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XS Scuba Inspire Regulator Service Manual

Required Tool List

Part #

Description

Application

TL123

Yoke Retainer Socket Set

Used to tighten / apply

torque to yoke retainer

TL118

Spanner Wrench
Round Surface

Loosen and tighten

diaphragm clamp

TL136

Multi-Purpose Tool

Remove and install parts

TL117

Regulator Cover
Removal Tool

Remove and install

front cover

n/a

Side cutters

Removes mouthpiece

tie wrap

n/a

Circlip Pliers

Removing/Installing

Circlip

TL121

Inline Adjuster w/ Gauge

Measures MP and adjusts

2nd stage

n/a

Torque Wrench
with Crows Feet
and Hex Key
Adapters

For applying proper torque

Summary of Contents for Inspire Octopus

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

Page 2: ...bols 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 p...

Page 3: ...actory mandated torque values using a calibrated torque wrench To do otherwise could lead to damage or failure of the product 8 Unless otherwise instructed the following is assumed a When instructed t...

Page 4: ...d the medium or interstage pressure Record the value and whether it stabilizes or creeps 5 Pressurize the regulator and submerge in a tub of water Are there any leaks If so document where the leaks ar...

Page 5: ...h Round Surface Loosen and tighten diaphragm clamp TL136 Multi Purpose Tool Remove and install parts TL117 Regulator Cover Removal Tool Remove and install front cover n a Side cutters Removes mouthpie...

Page 6: ...6 www XSscuba com XS Scuba Inspire Regulator Service Manual...

Page 7: ...7 www XSscuba com XS Scuba Inspire Regulator Service Manual...

Page 8: ...8 www XSscuba com XS Scuba Inspire Regulator Service Manual...

Page 9: ...9 www XSscuba com XS Scuba Inspire Regulator Service Manual...

Page 10: ...20 UNF end of the TL122 Regulator Support Handle Vise Mounting Tool into the HP port Be sure to fully engage the threads NOTE It will be necessary to use a bench mounted vise to hold the first stage...

Page 11: ...me in through the backside of the yoke retainer 7 and push out the filter 5 and its associated o ring 6 v Remove the o ring 8 from the underside of the yoke retainer 7 B Inspire with DIN connector Ref...

Page 12: ...regulator in the vise so that the turret 21 and turret bolt 28 are facing up B Using a 6 mm hex key remove the turret bolt as sembly 28 8 Remove the turret 21 A Remove the thrust washer 26 B Remove th...

Page 13: ...18 and remove it CCW B Lift out spring seat 15 12 Remove diaphragm washer 14 A Using a strong o ring pick get underneath the clear diaphragm washer 14 and lift it out 13 Remove the diaphragm 13 CAUTIO...

Page 14: ...phragm washer 10 and the inhalation diaphragm 9 Carefully inspect the diaphragm for small tears or holes If found in good condition it may be reused 3 Remove the Mouthpiece 3 A With a pair of side cut...

Page 15: ...ld it in place by turning the adjustment knob 26 CCW until it comes to a soft stop CAUTION Applying too much pressure to the adjustment knob 26 can result in bending the retaining pin 18 thus making i...

Page 16: ...retaining pin 18 If the retaining pin 18 does not fall out on its own you may push it out with the TL136 Multi Purpose Tool ii Turn the adjusting knob 26 CCW until it is free iii Remove and discard it...

Page 17: ...ove the crown orifice from the air barrel A Use the back end of the TL136 Multi Pur pose tool to push the orifice 13 out of the valve housing 17 If it doesn t move it is possible that it may still hav...

Page 18: ...w XSscuba com 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 8B...

Page 19: ...r the inside of the hose s Doing so may cause a breakdown of the inner hose lining which can lead to obstruction of the air passage way Preparing and Inspecting Parts Nitrox Preparation If you are pre...

Page 20: ...moves 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 07...

Page 21: ...t the diaphragm 13 into the under cut groove of the main body 11 Work the edges with your finger to make certain that is fully seated in the under cut 4 Install the diaphragm washer 14 on top of the d...

Page 22: ...turret bolt Use the TL136 multi tool to seat it evenly NOTE This is a dynamic o ring 24 The stem of the HP seat moves through the center of it with each breath Therefore lubricate it generously makin...

Page 23: ...10 in lbs 10 Nm 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 ii Ins...

Page 24: ...it will go vii Mount the body back into the vise viii Using the 19 mm socket TL123 with an extension attached to a ft lb torque wrench apply a torque to the retainer of 24 ft lbs 1 Nm ix Install the y...

Page 25: ...hreads facing upwards 6 vii Insert unlubricated filter o ring 5 into the DIN housing 7 Make sure that it lays flat viii Insert filter 4 pointed end first into the DIN housing 7 ix Install the two o ri...

Page 26: ...31 on to male end of MP hose B Install MP hose into its respective port Using a torque wrench and a 9 16 crow s foot torque the hose to 40 in lbs 4 5Nm C Slide the hose protector back into position Th...

Page 27: ...a MP port G Let the unit sit under pressure for 5 minutes The medium pressure should remain fairly stable It is common to see the pressure creep by a few psi The standard of acceptability for medium...

Page 28: ...oppet 21 with its two o rings 22 should be seated inside the balancing chamber 24 E Set aside for the next completed assembly NOTE The latest lp seat is the one that is orange in color This is the one...

Page 29: ...lp seat 20 past the lever feet and allow the L shaped sockets to engage When the L shaped features on the poppet 21 engage the lever feet they will lift the lever 19 upwards as you push the assembly...

Page 30: ...h Guide it up slowly B Confirm that the lever feet are between the molded tabs on the box bottom CAUTION Confirm that the lever feet are between the molded tabs on the box bottom This retains the leve...

Page 31: ...ow end of the valve housing B Using the Regulator In Line Adjusting Tool TL121 or a 3 16 hex key press the crown orifice in as far as it will travel Turn it CW two complete revolutions This is the pre...

Page 32: ...the crown orifice Failure to perform this step can cause changes to the regulator s adjustment 9 Continuation of Assembly A Install the diaphragm 9 i Position the diaphragm 9 into the main housing 1...

Page 33: ...o a container of water with the mouthpiece up Keep the diaphragm perfectly horizontal Place your ear close to the mouthpiece You should hear the demand valve open indicated by hissing air when the dia...

Page 34: ...epress the purge button to ensure an adequate volume of air needed to clear the regulator passes through the mouthpiece C Inhale slowly but deeply through the mouthpiece A properly serviced and adjust...

Page 35: ...e but too high Main spring force is too strong Turn the adjustment screw 19 CCW Restricted Air Flow Hard inhalation throughout entire system Cylinder valve not opened all the way Open valve all the wa...

Page 36: ...ice CCW until the lever is up against the back of the diaphragm Lever 19 bent Replace lever Excessive breathing resistance Adjusting knob 26 in too far Back out adjusting knob 26 Lever 19 is bent Repl...

Page 37: ...150 psi 9 10 bar 5 0 SCFM 142 L min minimum flow rate Leak Test Inlet 3000 psi 207 bar No leaks allowed Test Bench Specifications Part Description Key Item Torque RP450 08 Retaining Nut Valve Housing...

Page 38: ...registered in certain jurisdictions All other names are trademarks of their respective owners All products and prices are subject to change without notice Copyright 2017 by XS Scuba Inc All Rights Re...

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