Download
Share
Print this page
Cressi-sub XS Compact Regulators Repair And Maintenance
  1. Manuals
  2. Brands
  3. Cressi-sub Manuals
  4. Diving Instrument
  5. XS Compact
  6. Regulators repair and maintenance

Cressi-sub XS Compact Regulators Repair And Maintenance

Hide thumbs

Advertisement

Quick Links

Download this manual
XS Compact 2nd stage
Regulators repair and maintenance
January 2014
Rev XSC /3
Ed. C /14
1

Advertisement

loading
Need help?

Need help?

Do you have a question about the XS Compact and is the answer not in the manual?

Questions and answers

Related Manuals for Cressi-sub XS Compact

Summary of Contents for Cressi-sub XS Compact

  • Page 1 XS Compact 2nd stage Regulators repair and maintenance January 2014 Rev XSC /3 Ed. C /14...
  • Page 2 WARNING ! • This manual is intended for use by expert technicians who have already received training in equipment repairs and maintenance from Cressi-sub; • We decline all responsibility for any maintenance and/or repair performed by personnel not authorized by Cressi-sub;...
  • Page 3 (21% oxygen, 79% nitrogen); • The instructions provided in this document are based on the most recent information available about the equipment, and Cressi-sub reserves the right to make changes at any time. January 2014 Rev XSC /3...
  • Page 4 XS Compact 2nd stage: spare parts exploded diagram Regulators repair and maintenance XSCOMPACT 2 STAGE HZ 780060 ANNUAL REPLACEMENT KIT CHART (Real Size) Rev XSC /C January 2014 Ed. C /14...
  • Page 5 XS Compact 2nd stage Regulators repair and maintenance • XS Compact 2nd stage service kit HZ 780060 (Real Size) (Real Size) Go back to •Use only original Cressi-sub replacement parts. • Note: we recommend that complete maintenance be performed on the regulator at least once a year, or more frequently if used intensively.
  • Page 6 XS Compact 2nd stage Regulators repair and maintenance • Annual Maintenance • Cressi-Sub recommends complete regulator maintenance at least once a year, or more frequently in the case of particularly intense use; • Maintenance must include replacement of all components provided in the annual equipment maintenance kit;...
  • Page 7 Users must never perform maintenance themselves; all maintenance must be performed EXCLUSIVELY by an authorized Cressi-Sub center; • You can find your authorized Cressi-Sub center by asking your dealer, or Cressi Sub S.p.A. itself by sending an e-mail to: info@cressi-sub.it.
  • Page 8 XS Compact 2nd stage Special tools Regulators repair and maintenance Rev XSC /C January 2014 Ed. C /14...
  • Page 9 To replace the gaskets correctly, press on the sides of the O-Rings to create a protuberance under which you can insert the tool with the rounded tip used for removing O-Rings, as shown in the figure; • Important: ONLY USE ORIGINAL CRESSI-SUB GASKETS Rev XSC /C January 2014 Ed. C /14...
  • Page 10 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance • Place a 19 mm wrench on the 2nd stage valve seat nut and at the same time unscrew and remove the low pressure hose with a 17 mm wrench as shown in the figure;...
  • Page 11 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance • In the annual overhaul, the O- Rings inside the hose must be replaced, and check that the low pressure hose shows no clear signs of wear, cuts, or scrapes, especially near the threaded connections.
  • Page 12 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance 26 = HZ 780063 • Lever the dome lock retainer and pull it out of the 2nd stage as shown in the figure. Rev XSC /C January 2014 Ed. C /14...
  • Page 13 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance • Unscrew the dome as shown in the figure. Rev XSC /C January 2014 Ed. C /14...
  • Page 14 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance • Remove the dome, the button, and the button ring from the housing. Rev XSC /C January 2014 Ed. C /14...
  • Page 15 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance 27 = HZ 780062 26 = 780063 23 = HZ 780069 25 = HZ 780049 25 = HZ 780066 Lilla / Lilac Giallo / Yellow 24 = HZ 780068...
  • Page 16 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance • Remove the diaphragm from the 2nd stage case. 23 = HZ 780069 Rev XSC /C January 2014 Ed. C /14...
  • Page 17 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance • Push up on the end of the 2nd stage case side cap fastening tab while simultaneously pushing it out of the regulator, as shown in the figure. Rev XSC /C January 2014 Ed.
  • Page 18 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance HZ 709009 • Once the side cap is removed, fully unscrew the 5.5 mm nut using the socket screwdriver, inserting it through the hole in the case. Rev XSC /C January 2014 Ed.
  • Page 19 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance • Then remove the lever, the washer, and the nut from the 2nd stage. Rev XSC /C January 2014 Ed. C /14...
  • Page 20 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance 12 = HZ 780074 11K = HZ 746094 HZ 709009 Rev XSC /C January 2014 Ed. C /14...
  • Page 21 XS Compact 2nd stage: steps in disassembly Riparazione e Manutenzione Erogatori • Rest the regulator case on the work surface, and loosen the adjustable nozzle unit with a 19 mm wrench as shown in the figure; • Note: avoid forcing this motion if it proves difficult. Instead, it can be helpful to tap along the edge of the area to be unscrewed with a hammer made of synthetic material.
  • Page 22 XS Compact 2nd stage: steps in disassembly Riparazione e Manutenzione Erogatori • Then unscrew the adjustable nozzle assembly and remove the valve spindle and the spring from the 2nd stage as shown in the figures. 8 = HZ 730207 Rev XSC /C January 2014 Ed.
  • Page 23 XS Compact 2nd stage: steps in disassembly Riparazione e Manutenzione Erogatori • Replacing the 2nd stage poppet seat is very easy: simply slide the spindle bushing, removing the seat from its housing. Rev XSC /C January 2014 Ed. C /14...
  • Page 24 XS Compact 2nd stage: steps in disassembly Riparazione e Manutenzione Erogatori HZ 739001 • Using the plastic universal extractor tool, push and extract the valve body and the injector, removing both from the 2nd stage as shown in the figure.
  • Page 25 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance • Use a flathead screwdriver to fully unscrew the adjustable nozzle from its housing. Rev XSC /C January 2014 Ed. C /14...
  • Page 26 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance HZ709011 • Pull out the nozzle, inserting the plastic universal spring pusher into the side opposite the air intake for the nozzle unit. This tool is specially designed to avoid damaging the sharp edge of the nozzle;...
  • Page 27 XS Compact 2nd stage: steps in disassembly Riparazione e Manutenzione Erogatori 19 = HZ 782097 28 = HZ 780061 • Remove the deflector from the regulator case by pushing on the sides as shown in the figure, then pull out the discharge valve from its housing.
  • Page 28 XS Compact 2nd stage: steps in disassembly Regulators repair and maintenance 15 = HZ 810080 • Using a flat-tipped tool, remove the flow deviator clip ring, pushing outward. Then pull the flow deviator from its housing. Rev XSC /C January 2014...
  • Page 29 XS Compact 2nd stage Regulators repair and maintenance 2nd stage cap 2nd stage button Dome lock retainer 2nd stage button ring Flow deviator assembly 2nd stage diaphragm Valve spindle Movable nozzle Injector assembly unit + O-Ring Nut and washer Valve body...
  • Page 30 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • Insert the flow deviator in its housing after lubricating the O-Ring. • While doing so, be careful to line up the hole in the end of the flow deviator with the corresponding pin located inside the 2nd stage case, as shown in the figure.
  • Page 31 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance 15 = HZ 810080 • Push the flow deviator clip ring into place with one hand, and finish with a flat-tipped tool. Rev XSC /C January 2014 Ed. C /14...
  • Page 32 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance 19 = HZ 782097 • Insert the discharge valve into the 2nd stage, checking that it lies against the case with no obstructions for a perfect seal. The correct position of the valve stem inside the regulator is shown in the small photo.
  • Page 33 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance 4 = HZ 742013 • First assemble the regulator valve, reinserting the seat that was just removed in the seat-holder bushing of the valve spindle; • Note: the purpose of using the old seat - as we will see - is to prevent the new one from getting nicked in this step by the sharp edge of the nozzle.
  • Page 34 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance 8 = HZ 730207 • Insert the spring into the valve body, making sure that it inserts properly into its housing inside the valve body. Rev XSC /C January 2014...
  • Page 35 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance 7K = HZ 780077 • Insert the spindle assembly (with the old seat) into the spring inside the valve body as shown in the figure. Rev XSC /C January 2014...
  • Page 36 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance 3 = HZ 780080 10 = HZ 780075 • Screw the two assembled components all the way to the end of the thread, without tightening. Rev XSC /C January 2014...
  • Page 37 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • Secure the plastic universal tool in a clamp as shown in the figure to make this operation easier; • Then insert the end of the spring pusher into the...
  • Page 38 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • If no clamp is available, these same operations can still be performed using the HZ 739001 plastic universal tool as shown in the figure. HZ 739001 Rev XSC /C January 2014 Ed.
  • Page 39 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • Note: to make this operation easier, it can be helpful to rotate the end of the valve spindle so that its square section (visible through the air exhaust hole of...
  • Page 40 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • Once you have checked the alignment, push the valve assembly on the spring pusher in the vise, until the square section of the valve spindle comes fully out of the corresponding square section of the valve body, as shown in the figure.
  • Page 41 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance 12 = HZ 780074 • Then, in sequence insert the lever, the washer, and the nut as in the figure; • Note: make sure to insert the lever in the correct direction with respect to the valve body, using air exhaust hole for reference as shown in the figure.
  • Page 42 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance HZ 709009 • Then screw down the nut with a 5.5 mm socket screwdriver by a few threads, enough to hold the lever in the up position, while awaiting the proper calibration that will be performed on the assembled regulator.
  • Page 43 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • Check that the valve functions properly by running through the full range of the lever corresponding to the spindle square exiting completely with respect to the valve body square.
  • Page 44 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • Fully unscrew the movable nozzle unit from the valve body. Rev XSC /C January 2014 Ed. C /14...
  • Page 45 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance 4 = HZ 742013 • Remove the old seat from the valve spindle and replace it with the new one contained in the annual maintenance kit. Rev XSC /C January 2014 Ed.
  • Page 46 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance OR = HZ 810095 3 = HZ 780080 •After suitably lubricating the O-Rings, insert and push the movable nozzle into its seat to the beginning of the thread, following the direction of insertion shown in the figure;...
  • Page 47 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • Push the valve body, complete with lever, placing it inside the corresponding hexagonal seat of the injector, making sure that the air exhaust hole lines up with the injector hole, as shown in the figure.
  • Page 48 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • Push the injector complete with valve body and lever, placing it into the hexagonal set of the 2nd stage case; • The correct insertion direction and placement of the assembly is shown in the figure.
  • Page 49 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • Then, without applying excessive force, tighten the nozzle unit to the valve body with a 19-mm wrench, taking care to hold down the lever so that the seat does not accidentally touch the sharp edge of the nozzle, as shown in the figure;...
  • Page 50 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance 28 = HZ 780061 • Fasten the deflector to the 2nd stage case, sliding it against the appropriate stops, as shown in the figure. Rev XSC /C January 2014...
  • Page 51 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance 23 = HZ 780069 • Place the diaphragm in the 2nd stage case as shown in the figure; • Then, carefully ensure that the outer edges of the diaphragm are seated perfectly in the regulator case.
  • Page 52 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance 25 = HZ 780064 Bianco/White 24 = HZ 780068 25 = HZ 780065 Rosa/Pink 25 = HZ 780066 Giallo/Yellow 25 = HZ 780067 Grigio/Gray groove • Insert the button into the groove provided on the button ring as shown in the figure;...
  • Page 53 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • Insert the button and diaphragm centering ring assembly, rotated slightly, so that space A on the button is positioned near B (end of dome travel) on the case, as shown in the enlargement of the figure.
  • Page 54 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance 27 = HZ 780062 • Place the dome on the button, and then screw it on all the way so that the dome lock lines up with the corresponding one on the case.
  • Page 55 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • Rotate the flow deviator all the way to make this step easier, and then insert the dome lock retainer, pushing it into its seat on the case, as shown in the figures.
  • Page 56 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • Once in the correct position, press on the sides of the dome lock retainer until you hear a small click, which indicates that is has fitted perfectly with the 2nd stage case as shown in the figure.
  • Page 57 Regulators repair and maintenance • Calibrating the XS Compact second stage: adjusting the valve nozzle (pg. 59) • Screw the 2nd stage to the calibration gauge (HZ 710011) connected to a properly calibrated first stage with a low pressure hose;...
  • Page 58 Regulators repair and maintenance • Calibrating the XS Compact second stage: valve nozzle adjustment • N.B.: Be careful not to screw the valve nozzle too far, or the closing seat could cut be pressed into significantly, resulting in inhalation effort due to excessive compression of the valve spring;...
  • Page 59 XS Compact 2nd stage: calibration steps Regulators repair and maintenance • Calibrating the XS Compact second stage: valve nozzle adjustment HZ 710011 January 2014 Rev XSC /3 Ed. C /14...
  • Page 60 • Correct calibration of the XS Compact stage is achieved when, with the regulator under pressure, the lever has a short length of idle travel, about 1.5 - 2 mm from the diaphragm plate.
  • Page 61 XS Compact 2nd stage: calibration steps Regulators repair and maintenance • Calibrating the XS Compact second stage: lever height adjustment HZ 710011 HZ 709009 January 2014 Rev XSC /3 Ed. C /14...
  • Page 62 XS Compact 2nd stage: phases of assembly Regulators repair and maintenance • Once the 2nd stage has been correctly calibrated, insert the side cap, making sure to insert it in the right direction as shown in the figure; • The correct direction to insert the cap is shown in the figure.
  • Page 63 XS Compact 2nd stage: checking and inspection steps Regulators repair and maintenance • Once the regulator is calibrated, keeping the regulator under pressure with a properly calibrated 1st stage, making the following final checks: • Immerse the second stage slowly in water with the mouthpiece facing up, with the Venturi control lever in the Dive "+"...
  • Page 64 XS Compact 2nd stage: overhaul sheet Regulators repair and maintenance Download January 2014 Rev XSC /3 Ed. C /14...
  • Page 65 XS Compact 2nd stage: service records Regulators repair and maintenance Download Tab Maintenance / Service Record January 2014 Rev XSC /3 Ed. C /14...