricate and install the small O-ring(18) over the groove
on the opposite end of the poppet, being careful to avoid
stretching it excessively. Examine the poppet's features
to determine proper positioning. (See Fig. 8.)
6. While holding the air barrel with the at cut facing straight
down, guide the poppet into the tube, LP seat rst, with
the ears facing straight down. (See Fig. 9.)
NOTE: To better control the orientation of the poppet
inside the air barrel while the lever is being installed,
XS Scuba recommends using the Poppet Align/
Orifice Preset Tool (P/N 20-785-400), available from
Peter Built Co. (See Fig. 10.)
Fig. 7 – Air barrel Orientation
Fig. 6 – Lever Pad Features
Fig. 9 – Correct Poppet Orientation
Fig. 8 – Poppet Features
Fig. 11 – Correct Venturi Deflector Orientation
Fig. 10 – Poppet Alignment/ Preset Tool

AirWave Octo
14
AirWave Octo Service and Repair Manual
7. Apply a light coat of lubricant to both ends of the poppet
spring(4), and place the spring over the small end of the
poppet, inside the air barrel. Be careful not to disturb the
the orientation of the poppet inside the air barrel.
8. Insert the small end of the shuttle cap(20) into the end of
the poppet spring.
9. Install the O-ring(21) onto the groove of the venturi de-
ector(22). Mate the deector directly over the shuttle
cap, and screw it clockwise by hand onto the air barrel
until it stops. Then, turn it back one full turn counter-
clockwise until the deector vane is resting directly over
the at cut of the air barrel (see Fig. 11.).
10. Closely examine both holes where the lever pad is in-
stalled, to ensure that the ears of the poppet are properly
aligned as shown (see Fig. 12). While holding the air
barrel with the at cut facing down, insert one leg of the
lever(6) into one hole, so that it engages with the poppet
(see Fig. 13). Being careful to avoid stretching or bend-
ing the lever, rotate it over the air barrel until the opposite
leg engages with the opposite side. The lever should
now be standing up when released, pointing toward the
venturi deector. (See Fig. 14.)
11. While holding the second stage housing right side up with
the mouthpiece tube facing you, slide the valve assembly
into the opening in the right side of the housing. Gently
depress the lever, and then slide the valve assembly fully
into place so that the lever pad is seated ush. (See Fig.
15.)
12. Install the retaining clip(5) over the groove of the venturi
deector inside the housing, so that it snaps securely into
place. (See Fig. 16.)
13. Install the O-ring(8) over the threaded inlet of the air bar-
rel, being careful to avoid stretching it or rolling over the
threads. Use a smooth instrument to ensure that it is
seated at the base of the threads, against the wall of the
housing.
14. Mate the inlet tting(7) over the threads of the air barrel,
and turn it clockwise by hand until nger snug. Apply a n"
open end wrench to tighten it further by exactly 8 turn.
CAUTION: Be careful to avoid overtightening the inlet
fitting, which can crack if it is overtightened, requiring
its replacement.
Fig. 13 – Lever Installation
Fig. 14 – Correct Lever Orientation
Fig. 12 – Poppet Correcty Installed
Fig. 15 – Valve Assembly Completely Installed
Fig. 16 – Installing Retaining Clip

Service & Repair Manual
15 Copyright ©2008 XS Scuba
15. Install the O-ring(10) onto the head of the adjustable
orice(9) and carefully insert the orice into the inlet of the
air barrel with the polished cone facing in. Using a small
wooden or plastic down, press the orice in so that it rests
against the threads inside the air barrel. (See Fig. 17.)
16. While holding the retaining clip stationary, apply a wide
blade screwdriver to turn the venturi deector counter-
clockwise until a) it is perfectly ush with the outer surface
of the housing, b) the deector vane is resting directly
over the outlet port of the air barrel, and c) the slots are
straightly aligned. (See Fig. 18.)
17. Fit the deector switch(23) onto the venturi deector so
that the knob is seated against the forward stop. (See
Fig. 19.)
18. Mate the screw(24) into the outer center of the deector
switch, and apply a medium blade screwdriver to turn it
clockwise until snug. Do not overtighten.
19. Apply a medium blade screwdriver to the slotted head of
the orice inside the air barrel, and turn it clockwise while
closely watching the lever. When the lever starts to drop,
stop – do not turn the orice any further. This will indicate
that the orice has made contact against the LP seat.
(See Fig. 20.)
20. Lay the diaphragm(4) inside the housing, directly over the
lever with its raised surface facing up, and then the thrust
washer(3).
21. Fit the diaphragm cover(2) inside the housing so that it
seats directly over the diaphragm. Turn it as needed to
align the logo straight between the inlet and adjustment
knob.
22. Mate the retaining ring(1) over the diaphragm cover and
into the housing, and turn it clockwise to engage the
threads. While holding the front cover secure with one
hand, tighten the retaining ring until snug with the other.
Be careful to avoid over-tightening.
23 Install the mouthpiece(11) onto the housing, correctly ori-
ented with the top facing up. Fasten a tie-strap(12) over
the mouthpiece with the locking tab facing toward the
inlet coupling, and cinch it snug. Trim the excess material
close to the locking tab.
▼After completing the reassembly of the second stage,
proceed to Section 5 – Final Testing
Fig. 19 – Correct Position of Venturi Switch
Fig. 17 – Installation of Orifice
Fig. 20 – Preliminary Orifice Setting
Fig. 18 – Venturi Deflector Set Flush

AirWave Octo
16
AirWave Octo Service and Repair Manual
Final Testing Procedures
CAUTION: If the regulator will be used with EAN/
Nitrox, it is important to pressurize and flow test the
regulator using only hydrocarbon-free gas. The regula-
tor will otherwise become contaminated with hydrocar-
bons if normal compressed air is used. Industrial grade
compressed Nitrogen is strongly recommended as a
lower cost alternative to EAN/ Nitrox for the purposes
of flow testing.
First Stage Intermediate Pressure Test
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. Initially connect the rst stage to a supply of 300 psi
ltered test gas, and 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.
CAUTION: If the intermediate pressure continues to
rise above 200 psi, immediately shut the test gas supply
valve. Refer directly to the Troubleshooting guide, and
remedy as needed before proceeding any further.
3. When the intermediate pressure has been determined to
be 145 psi or less, close the supply valve and purge the
second stage to depressurize the system. Connect the
rst stage to a supply of 2,500 - 3,000 psi test gas.
5
SECTION

Service & Repair Manual
17 Copyright ©2008 XS Scuba
NOTE: Correct intermediate pressure for the first
stage is between 135-145 psi, with a supply pressure
of 2,500 - 3000 psi.
4. Open the supply valve again while monitoring the IP test
gauge to ensure that the intermediate pressure does not
rise above 145 psi. If the intermediate pressure rises
above 145 psi, immediately close the supply valve and
purge the system. Refer to the Troubleshooting Guide,
and remedy as needed before proceeding.
5. Repeatedly purge the second-stage approximately 15-20
times to cycle the regulator. Then, check the test gauge
to determine whether the intermediate pressure locks
up consistently after each cycle and remains stable at
140 (±5) psi, with no signs of creeping or uctuation. If
the intermediate pressure is not within the specied
range, or if it fails to lock up with no creep, refer to the
Troubleshooting Guideto determine the cause of the
problem. Repeat this procedure after it is corrected.
Second Stage Adjustment and Flow Test
1. Connect the IP Test Gauge onto the inlet tting of the
Inline Adjusting Tool , and mate the opposite tting of the
tool onto the inlet tting of the second stage. Pull back
the knurled knob to retract the slotted drive, and tighten
the tool clockwise onto the inlet tting only until nger
snug. (See Fig. 21.)
2. Mate the female tting of the LP hose onto the male tting
of the IP Test Gauge, and tighten the swivel nut clockwise
until nger snug.
3. Install the LP hose into an intermediate pressure port of
the rst stage regulator after it has been veried to be
properly serviced, with a stable intermediate pressure of
140 (±5) psi . Apply a torque wrench with 17mm crow-
foot to tighten to 38 (±2) inch-lbs.
4. Turn the venturi switch counter-clockwise until it stops.
5. Ensure that all the rst stage ports are sealed, and
connect the rst stage with a ltered gas supply of
2,500-3,000 psi. Slowly open the valve to pressurize the
regulator. Listen to verify that a leak can be heard from
the second stage valve, and proceed to step 6.
a. If airow cannot be heard, it will be necessary to
initiate a slight leak between the orice and poppet.
Press the knurled knob inward to engage the slotted
drive of the Inline Adjustment Tool with the head of
the orice inside the inlet tting. Then, turn the orice
Fig. 21 – Inline Adjustment Tool w/ IP Gauge

AirWave Octo
18
AirWave Octo Service and Repair Manual
slightly counter-clockwise while lightly depressing
the purge cover to prevent wear on the seat. Do not
adjust any further than is needed to establish a slight
leak.
6. Hold the drive of the Inline Adjustment Tool engaged with
the orice. While lightly depressing the purge cover, turn
the orice slightly clockwise a very small fraction of a turn.
Pause after each adjustment to listen, and be careful to
avoid over-adjusting beyond the point that the leak has
stopped. When the leak has stopped, purge the second
stage again to ensure that it does not return. Observe
the IP Test Gauge while purging to verify that it indicates
a stable intermediate pressure after each cycle, with no
creep or uctuation.
CAUTION: Over-adjustment of the orifice can cause
excessive spring load in the second stage valve, and
may impair the regulator’s performance.
8. When the second stage is properly adjusted with no leaks
or lever slack, depressurize and purge the system to dis-
connect the LP hose.
9. Reconnect the LP hose to the inlet coupling, and apply a
torque wrench with 17mm crow-foot to tighten the tting
to a torque measurement of 55 inch-lbs (±5).
Subjective Breathing Test
1. Connect the regulator to a cylinder containing 2,500 –
3,000 psi, and open the valve to pressurize the system.
2. Turn the venturi switch counter-clockwise to the open or
"dive" position.
3. Fully depress the second stage purge to ensure that an
adequate volume of air ows through the mouthpiece,
sufcient to clear the second stage. Then, breathe sev-
eral times from the second stage.
A properly serviced and adjusted regulator should de-
liver air upon deep inhalation without excessive inhala-
tion effort, freeow, or vibration. When exhaling, there
should be no resistance or sticking of the exhalation
valve. If any of these problems occur, refer to Table
2 - Troubleshooting.

Service & Repair Manual
19 Copyright ©2008 XS Scuba
Flowbench Testing (optional)
The Subjective Breathing Test, combined with the Inter-
mediate Pressure Test, will sufciently verify the regulator's
performance in most circumstances. As an additional test,
a Magnahelic owbench can be used to verify the opening
effort, which should not exceed 1.5 – 2.0 column inches H2O
with the venturi switch turned counter-clockwise to the open
or "dive" position.
External Leak Test
After rst stage reassembly and nal adjustment of the
second stage has been completed, submerge the entire
regulator in a test tank of clean water while pressurized
with 2,500-3000 psi. Observe any bubbles arising from the
submerged regulator over a one minute period. The recom-
mended time is necessary due to slower bubble formation
that occurs in smaller leaks. Disassemble the regulator at
the source of the leak to check sealing surfaces, assembly
sequence and component positioning in order to correct the
problem(s).
NOTE: The location of extremely small leaks can best
be detected by applying a soap solution to the leak area.
Before disassembling to correct any leaks, rinse the
entire regulator thoroughly with fresh water and blow
out all residual moisture with filtered, low-pressure (25
psi) test gas. Refer to the Troubleshooting Guide.
▼ When the second stage has been adjusted and tested
according to the prescribed procedures, close the cylinder
valve completely and purge the second stage to depres-
surize the system. Loosen the yoke screw to remove the
rst stage from the cylinder, and seal the dust cap over
the inlet. Disinfect the mouthpiece, and dry the regulator
completely with a clean towel. This completes the over-
haul service procedures for the AirWave regulator.

AirWave Octo
20
AirWave Octo Service and Repair Manual
1. Excessive intermediate pressure. 1. Refer to rst stage troubleshooting
2. Damaged or worn LP seat. 2. Replace with new.
3. Damaged orice sealing surface. 3. Replace with new.
4. Damaged orice O-ring. 4. Replace with new.
5. Orice incorrectly adjusted. 5. Reset to preliminary setting and
readjust.
6. Poppet spring damaged. 6. Replace with new.
1. Insufcent intermediate pressure. 1. Refer to rst stage troubleshooting
2. Orice incorrectly adjusted. 2. Reset to preliminary setting and
readjust.
3. Lever is damaged. 3. Replace with new.
1. Lever is slack, or orice incorrectly adjusted. 1. Reset to preliminary settings and
readjust.
2. Lever is bent. 2. Replace with new.
1. Exhaust valve worn or damaged. 1. Replace with new.
2. Mouthpiece worn or damaged. 2. Replace with new.
Symptom poSSible CauSe treatment
Freeow or leakage
Excessive Inhalation Resistance
or Hesitation
Insufcient airow when
purge is depressed
Troubleshooting Guide
Second Stage
Water entering second stage