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XS Scuba Inspire Regulator Service Manual

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XS Scuba Inspire Regulator Service Manual
Inspire Regulator Service Manual
Covers Inspire Regulator and Inspire Octopus
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Summary of Contents for XS Scuba Inspire Regulator

  • Page 1 XS Scuba Inspire Regulator Service Manual Inspire Regulator Service Manual Covers Inspire Regulator and Inspire Octopus www.XSscuba.com...

  • Page 2: Table Of Contents

    If you do not fully understand all of the procedures outlined described within. It covers disassembly, cleaning, in this manual, contact XS Scuba and speak with a inspection, reassembly, adjusting and testing of said regulator product. This publication assumes that the Technical Advisor before proceeding any further.

  • Page 3: Maintenance Schedules

    Soft parts wear out and lubricants counterclockwise. The manual abbreviates break down and wash away. As an XS Scuba Dealer, you counterclockwise with CCW. are advised to inform your staff and customers that b.

  • Page 4: Pre-Test & Inspection Prior To Disassembly

    XS Scuba Inspire Regulator Service Manual Pre-Test and Inspection Prior to Disassembly It is good practice to inspect the regulator prior to disassembly and to document your findings. You can use the following checklist for items to document. 1. Characterize the overall condition of the regulator. Is it “like new” or is it scratched, nicked or heavily corroded? 2.
  • Page 5 XS Scuba Inspire Regulator Service Manual Required Tool List Part # Description Application Used to tighten / apply TL123 Yoke Retainer Socket Set torque to yoke retainer Spanner Wrench Loosen and tighten TL118 Round Surface diaphragm clamp TL136 Multi-Purpose Tool...

  • Page 6: Exploded Diagrams And Part Lists

    XS Scuba Inspire Regulator Service Manual www.XSscuba.com...
  • Page 7 XS Scuba Inspire Regulator Service Manual www.XSscuba.com...
  • Page 8 XS Scuba Inspire Regulator Service Manual www.XSscuba.com...
  • Page 9 XS Scuba Inspire Regulator Service Manual www.XSscuba.com...

  • Page 10: 1St Stage Disassembly Procedure

    XS Scuba Inspire Regulator Service Manual Disassembly Procedure – Inspire 3. Remove the o-rings (29,31) from each port plug (30,32). 1st Stage CAUTION: Use only a plastic or brass o-ring removal tool when removing o-rings to prevent damage to the sealing surface. Do not use a steel dental pick or any other steel instrument.
  • Page 11 XS Scuba Inspire Regulator Service Manual B. Inspire with DIN connector (Reference exploded diagram with DIN version) i. Remove the handwheel retainer (2) using a 6 mm hex key. iii.Using circlip pliers, remove the circlip (4). ii. Remove the handwheel (6), dust cap (9) and iv.Tap the yoke retainer (7) on a hard surface...
  • Page 12 XS Scuba Inspire Regulator Service Manual 8. Remove the turret (21). A. Remove the thrust washer (26). B. Remove the turret (21) by pulling straight up on it. C. Remove the underlying o-ring (20). v. Remove the filter (4) and o-ring (5) from the top of the DIN housing (7).
  • Page 13 XS Scuba Inspire Regulator Service Manual 12. Remove diaphragm washer (14). 10. Remove the adjustment screw (19) and main spring (17). A. Using a strong o-ring pick, get underneath the clear diaphragm washer (14) and lift it out. A. Turn the regulator in the vise so that the Dia- phragm Cap (18) and Adjustment Screw (19) are facing up.

  • Page 14: 2Nd Stage Disassembly Procedure

    XS Scuba Inspire Regulator Service Manual B. Remove the front cover (12,11), the diaphragm Disassembly Procedure washer (10) and the inhalation diaphragm (9). Inspire 2nd Stage Carefully inspect the diaphragm for small tears or holes. If found in good condition, it may be reused.
  • Page 15 XS Scuba Inspire Regulator Service Manual B. Inspect the exhaust valve (4). Lift up the edges CAUTION: Applying too much pressure to and inspect the sealing surface underneath. It should the adjustment knob (26) can result in bending the be clean and free of scratches. The exhaust valve (4) retaining pin (18), thus making it difficult to should be flexible and have well defined edges.
  • Page 16 XS Scuba Inspire Regulator Service Manual ii. Turn the adjusting knob (26) CCW until it is free B. Separate the venturi deflector (16) from the valve assembly (17). i. Depress the lever (19) all the way down. Slide the venturi deflector (16) over the top of the lever (19) to remove it.
  • Page 17 XS Scuba Inspire Regulator Service Manual iv. Remove the o-ring (14) from the crown orifice (13). ii. Inspect the lever (19) to ensure that the two legs are parallel and that the two engagement feet are on the same plane. If the legs of the lever (19) are spread, squeeze them together until they are parallel.
  • Page 18 XS Scuba Inspire Regulator Service Manual ii. Again, using a fingernail, remove the low pressure seat (20) from the front of the poppet (21). This completes the Inspire 2nd Stage Disassembly. www.XSscuba.com...

  • Page 19: Cleaning Procedures

    The sealing edge of the crown orifice should be inspected under magnification whenever possible. If the end fittings are corroded, install XS Scuba hose plugs, p/n TL129, to seal the hose ends. The fittings may then be It is also very important to protect the crown orifice sealing...

  • Page 20: Recommended Cleaners And Lubricants

    XS Scuba Inspire Regulator Service Manual Recommended Cleaners and Lubricants Lubricant / Cleaner Application Source Liquid dishwashing detergent Degreaser for all metallic parts; Household grade - “Dawn” works diluted with warm water general cleaning solution for plas- very well tic and rubber parts...

  • Page 21: 1St Stage Reassembly Procedure

    XS Scuba Inspire Regulator Service Manual 5. Place the spring seat (15) in the center of Inspire 1st Stage Reassembly the diaphragm (13) with the perimeter tabs facing up. 1. Mount body (11) in vise. A. Install the TL122 Support Handle / Vise-Mounting Tool into one of the HP ports.
  • Page 22 XS Scuba Inspire Regulator Service Manual 9. Install the diaphragm clamp (18). A. Thread the diaphragm clamp (18) CW, by hand as far as you can. B. Install o-rings (25 & 28) on to the turret bolt. B. Engage the TL118 pin spanner and tighten it down until it stops.
  • Page 23 XS Scuba Inspire Regulator Service Manual F. Remove the regulator body from the vise. 13. Install the connector assembly. A. Inspire with yoke connection: i. Insert a non-lubricated o-ring (6) into the top of the yoke retainer (7). D. Lay the thrust washer (26) on top of the turret (21).
  • Page 24 XS Scuba Inspire Regulator Service Manual v. While continuing to hold the yoke retainer (7) assembly upside down, pass it through an upside down yoke (3). Add the upside down dustcap (9) and upside down saddle (10). NOTE: Keeping the assembly upside down prevents the bottom o-ring (8) from falling out of its recess.
  • Page 25 XS Scuba Inspire Regulator Service Manual iv. Using a 3/4” (19 mm) crows foot attachment or a deep socket, apply a torque of 24 ft/lbs (1 Nm) to the DIN housing (7). ix. Install the two o-rings (1,3) on either side of the handwheel retainer (2).

  • Page 26: 1St Stage Adjusting And Testing

    XS Scuba Inspire Regulator Service Manual 14. Clear air passageways. 16. Install MP regulator hose. A. Install o-ring (31) on to male end of MP hose. A. Attach the first stage to a scuba cylinder filled to approximately 3000 psi (200 bar). Slowly open the cylinder to blow out any debris or contaminants that may have entered during the assembly process.
  • Page 27 XS Scuba Inspire Regulator Service Manual 5 psi over a 5-minute period, this indicates that C. With the regulator under pressure, cycle the there is a leak. Refer to the Troubleshooting Table system several times by repeatedly pressing the located in the back of this manual.

  • Page 28: 2Nd Stage Reassembly Procedure

    XS Scuba Inspire Regulator Service Manual Step by Step Reassembly – Inspire D. Install the flat end of the balancing chamber (24) into the spring (23). The tail of the poppet (21), with 2nd Stage its two o-rings (22) should be seated inside the balancing chamber (24).
  • Page 29 XS Scuba Inspire Regulator Service Manual B. Add o-ring (6) to the valve housing (17) i. Install a new o-ring (6) into the o-ring groove on the valve housing (17) ii. Turn the adjusting knob (26) CW until the hole for the retaining pin (18) is clear.
  • Page 30 XS Scuba Inspire Regulator Service Manual D. Install the bushing (7) on to the threaded end of the valve housing (17). 6. Install the Completed Valve Assembly into the Main Housing (1) A. While keeping the lever depressed, slide the valve body assembly through the venturi deflector and into the main housing.
  • Page 31 XS Scuba Inspire Regulator Service Manual NOTE: As you apply torque to the locking nut (8) on the valve housing (17), inspect the two lever arms in relation to the rim of the main housing (1). If the torque on the nut causes the valve housing...
  • Page 32 XS Scuba Inspire Regulator Service Manual E. Once the lever is at its maximum height, drive the crown orifice in, CW, an additional 1/8th turn / 45 degrees. 45 degree F. Depress and release the lever several times to insure an airtight seal when the lever is released. This C.

  • Page 33: 2Nd Stage Adjusting And Testing

    XS Scuba Inspire Regulator Service Manual 3. Vacuum Test This concludes reassembly A. Do not pressurize the regulator in this step Adjusting and Testing B. Plug the mouthpiece NOTE: Prior to adjusting, understand that this C. Immerse the second stage into water so it is at...

  • Page 34: Troubleshooting Guides

    XS Scuba Inspire Regulator Service Manual 6. Install the MP Hose (28) A. Install o-ring (14) into the swivel nut assembly on the MP hose (28). B. Thread the MP hose on to the inlet fitting. While holding the adjacent retaining nut (8) stationary with an 11/16”...
  • Page 35 XS Scuba Inspire Regulator Service Manual First Stage Troubleshooting Guide ymptom oSSible auSe olution Try replacing the HP Seat (22) first. Pressure Creep (Drift) There is a problem with the Try replacing the HP o-ring (24). HP seat (22) / crown orifice interface The crown orifice in the main body (11) MP doesn’t stabilize or...
  • Page 36 XS Scuba Inspire Regulator Service Manual Second Stage Troubleshooting Guide ymptom oSSible auSe olution Drive crown in CW until leak stops. Make sure Crown orifice (13) is not adjusted properly that the lever does not drop below the rim of the case Adj knob (26) turned all the way out;...

  • Page 37: Torque Specifications

    XS Scuba Inspire Regulator Service Manual First Stage Torque Specifications eSCRiption oRque RP500-28 Turret Bolt 90 in/lbs (± 10) / 10 Nm RP500-07 Yoke Retainer (7) 24 ft. lbs (±1) / 33 Nm RP500-33 DIN Housing (7) 24 ft/lbs (1 Nm)
  • Page 38 XS Scuba equipment is for use only by persons trained and certified International Email: export@XSscuba.com by a nationally recognized scuba training agency. XS Scuba and the XS Scuba logo are trademarks of XS Scuba, Inc. facebook.com/XSscuba which may be registered in certain jurisdictions.

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Inspire octopus

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