XS Scuba VX200-N-VI Series User manual

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XS Scuba Valves Service Manual
XS Scuba Valve Service Manual

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XS Scuba Valves Service Manual
Part Number Description Image
VX100-30A-VI Deluxe K Valve
VX200-xxN-VI PRO Valve
VX250-22N-VI PRO Valve 1/2”-14 NGT Threads
VX2PVD-xxN-VI PVD PRO Valve
Products Covered By This Manual:
Document Change Notice (DCN)
Page # Rev. Date Revision Made
All 06/01/2020 First Release
This manual covers the service and repair of all XS Scuba Valve products, including, but not
limited to, K Valves, PRO Valves, DIN Valves, Modular Valves and Manifolds. A complete list of
specic models is found below.
Modular PRO Valve

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Part Number Description Image
VX378-43A-VI DIN Valve 7/8”-14 UNF Threads
VX2J-xxN-VI Reserve J Valve
VX200L-xxN-VI, VX200R-xxN-VI Modular PRO Valve
VX0V0-N-VI Crossbar with Isolator
VMX200-xxN-VI Isolation PRO Manifold
Since some valve models are offered with different working pressures, we use a “xx” in the part
number as a variable to denote an abbreviation for the different working pressures. For example, “xx”
could represent “33” which means the valve is offered set-up for a 3300psi working pressure.
Modular PRO Valve

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Table of Contents
Introduction 4
Warnings, Cautions and Notes 4
Maintenance Schedules 5
Standard Procedures 5
Nitrox Compatibility 5
Required Tools 7
Exploded Diagrams and Parts Lists 8
Pre-Test and Inspection Prior to Disassembly 14
Disassembly Procedure 14
Cleaning and Lubricating 17
Introduction
This manual outlines manufacturer prescribed
servicing procedures for the XS Scuba
Valve products described within. It covers
disassembly, cleaning, inspection, reassembly,
adjusting and testing of said valve products.
This publication assumes that the technician
performing the service is experienced,
mechanically inclined, and is using the proper
tools, parts and procedures prescribed
within. If you do not fully understand all of the
Warnings, Cautions and Notes
Pay special attention to information provided in Warnings, Caution and Notes that are accompanied by one of
these symbols:
WARNING indicates a procedure or situation that may result in serious injury or death
if instructions are not followed correctly
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
NOTE is used to emphasize important points, tips or reminders
Reassembly Procedure 20
Testing 22
Final Assembly 23
Servicing LH & RH Modular Valves 24
Servicing Crossbar with Isolation Valve 25
Servicing the “J” Reserve Mechanism 26
Dip Tube Instructions 28
Safety Handwheel 29
Safety Assembly 30
Troubleshooting Guide 31
Torque Specications 32
procedures outlined in this manual, contact
XS Scuba and speak with a Technical Advisor
before proceeding any further. There are many
XS Scuba Valve products. They use common
parts and common procedures. This manual
does not attempt to go step by step through
each individual product; rather, it focuses
on different parts of the valves that require
service. You must apply the appropriate
knowledge found within this manual to the
particular model that you are servicing.

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XS Scuba Valves Service Manual
Maintenance Schedules
How often a scuba valve should get serviced is very
subjective. Scuba valves are subjected to a variety of
environmental elements that, over time, can affect their
performance. Salt, sand, sediment, chlorine and other
chemicals all take their toll on a scuba valve. Soft parts
wear out and lubricants break down and wash away.
While it would be easy just to say, “Service your valves
once a year”, it would not be very forthcoming. Using
a calendar to determine servicing intervals is not
appropriate. Servicing depends upon the amount of use,
the environmental conditions and whether prescribed care
was met.
The preferred method is to evaluate the valve annually and
service it when one or more of the following indicators are
present:
• Air leaking from the handwheel / bonnet area
• Air leaking from the valve / cylinder interface
• Air leaking between modular valve and crossbar
• Corrosion on the exterior nish
• The handwheel does not spin true on its axis. It has a
wobble to it.
• The handwheel has to be closed more than “lightly”
snug to stop the air ow.
• The handwheel becomes difcult to rotate
• The handwheel does not operate smoothly and quietly
Since burst plugs weaken over time, soft parts wear and
lubricants wash away, it is required that you service the
valve at least once every 5 years whether it has seen
much use or not. Since most scuba cylinders require
hydrostatic testing every 5 years, it is recommended that
you service the valve while the cylinder is out getting
hydrostatically tested.
Standard Procedures
1. Preview the list of tools and parts required to perform
the prescribed service outlined in this manual. Follow
each step in the sequence provided. Have this manual
open next to you for reference. Do not rely upon
memory.
2. Numbers found in parenthesis reference the KEY
numbers in the exploded diagrams. If you are not sure
what a part is by its description, use this number to
cross reference it in the exploded diagrams.
3. All valve and manifold services should be performed
on a workbench specically set up and equipped for
this purpose. Adequate lighting and cleanliness along
with easy access to the required tools should be
considered mandatory.
4. Only use factory authorized parts provided by
XS Scuba. Do not attempt to substitute other
manufacturer’s parts regardless of any similarity in
appearance. This is especially true for o-rings!
5. Do not attempt to reuse mandatory replacement
parts regardless of how much use those parts were
subjected to.
6. When reassembling, it is important to follow factory
mandated torque values using a calibrated torque
wrench. To do otherwise could lead to damage or
failure of the product.
7. Unless otherwise instructed, the following is
assumed:
• When instructed to remove, unscrew or loosen
a threaded part, turn the part counterclockwise.
The manual abbreviates counterclockwise with
CCW.
• When instructed to install, screw in or tighten
a threaded part, turn the part clockwise. The
manual abbreviates clockwise with CW.
Nitrox Compatibility
Depending upon the model, when XS Scuba Valves are
sold new, they are designated for either Compressed
Air Only service or for Maximum 40% Oxygen Premixed
service. The service designation is shown in the XS
Scuba catalog, the XS Scuba website and on the valve
itself.
A valve model designated for Compressed Air Only
service is manufactured and prepared for use only with
breathing air (21% oxygen and 79% nitrogen by volume)
that is of quality Grade E or better.
A valve model designated for Maximum 40% Oxygen
Premixed service may be used for either oxygen
enriched breathing air with a maximum oxygen content
of 40% (premixed), or for standard breathing air (21%
oxygen and 79% nitrogen by volume) with a purity rating
as low as Grade E*. If the valve is used for standard
breathing air where the hydrocarbons exceed 0.1 mg/
m3, such as Grade E, then the valve must be dedicated
to breathing air service and MAY NOT be used for
oxygen enriched breathing air until such time as the
valve is disassembled, properly cleaned and lubricated,
and assembled for Maximum 40% Oxygen Premixed
service again.
WARNING: For the valve to remain Maximum
40% Oxygen Premixed compatible, only use
hyper-ltered compressed gas (hydrocarbons <
0.1 mg/m3). Ordinary compressed breathing air
(Grade E) usually does not meet this criterion.
Once ordinary breathing air is used, the valve
is no longer Maximum 40% Oxygen Premixed
compatible until it is cleaned and serviced again.

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Valves that are designated for Maximum 40% Oxygen
Premixed and are being used with elevated oxygen
percentages between 21% and 40% by volume, must
be installed in cylinders which have been cleaned and
tested for oxygen use. All other equipment attached
to the valve, which comes in contact with the oxygen
enriched breathing air (regulator, BC, pressure gauge
etc.) must also be approved by the manufacturer of that
equipment for use with oxygen enriched breathing air
and must be maintained in an oxygen clean condition
as set forth by the manufacturer.
In all cases, if a lubricant is used on the o-rings or upon
insertion of the valve into a cylinder, only use lubricants
approved for oxygen use.
Before attaching the regulator to the valve, open the
valve slightly for an instant to clear the opening of
particles of dust, dirt and to remove any moisture.
ALWAYS OPEN VALVE SLOWLY UNTIL PRESSURE
BUILDS UP THROUGHOUT THE REGULATOR!
All XS Scuba Valves and scuba valve parts are to
be used, installed and maintained per Compressed
Gas Association Pamphlet V-9 “STANDARD FOR
COMPRESSED GAS CYLINDER
VALVES”.
*At the time of this publication, The Compressed Gas
Association (CGA G-7.1) states that Grade E air can
have up to 5 mg/m3 of condensed hydrocarbons.

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Required Tool List
Part # Description Application
TL119 Scuba Valve Tester
Holds valve while
servicing / pressurizes
valve for leak checks
TL113 Valve Handwheel Tool
Removal and instal-
lation of handwheel
retaining nut(4)
n/a 11/16” wrench Bonnet removal
TL111 O-ring pick set Removing o-rings and
washers
n/a Needle nose pliers Removal and installa-
tion of washer(s)
n/a Torque Wrench lbs*in and lbs*ft Apply proper torque
values
n/a 3/8” socket Removal and torquing
the Safety Assembly
n/a 1/4” hex socket Removal and torquing
the DIN insert
n/a 11/16” deep socket or crow’s foot Torquing down the
bonnet
n/a Large Crescent Wrench at least 15 in. Removing the valve
from the cylinder
n/a Rubber mallet
Rapping crescent
wrench during valve
removal
n/a Large 1.5” Crow’s Foot Torquing valve back
into the cylinder
AC368 Tank Mufer
Used to quietly drain
a cylinder for valve
removal

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Deluxe K Valve
6 VP01S-30 Sticker - 3000 psi
7 VP07 Stem
8 VP08-E O-ring - EPDM (Stem)
9 VP09 Teflon Washer (Stem)
10 VX10 Bonnet - XS Scuba
11 VP11  TeflonWasher(Handwheel)
13 VP13 Spring
14 VP14 Nut
17 VX17-E O-ring EPDM (Bonnet)
20 VX20  SafetyHandwheelGreenSleeve&
   SafetyHandwheelRedSleeve
22 VX22 SafetyHandwheelBlack
VKX-K SERVICE KIT - XS SCUBA DELUXE K VALVE
1 VP01-20  SafetyAssembly2015psi(3358burst)
1 VP01-22  SafetyAssembly2250psi(3750burst)
1 VP01-24  SafetyAssembly2400psi(4000burst)
1 VP01-30  SafetyAssembly3000psi(5000burst)
2 VP02-B O-ring - BunaN (Outlet)
2 VP02-V O-ring-Viton(Outlet)
2 VP02-P O-ring-Polyurethane(Outlet)
3 VP03-B O-ring - BunaN (3/4” NPSM Inlet)
4 VP04 Dip Tube
5 VP05 Seat
6 VP01S-20 Sticker-2015psi
6 VP01S-22 Sticker-2250psi
6 VP01S-24 Sticker - 2400 psi
# Part # Description # Part # Description
Part numbers in bold italics are standard
replacement parts
2
5
7
8
9
1710
14
4
3
6
1
13 11
22 20
100 in. lbs
115 kg. cm
33 ft. lbs
460 kg. cm
40 in. lbs
46 kg. cm
50 ft. lbs
690 kg. cm
PRO Valve
7 VP07 Stem
8 VP08-E O-ring - EPDM (Stem)
9 VP09 Teflon Washer (Stem)
10 VX10 Bonnet - XS Scuba
11 VP11 Teflon Washer (Handwheel)
13 VP13 Spring
14 VP14 Nut
15 VP15-V O-ring - Viton (Outlet)
15 VP15-P O-ring - Polyurethane (Outlet)
16 VP16-V DIN Insert with both o-rings Viton
17 VX17-E O-ring EPDM (Bonnet)
20 VX20 Safety Handwheel Green Sleeve &
Safety Handwheel Red Sleeve
22 VX22 Safety Handwheel Black
VKX-P SERVICE KIT - XS SCUBA PRO VALVE
1 VP01-20 Safety Assembly 2015 psi (3358 burst)
1 VP01-22 Safety Assembly 2250 psi (3750 burst)
1 VP01-24 Safety Assembly 2400 psi (4000 burst)
1 VP01-30 Safety Assembly 3000 psi (5000 burst)
1 VP01-34 Safety Assembly 3442 psi (5250 burst)
3 VP03-V O-ring - Viton (3/4” NPSM Inlet)
4 VP04 Dip Tube
5 VP05 Seat
6 VP01S-20 Sticker - 2015 psi
6 VP01S-22 Sticker - 2250 psi
6 VP01S-24 Sticker - 2400 psi
6 VP01S-30 Sticker - 3000 psi
6 VP01S-33 Sticker - 3300 psi
6 VP01S-34 Sticker - 3442 psi
# Part # Description # Part # Description
Part numbers in bold italics are standard
replacement parts
15
16
15
5
7
8
9
17
10
14
4
3
6
1
13 11
22 20
85 in. lbs
100 kg. cm
33 ft. lbs
460 kg. cm
100 in. lbs
115 kg. cm
40 in. lbs
46 kg. cm
50 ft. lbs
690 kg. cm

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PRO Valve
7 VP07 Stem
8 VP08-E O-ring - EPDM (Stem)
9 VP09 Teflon Washer (Stem)
10 VX10 Bonnet - XS Scuba
11 VP11 Teflon Washer (Handwheel)
13 VP13 Spring
14 VP14 Nut
15 VP15-V O-ring - Viton (Outlet)
15 VP15-P O-ring - Polyurethane (Outlet)
16 VP16-V DIN Insert with both o-rings Viton
17 VX17-E O-ring EPDM (Bonnet)
20 VX20 Safety Handwheel Green Sleeve &
Safety Handwheel Red Sleeve
22 VX22 Safety Handwheel Black
VKX-P SERVICE KIT - XS SCUBA PRO VALVE
1 VP01-20 Safety Assembly 2015 psi (3358 burst)
1 VP01-22 Safety Assembly 2250 psi (3750 burst)
1 VP01-24 Safety Assembly 2400 psi (4000 burst)
1 VP01-30 Safety Assembly 3000 psi (5000 burst)
1 VP01-34 Safety Assembly 3442 psi (5250 burst)
3 VP03-V O-ring - Viton (3/4” NPSM Inlet)
4 VP04 Dip Tube
5 VP05 Seat
6 VP01S-20 Sticker - 2015 psi
6 VP01S-22 Sticker - 2250 psi
6 VP01S-24 Sticker - 2400 psi
6 VP01S-30 Sticker - 3000 psi
6 VP01S-33 Sticker - 3300 psi
6 VP01S-34 Sticker - 3442 psi
# Part # Description # Part # Description
Part numbers in bold italics are standard
replacement parts
15
16
15
5
7
8
9
17
10
14
4
3
6
1
13 11
22 20
85 in. lbs
100 kg. cm
33 ft. lbs
460 kg. cm
100 in. lbs
115 kg. cm
40 in. lbs
46 kg. cm
50 ft. lbs
690 kg. cm

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XS Scuba Valves Service Manual
DIN Valve (7/8”-14 UNF Threads)
8 VP08-E O-ring - EPDM (Stem)
9 VP09 TeflonWasher(Stem)
10 VX10 Bonnet
11 VP11 TeflonWasher(Handwheel)
13 VP13 Spring
14 VP14 Nut
17 VX17-E O-ringEPDM(Bonnet)
20 VX20  SafetyHandwheelGreenSleeve&
   SafetyHandwheelRedSleeve
22 VX22 SafetyHandwheelBlackKnob
VKX-D SERVICE KIT - XS SCUBA DIN VALVE
1 VP01-34 SafetyAssembly3442psiand3500psi
   (5250burst)
1 VP01-43 SafetyAssembly4350psi(7250burst)
3 VP24-V O-ring-Viton(7/8”UNFInlet)
4 VP04 DipTube
5 VP05 Seat
6 VP01S-34 Sticker-3442psi
6 VP01S-43 Sticker-4350psi
7 VP07 Stem
# Part # Description # Part # Description
Partnumbersinbolditalicsarestandard
replacementparts
11081A-A
VX378-43A
11081A-A
VX378-43A
14 13 11
22 20
57
8
917
10
4
3
6
1
33 ft. lbs
460 kg. cm 100 in. lbs
115 kg. cm
40 in. lbs
46 kg. cm
50 ft. lbs
690 kg. cm

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Reserve “J” Valve
9 VP09 TeflonWasher(Stem)
10 VX10 Bonnet - XS Scuba
11 VP11 TeflonWasher(Handwheel)
13 VP13 Spring
14 VP14 Nut
15 VP15-V O-ring-Viton(Outlet)
15 VP15-P O-ring-Polyurethane(Outlet)
16 VP16-V DINInsertwithbotho-ringsViton
17 VX17-E O-ringEPDM(Bonnet)
20 VX20  SafetyHandwheelGreenSleeve&
   SafetyHandwheelRedSleeve
22 VX22  SafetyHandwheelBlackKnob
23 VP23 ReserveAssembly
24 VP24 SSWasher
25 VP26 ReserveStem
26 VP29-PVD ReserveBonnet-PVD
27 VP30 ReserveLever
28 VP31 ReserveSpring(Black)
 VKX-P  SERVICEKIT-JVALVEMAINSIDE
 VKX-J  SERVICEKIT-JVALVERESERVESIDE
1 VP01-20 SafetyAssembly2015psi(3358burst)
1 VP01-22 SafetyAssembly2250psi(3750burst)
1 VP01-24 SafetyAssembly2400psi(4000burst)
1 VP01-30 SafetyAssembly3000psi(5000burst)
1 VP01-33 SafetyAssembly3300psi(5500burst)
1 VP01-34 SafetyAssembly3442psi(5250burst)
3 VP03-V O-ring-Viton(3/4”NPSMInlet)
4 VP04 DipTube
5 VP05 Seat
6 VP01S-20 Sticker-2015psi
6 VP01S-22 Sticker-2250psi
6 VP01S-24 Sticker-2400psi
6 VP01S-30 Sticker-3000psi
6 VP01S-33 Sticker-3300psi
6 VP01S-34 Sticker-3442psi
7 VP07 Stem
8 VP08-E O-ring-EPDM(Stem)
# Part # Description # Part # Description
Partnumbersinbolditalicsarestandardreplacementparts
11073J-A
VX2J-30N-V1
11073J-A
VX2J-30N-V1
11073J-A
VX2J-30N-V1
11073J-A
VX2J-30N-V1
5
7
8
9
17
10
15 16 15
26
17
9
8
25
11
4
1
3
27 28 14
6
24
11
22
13
14
20
23
40 in. lbs
46 kg. cm
29 ft. lbs
400 kg. cm
50 ft. lbs
690 kg. cm
100 in. lbs
115 kg. cm
33 ft. lbs
460 kg. cm
85 in. lbs
100 kg. cm

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XS Scuba Valves Service Manual
Modular Valves - Crossbar
11085-A
VXOVO-N
14
13
22
11
10
7
5
17
8
9
20
18
23 23
23 23 19
90 in. lbs
100 kg. cm
90 in. lbs
100 kg. cm
33 ft. lbs
460 kg. cm
VKX-K SERVICE KIT - XS SCUBA K VALVE,
+4 ea. VP25-V O-rings Required to
Service Crossbar
5 VP05 Seat
7 VP07 Stem
8 VP08-E O-ring - EPDM (Stem)
9 VP09 TeflonWasher(Stem)
10 VX10 Bonnet
11 VP11 TeflonWasher(Handwheel)
13 VP13 Spring
14 VP14 Nut
17 VX17-E O-ring EPDM (Bonnet)
18 VP18-R BarrelJamNut-Right(withnotches)
19 VP18-L BarrelJamNut-Left
20 VX20  SafetyHandwheelGreenSleeve&
21   SafetyHandwheelRedSleeve
22 VX22 SafetyHandwheelBlackKnob
23 VP25-V O-ring - Viton (Barrel)
# Part # Description
Part numbers in bold italics are standard replacement parts
VKX-P SERVICE KIT - XS SCUBA PRO VALVE,
+2 ea. VP25-V O-rings Required to
service each Modular PRO Valve
VKX-D SERVICE KIT - XS SCUBA DIN VALVE,
+2 ea. VP25-V O-rings Required to
service each Modular DIN Valve
1 VP01-20 Safety Assembly 2015 psi (3358 burst)
1 VP01-22 Safety Assembly 2250 psi (3750 burst)
1 VP01-24 Safety Assembly 2400 psi (4000 burst)
1 VP01-27 Safety Assembly 2730 psi (4550 burst)
1 VP01-30 Safety Assembly 3000 psi (5000 burst)
1 VP01-31 Safety Assembly 3130 psi (4694 burst)
1 VP01-33 Safety Assembly 3300 psi (5500 burst)
1 VP01-34 Safety Assembly 3442 psi (5250 burst)
1 VP01-43 Safety Assembly 4350 psi (7250 burst)
3 VP03-V O-ring - Viton (3/4” NPSM Inlet)
4 VP04 Dip Tube
5 VP05 Seat
6 VP01S-20 Sticker - 2015 psi
6 VP01S-22 Sticker - 2250 psi
6 VP01S-24 Sticker - 2400 psi
6 VP01S-30 Sticker - 3000 psi
6 VP01S-33 Sticker - 3300 psi
6 VP01S-34 Sticker - 3442 psi
6 VP01S-43 Sticker - 4350 psi
7 VP07 Stem
8 VP08-E O-ring - EPDM (Stem)
9 VP09 Teon Washer (Stem)
10 VX10 Bonnet
11 VP11 Teon Washer (Handwheel)
13 VP13 Spring
14 VP14 Nut
15 VP15-V O-ring - Viton (Outlet)
15 VP15-P O-ring - Polyurethane (Outlet)
1 6 V P 1 6 - V D I N I n s e r t w i t h b o t h o - r i n g s V i t o n
17 VX17-E O-ring EPDM (Bonnet)
20 VX20 Safety Handwheel Green Sleeve &
Safety Handwheel Red Sleeve
22 VX22 Safety Handwheel Black
23 VP25-V O-ring - Viton (Barrel)
25 VP19-R Modular Access Plug-Right (with notches)
26 VP19-L Modular Access Plug - Left
# Part # Description
Part numbers in bold italics are standard
replacement parts
Modular DIN Valve - Left Hand
Modular PRO Valve - Right Hand
26
10
14
25
2323
16
4
3
13
22
11
17 987 5
15 15
16
578 9 17 10
11
22
13 14
23
23 6
1
3
420
20
18 ft. lbs
250 kg. cm
85 in. lbs
100 kg. cm
33 ft. lbs
460 kg. cm
33 ft. lbs
460 kg. cm
40 in. lbs
46 kg. cm
50 ft. lbs
670 kg. cm
100 in. lbs - 115 kg. cm
18 ft. lbs
250 kg. cm
40 in. lbs
46 kg. cm
50 ft. lbs
670 kg. cm
100 in. lbs
115 kg. cm

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XS Scuba Valves Service Manual
Modular Valves - Crossbar
11085-A
VXOVO-N
14
13
22
11
10
7
5
17
8
9
20
18
23 23
23 23 19
90 in. lbs
100 kg. cm
90 in. lbs
100 kg. cm
33 ft. lbs
460 kg. cm
VKX-K SERVICE KIT - XS SCUBA K VALVE,
+4 ea. VP25-V O-rings Required to
Service Crossbar
5 VP05 Seat
7 VP07 Stem
8 VP08-E O-ring - EPDM (Stem)
9 VP09 TeflonWasher(Stem)
10 VX10 Bonnet
11 VP11 TeflonWasher(Handwheel)
13 VP13 Spring
14 VP14 Nut
17 VX17-E O-ring EPDM (Bonnet)
18 VP18-R BarrelJamNut-Right(withnotches)
19 VP18-L BarrelJamNut-Left
20 VX20  SafetyHandwheelGreenSleeve&
21   SafetyHandwheelRedSleeve
22 VX22 SafetyHandwheelBlackKnob
23 VP25-V O-ring - Viton (Barrel)
# Part # Description
Part numbers in bold italics are standard replacement parts

14 www.XSscuba.com
XS Scuba Valves Service Manual
Annual Inspection and Pre-Test Prior
to Disassembly
NOTE: Prior to inspection, please note that
the XS Scuba K valve is designed with an “upset”
in the bottom of the o-ring groove. This allows air
to escape from behind the o-ring when removing
your regulator so that the o-ring doesn’t blow out
of the groove.
• Inspect the valve for bent, deformed, corroded or
worn parts.
• Check the exterior of the valve for damaged,
corroded or worn surfaces. This includes the
outlet, the valve body, handwheel and any visible
areas of the valve.
• Check for any contamination in the outlet of the
valve.
• Conrm that the service pressure of the valve and
safety assembly rating is correct for the cylinder
in which it is installed.
Leak Inspection Procedure
• Start with full working pressure in cylinder and
a properly functioning regulator attached to the
outlet.
• Open and close the valve while it is installed in the
cylinder and feel for smooth operation. If the valve
seems to be difcult to operate or any roughness
is felt, the valve must undergo full maintenance.
• Slowly open the valve fully.
• Remove handwheel from valve body by turning
handwheel screw in a counterclockwise direction
and remove handwheel. DO NOT REMOVE
BONNET NUT!
WARNING: Removing a bonnet nut(10) while
the valve is pressurized will result in a rapid and
violent release of air. This can lead to serious injury.
• Apply a non-ammonia soap and water solution
(or a recognized leak detection agent such as
“Snoop”), to the valve bonnet nut area, the inlet
neck o-ring area, the safety assembly area and the
outlet area.
• Allow the soap solution to sit for at least 15
seconds and check for signs of leakage. If
you nd leaks, the valve MUST undergo full
maintenance.
• Turn the valve off. Purge and remove the regulator
from the valve. Apply the soap solution to the
valve outlet and check for leakage.
• If after performing all the items shown above
and nding no irregularities or leakage, the valve
may be returned to service. If any irregularities
or leakage is found, the valve must undergo full
maintenance.
Disassembly Procedure
1. Remove the Valve from the Cylinder
A. Drain the cylinder completely.
NOTE: Using an XS Scuba AC368 Tank
Mufer is a quick and quiet way to drain a scuba
cylinder.
B. Secure a large crescent wrench (at least 15 in.) to
the wrench ats at the base of the valve so that the
xed jaw of the crescent wrench is on the far side of
the valve.
C. Hit the end of the crescent wrench handle with a
rubber mallet.
D. Spin out the valve.
2. Remove Inlet O-ring(3)
A. Using your ngers or a brass or plastic pick,
remove inlet (neck) o-ring(3).

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XS Scuba Valves Service Manual
3. Mount the Valve
A. While you can mount the valve in an empty scuba
cylinder, it is much more effective to mount it in a
built-for-purpose Scuba Valve Tester, p/n TL119.
NOTE: The TL119 Scuba Valve Tester is a
threaded sleeve that mounts to a bench vise. The
sleeve attaches to a scuba cylinder by means of a
high-pressure hose. Insert your valve into the sleeve
for disassembly and reassembly. Once reassembled,
you can pressurize your valve and submerge it into a
bucket of water to conduct leak checks.
4. Remove Outlet O-ring(s)
A. K valve - Using a brass or plastic pick, remove
outlet oring(2).
B. Pro Valve – Using a ¼” hex key, remove the DIN
insert assembly(16) by turning CCW.
i. Using a brass or plastic pick remove the front
and back o-rings(15) from the DIN insert(16).
C. DIN Valve – There is not an outlet o-ring.
5. Remove Safety Handwheel(22)
A. Using the Valve Handwheel Tool, remove the
Safety Handwheel from the valve by turning the
handwheel nut(14) CCW. Locate and identify the
nut(14), spring(13), Safety Handwheel(22), Safety
Handwheel red sleeve and Safety Handwheel green
sleeve(20), and handwheel washer(11).

16 www.XSscuba.com
XS Scuba Valves Service Manual
WARNING: If you are working on a valve that
is located in a cylinder, you must insure that the
cylinder is completely empty before the next step:
loosening the bonnet nut.
WARNING: Removing a bonnet nut(10) while
the valve is pressurized will result in a rapid and
violent release of air. This can lead to serious injury.
6. Remove Bonnet Assembly
A. Using a 11/16” wrench, remove the bonnet nut(10),
by turning it CCW. Remove the bonnet nut(10) /
stem(7) assembly from the valve body. Separate
the pieces and locate the bonnet nut(10), bonnet
o-ring(17), stem washer(9), stem o-ring(8) and stem(7).
7. Remove Seat Assembly(5)
A. Using the stem(7) as a removal tool or a pair of
needle nose pliers, remove the seat assembly(5) by
rotating it CCW.
8. Remove Safety Plug(1)
A. Using a 3/8” socket, remove the safety plug
assembly(1) by turning it CCW.

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XS Scuba Valves Service Manual
9. There is no need to remove the diptube(4).
Unless it is damaged, it can remain in place.
This completes the XS Scuba Valve Disassembly.
Cleaning and Inspection Procedures
All reusable parts, metallic and soft, should be cleaned
in a warm (not over 120°F / 50°C) dish soap and water
solution. Use a soft, nylon bristle brush to remove any
stubborn deposits. The dish soap helps to remove grease
and old lubricant.
Plastic and Rubber Parts
After cleaning, rinse in fresh water. If your local tap water
is hard, consider using distilled water. Dry with hyper-
ltered compressed air.
Metallic Parts
CAUTION: Be sure to use hand and eye
protection when handling chemical cleaning
solutions.
While dish soap is an excellent degreaser, it may not
remove corrosion and mineral build up on metallic parts.
That is where acid is effective. Metal parts may be
immersed in a sonic cleaner with a diluted acetic acid
(vinegar) and water solution (50:50).
If you really want your metal parts to sparkle, consider
using a diluted solution of Oakite 31 in your sonic cleaner.
Be sure to follow the manufacturer’s instructions for
dilution.
After cleaning, rinse in fresh water. If your local tap water
is hard, consider using distilled water. Dry with hyper-
ltered compressed air.
CAUTION: Never place soft parts e.g.
rubber, plastic, urethanes, silicones into any
acidic solutions. Doing so may alter their physical
properties, causing them to break, degrade
prematurely or no longer t.
NOTE: Many technicians nd that a solution
of diluted dish soap and diluted vinegar in their
sonic cleaner is all they need to clean the metal
parts. It is inexpensive and effective.
Preparing and Inspecting Parts
Nitrox Preparation
If you are preparing the valve to place back into nitrox
service (O2 not to exceed 40%), you should use
powderless latex or nitrile gloves to keep nger oils off of
the clean parts.
O-rings: All O-rings should be replaced at every
servicing. New O-rings should be inspected for
contamination and/or imperfections, and lightly dressed
with a thin lm of approved lubricant prior to installation.
See Recommended Cleaner and Lubricant Table below.
CAUTION: Do not use any petroleum based
lubricants or products, or any aerosol silicone
sprays on any part of the valve.
Crown Orice: The crown orice is machined into the
valve body. It mates up against the seat assembly(5).
The critically machined sealing edge of the crown orice
is important to reducing sealing force. The sealing edge
must be free from nicks or scratches and square with the
centerline of the orice. Any imperfection can allow small
amounts of air to leak between the crown orice and the
seat assembly, and require an excessive amount of hand
torque on the handwheel to make an airtight seal. The
sealing edge of the crown orice should be inspected
under magnication whenever possible.
Stem(7): The stem will normally get reused. Roll it on a
hard surface and conrm that it is true. If it is bent, it must
get replaced.
Bonnet(10): Inspect the hex head and the threads on the
bonnet. If all are good, the bonnet may be reused.
Seat(5): The HP Seat, a mandatory replacement part,
VP05, is used in all XS Scuba Valve models.

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XS Scuba Valves Service Manual
Mandatory Replacement Parts: The following parts are
considered mandatory replacement parts during a routine
servicing:
Outlet o-ring(2) or (15)
Inlet (neck) o-ring(3)
Seat assembly(5)
Stem o-ring(8)
Stem washer(9)
Bonnet o-ring(17)
Safety Assembly(1)
Service Kits: The best way to service a valve is to use
the appropriate XS Scuba Valve service kit. It contains all
the mandatory replacement parts that go into a routine
servicing of the valve except the Safety Assembly(1) which
must get ordered separately.

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XS Scuba Valves Service Manual
Lubricant / Cleaner Application Source
Liquid dishwashing detergent
diluted with warm water
Degreaser for all metallic parts;
general cleaning solution for plas-
tic and rubber parts
Household grade - “Dawn” works
very well
Vinegar (acetic acid)-diluted Removes corrosion and mineral
build up from metallic parts
Household grade
Oakite31 diluted with water Use in sonic cleaner to clean
metal parts
Oakite Products, Inc.
50 Valley Road
Berkeley Heights, NJ 07922
www.chemetallna.com
Christo-lube MCG 111 o-ring dressing XS Scuba
4040 W. Chandler Ave.
Santa Ana, CA 92704
866.977.2822
www.XSscuba.com
Tribolube 71 o-ring dressing Aerospace Lubricants
1600 Georgesville Road
Columbus, Ohio 43228
614.878.3600
www.aerospacelubricants.com
Recommended Cleaners and Lubricants

20 www.XSscuba.com
XS Scuba Valves Service Manual
Reassembly Procedure
1. Install Inlet (Neck) O-ring(3)
A. Install a lubricated inlet o-ring(3) onto the valve
neck. A Buna-N o-ring is good for compressed
air use only, a viton o-ring is required for oxygen
enriched mixtures 21.5% - 40% pre-mixed.
2. Mount the Valve
A. Mount the valve into the valve tester or an empty
scuba cylinder.
3. Insert Seat Assembly(5)
A. Using the stem(7) as a tool, or needle nose pliers,
install the seat assembly(5) CW until it contacts the
crown orice inside.
4. Install Bonnet O-ring(17) on the Bonnet(10)
5. Install Stem O-ring(8)
A. Install a lubricated stem o-ring(8) on to the stem(7).