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INTERSPIRO DIVATOR Maintenance And Repair Manual

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336100529C01
DIVATOR
MAINTENANCE AND REPAIR MANUAL

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  • Page 1 336100529C01 DIVATOR MAINTENANCE AND REPAIR MANUAL...
  • Page 2 © 2008 Interspiro AB, Sweden. This publication contains or refers to proprietary information which is protected by copyright. All rights are reserved. Interspiro® and Divator® are registered trademarks belonging to Interspiro. This publication may not be copied, photocopied, reproduced, translated, or converted to any electronic or machine-...

  • Page 3: Table Of Contents

    COnTenTs COnTenTs......................3 1. InTRODuCTIOn....................5 2. GeneRAl.InfORmATIOn................. 7 2.1. sAfeTy.nOTICe.............................. 7 2.2. COmpOunDs.fOR.seRVICe..........................7 2.3. seRVICe.InTeRVAls............................7 3.. OVeRVIeW..................... 9 3.1.. use................................9 3.2.. mAIn.pARTs..............................9 3.3.. sTORAGe................................ 9 4.. pROTeCTIOn,.sAfeTy.AnD.enVIROnmenT........... 11 4.1..
  • Page 4 7.6. AIR.supply..............................64 7.6.1. AIR.CylInDeR.pACKCylInDeR.VAlVe..................64 7.6.2. HAnDle............................66 7.6.3. TensIOn.sTRAps......................... 66 7.6.4. InspeCTIOn.Of.COmpOsITe.CylInDeRs..................67 7.7. TesTInG.In.A.TesT.unIT..........................68 7.8. DIVATOR.bCW............................... 68 7.8.1. InflATOR.Assembly........................68 7.8.2. bCW.-.exHAusT.VAlVe......................... 72...

  • Page 5: Introduction

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 1. InTRODuCTIOn Divator is a self-contained underwater breathing apparatus (SCUBA). The apparatus is designed to suit every category of diver that works under water with air. Environmental factors such as cold, heat, or type of water (chemical compounds, salt or ice) have little or no effect on the operation of the apparatus.
  • Page 6 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl.

  • Page 7: General.information

    Parts that are secured with locking compound must be well cleaned and free from grease before the locking Only holders of a valid Interspiro Service Cer- compound is applied. It is advisable to use an alcohol- tificate for the equipment in question may carry...
  • Page 8 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl.

  • Page 9: Overview

    The BC / Life jacket should be cleaned, dried and 3.2.. mAIn.pARTs stored in a dry place. The Divator MK II diving apparatus consists of the following main parts: full.fACe.mAsK.OR.mOuTH.pIeCe.WITH.bReATHInG.VAlVe All parts made of rubber or parts containing rub- ber components should be stored in a cool, dry and dark place and in a sealed plastic bag.
  • Page 10 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl.

  • Page 11: Protection,.Safety.and.environment

    4..pROTeCTIOn,.sAfeTy.AnD.enVIROnmenT 4.1.. GeneRAl 4.5. CHemICAls Divator MK II diving apparatus may only be used, The presence of chemicals, oils (e.g. diesel) or sol- maintained and repaired by trained and certified vents in the water or in the air may affect the life of personnel.
  • Page 12 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl.

  • Page 13: Data.and.performance

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 5... D ATA.AnD.peRfORmAnCe See User Manual Divator...
  • Page 14 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl.

  • Page 15: Maintenance

    The recommended time between maintenance according to specification. actions and replacement of parts is based on interna- tional standard requirement as well as on Interspiro's The manual is divided into three chapters describ- experience and tests. ing:...

  • Page 16: Annual.maintenance

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. Year 6.4. AnnuAl.mAInTenAnCe The annual maintenance mainly covers: - external cleaning of regulator, cylinder pack, hoses, breathing valves and full face mask. - checks of pressure gauge, hoses, cylinder connection, antifreezing caps and cylinder straps. TOOls. TOOls.pART. pART.nO... nOTes...
  • Page 17 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. spARe.pARTs All service kits and service parts listed below shall be replaced during service. full.fACe.mAsK.-.eVeRy.yeAR.. spARe.pART. pART.nO... nOTes Service kit for 1 apparatus 460 190 900 Service kit for 10 apparatus 460 190 901 bReATHInG.VAlVe.-.eVeRy.yeAR.. spARe.pART. pART.nO... nOTes Service part for 10 apparatus 336 190 226 ReGulATOR.-.eVeRy.yeAR..

  • Page 18: Cleaning

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 6.4.1. CleAnInG ReGulATOR.AnD.AIR.CylInDeR.pACK 2. Wash the breathing valve with a mild hand de- 1. Assemble air cylinder pack, regulator and breath- tergent and warm water (not above 40 °C). Use a ing valve. Open the cylinder valve. If the pressure brush if necessary.

  • Page 19: Checking

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 6.4.2. CHeCKInG 3. For instruction on how to change hoses see chap- ter Repair below. mOVemenT.Of.THe.pRessuRe.GAuGe.pOInTeR. full.fACe.mAsK. The restrictor orifice in the pressure gauge hose Equipment that has been exposed to sunlight, salt may get blocked if moisture gets into the breathing water, chemicals (including mild detergents) and circuit.

  • Page 20: Preventive.maintenance

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. mOIsTuRe.ACCumulATIOn pack the pressure can be checked using the Interspiro pressure check gauge, part number 99804-01 (bar) Even though the fill air contains less than 30 mg or 99804-02 (psi). of water/m3, there is a risk of moisture accumulating in the air cylinder pack.
  • Page 21 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. all round the valve seat 2. Lift spring (#24) and guide disc (#23) (assembled together) out of the cover (#22). bReATHInG.VAlVe For dismantling and assembly of the breathing valve see Spare Parts List. 3. Disassemble the diaphragm assembly (#35).
  • Page 22 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. this is not the case, the shape of the outside of 7. Fit the exhalation diaphragm (#26) to the center the diaphragm will be oval. Then press the outer pin on the diaphragm ring (#28). Press the exha- edge out and in to give an equal gap all round. If...
  • Page 23 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 11. Place the locking ring on the valve housing and The valve insert assembly consists of the following screw the positive pressure attachment on to the main components: valve insert (#16), retaining valve. ring (#7), connection nipple (#4) and O-rings (#5 and 6).
  • Page 24 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. Installing the valve insert 9. Check that the height of the lever fork above the valve housing is 7.0-8.5 mm (see illustration below. 1. Lubricate the O-rings (#5 and #6) very thinly with NOTE! Locking removed.) Lubricant (tool #25), and fit them to the connec- tion nipple (#4).
  • Page 25 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 17. Close the cylinder valve. Assemble the antifreezing cups and cover 18. Let the valve housing dry thoroughly in the air. 5. Mount the antifreeze cover (#22) onto the regula- tor housing. Carefully pull the antifreeze cover up against the flange on the regulator housing. Pull AnTIfReezInG.CAp.

  • Page 26: Cylinder Connection

    User manual for test unit. Test results shall be logged using a Interspiro test Cylinder connection protocol. 1. Place the regulator housing in a fixture (tool #19) secured in a vice, to void damages on the regulator housing.

  • Page 27: Six-Yearly.maintenance

    Long nosed pliers 331 190 033 Tool #31 Wrench, hexagonal key 1/4" Tool #37 Wrench, hexagonal key 3/16" long Tool #38 Socket 15 mm long 336 900 221 Tool #43 DOCumenTs. pART.nO... User manual, Divator Scuba 99 841 Test report...
  • Page 28 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. spARe.pARTs. spARe.pART. pART.nO... full.fACe.mAsK.-.eVeRy.yeAR.. Service kit for 1 apparatus 460 190 900 Service kit for 10 apparatus 460 190 901 bReATHInG.VAlVe.-.eVeRy.yeAR.. Service part for 10 apparatus 336 190 226 bReATHInG.VAlVe.-.eVeRy.6TH.yeARs.. Service kit for 1 apparatus 460 190 902 Service kit for 10 apparatus...

  • Page 29: Cleaning

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 6.5.1. CleAnInG ReGulATOR.AnD.AIR.CylInDeR.pACK 2. Wash the breathing valve with a mild hand de- 1. Assemble air cylinder pack, regulator and breath- tergent and warm water (not above 40 °C). Use a ing valve. Open the cylinder valve. If the pressure brush if necessary.

  • Page 30: Checking

    If no regulator manifold is connected to the cylinder Air cylinder packs of composite expand considerably pack the pressure can be checked using the Interspiro when pressurised. This increases the strain on the pressure check gauge, part number 99804-01 (bar) tension straps.

  • Page 31: Preventive.maintenance

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 6.5.3.pReVenTIVe.mAInTenAnCe For references to parts when dismantling and assembly see Spare Part List DIVATOR. To minimise the risk of malfunctions and increase 6. Remove the cover (#10) by unscrewing the two user safety, it is recommended that parts should be screws.
  • Page 32 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. Dismantling the positive pressure assembly 1. Carefully take the diaphragm assembly (#35) out of the cover (#22) by squeezing the thread of the cover and at the same time grasping the outer flange of the diaphragm assembly so that it comes free and can be caught in a hand.
  • Page 33 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 4. Pull out the lever (#14a) holding a finger over the lever spring (#14b). Remove distance ring (#14c), O-ring (#15) and lever spring (#14b). 10. Check that the front part of locking spring (#14d) is 1 - 3.5 mm above the plane of the valve housing.
  • Page 34 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. VAlVe.InseRT.Assembly 3. Press the units together and fit the retaining ring (#7). Press down the retaining ring (#7) and make See the spare parts list for references. sure that its latching lug goes down and engages Note that there are two different types of valve...
  • Page 35 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 10. Check that the height of the lever fork above 5. Check that no water leaks into the breathing the valve housing is 7.0-8.5 mm (see illustration valve. The level in the valve housing must not below. NOTE! Locking removed.) drop.
  • Page 36 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 2. Open the cover assembly (#23). It is hinged at the 3. Remove the O-ring (#12) from the nipple (#13). top. Remove the cover assembly from the regulator Discard the O-ring. housing. N O T E >> 3. Remove (pull away) and discard the antifreezing...
  • Page 37 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 5. Use a wrench and a 29 mm torque wrench adapter (tool #23) to unscrew the regulator head with the swivel axis. 6. Remove and discard the O-ring (#4) from the 11. Unscrew the adjustment screw (#19) and remove swivel axis (#29).
  • Page 38 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 2. Apply a thin layer of lubricant (tool #25) inside 8. Clean the inside of the cover/axis (#29), the diffu- the regulator housing where the large diameter sor (#28) and the stop ring (#6). Mount the items of the piston (#7) is located and on the part of the back into the cover/axis.
  • Page 39 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. cated (tool #25), O-ring (#30) around the top of the axis. 20. Attach the adjusting screw (#19) and screw it down until the back of the adjusting screw levels with the start of the threads of the housing. 14.Apply a drop of locking compound (tool #27) on the screw (#34).
  • Page 40 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 1. Remove the covers (#18) and the retraining clip 2. Place the manifold in the fixture and loosen the (#25) by loosing the two screws (#22). Use a slot plug (#16) with help of a 15 mm U-spanner (tool screw driver (tool #5).
  • Page 41 Turn the adjustment nipple a extra one quarter turn (90 degrees) inwards. This is a basic the nut (#3) until the handle remains in this posi- adjustment of the warning pressure that needs to tion. be checked with the Interspiro test equipment. See test equipment instruction.
  • Page 42 1. Install the regulator in the Test unit for Diva- tor. For a general description of and operating instructions for the test unit, see User manual Spiromatic-Test unit for Divator. Perform the test according to the test instruc- tions for the test equipment.
  • Page 43 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. (#10), pull out and discard the backup ring (#7) and the O-ring (#8). 3. Use the valve stem (#10) to install the valve slug (#11), tightening the valve slug to the stop. Place valve stem (#10) with glide washer (#9) on the 4.

  • Page 44: Testing.in.a.test.unit

    - Screwdriver socket 5/16" (tool #6) - 3/16" hex key long (tool #38) Dismantling 1. Open up the velcro band holding the Divator infla- tor assembly. 2. Unscrew the inflator connection to the outer blad- der (#9a). Do not drop the seal ring (#1).
  • Page 45 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 2. Apply a thin layer of lubrication on the new O-ring 6. Pull out valve insert (#12) and spring (#11). (#5) and place it on the bump valve (#6). 7. Unscrew screw (#2) from the inflate shaft (#10). Remove the inflate button (#3) and the inflate shaft (#10).
  • Page 46 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 5. Place the dump valve (#6) (with O-ring) on the 3/16" hex key (tool # 38), push it in to the valve housing (#13) and screw it in the dumb button (#16) 11. Mount a new label sticker (#1) on the dump button (#3).
  • Page 47 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. Put the valve on top of the valve seat (#2). 21. Push on the filling hose onto the hose connection. 16. Attach the cap (#5) to secure the dump valve. Attach a a new tie wrap band (#18) around the hose at the hose connection.
  • Page 48 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl.

  • Page 49: Repair

    TOOls After degreasing the parts, wipe them with a clean A test unit and tool kit for the Divator apparatus lint-free cloth. shall be available for maintenance work and function Do not use degreasants on plastics or rubber parts.

  • Page 50: Full.face.mask

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 7.2. full.fACe.mAsK 5 Fit the two stainless screws (#14) and tighten them alternately. The frame halves (#13) has a stud that protect the visor from being crushed by the frame halves. 7.2.1. ReplACInG.THe.VIsOR.AnD.fRAme Test See the spare parts list for references.

  • Page 51: Replacing.the.pressure.equalizing.pad

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 2. Unscrew the single screw (#4) securing the re- 2. Position the inner mask (#1) with the retaining training plate (#6). Use a slotted screw driver plate (#6) in the full face mask. Fit the screw (#4) (tool #5).

  • Page 52: Replacing.the.valve.seat.and.the.valve.disc

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 7.3. bReATHInG.VAlVes.. 7.2.5. ReplACInG.THe.VAlVe.seAT.AnD.THe.VAlVe.DIsC Tools The Divator breathing valves are of two types - with and without safety pressure. When performing - No tools requiered repair work on the breathing valves make sure not See the spare parts list for references.

  • Page 53: Valve.housing

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. Dismantling the positive pressure assembly 1. Carefully take the diaphragm assembly (#35) out of the cover (#22) by squeezing the thread of the cover and at the same time grasping the outer flange of the diaphragm assembly so that it comes free and can be caught in a hand.

  • Page 54: Valve.insert.assembly

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 4. Pull out the lever (#14a) holding a finger over the lever spring (#14b). Remove the distance ring (#14c), O-ring (#15) and lever spring (#14b). 11. Turn the lever (#14a) out from the valve housing and check that the locking spring lies flat against the valve housing and the tip is 0 - 0.8 mm from...
  • Page 55 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. N OT E 8. After adjustment, check that the lever pin has re- >>> turned to the deep groove in the lever support. If moisture has got into the inhalation side of the valve insert, the entire valve insert must be thoroughly dried, 9.

  • Page 56: Regulator

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 7.4. ReGulATOR 3. Open the cylinder valve and pressurize the valve. Faulty regulators shall be replaced with a factory 4. Fill the free space in the non-return valve disc repaired regulator at certified workshop. with water. 5. Check that no water leaks into the breathing Regulator housing valve.
  • Page 57 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 6. Remove and discard the O-ring (#4) from the DIsmAnTlInG.Of.pRessuRe.ReGulATOR. swivel axis (#29). Dismantling the 4-port swivel Tools Awl 336 900 065 (tool #1) Assembly tool (tool #2) Piston extractor (tool #10) 13 mm U-spanner (tool #12) Regulator fixture (tool #19) 7.
  • Page 58 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 12. Push, with help of the assembly tool (#tool 2), from 5. Slide the narrow end of the punch tool (tool #2) the piston side out the two support rings (#14) and into the piston shaft. the O-ring (#15).
  • Page 59 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 11. Fit a new O-ring (#30) on the lower end of the axis 16. Apply a fine layer of lubricant (tool #25) on the of the regulator cover (#29). O-ring (#15), slide it onto the punch tool (tool #23) together with the other support ring (#14) - the O-ring first.
  • Page 60 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 21. Mount the sealing plate (#20) 3. Remove and discard the locking pin (# 2) using a long nosed pliers (tool # 31) and unscrew the nut (#3) by hand. WARnInG.DeVICe 4. Remove and discard the handle (#4) and the tor- Tools sion spring (#5).
  • Page 61 Turn the adjustment nipple a extra one quarter turn (90 degrees) inwards. This is a basic adjustment of the warning pressure that needs to be checked with the Interspiro test equipment. See test equipment instruction. 2. Assemble guide bushing (#12), spring (#13) and piston (#14) and place them in to the primary pressure side with the guide bushing (#12) first.

  • Page 62: Extra.air.outlet

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. that the torsion spring end is still in the groove Dismantling the extra air connection of the handle. 1. Place the manifold in the manifold fixture (tool 9. If correctly assembled the handle should spring #29). back approx. 1/4 turn when turned against the 2.

  • Page 63: Hoses

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 7.5. HOses 3. Apply a small drop of locking compound (tool #27) on the threads of the quick coupling (#28). Normally hoses in a diving apparatus should last for many years, but in view of the severe wear and tear that hoses in diving apparatus can be subjected to it’s recommended to closely inspect...

  • Page 64: Air.supply

    DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 7.6. AIR.supply 7.6.1. AIR.CylInDeR.pACK. CylInDeR.VAlVe Cylinder valves are normally serviced in conjunc- tion with hydrostatic test of the cylinders. Always empty the air supply before starting work. N OT E >>> Tools: A damaged suit hose can allow just as much air to...
  • Page 65 (#10). that it does not exceed 30 bar/435 psi per minute. It is recommended to use the Interspiro Filling Adapter. See Product Bulletin - 99370A01 6. Fit the blanking plug (#17) by hand.

  • Page 66: Handle

    The assembly fixture and gauge are not included in the tool kit for Divator. If maintenance is required, contact the manufacturer. 2. Open the cover assembly (#23). It is hinged at the top.

  • Page 67: Inspection.of.composite.cylinders

    7.6.4. InspeCTIOn.Of.COmpOsITe.CylInDeRs the regulator. Blow the regulator housing dry. Interspiro composite cylinders are designed for long 5. Place the regulator house in the regulator fixture service life for intended use.

  • Page 68: Testing.in.a.test.unit

    (tool #37) - 3/16" hex key long (tool #38) Dismantling 1. Open up the walcro band holding the Divator Inflator assembly. 2. Unscrew the inflator connection to the outer blad- der (#9a). Do not drop the seal ring (#1). 3. Cut the tie wrap band (#18) securing the inflator...
  • Page 69 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 4. Pull of the filling hose form the inflator house and 10. Check the mouth piece (#17), replace if neces- push out the locking pin (#4) to release the wire sary. to the exhaust valve seat (#2). Use an awl (tool #1).
  • Page 70 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 5. Place the dump valve (#6) (with O-ring) on the 10. Put the valve insert assembly (#12) in the valve 3/16" hex key (tool # 38), push it in to the valve housing (#13). Tighten the valve assembly using housing (#13) and screw it in the dumb button a 1/4"...
  • Page 71 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 15. Inspect the one-way valve, it shall be free from 20. Push the pin (#4) half way through the hose con- damages. The valve membrane shall be smooth nection on the inflator house. Pull out and hook and lay flat on the seat. Replace it if necessary.

  • Page 72: Bcw.-.Exhaust.valve

    6. Take out the one-way-valve (#4) and discard the O-ring (#3). Pull out the valve set (#2). Dismantling Assembling 1. Open up the walcro band holding the Divator inflator assembly. 1. Push a new valve set (valve with spring) through the filling hose.
  • Page 73 DIVATOR.mAInTenAnCe.AnD.RepAIR.mAnuAl. 10. Fasten the inflator hose to the shoulder straps 5. Check that the exhaust valve gasket (#1) and the with the welcro band. bladder connection is clean and soft. 6. Place the exhaust gasket (#1) into the seat. 11. Connect the air supply from the regulator. Pres- surize the regulator and fill the BCW.
  • Page 76 E-MAIL SCANDINAVIA, ASIA/PACIFIC & MIDDLE EAST SWITZERLAND SWEDEN INTERSPIRO AG www.interspiro.de NORDIC & EXPORT SALES DIVISION www.interspiro.com Güterstraße 47 CH-4133 PRATTELN SWITZERLAND Box 10060 S-181 10 LIDINGÖ SWEDEN +41 61 827 99 77 +41 61 827 99 70 info@interspiro.ch...