XS Scuba AltAir Octo Installation and operating manual

Service & Repair Manual
SERVICE AND REPAIR MANUAL
ALTAIR OCTO
PN RG300
Revised - 02/11

2
AltAir Octo Service and Repair Manual
AltAir Octo
Contents
Section 1 - Introduction
Scheduled Service................................................................................................................................. 3
EAN/ Nitrox Service............................................................................................................................... 3
Facility Requirements............................................................................................................................ 4
Specialty Tools....................................................................................................................................... 5
Section 2 - Preliminary Inspection
External Inspection................................................................................................................................ 6
Immersion / Leak Test ........................................................................................................................... 6
Section 3 - Disassembly Procedures
General Guidelines................................................................................................................................ 7
Section 4 - Reassembly Procedures
General Guidelines...............................................................................................................................11
Section 5 - Final Testing Procedures
Subjective Breathing Test .................................................................................................................... 16
Flowbench Testing (optional)............................................................................................................... 16
External Leak Test ............................................................................................................................... 17
Troubleshooting Guide................................................................................................ 18
Schematic & Parts List............................................................................................ 19

3Copyright ©2011 XS Scuba
Service & Repair Manual
This manual provides factory prescribed procedures for the correct service and repair of
the AltAir™ 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 AltAir™ 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 - de-
pending on the conditions of use and the manner in which it is maintained. (Refer to the
care and maintenance procedures outlined in the AltAir User's Guide.)
When performing service, whether it is a routine overhaul or a repair of a specific 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, howev-
er, 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

4
AltAir Octo Service and Repair Manual
AltAir Octo
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 commodity 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 regu-
lator secure – especially when removing the first 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 pro-
vided in this manual.
NOTE: XS Scuba especially endorses and recommends the Jaws
Gripmaster Bench Vise, available from Peter Built Co. It is designed
specifically for the professional dive store service bench, and will pre-
vent damage that can easily be caused by a conventional vise.
❏Magnification Lamp – Strong lighting and magnification 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
fits 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 specified, in order to avoid overtightening or undertightening a part.
This is especially important for smaller parts and fittings, 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
specific range.

5Copyright ©2011 XS Scuba
Service & Repair Manual
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
Intermediate Pressure
Te st Gauge, #20-510-100
O-ring Tool Set #10-102-100
Dual Drive In-Line Adjusting Tool # 20-500-200 Alt Air Retaining Ring Clamp # 20-795-200
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
selection 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
11/16" Open End Wrench
3/4" Open End Wrench

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AltAir Octo Service and Repair Manual
AltAir Octo
Preliminary Inspection
External Inspection
1. Closely examine the conical lter inside the rst stage
yoke 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
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 guards, if present, to visually inspect
the condition of the hoses at their ttings.
3. Check the overall condition of the mouthpiece, exhaust
grill, and other external parts to evaluate the type of use
and maintenance the regulator has received.
Immersion / Leak Test
1. Check to ensure that the regulator is fully assembled and
connected to a rst 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
Troubleshooting Guide to determine its possible cause.
4. Close the cylinder valve and depress the second stage
purge button to depressurize the regulator before
performing the next procedure.
2
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7Copyright ©2011 XS Scuba
Service & 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 instill condence that
complete overhaul service has been performed.
▼Inspect all reusable parts as directed, either during or
immediately following the disassembly procedures. When
in doubt, compare the part with one that is new to best
determine its condition.
3
SECTION

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AltAir Octo Service and Repair Manual
AltAir Octo
Second 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. Slide back the hose guard(25) to expose the connection
of the LP hose.
2. While holding the inlet tting(22) secure with a w" open-
end wrench, apply a n" open-end wrench to the tting of
the LP hose(26). Turn the tting counter-clockwise to
loosen and remove. (See Fig. 1.)
3. Using a plastic or brass O-ring tool, carefully remove the
O-ring(27) from the post inside the hose tting. (See Fig.
2.)
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. Snip the plastic tie-strap(6) that holds the mouthpiece(7),
and gently pull the mouthpiece off the second stage
housing(5). Inspect the mouthpiece to ensure that it is
supple and free of any tears or corrosion. If any damage
is found that could result in discomfort or leakage, discard
the mouthpiece and do not reuse.
5. Hold the diaphragm purge cover(2) lightly depressed,
and apply a a w" open end wrench to turn the inlet tting
counter-clockwise until loose. Then, unscrew it complete-
ly by hand to remove.
6. Squeeze the O-ring(21) between thumb and forenger to
remove it from the inlet tting. Discard the O-ring and do
not reuse.
7. While holding the inlet tting secure, apply a medium
blade screwdriver to the slotted head of the adjustable
orice(23), and turn it counter-clockwise to disengage its
threads.
NOTE: The orice is O-ring sealed, and it will remain
inside the lever support after it has been unthreaded.
The following step must be performed correctly in order
to remove the orice without damaging its polished
sealing surface.
Fig. 1 – Removal of LP Hose
Fig. 2 – Removal of LP Hose O-ring

9Copyright ©2011 XS Scuba
Service & Repair Manual
8. When the orice has been unthreaded from the inlet
tting, 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. 3.)
9. To avoid using a sharp tool that can damage the orice,
squeeze the O-ring(24) between thumb and forenger to
remove it from the orice head. Discard the O-ring and
do not reuse.
10. 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. 4). 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.
11. While holding the second stage secure in one hand with
the purge facing up, rmly grasp the retaining ring(1) with
the other, and turn the ring counter-clockwise to loosen
and remove it.
NOTE: If the retaining ring is difcult to loosen, XS
Scuba recommends using the Rim Clamp (P/N 20-
795-200), available from Peter Built Co. Complete
instructions are provided with the tool.
12. Lift off the diaphragm purge cover, and then gently pull
out the diaphragm(4) with the thrust washer(3). Closely
inspect these parts to ensure they are perfectly round and
free of any distortion, tears, or other damage. If any part
is found to be damaged, discard it and replace with new.
NOTE: Do not attempt to disassemble the anti-friction
disc from the center of the diaphragm.
13. Through the inlet opening of the second stage housing,
gently press the lever support(17) with the complete valve
assembly into the second stage housing to remove.
14. Reassemble the inlet tting with the lever support by hand
until nger snug, in order to hold the shaft of the pop-
pet(19) in place without turning, inside the keyed (square)
hole of the lever support.
15. While holding the assembly secure, apply a 4" nut driver
to turn the locknut(14) counterclockwise until it is com-
pletely unthreaded from the poppet (see Fig. 5).
Discard the locknut and do not reuse. Remove the spacer(15)
Fig. 5 – Disassembly of Valve Mechanism
Fig. 3 – Removal of Adjustable Orifice
Fig. 4 – Orifice Inspection

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AltAir Octo Service and Repair Manual
AltAir Octo
and lever(16), and examine the lever to ensure that it is
not bent or damaged. Replace with new if any damage is
found.
16. Disassemble the inlet tting from the lever support, and
remove the poppet and low pressure spring(18). Closely
examine the spring under strong magnication to check
for any signs of corrosion, and replace with new if any
corrosion is found.
17. Using a sharp pick or straight pin, lightly pierce the center
of the LP seat(20) and remove from the poppet. Discard
the seat and do not reuse.
18. Examine the condition of the lever support and poppet
to check for any signs of thread damage, corrosion or
chrome loss. Replace with new if signicant damage is
found.
19. Remove the exhaust grill(9) from the second stage hous-
ing by inserting a small (.02mm) at blade screwdriver
into both slots on either side of the second stage housing.
(See Fig. 6.) Gently pull the grill out of the housing, being
careful to avoid bending.
20. Remove and discard both of the exhaust valves(8) by
pulling each one straight out of the housing. Do not at-
tempt to reuse.
21. If the male portion of the quick disconnect assembly(12)
is undamaged, no further disassembly is required. To
remove the QD clip from the second stage housing, follow
these steps (see Fig. 7):
a. Remove the small C-clip(13) from the underside of the
stainless steel post.
b. Tap out and remove the stainless steel post(11), and
pull the male clip away from the housing.
c. Examine the housing to check for any damage that
may impair a secure connection of the QD Clip. If found,
it will be necessary to replace the housing.
d. Reassemble the QD Clip in reverse order.
▼After completing the disassembly of the second stage,
refer to the instructions provided in the XS Scuba Autho-
rized Service Document, titled - Cleaning & Lubrication.
Fig. 6 – Exhaust Grill Removal
Fig. 7 – Disassembly of QD Cllip

11 Copyright ©2011 XS Scuba
Service & Repair Manual
Reassembly Procedures
General Guidelines
▼Refer to the schematic parts list, that highlights automatic
replacement 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 individu-
ally 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 en-
sure 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 tempera-
ture conditions. It is also non-reactive to oxygen, and is ap-
proved 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
regulator will otherwise become contaminated, and ren-
dered 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
matter 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
petroleum base may attack or weaken plastic or rubber
parts.
▼ Use all replacement parts provided in the XS Scuba Authorized
Dealer parts kit.
4
SECTION

12
AltAir Octo Service and Repair Manual
AltAir Octo
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 both exhaust valves(8), if they were removed, into
the second stage housing(5) 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. Trim the excess stem material close to
the barb.
2. Fit two tabs on one side of the exhaust grill(9) into the
mating slots of the second stage housing, and then ex
it inward slightly to engage the tabs on the opposite side.
(See Fig. 8.)
3. Install a new LP seat(20) into the head of the poppet(19)
with the smooth side facing out, and press it into place so
that it is seated ush. DO NOT use adhesive.
4. Apply a light coat of lubricant to both ends of the LP
spring(18), and place the spring over the threaded shaft
of the poppet.
5. Mate the squared poppet shaft through the lever sup-
port(17), and then t the inlet tting(22) over the poppet
head. Screw the inlet tting clockwise into the lever sup-
port by hand, in order to hold the poppet shaft securely in
place without turning.
6. Place the lever(16) over the poppet shaft inside the ange
of the lever support as shown in Fig. 9, followed by the
spacer(15).
7. Turn the locknut(14) clockwise by hand until the threads
are engaged by at least two turns. Apply a 4" nut driver
to turn the locknut clockwise until exactly two threads of
the poppet shaft are visible outside the locknut. (See Fig.
10.)
8. Remove the inlet tting from the lever support, and install
the O-ring(21) onto the groove of the inlet tting above
the smaller section of threads.
9. Install the valve assembly into the second stage housing
with the lever facing up (see Fig. 11). While holding it se-
curely in place, mate the inlet tting through the opposite
side of the second stage housing, and turn clockwise by
hand until nger snug.
Fig. 9 – Correct Lever Orientation
Fig. 8 – Exhaust Grille Installation
Fig. 10 – Valve Reassembly
Fig. 11 – Installation of Inlet Fitting

13 Copyright ©2011 XS Scuba
Service & Repair Manual
10. Apply an inch-lbs torque wrench with w" socket to tighten
the inlet tting to a torque measurement of 90(±5) inch-
lbs.
11. Install the O-ring(24) onto the head of the orice(23), and
insert the orice into the open end of the inlet tting with
the threaded end facing in. Apply a blunt probe, such as
a pencil or wooden dowel, to seat the orice against the
threads inside the inlet coupling.
12. Apply a medium blade screwdriver to engage the slotted
head of the orice, and turn it clockwise approximately 5
full revolutions. Then, grasp the screwdriver by the shaft,
rather than the handle, for best sensitivity of touch (see
Fig. 12). Continue turning the orice very slowly while
closely observing the lever. STOP turning the orice
when the lever begins to drop. This will indicate that the
orice has made contact against the LP seat.
CAUTION: Do not continue to turn the orice further
beyond the point where it makes contact with the
low pressure seat. Doing so may wear the LP seat or
sealing surface of the orice, and can also result in an
incorrect adjustment of the second stage.
13. Lay the diaphragm(4) inside the second stage housing,
directly over the lever, with its raised surface facing up.
14. Fit the thrust washer(3) over the diaphragm and press it
into place so that it is seated at the base of the housing
threads on all sides.
15. Place the diaphragm purge cover(2) over the the dia-
phragm and thrust washer, followed by the retaining
ring(1). Turn the purge cover as needed to align the logo
straight between the mouthpiece and inlet, and hold in
place while tightening the retaining ring clockwise until
snug.
16. Install the mouthpiece(7) onto the mouthpiece tube of the
second stage housing. Fit a tie-strap(6) over the mouth-
piece with the locking tab facing toward the retaining clip,
and cinch it snug. Snip off the excess strap that extends
outside the locking tab.
▼After completing the reassembly of the second stage,
proceed to Section 5 – Final Testing
Fig. 12 – Preliminary Setting of Orifice

14
AltAir Octo Service and Repair Manual
AltAir Octo
Final Testing Procedures
CAUTION: If the regulator will be used with EAN/ Nitrox,
it is important to pressurize and ow test the regulator
using only hydrocarbon-free gas. The regulator will
otherwise become contaminated with hydrocarbons
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 ow testing.
1. Connect the IP Test Gauge onto the inlet tting of the In-
line 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. 13.)
2. Install the O-ring(27) onto the post inside the female tting
of the LP hose(26). 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 O-ring(28) onto the male tting of the LP hose,
and install the hose into an intermediate pressure port of
a rst stage regulator that has been veried to be properly
serviced, with a stable intermediate pressure of 140 (±5)
psi . Apply a torque wrench with a crow-foot to tighten
the tting to 38 (±2) inch-lbs.
CAUTION: If the second stage has been cleaned and
serviced for use with EAN/ Nitrox, it is important to con-
nect it with a rst stage that has also been cleaned and
serviced accordingly, and to use only hydrocarbon-free
gas while performing this procedure. Use of standard
compressed air will otherwise contaminate the system.
4. Ensure that all the rst stage ports are sealed, and con-
nect the rst stage with a ltered gas supply of 2,500-
3,000 psi. Slowly pressurize the regulator. Listen to
verify that a leak can be heard from the second stage
valve, and proceed to step 5.
5
SECTION

15 Copyright ©2011 XS Scuba
Service & Repair Manual
a. If airow cannot be heard, it will be necessary to initi-
ate 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 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.
NOTE: If more than a slight adjustment is required to
initiate a leak, it is important to check the adjustment of
the locknut on the poppet shaft to verify once again that
it is set correctly to its preliminary setting, as specied
in Step 8 of the Reassembly Procedure.
5. 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 several times to ensure that it does not return. Ob-
serve the IP Test Gauge while purging the second stage to
verify that it indicates a stable intermediate pressure after
each cycle, with no creep or uctuation.
CAUTION: Over-adjustment of the orice can cause
excessive spring load in the second stage valve, and
may impair the regulator’s performance.
6. While holding the second stage with the mouthpiece fac-
ing down, gently shake it up and down. Listen closely
to determine whether any movement of the lever can be
heard inside, indicating that the lever has dropped. If lever
movement cannot be detected, proceed to step 8. Other-
wise, perform the following steps to raise the lever:
a. Remove the retaining ring, purge cover, thrust washer
and diaphragm to expose the valve assembly.
b. Apply a 4" open-end wrench to turn the locknut clock-
wise a small fraction of a turn. Do not over-adjust,
since it is important to tighten the nut onto the poppet
only as far as necessary to remove lever slack.
c. Repeat the above step until lever slack is eliminated.
d. Reinstall the diaphragm, thrust washer, purge cover,
and retaining ring.
Fig. 13 – Inline Adjustment Tool w/ IP Gauge

16
AltAir Octo Service and Repair Manual
AltAir Octo
CAUTION: Over-adjustment of the locknut can cause
excessive spring load in the second stage valve, and
may impair the regulator’s performance. If leakage
returns after following the above steps, disassemble
the second stage valve assembly and repeat the above
procedure following a close inspection of the orice
and LP seat and reassembly.
7. When the second stage is properly adjusted with no leaks
or lever slack, depressurize and purge the system to dis-
connect the LP hose.
8. If the inlet coupling was removed, apply a torque wrench
with w" socket to tighten it to a torque measurement of 90
inch-lbs (±5).
9. Reconnect the LP hose to the inlet coupling, and apply
a torque wrench with n" crow-foot to tighten the LP hose
tting to 55(±5) inch-lbs.
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. 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.
NOTE: A properly serviced and adjusted regulator
should deliver air upon deep inhalation without ex-
cessive inhalation 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.
Flowbench Testing (optional)
The Subjective Breathing Test, combined with the
Intermediate 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.

17 Copyright ©2011 XS Scuba
Service & Repair Manual
External Leak Test
After rst stage reassembly and nal adjustment of the
second stage has been completed, submerge the entire regu-
lator 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 recommended 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 com-
ponent 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 ltered, 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 tting. Disinfect the mouthpiece, and dry the
regulator completely with a clean towel. This completes
the overhaul service procedures for the ALTAIR regulator.

18
AltAir Octo Service and Repair Manual
AltAir Octo
1. Excessive intermediate pressure. 1. Refer to first stage troubleshooting
2. Damaged or worn LP seat. 2. Replace with new.
3. Damaged orifice sealing surface. 3. Replace with new.
4. Damaged orifice O-ring. 4. Replace with new.
5. Orifice incorrectly adjusted. 5. Reset to preliminary setting and
readjust.
6. Poppet spring damaged. 6. Replace with new.
1. Insufficent intermediate pressure. 1. Refer to first stage troubleshooting
2. Orifice incorrectly adjusted. 2. Reset to preliminary setting and
readjust.
3. Lever is damaged. 3. Replace with new.
1. Lever is slack, or orifice incorrectly adjusted. 1. Reset to preliminary settings and
readjust.
2. Lever is bent. 2. Replace with new.
1. Exhaust valve diaphragm worn or damaged. 1. Replace with new.
2. Mouthpiece worn or damaged. 2. Replace with new.
Symptom poSSible CauSe treatment
Freeflow or leakage
Excessive Inhalation Resistance
or Hesitation
Insufficient airflow when
purge is depressed
Troubleshooting Guide
Second Stage
Water entering second stage

19 Copyright ©2011 XS Scuba
Service & Repair Manual
* Bold Indicates Overhaul Replacement Part - Provided In Parts Kit #RK4
EXPLODED VIEW
L
P
Service Notes:
Adjust with intermediate pressure
125 to 140 psi
Lightly lubricate with Christo-Lube
MCG-111 part number TL108
Tighten nut until two full threads show
Protect the sealing edge of the orifice from
damage
Remove o-rings without damaging parts
using brass pick part number TL111
# Part # Description Dealer # Part # Description Dealer
1.00
2.00
5.00
2.00
3.00
2.00
1.00
4.00
3.00
1.00
2.00
12.00
1.00
1.00
3.00
4.00
4.00
3.00
8.00
0.50
3.00
2.00
3.00
3.00
1.00
2.00
1.00
1.00
15 RP300-15 Spacer
16 RP300-16 Lever
17 RP300-17 Lever Support
18 RP300-18 Spring
19 RP300-19 Poppet
20 RP300-20 Seat
21 RP300-21 O-ring
22 RP300-22 Inlet Fitting
23 RP300-23 Adjustable Orifice
24 RP300-24 O-ring
25 RP300-25 Hose Guard
26 LP36YL LP Hose - 36” Yellow
27 RP300-27 O-ring
28 RP300-28 O-ring
Part # RK4
Dealer 8.00
Service Kit
21
6
20 24
8
27
8
28
Includes:
I
I
N
O
27
28
24
21
20
14
13
8
6
25
23
22
19
18
17
15
12
11
10
3
4
2
1
5
7
9
26
16
1 RP300-01 Retaining Ring
2 RP300-02 Purge Cover
3 RP300-03 Diaphragm
4 RP300-04 Thrust Washer
5 RP300-05 Housing
6 RP250-11 “No Bump” Tie Strap
7 RP300-07 Mouthpiece
8 RP300-08 Exhaust Valve
9 RP300-09 Exhaust Grill
10 RP300-AH Female Buckle Assembly
11 RP300-11 Attachment Post
12 RP300-12 Male Buckle
13 RP300-13 C-Clip
14 RP300-14 Locknut
L
P
N
O
OCTO
OCTO
13 14