Apeks XTX 2nd Stage Regulator

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©2006 Aqua Lung International, Inc Apeks XTX Service Program Copyright Notice This program is copyrighted, all rights reserved. It may not in whole or in part, be copied, photocopied, reproduced translated, or reduced to any electronic medium or machine readable form without prior consent in writing from Aqua Lung International. It may not be distributed through the internet or computer bulletin board systems without prior consent in writing from Aqua Lung International ©2006 Aqua Lung International, Inc Apeks XTX Service Program

Features Pneumatically Balanced Valve Design Ratcheting, indexable venturi control and user adjustment knob (200,100 & 50) Diver Changeable Exhaust (DCE) Allows diver to change between a large tee for bubble dispersion and a small tee for compactness Left/Right Hose Reversibility Can be configured for left or right hand use Suitable For Coldwater Use Can be used in water temps below <50F (Except XTX20)

Begin Disassembly Click here for left-handed conversion

Remove Hose Use two 11/16” wrenches

Remove Hose O-rings Use O-ring removal tool (p/n 944022)

Inspect Hose Crimps

Remove Case Cover XTX Cover Tool (p/n AT20)

Remove Washer & Diaphragm

Remove Purge Button (optional) Press in tabs Remove spring & purge button

Turn Adjustment Knob Out Prevents pin from falling out

Remove Heat Exchanger 11/16” wrench

Remove Valve Spindle Hold lever down Slide out valve spindle assembly

Remove Blanking Piece & O-rings

Remove Venturi & O-ring

Separate Ring From Venturi (optional) Only necessary if changing hose direction

Remove Pin & Adjustment Knob Turn in adjustment knob Pin should fall out Remove adjustment knob

Remove Adjustment Knob O-ring Pinch method: Push on opposite sides to create a protrusion

Remove Plug & Spring Adjuster 5mm hex key

Remove O-rings

Remove Valve Spindle O-ring

Remove Shuttle Valve Assembly Push out with 1/16” dowel

Separate Shuttle Valve Assembly

Remove LP Seat & Balance O-ring

Inspect Counter Balance Chamber Inside sealing area

Remove Crown Use a medium bladed screwdriver Carefully push out crown Loosen crown 6-7 turns to disengage threads Carefully push out crown Use seat extraction tool (p/n 109437)

Remove Crown O-ring

Critically Inspect Crown Sealing area O-ring groove

Remove Lever (optional)

Inspect Lever

Straighten Legs If Necessary

Remove Spindle Collar

Remove Exhaust Tee Push on button to disengage exhaust tee Slide left and right exhaust tee away from case

Remove Exhaust Rib (optional) Remove if damaged Only on large exhaust tee Lift up on rib to remove

Inspect Exhaust Valve Normally not replaced Remove if damaged

Remove Mouthpiece Side cutters Inspect mouthpiece for holes or tears Snip tie wrap buckle Inspect mouthpiece for holes or tears

Cleaning & Lubrication Procedures Click here to skip past Cleaning & Lubrication Procedures and go straight to Reassembly

Cleaning & Lubrication Brass and Stainless Steel Parts Pre-clean in warm soapy water; nylon bristle brush Ultrasonically clean with soapy water; vinegar OK on tough corrosion Rinse in fresh water; use distilled water if tap water is “hard” Blow dry with LP hydrocarbon free gas (for EAN use)

Cleaning & Lubrication Aluminum, Plastic & Rubber Parts Soak in warm, soapy water Use soft nylon bristle brush to remove deposits Rinse with fresh water Blow dry with LP hydrocarbon free gas (for EAN use) ! CAUTION: DO NOT soak plastic parts in acidic solutions

Cleaning & Lubrication Hoses Soak hose ends only Do not allow solution to enter hose Rinse with fresh water Dry with hose ends hanging down Blow out hose before installing

Cleaning & Lubrication Christo-lube MCG 111 Light film only Rinse with fresh water Remove visible excess If regulator will be used with EAN, you should wear powderless, latex gloves (or equivalent) when lubricating and handling o-rings

Begin Reassembly

Install Exhaust Valve (if removed) Make sure barb pulls completely thru hole Trim exhaust barb Leave 5mm

Install Exhaust Rib (if removed) Place into left side of large exhaust tee

Install Exhaust Tee Slide left tee into groove Slide right tee on until button engages

Install Valve Spindle O-ring

Install Spindle Collar Square hole on spindle collar faces threaded end of valve spindle Use reversible circlip pliers Square hole Spread collar & place onto valve spindle

Rotate Spindle Collar With lever to the right & upward Rotate spindle collar for right hand use Opening on valve body should be clear

Install Shuttle Valve O-ring & MP Seat

Assemble Shuttle Valve Push spring onto counter balance chamber Insert shuttle valve into CB chamber

Install Shuttle Valve Assy Lever points upward Shuttle valve feet face down from lever

Install Adjustment Knob O-ring

Install Adjustment Screw O-rings

Install Adjustment Screw 5mm hex key Screw in until head of adj. screw is flush with end of knob Turn in 6-additional revolutions

Install Adjustment Knob Lever should have tension Screw in until pin hole is clear Pin hole

Install Pin Pin should stick out evenly on both sides Back out knob to hold pin in place

Install Ring On Venturi Slide ring onto venturi lever Align arrow on ring to “RIGHT” mark on venturi

Install Ring On Venturi Pull ring firmly to install Ring will audibly click into place Install new O-ring

Install Venturi On Right Side Look for “RIGHT” marking inside case

Install O-ring & Blanking Piece

Install Valve Spindle Hold lever down Slide in valve spindle assembly Do not allow lever to spring back up quickly

Install O-ring & Heat Exchanger

Torque Heat Exchanger Use a torque wrench & 11/16” crow foot Torque the heat exchanger to 45 in/lbs Make sure lever is straight

Air Hole Should Face Up

Install Crown Install new O-ring Use blunt end of seat tool Press crown into valve spindle until it stops

Adjust Crown Use a medium bladed screwdriver Turn crown in until lever drops ¼ inch Back crown out until lever is even with the case rim

Replace Purge Button Set spring onto purge button Turn purge button over and push into case cover

Install Diaphragm & Washer

Install Case Cover Use AT20 tool Tighten cover until it stops Confirm the purge button is properly aligned

Install Hose O-rings

Final Testing Attach Inline tool (p/n:100190) onto second stage Use a properly adjusted first stage or test bench, slowly pressurize to 3000 psi

Final Testing Use AT20 tool Push “NO GAS FLOW” side of tool into purge button until it stops There should be no audible flow of air If there is airflow, use inline tool and turn crown clockwise 1/16 turn Repeat first step

Final Testing Use AT20 tool Push “GAS FLOW” side of tool into purge button until it stops There should be an audible flow of air If there is no airflow, use inline tool and turn crown counter- clockwise 1/16 turn Repeat first step

Final Testing Install hose Use a torque wrench & 11/16” crow foot Torque the hose to 45 in/lbs

Final Testing Opening effort specifications Use a magnehelic, the opening effort should be between 1.0-1.5 inches of water To adjust opening effort, use a 5mm hex key & turn the adj. screw Clockwise will increase the effort Counter-clockwise will decrease the effort

Final Testing Install cap

Final Testing Check for leaks Immerse second stage underwater Look for streaming bubbles; don’t mistake trapped air for leaks Note leak source; refer to troubleshooting table in service manual

Install Mouthpiece

This Concludes The XTX Repair Course

Begin Left-Hand Conversion Click here to return to repair course

Remove Hose & Case Cover Use two 11/16” wrenches XTX Cover Tool (P/N AT20)

Remove Washer & Diaphragm

Turn Adjustment Knob Out Prevents pin from falling out

Remove Heat Exchanger 11/16” wrench

Remove Valve Spindle Hold lever down Slide out valve spindle assembly

Remove Blanking Piece & Venturi There are two O-rings with the blanking piece Remove O-ring from venturi

Disengage Ring From Venturi Push down on ring to disengage from venturi body

Rotate Ring 180 Degrees Align arrow on ring to “LEFT” mark on venturi Pull ring into position Ring will audibly click into place

Install Venturi O-ring

Install Venturi On Left Side Look for “LEFT” marking inside case

Install Blanking Piece

Rotate Spindle Collar Turn spindle collar 180 degrees Make sure air hole is completely exposed Confirm spindle collar is correctly positioned

Install Valve Spindle Hold the lever down Install O-ring Insert valve spindle into left side of case Do not allow the lever to spring back up quickly Install O-ring

Torque Heat Exchanger Install Heat Exchanger finger tight Use a torque wrench & 11/16” crow foot Torque the heat exchanger to 45 in/lbs Make sure lever is straight

Air Hole Should Face Up

Install Diaphragm & Washer

Install Case Cover & Hose XTX Cover Tool Tighten cover until it stops Confirm purge button is properly alligned Use a torque wrench & 11/16” crow foot Torque the hose to 45 in/lbs

Pressurize & Test Pressurize to 3000 psi Check breathing performance

Check For Leaks Immerse second stage underwater Look for streaming bubbles; don’t mistake trapped air for leaks Note leak source; refer to troubleshooting table in service manual

This Concludes Left-Hand Conversion