XS Scuba SEAAIR Installation and operating manual

Service & Repair Manual
SERVICE AND REPAIR MANUAL
SEAAIR REGULATOR
PN RG200
Revised - 02/11

SeaAir Regulator
2
SeaAir Regulator Service and Repair Manual
Contents
Section 1 - Introduction
Warnings, Cautions, & Notes................................................................................................................................................3
Scheduled Service...................................................................................................................................................................3
EAN/ Nitrox Service ..............................................................................................................................................................3
Facility Requirements ............................................................................................................................................................4
Specialty Tools ........................................................................................................................................................................5
Section 2 - Preliminary Inspection
External Inspection ................................................................................................................................................................6
Immersion / Leak Test ...........................................................................................................................................................6
Intermediate Pressure Test ....................................................................................................................................................7
Section 3 - Disassembly Procedures
General Guidelines.................................................................................................................................................................8
First Stage Disassembly .........................................................................................................................................................9
Second Stage Disassembly...................................................................................................................................................13
Section 4 - Reassembly Procedures
General Guidelines...............................................................................................................................................................16
First Stage Reassembly.........................................................................................................................................................17
Second Stage Reassembly ....................................................................................................................................................21
Section 5 - Final Testing Procedures
First Stage Intermediate Pressure Test...............................................................................................................................24
Second Stage Adjustment and Flow Test...........................................................................................................................25
Subjective Breathing Test.....................................................................................................................................................26
Flowbench Testing (optional).............................................................................................................................................27
External Leak Test ................................................................................................................................................................27
Troubleshooting Guide - First Stage..........................................................................28
Troubleshooting Guide - Second Stage .................................................................29
Schematics & Parts Lists
SeaAir First Stage..................................................................................................................................................................30
SeaAir Second Stage.............................................................................................................................................................31

Service & Repair Manual
3Copyright ©2015 XS Scuba
is manual provides factory prescribed procedures for the correct service and repair of the SeaAir
regulator, including the rst and second stage. It is not intended to be used as an instructional manual for
untrained personnel. e 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 accompanied
by one of these symbols:
A WARNING indicates a procedure or situation that may result in serious injury or death if instructions 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 SeaAir regulator is considered to be a life-supporting product, it is extremely critical that it
receives service according to the procedures outlined in this manual on a regularly scheduled basis; at least
once a year with normal or infrequent use.
NOTE: A unit that receives heavy or frequent use, such as in rental, instruction, or commercial ap-
plications, 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 SeaAir User's Guide.)
When performing service, whether it is a routine overhaul or a repair of a specic problem, it is im-
portant to understand how the regulator is designed and how it operates. If you have any questions, please
consult your XS Scuba representative.
EAN/ Nitrox Service
Newly manufactured XS Scuba regulators are assembled and packaged to be compatible with oxygen
enriched air (EAN/ Nitrox), not to exceed 40% oxygen content. If the regulator is going to be used for this
application, however, it must be dedicated and clearly labled as such, in order to prevent any crossover use
with standard compressed air. Refer to the instructions provided in the XS Scuba Authorized
Service Document, titled - Regulator Parts Cleaning Procedures.
CAUTION: It is important to avoid using, testing, or otherwise pressurizing a dedicated EAN
regulator with standard compressed air, which contains hydrocarbon contaminants.
Introduction
1
SECTION

SeaAir Regulator
4
SeaAir Regulator 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 aer the sale. Next to
airlls and gas blending, it is the single most important commodity your
store can provide.
e service department is therefore the most important part of your
store. It should be clean and well lighted, and stocked with a complete in-
ventory 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 regula-
tor 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.

Service & Repair Manual
5Copyright ©2015 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 oers a wide selection of
the most innovative specialty tools found anywhere to help you get the job done eciently - and done right.
Illustrations courtesy of Peter Wolfinger.
Galion, OH 44833
Phone: [phone]
www.scubatools.com
[phone]
Breaker Bar # 20-157-500
PETER BUILT
1" - SIX POINT
3/8"
Drive
I” Yo ke Nut Socket #20-155-500
Custom (narrow diameter)
3/8" x 3" Drive Extension #20-156-500
100
200
80
60
40
20 180
160
120
IP RANGE
125-150 PSI
PSI
PETER BUILT
"Quality in the making"
[phone]
USE NO OIL
140
25
50
150
125
100
75
175
200
225
250
275
300
0
IP RANGE
125-150 PSI
PSI
USE NO OIL
PETER BUILT CO.
"Quality in the making"
[phone]
260 3.5 x 60
260 2.0 x 50
Select Tool Kit (5 pcs) # 11-090-500
Poppet Align/ Orifice Preset Tool, #20-785-400
Intermediate Pressure
Te st Gauge, #20-510-100
Snap Ring Pliers # 10-101-500
O-ring Tool Set #10-102-100
No. 4 Hook Spanner, #20-404-200
Dual Drive In-Line Adjusting Tool # 20-500-200 Second Stage Rim Clamp #20-790-200
M
Piston Installation Bullet
Required Tools/ Lubricant
No. 4 Hook Spanner Wrench PN #20-404-200
Dual Drive Adjusting Tool PN #20-500-200
Tech Driver IPG PN #20-165-111
O-ring Tool Set PN#10-125-400
1/4" Slotted Screwdriver PN #11-465-500
1/4" Nut Driver PN #11-168-500
Small (.02) Blade Screwdriver PN #11-133-500
Cristo Lube PN #MS150
Hakko Side Cuts, 5" PN #16-020-500
Snap Ring Pliers
11/16" Open End Wrench
3/4" Open End Wrench

SeaAir Regulator
6
SeaAir Regulator Service and Repair Manual
Preliminary Inspection
External Inspection
1. Closely examine the conical lter to check for any signs that
contaminants have entered the system, including sea water, rust,
or aluminum oxide.
NOTE: A green discoloration of the filter 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 protectors, if present, to visually inspect the
condition of the hoses, especially at their ttings.
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 con-
nected 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 regula-
tor.
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 t-
tings 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 performing the next
procedure.
Intermediate Pressure Test
2
SECTION

Service & Repair Manual
7Copyright ©2015 XS Scuba
NOTE: It is not necessary to perform this test unless a prob-
lem has been reported that requires diagnostic troubleshoot-
ing and repair. When performing routine overhaul service,
proceed directly to the following section, Disassembly.
1. Connect a calibrated intermediate pressure test gauge to the
regulator, either with a quick-disconnect inator hose or with
the female tting of a second stage LP hose, depending on the
connection of the test gauge.
CAUTION: To provide a safety relief valve in the event that
intermediate pressure exceeds 155-170 psi, ensure that a fully
assembled and properly adjusted second stage is connected
to the first stage before pressurizing. Failure to relieve inter-
mediate 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. Close-
ly monitor the IP test gauge to determine whether the interme-
diate 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 uctuates
aer 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 but-
ton to depressurize the system before attempting to perform any
disassembly.
▼After completing the Preliminary Inspection, proceed
to Section 3 – Disassembly

SeaAir Regulator
8
SeaAir Regulator Service and Repair Manual
Disassembly Procedures
General Guidelines
▼Prior to performing any disassembly, check to ensure that the
service facility is well equipped with all the tools and parts need-
ed 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 move-
ment, 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. Aer passing close
inspection, static
O-rings may sometimes be reused, although this is not neces-
sarily 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 proce-
dure.
▼Do not attempt to reuse parts that are designated to be auto-
matically discarded and replaced with the parts provided in the
overhaul parts kit. ese parts should be shown to the cus-
tomer, however, to ensure their condence and satisfaction that
complete overhaul service has been performed.
▼Inspect all reusable parts as directed, either during or imme-
diately 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 ©2015 XS Scuba
First Stage Disassembly
CAUTION: Whenever possible, use only plastic or brass O-ring
tools for removing O-rings in order to prevent damage to the sealing
surface. Steel instruments, such as dental picks, can easily dam-
age the sealing surface of a softer brass part, causing irreparable
leakage and requiring the part to be replaced with new.
1. Before disassembling the rst stage, remove the low pressure
second stage hose with a 15mm open end wrench, the high
pressure hose with a s" open end wrench, and the low pressure
inator hose with a 2" (or other size required) open end wrench.
Remove all remaining port plugs(17&32) with a x" hex key.
2. Remove and inspect the O-rings(16&31) on these items to de-
termine their condition, and discard them if any signs of decay
are found.
3. Remove the dust cap(3) from the yoke(4).
NOTE: It will be necessary to use a bench mounted vise to
hold the first stage secure throughout this procedure. This
ensures the best protection against slippage and accidental
damage to soft metal parts. If an ordinary bench vise will be
used, the first stage must be mounted outside the vise with
the use of a vise mounting tool fastened into the high pressure
port. To ensure the best available protection against
damage, XS Scuba specifically recommends the
Gripmaster Vise, available from Peter Built Co.
4. Secure the rst stage in a vise as described above, with the yoke
and yoke screw(2) facing up (See Fig. 1).
5. Disassembly of the Yoke Connector
a. Loosen the yoke screw several turns counter-clockwise.
Place a 1" Yoke Retainer Socket (available from Peter Built
Co.) inside the yoke and over the hex features of the yoke
retainer(8). Pass a Breaker Bar (available from Peter Built
Co.) through the yoke, and tighten the yoke screw clock-
wise until it is lightly snug over the dimpled feature of the
breaker bar (see Fig. 2). en, grasp the breaker bar with
both hands on opposite ends and turn the socket counter-
clockwise with steady force to loosen the yoke retainer. Do
not use impact.
CAUTION: The socket and breaker bar combination provide
the best insurance against damage while removing the yoke
retainer, using the procedure described above. DO NOT, un-
Fig. 1 – Correct vise mounting
Fig. 2 – Yoke Retainer Removal

SeaAir Regulator
10
SeaAir Regulator Service and Repair Manual
der any circumstances, use an adjustable wrench or an open
end wrench that does not fit completely over the flats on both
sides. Doing so may result in permanent damage to the yoke
retainer, requiring its replacement.
b. Turn the yoke screw counter-clockwise to remove it from
the yoke, and set aside the breaker bar and socket.
c. Unscrew the yoke retainer counter-clockwise to remove
from the body, along with the yoke and saddle(10).
d. Remove the main seal O-ring(9) from the yoke retainer.
Discard the O-ring and do not reuse, regardless of its condi-
tion.
e. While holding the yoke retainer secure, apply a pair of Snap
Ring Pliers to remove the retaining ring(5) from the yoke
retainer (see Fig. 3). Tap out the lter(6), and remove the
O-ring(7) inside with a brass O-ring tool. Discard the lter
and O-ring, and do not reuse either part regardless of their
condition.
6. Disassembly of the DIN Connector
a. Secure the rst stage in the vise with the DIN connector fac-
ing straight up. (See Fig. 4.)
b. Apply a 4" hex key to the DIN retainer(4f), and turn it
counter-clockwise to loosen and remove from the body,
along with the handwheel(4a) and saddle(4d).
c. Remove the DIN retainer from the handwheel, and then re-
move and discard: the lter(4g) and both O-rings(4e&4h).
Do not attempt to reuse these parts.
c. Closely inspect the condition of the DIN retainer and
handwheel to ensure that the threads are free of any burrs or
other damage. If thread damage is found that could impair
a proper connection, it is important to replace the part with
new.
d. Inspect the condition of the thrust washer(4b), spacer(4c),
and saddle, and replace if needed.
7. Resecure the rst stage in the vise with the body(18) positioned
vertical, and the LP swivel facing down.
8. Apply a 4" hex key to the HP seat retainer(11) and turn it coun-
ter-clockwise to loosen and remove (see Fig. 5). Remove and
discard the O-ring(12).
9. Using a brass O-ring tool, carefully li out the O-ring(14) inside
the HP chamber (see Fig. 6). Be careful to avoid touching the
exposed seating edge of the piston sha. Discard the O-ring,
regardless of its condition.
10. While holding the HP seat retainer secure with a cloth covering
Fig. 3 – Removal of Filter Retaining Ring
Fig. 4 – Removal of DIN Retainer
Fig. 5 – Removal of HP Seat Retainer

Service & Repair Manual
11 Copyright ©2015 XS Scuba
the HP seat, apply a short blast of low pressure air through the
small hole to dislodge the HP seat(13). (See Fig. 7.) Discard the
seat, and do not reuse.
11. Resecure the rst stage in the vise with the body positioned
vertical, and the LP swivel facing up.
12. Apply a spanner wrench to one of the larger bore holds of the
piston cap(25), and hold it securely seated to turn the cap coun-
ter-clockwise to loosen it from the rst stage body. (See Fig. 8.)
Turn the piston cap further by hand to loosen and remove, until
it can be carefully lied straight o the body, along with the
piston(22).
13. Gently remove the piston from the piston cap, and then remove
and discard the piston head O-ring(23). Set the piston aside
with the sha facing up, to be kept isolated from other metal
parts or work surfaces that might damage the polished seating
edge.
14. Remove the high pressure valve spring(21) and spring isola-
tor(20) from the body. Inspect the spring isolator for any signs
of damage or distortion, and discard if any is found. Closely
inspect the spring with a magnier to check for any signs of
damage or corrosion that has permeated the wall of the metal.
Set the spring aside to be reused if it is determined to be in
satisfactory condition with no signs of permanent corrosion or
damage.
CAUTION: If damage is found, or if the intermediate pres-
sure was measured lower than 135PSI during preliminary
inspection, replace the spring with new. DO NOT attempt to
boost the intermediate pressure by adding spring isolators
unless a new spring has first been installed.
NOTE: If corrosion is found on the spring, check for any
signs that moisture may have entered the first stage. If evi-
dence of moisture is found inside the first stage, it is important
to inspect all parts that could provide a possible leak path,
either due to damage or improper assembly.
15. Remove the rst stage from the vise, and remove the vise
mounting tool if one was used.
16. Using a brass O-ring tool, remove the small dynamic O-ring(19)
from the rst stage body, being careful to avoid damaging the
sealing surface of the internal groove.
17. To remove the large external O-ring(15), pinch it between
thumb and forenger with one hand, and then apply an O-ring
Fig. 6 – Removal of HP Static Oring
Fig. 8 – Loosening Piston Cap
Fig. 7 – Removal of HP Seat

SeaAir Regulator
12
SeaAir Regulator Service and Repair Manual
tool to remove it with the other.
18. Secure the swivel cap(30) in a vise, using either the "Jaws Grip-
master," or with a vise mounting tool installed in one of the LP
ports. Ensure that the piston cap is facing up.
19. Mate a c" (8mm) hex key through the open piston cap and
into the hex of the swivel retainer(24). (See. Fig. 9.) Turn the
swivel retainer counter-clockwise to loosen and remove, and
li the piston cap o the swivel cap.
20. Remove the swivel retainer from the piston cap, along with the
swivel washer(27). Examine the condition of the washer, and
reuse or replace it as needed.
21. Remove and discard both O-rings(27&28) from the swivel cap,
and automatically discard them regardless of their condition.
22. Using a smooth plastic or brass probe, remove the rubber col-
lar(26) from the piston cap. Examine the ring to determine its
condition, and replace with new as needed.
23. Under strong lighting, closely inspect the inner bore and all
sealing surfaces of the rst stage body with a magnier, includ-
ing the intermediate and high pressure ports, and the inlet
port. Check to ensure there are no scratches or other damage
that could contribute to leakage. If damage is found that is
determined to cause irreparable leakage, it will be necessary to
discard the rst stage body and replace it with new.
▼After completing the disassembly of the rst stage,
proceed to the following procedure - Second Stage
Disassembly.
Fig. 9 – Removal of Swivel Retainer

Service & Repair Manual
13 Copyright ©2015 XS Scuba
Second Stage Disassembly
CAUTION: Whenever possible, use only plastic or brass
O-ring tools for removing O-rings in order to prevent dam-
age 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 cover to expose the connection of the LP
hose.
2. While holding the inlet tting(20) secure with a n" open-end
wrench, apply another n" open-end wrench to the tting of
the LP hose. Turn the 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 care-
ful 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.
5. Snip the plastic tie-strap(21) that holds the mouthpiece(23), and
gently pull the mouthpiece o the second stage housing(12).
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.
6. While holding the second stage secure with one hand, rmly
grasp the retaining ring(17) with the other, and turn the ring
counter-clockwise to loosen and remove it, along with the dia-
phragm cover(16).
NOTE: If the retaining ring is difficult to loosen, XS Scuba
recommends using the Rim Clamp (P/N 20-790-200), avail-
able 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 any distortion or other damage. If any damage is found,
discard the cover and replace with new.

SeaAir Regulator
14
SeaAir Regulator Service and Repair Manual
8. Li out the diaphragm(14) and thrust washer(15) from the
second stage housing. Inspect the diaphragm to ensure that it is
supple and free of any pinholes, tears, corrosion, or other dam-
age. If any damage is found, discard it and replace with new.
9. Using a small at blade screwdriver, rotate the metal retaining
clip(13) over the groove of the adjustment knob(1) 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 li the clip o
the groove. (See Fig. 10.)
10. While holding the lever(18) lightly depressed, slide the entire
valve assembly out of the second stage housing, adjustment
knob rst (see Fig. 11). Remove and discard the inlet tting O-
ring(19).
11. Unscrew the adjustment knob counter-clockwise from the air
barrel(8), and carefully remove the O-ring(2) with a plastic tool.
12. Turn the air barrel over to allow the balance shuttle cap(3) and
LP spring(4) to drop out (see Fig. 12). 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.
13. Gently remove the lever from the air barrel by liing out one leg
rst, and then the other. Be careful to avoid bending or stretch-
ing either leg.
14. Turn the air barrel over to allow the poppet(6) to drop out. Us-
ing ngernails or a plastic tool, carefully remove the LP seat(7)
and small O-ring(5). Discard both so parts, and do not re-
use. 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.
15. Remove the white lever pad(9) from the air barrel. Discard, and
do not reuse.
16. While holding the air barrel secure, apply a medium blade
screwdriver to the slotted head of the adjustable orice(10), and
turn it counter-clockwise to disengage its threads.
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 correctly in order to remove the orifice
without damaging its polished sealing surface.
17. When the orice has been unthreaded from the air barrel, care-
fully insert a small wooden or plastic dowel through the oppo-
site end of the valve body, directly over the sealing edge of the
orice. Gently press out the orice. (See Fig. 13.)
18. To avoid using a sharp tool that can damage the orice, squeeze
the O-ring(11) between thumb and forenger to remove it from
Fig. 10 – Removal of Retaining Clip
Fig. 12 – Removal of Adjustment Knob
Fig. 11 – Removal of Valve Assembly

Service & Repair Manual
15 Copyright ©2015 XS Scuba
the orice head. Discard the O-ring and do not reuse.
19. Closely examine the orice with the use of a magnier, check-
ing for any scratches or other damage to the sealing edge and
the groove that holds the O-ring (see Fig. 14). 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 so surface to keep it
isolated from other metal parts.
20. Remove the exhaust deector(24) from the second stage hous-
ing to expose the exhaust valve(22) for inspection.
NOTE: To facillitate the removal of the exhaust deflector,
first place it in hot (120°-150°F) water for 2-3 minutes and
allow it to soften.
21. Closely inspect the exhaust deector to check for any signs of
damage that may have been caused by abuse or improper disas-
sembly. If found, discard it and replace with new.
22. 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 origi-
nal position. If any wear or damage is detected, or if the mate-
rial feels sti 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 in-
spection. Once the diaphragm is removed, however, it will be
permanently stretched and then must be replaced 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. 14 – Orifice Inspection
Fig. 13 – Removal of Adjustable Orifice

SeaAir Regulator
16
SeaAir Regulator Service and 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 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 magnification 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 ex-
clusively for the lubrication and dressing of O-rings and other internal parts.
Christo-Lube®provides superior lubrication to that of silicone grease, espe-
cially 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 regulator will otherwise
become contaminated, and rendered unsafe for use with any mixture
of oxygen enriched air.
▼Dress all O-rings with a visible film of Christo-Lube, but avoid applying exces-
sive amounts, as this may attract particulate matter that can cause acceler-
ated 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

Service & Repair Manual
17 Copyright ©2015 XS Scuba
First Stage Reassembly
WARNING: DO NOT attempt to use any other manufacturer's
part as a substitute for any XS Scuba part, regardless of
any similarity in shape, size, or appearance. Doing so may
render the product unsafe, and could result in serious injury
or death.
1. Lubricate and install the small dynamic O-ring(19) into the
rst stage body(18), checking to ensure that it is seated properly
inside the groove.
2. Install the large external O-ring(15) onto the groove near the
end of the body.
3. Generously lubricate and install the large dynamic O-ring(23)
onto the head of the piston(22), and stand the piston on its
head.
4. Apply a light lm of lubricant to both ends of the high pressure
spring(21), and place the spring over the sha of the piston.
5. Lay the spring washer(20) over the top of the spring.
NOTE: If more than one washer was removed during disas-
sembly, be sure to reassemble the first stage using the same
number of washers, unless the HP spring has been discarded
and replaced with new. Up to three washers may be used.
▼If one is needed, install between the spring and body.
▼If two are needed, install on opposite sides of spring.
▼If three are needed, install one between the spring and body,
and two between the spring and piston.
6. Insert a piston installation bullet into the end of the piston sha.
is will protect the small dynamic O-ring inside the body, and
also the polished sealing surface of the piston (see Fig. 15).
7. Gently lower the threaded end of the body over the piston sha,
until the body is supported by the spring . While holding the
piston and body together, turn the body over to allow the piston
installation bullet to drop out of the opposite end, tapping it
loose if necessary (see Fig. 16). Stand the body on end, with the
piston head facing up.
8. Lubricate and install the large O-ring(28) into the groove of the
swivel cap(30), and the smaller dynamic O-ring(28) onto the
swivel stem. (See Fig. 17.)
9. Mate the smaller end of the piston cap(25) over the stem of the
swivel cap, and press it downward so that it snaps securely into
place.
Fig. 15 – Piston w/ Installation Bullet
Fig. 17 – Swivel Retainer w/ O-rings
Fig. 16 – Removal of Bullet

SeaAir Regulator
18
SeaAir Regulator Service and Repair Manual
10. Install the swivel washer(27) over the shoulder of the swivel
stem, inside the piston cap, and ensure that it is seated securely
and evenly around the base.
11. Being careful to avoid disturbing the position of the swivel
washer, mate the threaded end of the swivel retainer(24)
through the piston cap and into the stem of the swivel cap. Turn
it clockwise to engage the threads, and tighten it until nger
snug.
12. Secure the swivel cap(30) in a vise, using either the "Jaws Grip-
master," or with a vise mounting tool installed in one of the LP
ports. Ensure that the piston cap is facing up.
13. Apply an inch-pounds torque wrench with c" (8mm) hex key to
tighten the swivel retainer to a torque measurement of 80 inch-
lbs, and remove the swivel assembly from the vise.
14. Fit the large diameter end of the rubber collar(26) over the
swivel cap, and press it down until the smaller end seats into
place.
NOTE: If the first stage is going to be prepared for use in
severe conditions (cold or silty water), do not install the collar
at this time. Refer to the instructions provided at the end of
this procedure for installing the IceBreaker™ environmental
sealing collar.
15. Gently mate the piston cap straight down over the head of the
piston, and tighten the piston cap and body together by hand
until snug. (See Fig. 18.)
16. Lubricate and install the O-ring(12) onto the HP seat retainer, at
the base of the threads.
17. Install the high pressure seat(13) into the HP seat retainer(11)
with the concave dimple facing out. (See Fig. 19.)
18. Lubricate and install the O-ring(14) inside the rst stage body,
using a smooth probe if necessary to ensure that it is seated
evenly over the shoulder at the base of the high pressure cham-
ber.
19. Mate the HP seat retainer into the rst stage body, and turne
clockwise by hand until nger snug.
20. Secure the rst stage vertically in a vise, with the LP swivel as-
sembly facing down.
21. Apply an foot-pounds torque wrench with 4" hex key to tighten
the HP seat retainer to a torque measurement of 18 foot-lbs.
22. Resecure the rst stage in the vise, turned over with the LP
swivel assembly and piston cap facing straight up.
Fig. 18 – Assembly of Piston Cap w/ Body
Fig. 19 – HP Seat Installation

Service & Repair Manual
19 Copyright ©2015 XS Scuba
23. Apply a spanner wrench to one of the larger bore holes of the
piston cap(25), and hold it securely seated to tighten the cap
clockwise until snug. Do not overtighten. (See Fig. 20.)
24. Resecure the rst stage in the vise, positioned horizontal, with
the inlet port facing up.
25. Reassembly of the Yoke Connector
a. Install the O-ring(7) into the yoke retainer(8), followed by
the conical lter(6). Closely examine the retaining clip(5)
to compare the dierence of one side, which is at, from the
other which is rounded. Using snap ring pliers, install the
retaining ring into the groove above the lter, with the at
side facing out.
b. Lubricate and install the main seal O-ring(9) into the groove
in the bottom of the yoke retainer.
c. Being careful to ensure that the O-ring remains properly
seated, insert the threaded end of the yoke retainer through
the bottom of the yoke(4). While holding the saddle in
place together with the rst stage body, mate the yoke
retainer into the inlet port of the body. Tighten the yoke
retainer clockwise by hand until nger snug.
d. Apply a torque wrench with the 1” Yoke Nut Socket and
3"xa" Socket Drive Extension (available from Peter Built
Co.). Tighten the yoke retainer to 24 foot-lbs (±1). (See Fig.
21.)
e. Install the dust cap(3) onto the yoke, and mate the yoke
screw(2) into the yoke. Turn the screw one to two revolu-
tions clockwise to engage the threads.
26. Reassembly of the DIN Connector
a. Mate the threaded end of the DIN retainer through the
threaded side of the handwheel.
b. While holding the retainer and handwheel together, t
the thrust washer(4b), spacer(4c), and saddle(4d) over the
threaded end of the DIN retainer, in respective order.
c. Install the lter(4g) and both O-rings(4e&4h)into the DIN
retainer.
d. Mate the DIN retainer into the inlet port of the rst stage
body, and turn clockwise by hand until snug. Apply a
torque wrench with a 4” hex key to tighten the DIN retainer
to a torque measurement of 24 foot-lbs (±1).
27. Loosen the vise to remove the rst stage, and remove the vise
mounting tool if one was used.
Fig. 21 - Torquing Yoke Retainer
Fig. 20 – Tightening Piston Cap
PETER BUILT
(419) 468-2212
3/8” Drive Torque Wrench
PETER BUILT
1" - SIX POINT
3500 PSI

SeaAir Regulator
20
SeaAir Regulator Service and Repair Manual
28. Lubricate and install the O-rings(16&31) onto all hoses and
port plugs. Install the LP hoses and port plugs(17&32) into
their respective ports in the rst stage. Apply a calibrated
torque wrench with x" hex key socket (or appropriate size crow
foot for hoses) to tighten the port plugs and hoses to a torque
measurement of 38 inch-lbs (±2).
IceBreaker™ Environmental Seal Instructions
WARNING: DO NOT install the IceBreaker™ environmental
sealing collar without first packing the ambient chamber with
silicone grease purchased directly from XS Scuba, according
to the following instructions. Failure to do will seriously af-
fect the regulator's performance, and could result in serious
injury or death.
1. Using a narrow tipped oral syringe, slowly inject silicone grease
through the ports on all sides of the piston cap. Rotate among
opposing ports, and repeat as needed until the pressure forces
excess grease to exit the opposite sides, indicating that the
chamber is full.
2. Aer verifying that the chamber is complete lled with grease,
wipe the outer surface of the piston cap clean with a so cloth.
3. Fit the larger end of the IceBreaker™ collar down over the top of
the swivel cap, until it is securely in place over the piston cap,
and the smaller end is seated in the groove just below the swivel
(see Fig. 22).
• After completing the reassembly of the rst stage,
proceed to the following procedure - Second Stage
Reassembly
Fig. 22 – IceBreaker Environmental Collar