XLC 2nd Stage Service Manual.pdf - Aberdeen Watersports

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Table of ContentsIntroduction .................................................................................................... 3Warnings, Cautions, & Notes ........................................................................................... 3Scheduled Service ........................................................................................................... 3General Guidelines ........................................................................................................... 3Initial Inspection Procedure .......................................................................... 4External Inspection ........................................................................................................... 4Pressure Test .................................................................................................................... 4Disassembly Procedures............................................................................... 5Reassembly Procedures................................................................................ 8Adjustment Procedures ............................................................................... 11Final Assembly & Testing ............................................................................ 12Second stage Air Flow Test ............................................................................................ 13Second stage Opening Effort Test .................................................................................. 13Second Stage Purge Flow Test ...................................................................................... 13External Leak Test .......................................................................................................... 14Subjective Breathing Test ............................................................................................... 14Table 1 – Troubleshooting Guide ................................................................ 15Table 2 – Recommended Tool List .............................................................. 16Table 3 – Standard Parts Replacement Schedule ..................................... 16Table 4 – Torque Specifications .................................................................. 17Table 5 – Test Bench Specifications ........................................................... 17Procedure A – Cleaning & Lubrication....................................................... 18Table A – Recommended Lubricants & Cleaners...................................... 19Schematic Drawing ...................................................................................... 20
Doc. #7803-02Service & Repair Manual - XLC Second Stage RegulatorIntroductionThis manual provides factory prescribed proceduresfor the service and repair of the XLC secondstage regulator. It is not intended to be used as aninstructional manual for untrained personnel. Theprocedures outlined within this manual are to beperformed only by personnel who have receivedfactory authorized training through a factory sponsoredAqua Lung Service & Repair Seminar.If you do not completely understand all of theprocedures outlined in this manual, contact AquaLung to speak directly with a Technical Advisorbefore proceeding any further.Warnings, Cautions, & NotesPay special attention to information provided inwarnings, cautions, and notes that are accompaniedby one of these symbols:A WARNING indicates a procedure or situationthat may result in serious injury or death ifinstructions are not followed correctly.A CAUTION indicates any situation or techniquethat will result in potential damage to theproduct, or render the product unsafe if instructionsare not followed correctly.A NOTE is used to emphasize importantpoints, tips, and reminders.Scheduled ServiceRegulators should be given the same care andmaintenance as life support equipment. It is thereforeimportant to perform scheduled overhaul servicefor the XLC, complete with first stage, according tothe procedures outlined in this manual; at least oncea year with normal or infrequent use.NOTE: A unit that receives heavy or frequentuse, such as in rental, instruction, or commercialapplications, should be serviced at leasttwice each year - or more often - depending onthe conditions of use and the manner in whichit is maintained. (Refer to the care and maintenanceprocedures outlined in the RegulatorOwner’s Manual.)General Guidelines1. In order to correctly perform the proceduresoutlined in this manual, it is important to followeach step exactly in the order given. Read overthe entire manual to become familiar with allprocedures before attempting to disassemble orservice the XLC second stage, and to learnwhich specialty tools and replacement parts willbe required. Keep the manual open beside youfor reference while performing each procedure.Do not rely on memory.2. All service and repair should be carried out in awork area specifically set up and equipped forthe task. Adequate lighting, cleanliness, andeasy access to all required tools are essential formaintaining a professional repair facility.3. Before beginning any disassembly, it is importantto first perform the Initial Inspection procedure,and refer to Table 1 - Troubleshooting todetermine the possible cause of any symptomswhich may be present.4. As each individual regulator is disassembled,reusable components should be segregated toprevent them from mixing with non-reusableparts or parts from other regulators. Delicateparts, and those which contain critical sealingsurfaces, must be protected and isolated fromother parts to prevent damage during the cleaningprocedure.5. Use only genuine Aqua Lung parts purchaseddirectly from Aqua Lung when servicing anyAqua Lung product. Substitution with anothermanufacturer’s parts constitutes an after-marketmodification of the product, and renders theoriginal warranty null and void.6. Do not attempt to reuse mandatory replacementparts under any circumstances, regardless of theamount of use the product has received since itwas manufactured or last serviced.7. When reassembling, it is important to followevery torque specification prescribed in thismanual, using a calibrated torque wrench. Mostparts are made of either marine brass or plastic,and can be permanently damaged by unduestress caused by overtightening.
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XLC 2nd Stage Service Manual.pdf - Aberdeen Watersports

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