regulators repair and maintenance

Regulators repair and maintenance

January 2014 Rev XSC /3 Ed. C /14 1

XS Compact 2nd stage



• This manual is intended for use by expert technicians who have alreadyreceived training in equipment repairs and maintenance from Cressi-sub;

• We decline all responsibility for any maintenance and/or repair performed bypersonnel not authorized by Cressi-sub;

• Avoid performing maintenance and/or repair operations on the equipmentwithout the proper training required to conduct these operations;

• Users must never perform maintenance themselves; all maintenance must beperformed EXCLUSIVELY by an authorized Cressi-Sub center;

• If the information provided in this document is unclear or not fully intelligible,please contact Cressi-sub before proceeding with any disassembly ormaintenance procedures;

• Before proceeding, Cressi-sub recommends that you read the followingdocument carefully to familiarize yourself with all the tools and techniquesneeded to perform proper equipment maintenance and/or repair;

• Use this document as a guide during the various steps of maintaining and/orrepairing the equipment;


WARNING !




WARNING !

• All operations must be carried out strictly in the order provided in thisdocument. Failure to do so could lead the equipment to function poorly, orworse, result in an accident;

• To prevent any assembly errors when performing maintenance and/orrepairs, we recommend using all the replacement parts provided byCressi-Sub in every operation;

• Pay special attention to the recommendations provided in the margin ofthe figures that show the various sequences of equipment maintenanceand/or repair in order to avoid any problems that could result in anaccident;

• The document below in no way replaces the equipment's instructionmanual;

• The procedures described in this document are pertinent to and intendedonly for the disassembly, maintenance, and assembly of equipment meantfor use with air (21% oxygen, 79% nitrogen);

• The instructions provided in this document are based on the most recentinformation available about the equipment, and Cressi-sub reserves theright to make changes at any time.


January 2014 Rev XSC /C Ed. C /14 4

XS Compact 2nd stage:

spare parts exploded diagram

XSCOMPACT 2nd STAGE HZ 780060 ANNUAL REPLACEMENT KIT CHART

(Real Size)




•Use only original Cressi-sub replacement parts.

• Note: we recommend that complete maintenance be performed on theregulator at least once a year, or more frequently if used intensively.

• XS Compact 2nd stage service kit

(Real Size)

(Real Size)

Go back to

HZ 780060




• 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 theannual equipment maintenance kit;

• The special tools for maintenance of this equipment are illustrated on page 8of this document;

• Metal parts must be washed with hot water and neutral detergent and rinsedin fresh water. Any concretions must be removed using ultrasound cleaning orwith diluted acid solutions, always followed by long and thorough rinsingunder running water;

• Do not use acids or solvents on rubber components;

• The new ORs must be greased with a thin layer of silicon grease: thisprocedure reduces to a minimum the risk of damage during assembly;

• The metal threading can be lubricated with grease on the first two rings ofthreading.




• Annual Maintenance

•Use only original Cressi-sub replacement parts

• The procedures described in this document are pertinent to and intendedonly for the disassembly, maintenance, and assembly of equipment meantfor use with air (21% oxygen, 79% nitrogen);

• Users must never perform maintenance themselves; all maintenance mustbe performed EXCLUSIVELY by an authorized Cressi-Sub center;

• You can find your authorized Cressi-Sub center by asking your dealer, orCressi Sub S.p.A. itself by sending an e-mail to:

[email protected].

http://[email protected]/




Special tools




steps in disassembly

• Remove and replace all gaskets in the 2nd stage;

• To remove the O-Rings, use a plastic tool, or a metal one, but with arounded tip in order to avoid damaging the gasket seat;

• To replace the gaskets correctly, press on the sides of the O-Rings to createa protuberance under which you can insert the tool with the rounded tipused for removing O-Rings, as shown in the figure;

• Important: ONLY USE ORIGINAL CRESSI-SUB GASKETS





• Place a 19 mm wrench on the2nd stage valve seat nut and atthe same time unscrew andremove the low pressure hosewith a 17 mm wrench as shownin the figure;

• Check that the low-pressurehose shows no clear signs ofwear, cuts, or scrapes, especiallynear the threaded connections.





• In the annual overhaul, the O-Rings inside the hose must bereplaced, and check that the lowpressure hose shows no clearsigns of wear, cuts, or scrapes,especially near the threadedconnections.





• Lever the dome lock retainerand pull it out of the 2nd stageas shown in the figure.

26 = HZ 780063





• Unscrew the dome as shown in the figure.





• Remove the dome, the button, and the button ring from the housing.





27 = HZ 780062

26 = 780063

23 = HZ 780069

24 = HZ 780068

25 = HZ 780067

Grigio / Gray

25 = HZ 780065

Rosa / Pink

25 = HZ 780064

Bianco / White

25 = HZ 780066

Giallo / Yellow

25 = HZ 780049Lilla / Lilac





• Remove thediaphragm fromthe 2nd stage case.

23 = HZ 780069





• Push up on the end of the 2nd stagecase side cap fastening tab whilesimultaneously pushing it out of theregulator, as shown in the figure.





• Once the side cap is removed, fully unscrew the 5.5 mm nutusing the socket screwdriver, inserting it through the hole inthe case.

HZ 709009





• Then remove the lever, the washer, and the nut from the 2nd stage.





HZ 709009

11K = HZ 746094

12 = HZ 780074

Riparazione e Manutenzione Erogatori




• Rest the regulator case on the work surface, and loosen theadjustable nozzle unit with a 19 mm wrench as shown in thefigure;

• Note: avoid forcing this motion if it proves difficult. Instead, it canbe helpful to tap along the edge of the area to be unscrewed witha hammer made of synthetic material. This will free the threadsand make removal easier.





• Then unscrew the adjustablenozzle assembly and removethe valve spindle and thespring from the 2nd stage asshown in the figures.

8 = HZ 730207





• Replacing the 2nd stage poppet seat is very easy: simplyslide the spindle bushing, removing the seat from itshousing.





• Using the plastic universal extractor tool, push and extract the valvebody and the injector, removing both from the 2nd stage as shown inthe figure.

HZ 739001





• Use a flathead screwdriver to fully unscrew the adjustable nozzlefrom its housing.





• Pull out the nozzle, inserting the plastic universal spring pusher into the sideopposite the air intake for the nozzle unit. This tool is specially designed toavoid damaging the sharp edge of the nozzle;

• NOTE: you need to push firmly to exceed the friction exerted by the O-Ringon the wall of the body, before you can push the nozzle fully out of thenozzle unit.

HZ709011





• Remove the deflector from the regulator case by pushing on thesides as shown in the figure, then pull out the discharge valvefrom its housing.

28 = HZ 780061

19 = HZ 782097





• Using a flat-tipped tool, remove the flow deviator clip ring, pushingoutward. Then pull the flow deviator from its housing.

15 = HZ 810080




Movable

nozzle + O-

Ring

Movable nozzle

unit + O-Ring

Spindle seat

Valve spindle

assembly

Valve spring Valve body

Side cap + O-Ring

Nut and washer

2nd stage cap

2nd stage button

2nd stage button ring

2nd stage

diaphragm

2nd stage lever Exhaust valve

2nd stage deflector

Injector

2nd stage case

Flow deviator assembly

Dome lock retainer




phases of assembly

• 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 theflow deviator with the corresponding pin located inside the 2ndstage case, as shown in the figure.

!




phases of assembly

• Push the flow deviator clip ring into place with one hand, and finishwith a flat-tipped tool.

15 = HZ 810080




phases of assembly

• Insert the discharge valve into the 2nd stage, checking that it liesagainst the case with no obstructions for a perfect seal. The correctposition of the valve stem inside the regulator is shown in the smallphoto.

19 = HZ 782097




phases of assembly

• First assemble the regulator valve, reinserting the seat that was justremoved in the seat-holder bushing of the valve spindle;

• Note: the purpose of using the old seat - as we will see - is toprevent the new one from getting nicked in this step by the sharp edgeof the nozzle.

4 = HZ 742013




phases of assembly

• Insert the spring into the valve body, making sure that it insertsproperly into its housing inside the valve body.

8 = HZ 730207




phases of assembly

• Insert the spindle assembly (with the old seat) into the spring insidethe valve body as shown in the figure.

7K = HZ 780077




phases of assembly

• Screw the two assembled components all the way to the end of thethread, without tightening.

3 = HZ 780080

10 = HZ 780075




phases of assembly

• Secure the plasticuniversal tool in a clampas shown in the figure tomake this operationeasier;

• Then insert the end of thespring pusher into thenozzle seat to properlypush out the squaredsection of the valvespindle in thecorresponding squaresection of the valve body;




phases of assembly

HZ 739001

• If no clamp is available,these same operations canstill be performed using theHZ 739001 plastic universaltool as shown in the figure.




phases of assembly

• Note: to make thisoperation easier, itcan be helpful torotate the end of thevalve spindle so thatits square section(visible through theair exhaust hole ofthe valve body) islined up with thecorresponding squaresection of the valvebody in the outwarddirection.




phases of assembly

• 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 comesfully out of the corresponding square section of the valve body, as shown inthe figure.




phases of assembly

• 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 tothe valve body, using air exhaust hole for reference as shown in the figure.

!

12 = HZ 780074




phases of assembly

• Then screw down the nut with a 5.5 mm socket screwdriver by afew threads, enough to hold the lever in the up position, whileawaiting the proper calibration that will be performed on theassembled regulator.

HZ 709009




phases of assembly

• Check that the valvefunctions properly byrunning through thefull range of the levercorresponding to thespindle square exitingcompletely withrespect to the valvebody square.




phases of assembly

• Fully unscrewthe movablenozzle unitfrom the valvebody.




phases of assembly

• Remove the old seat from the valve spindle and replace it withthe new one contained in the annual maintenance kit.

4 = HZ 742013




phases of assembly

3 = HZ 780080

OR = HZ 810095

•After suitably lubricating the O-Rings, insertand push the movable nozzle into its seat to thebeginning of the thread, following the directionof insertion shown in the figure;•Screw the nozzle a few turns in its housing, butnot too far, to prevent the sharp edge of thenozzle from nicking the seat during assemblywith the valve body;•Correct calibration will be done when theregulator is assembled.




phases of assembly

• Push the valve body, complete with lever, placing it inside thecorresponding hexagonal seat of the injector, making sure thatthe air exhaust hole lines up with the injector hole, as shown inthe figure.




phases of assembly

• Push the injector complete with valve body and lever, placing itinto the hexagonal set of the 2nd stage case;

• The correct insertion direction and placement of the assembly isshown in the figure.




phases of assembly

• Then, without applying excessive force, tighten the nozzle unit tothe valve body with a 19-mm wrench, taking care to hold down thelever so that the seat does not accidentally touch the sharp edge ofthe nozzle, as shown in the figure;

• Check for correct insertion of the walls of the injector on thecorresponding stops of the 2nd stage case, which ensure the properplacement of the lever with respect to the diaphragm.




phases of assembly

• Fasten the deflector to the2nd stage case, sliding itagainst the appropriatestops, as shown in the figure.

28 = HZ 780061


Ed. C /14 51 Ed. A /11 51


phases of assembly

• Place the diaphragm in the 2nd stage case as shown in the figure;

• Then, carefully ensure that the outer edges of the diaphragm areseated perfectly in the regulator case.

23 = HZ 780069

January 2014 Rev XSC /C


January 2014 Rev XSC /3 Ed. C /14 52 52


phases of assembly

• Insert the button into the groove provided on the button ring asshown in the figure;

• This combination serves to center and anchor the diaphragm in itsworking seat inside the 2nd stage case.

groove

25 = HZ 780066 Giallo/Yellow

24 = HZ 780068

25 = HZ 780067 Grigio/Gray

25 = HZ 780064 Bianco/White

25 = HZ 780065 Rosa/Pink


January 2014 Rev XSC /3 Ed. C /14 53 53


phases of assembly

• Insert the button and diaphragm centering ring assembly, rotatedslightly, so that space A on the button is positioned near B (end ofdome travel) on the case, as shown in the enlargement of thefigure.

A

B




phases of assembly

• Place the dome on the button,and then screw it on all the wayso that the dome lock lines upwith the corresponding one onthe case.

27 = HZ 780062




phases of assembly

• Rotate the flow deviator all theway to make this step easier,and then insert the dome lockretainer, pushing it into its seaton the case, as shown in thefigures.




phases of assembly

• Once in the correctposition, press on thesides of the dome lockretainer until you heara small click, whichindicates that is hasfitted perfectly with the2nd stage case asshown in the figure.




calibration steps

• Calibrating the XS Compact second stage: adjusting the valve nozzle (pg. 59)

• Screw the 2nd stage to the calibration gauge (HZ 710011) connected to aproperly calibrated first stage with a low pressure hose;

• Mount the regulator assembly (1st + 2nd stage) on a tank filled to 200 bar,or on a test bench with similar pressure, and then slowly open the air valvewhile simultaneously pushing the 2nd stage purge button;

• If the regulator releases slowly, press and simultaneously rotate thecalibration gauge ring (HZ 710011) clockwise (+) until flow ceases; thisway, the sharp valve edge should just rest against the closing seat,ensuring proper operation;

• Next, rotate the nozzle just over ½ a turn;

• Once the valve nozzle has been adjusted correctly, the gauge indicates thecorrect calibration of the 1st stage;




calibration steps

• Calibrating the XS Compact second stage: valve nozzle adjustment

• N.B.: Be careful not to screw the valve nozzle too far, or the closing seatcould cut be pressed into significantly, resulting in inhalation effort due toexcessive compression of the valve spring;

• What's more, excessive compression of the valve spring will change thecorrect height of the lever, compromising the regulator's breathingperformance.




calibration steps

-

+

HZ 710011

• Calibrating the XS Compact second stage: valve nozzle adjustment




calibration steps

• Once the correct depth of the valve nozzle has been adjusted, you canproceed with final calibration, adjusting the height of the valve flow lever;

• This move is performed with the regulator under pressure, connecting the 2ndstage to a properly calibrated first stage with an intermediate pressure hose;

• Insert a 5.5 mm socket screwdriver (HZ 709009) into the side opening androtate the valve nut clockwise (+) until the regulator starts flowing gently;

• Then rotate the calibration nut counter-clockwise (-) until flow stops, and thencontinue a bit further to ensure short length of idle travel for the lever;

• Correct calibration of the XS Compact stage is achieved when, with theregulator under pressure, the lever has a short length of idle travel, about 1.5- 2 mm from the diaphragm plate.

• Calibrating the XS Compact second stage: lever height adjustment (pg. 61)




calibration steps

HZ 710011

HZ 709009

-

+

• Calibrating the XS Compact second stage: lever height adjustment




phases of assembly

• Once the 2nd stage has been correctlycalibrated, insert the side cap, makingsure to insert it in the right direction asshown in the figure;

• The correct direction to insert the capis shown in the figure.

• Note: check the O-Ring of the side capand replace it if necessary.




checking and inspection steps

• Once the regulator is calibrated, keeping the regulator underpressure with a properly calibrated 1st stage, making the followingfinal checks:

• Immerse the second stage slowly in water with the mouthpiecefacing up, with the Venturi control lever in the Dive "+" position,and without letting water enter from the mouthpiece;

• After about 5 cm of water, the regulator should start to release air,until the second stage free flows completely;

• Then check the proper operation of the Venturi flow deviator,swiveling the lever to the "-" position; the continuous flow mustcease;

• Completely immerse the regulator in water with the flow deviator inthe pre-dive position (-):

• Wait about a minute, and then check that there are no leaks bylooking for any columns of bubbles that indicate a leak (do notconfuse these with the exit of air trapped in the 2nd stage);

• In the event of leaks, refer to the manual about the steps ofcalibration.




overhaul sheet

Download Tab

http://www.cressi.com/easyUp/file/service/SchedaRevisioneErogatoriCressiSub_en.pdf




service records

Download TabMaintenance / Service Record

http://cressi.com/easyUp/file/service/ServiceRecordErogatoriCressiSub_en.pdf

regulators repair and maintenance

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