FX Maverick dumps air from valve during refill.

I just had this happen on my Maverick. I removed the valve completely and found the top o-ring to be split. I re-installed the valve a couple times and managed to get it to seal and I was able to shoot but all the air ended up leaking out over night. I reached out to FX USA ( [email protected] ) to inquire where I could purchase these o-rings and much to my surprise, they opened a warranty claim and sent me 2 new o-rings ( 2mm x 1mm ) FedEx 2-day. They are tiny and not easy to replace. Getting the old ones off was somewhat time consuming too. I saw someone here mention putting the new rings in warm/hot water to soften them up a bit prior to installation. Of course, I saw that tip after wrestling with mine for several minutes. Long story short, I replaced both o-rings and it's all good again.... Good Luck
 
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There is two things I might believed could happened:
First, when you said you closed first reg, did you actually screw it all the way in until it bottomed, and left it there? If you did, you might have stopped the air entering the plenum, and when you took a shot, there was not enough pressure to hold the valve back. And when the air slowly leaked in, the valve was already open. You must be wery carefull when screwing the reg all the way in, and stop the moment you feel it has reach the bottom, as you might damage it.
It is probably a good advise to open the reg slightly, before pressurising system, to let the reg piston have room to move. No matter what, a reg is never supposed to be closed.

The seccond thing wich might have happened, is that you had to much hammer spring force from your previous tune, and forgot to lower it when you had reduced pressure. If you reduced reg pressure "allot", but did not reduce hammer spring force also, the force may be able to knock the valve pin out of position.
 
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There is two things I might believed could happened:
First, when you said you closed first reg, did you actually screw it all the way in until it bottomed, and left it there? If you did, you might have stopped the air entering the plenum, and when you took a shot, there was not enough pressure to hold the valve back. And when the air slowly leaked in, the valve was already open. You must be wery carefull when screwing the reg all the way in, and stop the moment you feel it has reach the bottom, as you might damage it.
It is probably a good advise to open the reg slightly, before pressurising system, to let the reg piston have room to move. No matter what, a reg is never supposed to be closed.

The seccond thing wich might have happened, is that you had to much hammer spring force from your previous tune, and forgot to lower it when you had reduced pressure. If you reduced reg pressure "allot", but did not reduce hammer spring force also, the force may be able to knock the valve pin out of position.
Yeah I did not close the 1st tight, just enough so it would pressurize. opened it and air started dumping out the valve housing. Then tried the same process with the 1st reg opened and the same thing. The air is actually escaping from the valve housing. So I’m thinking it might be the the top hat seal in the top of the housing.
 
Thinking this is the culprit. 1.5 x 2.5mm o ring. I can put a small screwdriver through the window by the gauge and open the valve. Air will flow out the barrel and when I release the valve to close, the air then dumps out of the front of the valve housing.

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My 25 compact leaked the day I got it. Right out of the valve pin cap. called the dealer and they suggested it may be the valve seat. It would seal once I got the plenum to about 80 bar. So I just shot it as i had the 2nd reg set at 100.
about 2 month later it started leaking again.
Called FX USA. They diagnosed the problem right away. Part # 59 in the above diagram but they sent me a new valve pin too just in case.
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Yep I was right. Part 59 in the diagram. 1.5x2.5 NBR 90. You can see the damage in the pics. Makes ya wonder how it was holding air perfectly before I degassed to decrease my first reg. The tip of the valve rod oscillates through this o ring when hit by the hammer. Should make the valve housing cap a little deeper without the hole. See third pic, circled in red. They have room to do so. Anyway, I happy again. Thanks for all the suggestions. The airgun community and AGN is awesome! Thanks again guys.

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@SimpleGuy Yeah I tried all that. I already replaced it. It was definitely the O ring. The one in the pics is the one that I replaced. All is good so far. Took a picture of the gauge and will check it tomorrow to see if it leaks down any. Thanks for your comment.
You can place a piece of tape on the gauge as well to see if needle moves
 
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