XLC 2nd Stage Service Manual.pdf - Aberdeen Watersports

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14 XLC Second Stage Service & Repair ManualExternal Leak Test1. After disconnecting the regulator from the flow bench, connectit to a scuba cylinder filled to approximately 3,000 psi.Open the cylinder valve to repressurize the regulator, andsubmerge the entire system in a test tank of clean water.2. Observe any bubbles arising from the submerged regulatorover a one minute period. The recommended time is necessarydue to slower bubble formation that occurs in smallerleaks. Bubbles indicate a leak, which requires that the systemmust be disassembled at the source to check sealing surfaces,assembly sequence and component positioning in order tocorrect the problem(s).NOTE: Extremely small leaks may be better detected byapplying a soap solution or Snoop to the leak area.Bubble streams will indicate the source of the leak. Beforedisassembling to correct any leaks, rinse the entire regulatorthoroughly with fresh water and blow out all residual moisturewith filtered, low-pressure (50 psi) air. Disassemble andremedy the problem, referring to Table 1 - Troubleshooting.Subjective Breathing Test1. Depress the purge cover fully to ensure that an adequatevolume of air needed to clear the second stage flows throughthe mouthpiece. Then, inhale slowly but deeply from themouthpiece. A properly serviced and adjusted regulatorshould deliver air upon deep inhalation without excessiveinhalation effort, freeflow, or “fluttering” of the second-stagediaphragm. When exhaling, there should be no fluttering orsticking of the exhalation valve. If any of these problemsoccur, refer to Table 1 - Troubleshooting.This concludes annual service procedures for the XLCSecond Stage Regulator.© 1999 Aqua Lung America, Inc.
XLC Second Stage Service & Repair Manual 15Table 1Troubleshooting Guide – XLC Second StageSYMPTOM POSSIBLE CAUSE TREATMENTLeakage or freeflow from 1. High first-stage intermediate pressure. 1. Refer to first-stage Troubleshootsecondstage (should be 135-140 psi) ing Guide.2. LP seat(14) damaged or worn. 2. Replace LP seat.3. Crown(19) and/or locknut(7) adjusted 3. Reset crown and locknut toincorrectly, lever set too high.preliminary settings, and repeatAdjustment Procedures.4. Crown(19) sealing surface damaged. 4. Replace crown.5. Poppet spring(12) damaged. 5. Replace poppet spring.Low purge or excessive work 1. Low intermediate pressure. 1. Refer to first-stage Troubleshootofbreathing (full cylinder) (should be 135-140 psi) ing Guide.2. Crown(19) and/or locknut(7) adjusted 2. Reset crown and locknut toincorrectly, lever set too low.preliminary settings, and repeatAdjustment Procedures.3. Intermediate pressure hose(16) 3. Clean or replace hose.clogged or obstructed.External air leakage 1. Intermediate pressure hose loose. 1. Tighten to 40 inch-lbs at female(Immersion Test)second-stage fitting.2. Crown O-ring(18) damaged. 2. Disassemble and replace O-ring.3. Box bottom(22) damaged. 3. Disassemble and replace boxbottom.Water entering second-stage 1. Hole in mouthpiece(25). 1. Replace mouthpiece.2. Demand diaphragm(5) damaged. 2. Replace demand diaphragm.3. Exhaust diaphragm(27) damaged. 3. Replace exhaust diaphragm(s).4. Vane Adjustment Switch O-ring(23) 4. Disassemble and replace O-ring.dirty, damaged, or worn.5. Diaphragm improperly seated 5. Remove front cover(3) and propbetweenbox bottom(22) anderly reassemble sealing ring withsealing ring(4).diaphragm . (Check for distortion.)6. Box bottom damaged. 6. Disassemble and replace box(Check exhaust valve sealing surface.) bottom.7. Valve insert O-ring(21) damaged. 7. Disassemble and replace O-ring.8. End plug O-ring(29) worn or damaged. 8. Disassemble and replace O-ring.CAUTION: Recommended treatments which require disassembly of the regulatormust be performed during a complete overhaul, according to the prescribed proceduresfor scheduled, annual service. Do not attempt to perform partial service.NOTE: This is a partial list of possible problems and recommended treatments. Formore information, refer to the second-stage troubleshooting guide, or contact theRepair Department for assistance with problems not described here.© 1999 Aqua Lung America, Inc.
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