SERVICE AND REPAIR MANUAL DIVATOR DP1
Contents
1. Start by loosing and unscrew the screw and nut in the bracket holding the valve block on the inside of the case lid Use a U spanner 10 mm and a5 mm hexagon wrench With help ofa 3 mm hexagonal wrench unscrew the second screw for the valve block from the outside of the case lid 32 SERVICE AND REPAIR MANUAL DIVATOR DP1 8 Remove the valve block and attach it to the mani fold fixture 9 Remove the valve block from the surface unit case Start by loosening and unscrewing the screw and nut in the bracket holding the valve block on the inside of the case lid Use a U spanner 10 mm and a 5 mm hexagon wrench With help ofa 3 mm hexagonal wrench unscrew second screw for the valve block from the outside of the case lid 10 Remove the valve block and attach it to mani fold fixture 11 Use a U spanner 12 mm to remove the pressure gauge and a U spanner 15 mm as a counter hold Remove and discard copper gasket 12 Unscrew and remove the adapter from the valve block using a 15 mm U spanner 13 Clean with the barrel brush the threads on the Pressure gauge the adapter and the valve block SERVICE AND REPAIR MANUAL DIVATOR 1 Fitting the pressure gauge 7 Push in the screw form the outside of the lid and 1 Apply two drops of locking compound to the male M the SpACET threads of the valve block Apply a drop of locking compound at the end of the Fit the adapter to the male thread of the valv2. B 2 Install the anti freezing cover A and clamp C with a screwdriver so that the plastic halves do not pinch the anti freezing cap B or crush the anti freezing cap at any point The clip must be tightened moderately Check this by manu ally turning the anti freezing cover A The anti freezing cap B must not rotate with the anti freezing cover A gt Replacing the protective band 1 Remove the protective band J from the relief valve and fit a new one Fitting a hose connection N gt 9 J 1 Lubricate the O ring A with a thin coating of lubricant and position it in the groove on the hose nipple 2 Fit the hose to the P regulator Tighten to 15 Nm with a 13 mm torque wrench 3 Push the hose bend restrictor back over the hose end SERVICE AND REPAIR MANUAL DIVATOR DP1 3 5 6 TESTING gt gt Testing in a test unit The DIVATOR DP1 must be tested with Interspiro test equipment at every annual or six year inspection and after repair at a service workshop For a general description of and operating instruc tions for the test unit see the user manual for the test equipment Tests must be done in accordance with test protocol for DIVATOR DP1 gt Logging of test results and comments Test results must be logged according to the instruc tion for the specific test equipment 4 REPAIR GENERAL INSTRUCTIONS Preventive service for users is described in the
3. l A Check that the threaded connections A not are damaged gt Replace the O rings 1 Unscrew and remove nipples in both ends with help of a 5 mm hexagon wrench Remove and discard the O rings B from the nipples and clean the threads from locking com pound residue from Apply a thin later of silicone lubrication on two new O rings and attach them in the groove on each nipple ends Apply two drops of locking compound on the threads of the nipple Fit the nipples into the connection nipples Tighten the nipples gently by hand torque 1 Nm 18 SERVICE AND REPAIR MANUAL DIVATOR DP1 SERVICE AND REPAIR MANUAL DIVATOR 1 3 5 2 WHISTLE INSERT N 1 NG J Removing the whistle insert 3 Hold the whistle cylinder I with a 20 mm U spanner and loosen the locking nut B with the 1 th taini i z ning W sleeve tool for the whistle 2 Remove the locking clip R with the circlip pliers r 4 Remove the remains of sealing label 1 5 Unscrew whistle cylinder I with a 20 mm U spanner gt Dismount the whistle insert 1 Remove the two O rings with back up rings O from the whistle insert cylinder 2 Place the whistle unit in the plug in whistle fix ture and secure the fixture in the vice 19 Use protective pin to press out nozzle and regula
4. Check that the valve block has no mechanical damage bPressure gauge Check that the pressure gauge is free from scratches and other mechanical damage gt gt Whistle insert Check the whistle insert Check that the retaining ring and locking clip F are in place gt gt Shuttle insert Check the shuttle insert G for deposits and me chanical damage Check that the shuttle insert can swivel Check that the retaining ring and locking clip are in place gt Valve block connection manifold Check the valve block H for deposits and mechani cal damage Check that the venting part of the valve block can swivel 10 SERVICE AND REPAIR MANUAL DIVATOR DP1 2 5 ANNUAL SERVICE ts Content Connection nippels exchange Filter amp O rings T pice change O rings 2 5 1 CONNECTIONS gt Valve block connection manifold gt Connection manifold and Valve block gt and O rings 1 Unscrew and remove nipple with help of a 5 mm hexagon wrench Remove and discard filter A fall out of the con nection nipple Carefully knock the connection nipple against a soft surface to let that any possible loose particles fall out Remove and discard the O ring B from the nip ple Apply a thin layer of silicone lubrication on the a new O ring B and position is in the grove of the nipple Drop a new filter A down
5. a clean lint free cloth Do not use degreasants on plastics or rubber parts 4 1 REPAIR 4 1 1 REPLACING THE HAND WHEEL AND OR THE CON NECTION NIPPLE NG J gt Tools Socket 19 mm 460 190 567 Barrel brush 460 200 030 U spanner 10 13 mm 460 190 774 U spanner 24mm 99 519 51 Hexagonal key 5mm 460 200 008 Hexagonal key 3mm 460 200 008 Torque wrench adapter 13 15 mm 460 190 852 Torque wrench assy 5 50 Nm 336 190 478 O ring tool kit 30 042 51 Silicone lubricant 331 900 269 Locking compound 460 190 846 Manifold fixture 95 927 01 gt Dismounting the valve block 1 Pull back the hose bend protector on the left side of the valve block 2 Loosen and unscrew the left hose with 13 mm and 24 mm U spanners 3 Remove and discard the O ring at the end of the hose 4 Remove by hand the retaining rings on the shut tle valve as well as on whistle Remove with help of a circlip pliers also the locking clips from the shuttle insert and the whistle a N 30 SERVICE AND REPAIR MANUAL DIVATOR DP1 Disconnect the whistle and the shuttle valve from the valve block Remove the valve block from the surface unit case Start by loosing and unscrew the screw and nut in the bracket holding the valve block on the inside of the case lid Use U spanner 10 mm 5 mm hexagon wrench With help ofa 3 mm hexagonal wrench unscrew the second screw for
6. user manual for DIVATOR DP1 The instructions below describe the repair replace ment of Hand wheel Connection nipple Pressure gauge Relieving loop Hose bend restrictor TOOL INFORMATION To make service easier DIVATOR DP1 is largely assembled with threaded joints allowing the replace ment of individual parts instead of major components In certain cases threaded components must be tight ened to a given torque partly to achieve the desired strength and partly to avoid overloading the threads The instructions state when a torque wrench must be used and specify the correct torque for each part 29 SERVICE AND REPAIR MANUAL DIVATOR DP1 LUBRICANTS LOCKING COMPOUND AND DEGREASANTS The instructions below specify lubricants and locking compound with part numbers see under Tools in this manual Locking compound must not come into contact with plastics or rubber parts In other respects follow the instructions for use and the safety regulations given by the manufacturer on the pack It is very important that surfaces which are to be treated with locking compound are completely free from grease and that every trace of old locking com pound has been removed Remove locking compound with a steel wire brush Avoid touching the threads Greasy and dirty parts must be degreased before locking compound is applied It is advisable to use alcohol based oil free degreasants After degreasing the parts wipe them with
7. 5 Nm 20 Attach a new sealing label J with the warning pressure and date to the locking clip whistle cylinder 21 Push the whistle into the valve block 22 Turn the whistle so that its opening points down wards 23 F it a new locking clip and a new retaining ring Q gt gt NOTE Check that the grips of the locking clip fit into the recesses in the retaining ring 21 SERVICE AND REPAIR MANUAL DIVATOR DP1 3 5 3 SHUTTLE INSERT SERVICE AND REPAIR MANUAL DIVATOR DP1 va Ne Old versions of shuttle insert Earlier versions of the Divator DP1 has the old type of shuttle kit as illustrated below This shuttle kit was replaced in April 2006 gt Disassemble shuttle insert 1 Pull back the hose bend protection Loosen and unscrew the two hoses with 13 mm and 24 mm U spanners Remove and discard the O ring F on both hos es Remove the retaining ring A by hand Remove the locking clip B with help of a circlip pliers from the shuttle insert Discard the retaining ring and the locking clips 22 5 Pull out the shuttle insert E Push out and discard the shuttle C3 and the seat C1 using the punch tool for shuttle valve Remove and discard the inner O ring C2 with O ring tool 2 Turn shuttle insert and push out and discard the other seat C2 using the punch too
8. B The clip must be tightened moderately Check this by manually turning the anti freezing cover A The anti freezing cap B must not rotate with the anti freezing cover 2 5 3 TESTING gt Testing in test unit The DIVATOR DP1 must be tested with Interspiro test equipment at every annual or six year inspection and after repair at a service workshop For a general description of and operating instruc tions for the test unit see the user manual for the test equipment Tests must be done in accordance with test protocol for DIVATOR DP1 gt Logging of test results and comments Test results must be logged according to the instruc tion for the specific test equipment 12 SERVIGE AND REPAIR MANUAL DIVATOR DP1 3 SIX YEAR SERVICE This chapter describes everything that needs to be done during six year service provided that the equipment is not dam aged For damaged equipment repair work can be done according to chapter Repair 6 Years This chapter is divided into the following parts which should be carried out in chronological order gt Cleaning Every form of service must be preceded by cleaning gt Checking Certain parts need to be checked gt Service Certain parts need to be replaced to ensure high degree of safety Testing Service and repair work on the equipment shall be completed by a full functional test 13 3 1 SERVIGE AND REPAIR MANUAL DIVATOR DP1 TOOLS AND CON
9. F then the spring H 20 SERVICE AND REPAIR MANUAL DIVATOR DP1 10 Insert the regulating piston into the whistle cylinder I 11 Lubricate a new O ring D with a thin coating of silicone lubricant and fit it on nozzle 12 Insert the nozzle in to the whistle cylinder 13 Screw the whistle A down into the whistle cylinder I so that the locking nut covers the threads of the whistle when it has been tight ened 14 Lubricate two new O rings and back up rings O with a thin coating of silicone lubricant gt gt Itis important to install the O rings and back up rings M correctly The order must be from the groove nearest the whistle A back up ring gt O ring gt and in the next groove O ring gt back up ring The O rings are on the inside the pressure side and the back up rings are on the outside 15 Thread the whistle assembly tool on to the whistle insert cylinder P then a back up ring O on to the tool 16 Press by hand the back up ring part of O over the assembly tool and down into the inner groove of the whistle insert cylinder p 17 In the same way but in the reverse order fit the other O ring and back up ring 0 to the outer groove of the whistle insert cylinder 18 Test and adjust whistle as described in the Interspiro test instructions 19 Lock the whistle with the locking nut B and sleeve tool with a torque of 1
10. INTERSPIRO MODULE 22 SERVIGE AND REPAIR MANUAL DIVATOR DP1 Surface Supply 2011 Interspiro AB Sweden This publication contains refers to information protected by copyright legislation All rights reserved Interspiro and Spiromatic are registered trademarks that are the property of Interspiro This publication must not be copied photocopied reproduced translated or converted into any electronic or machine readable form in parts or in its entirety without the written consent of Interspiro 1 1 1 2 2 1 2 2 2 3 2 4 2 5 3 1 3 2 3 3 3 4 3 5 41 CONTENTS INTRODUCTION sudanske 5 GENERAL SERVICE STEPS ingen eel 5 THESURFAGE PA sert Oe ame 5 ANNUAL SERVIGE a 6 TOOLS 8 CONSUMABLES ae kadre 6 SERVICEKITS at ee Eee an 7 GE ANIM Ges tS SG EE OT ste redd ad pen JE 8 CHECKING reneste dalit nl 8 ITEM EE EN 10 SIX YEAR SERVIG Ess 13 SE SLR EN 13 SALE Seat P 14 ta ete cee a at tene 15 HEN S 15 YEAR SERVICE cea rt net a ec cre 17 REPAIR uaa Ne tie 29 30 STORAGE EE ER 37 1 INTRODUCTION Thisserviceandrepairmanualdescribestherecommended serviceas well asrepair ofthe Divator DP1SurfaceSupply Unit The recommended time between services including replacement of service parts is based o
11. PART NO NOTES Anti freezing cap 6 pack 460 190 507 6 x 336 100 425 DP1 T STYGKE PART NO NOTES O ring for T pice 10 pack 336 190 272 10 x 331 100 767 2 3 CLEANING 1 Assemble hose surface unit and air supply both connections must be connected Open the cylinder valves Before cleaning check the pressure gauge reading If the pressure gauge shows that the air cylinder pack contains less than 65 bar 6 5 MPa or 945 psi the air cylinder pack must be replaced or filled before you continue If the system has not already been pressurized do so now 2 Place the unit on a washing surface Use low pH hand detergent soap a washing brush and a sponge Rinse off with a hose or pressure jet do not apply a pressure jet to the warning unit or the P regulator 3 Position the equipment so that the water drains off and does not collect in the box 2 4 CHECKING If a part fails on checking replace it as described in chapter Repair and correct the fault Then resume the inspection where it was stopped 2 4 1 INSPECTION OF HOSE LIFELINE gt Hose If the hose shows any visible signs of damage bending or creases it should be sent to Interspiro for repair which is ordered using item number 30617 01 During repair the damaged area plus an extra meter is cut off from the hose a new end nipple is fitted and the hose is pressure tested If the damage is a long way from any of the ends of the hose the hose will be dealt with accordi
12. SUMABLES gt Tools Assembly tool for whistle Assembly tool for shuttle valve Awl Circlip pliers Fixture whistle Fixture regulator U spanner 10 13 mm U spanner 18 19 mm U spanner 20 mm U spanner 24 mm Screwdriver 1 x 5 5 Piston extractor Protective pin Punch tool Punch tool for Shuttle valve Socket whistle Barrel brush Torque wrench assy 5 50 Nm Torque wrench adapter 13 15 mm Torque wrench adapter 21 26 mm Vice Ball hammer Lint free cloths Washing brush Sponge 95 926 01 95 925 01 460 190 768 460 200 519 460 190 848 460 190 855 460 190 774 460 190 755 460 200 010 99 519 51 460 190 767 99 211 01 460 190 565 460 190 566 31 272 51 460 190 849 460 200 030 336 190 478 460 190 852 460 190 773 Breathing valve tested and approved gt Consumables Curacid PSA Rinse 1 L or hand detergent low pH Locking compound Silicone lubricant Cotton buds 336 921 330 460 190 846 331 900 269 SERVICE AND REPAIR MANUAL DIVATOR 3 2 SERVICE KITS SURFACE SUPPLY UNIT PART NO NOTES Service kit for 1 unit 460 190 702 DP1 REGULATOR P PART NO NOTES Service kit for 1 unit 460 190 703 14 3 3 CLEANING 1 Assemble hose surface unit and air supply both connections must be connected Open the cylinder valves Before cleaning check the pres sure gauge reading If the pressure gauge shows that the air cylinder pack contains less than 65 bar 6 5 MPa or 945 psi the
13. air cylinder pack must be changed or filled before you continue If the system has not already been pressurised do so now 2 Place the unit on a washing surface Use low pH hand detergent soap a washing brush and a sponge Rinse off with a hose or pressure jet do not apply a pressure jet to the warning unit or the P regulator 3 Position the equipment so that the water drains off and does not collect in the box 3 4 CHECKING m If a part fails on checking replace it as described in chapter Repair and correct the fault Then resume the inspection where it was stopped 3 4 1 INSPECTION OF CONNECTION HOSE AND LIFELINE gt Hose If the hose shows any visible signs of damage bending or creases it should be sent to Interspiro for repair which is ordered using item number 30617 01 During repair the damaged area plus an extra meter is cut off from the hose a new end nipple is fitted and the hose is pressure tested If the damage is a long way from any of the ends of the hose the hose will be dealt with according to an agreement between Interspiro and the user Check that there are no deposits If there are remove them and resume inspection under them Check that there are no discolorations caused by chemical attack for instance Chemical attack may weaken the hose If the hose is used in environments where it may be subject to chemical attack keep a detailed log gt gt NOTE Even if the equipment was cleaned a
14. e block screw and fit it in the valve block Tighten the screw so that there is a gap about 2 mm wide between firmly by hand using a 3 mm hexagonal wrench the valve block and the adapter 2 Apply two drops of locking compound to the male 3 P sh the whistleinto thevalye block threads of the pressure gauge 9 Turn the whistle so that its opening points down 3 Hold the pressure gauge with the connection wards upwards and place a gasket in the recess in the pressure gauge 10 Fit a new locking clip and the retaining ring 4 Fit the valve block to the inverted pressure gauge 5 Adjust the position of the adapter to give at least NOTE one half to one full turn to tighten the pressure Check that the grips of the locking clip fit into the gauge recesses n the retaining ring Tighten the pressure gauge to correct position us ing a 13 mm and 15 mm open end wrench 11 Push shuttle valve into the valve block 6 Refit the valve block to the bracket in the surface unit case and secure it with the screw Note the position of the two white gliding cases 12 Screw the second hose into the shuttle insert in valve block 13 Tighten the hose to 15 Nm with a 13 mm torque wrench and put counter force with a 24 mm U spanner Apply a drop of locking compound to the end of the screw and attach the nut and tighten it firmly using a 10 mm U spanner and a 5 mm hexagonal wrench 14 Pus
15. ert can swivel Check that the retaining ring and locking clip are in place gt Valve block connection manifold Check the valve block H for deposits and mechani cal damage Check that the venting part of the valve block can swivel 17 SERVICE AND REPAIR MANUAL DIVATOR DP1 3 5 SIX YEAR SERVICE Content v v y yy yy y Connection nippels exchange Filter amp O rings T pice change O rings Whistel insert exchange of service components Shuttle insert exchange of service components Vent insert exchange of service components P regulator exchange of service components 3 5 1 CONNECTION NIPPLES oe N 2 gt Connection manifold and Valve block gt and O rings 1 Unscrew and remove nipple with help of 5 mm hexagon wrench Remove and discard filter A fall out of the con nection nipple Carefully knock the connection nipple against a soft surface to let that any possible loose particles fall out Remove and discard the O ring B from the nipple Apply a thin layer of silicone lubrication on the a new O ring B and position is in the grove of the nipple Drop a new filter A down into the connection nipple The filter shall be centred so that the point of the nipple fits into the hole in the filter Screw in and tighten the nipple by hand to stop using a 5 mm hexagonal wrench gt B
16. gulator housing 11 Clean regulator housing with lint free cloths and cotton buds gt Fitting the P regulator 1 Apply a thin layer of silicone lubrication on all O rings before assembly 2 Fit anew O ring O to the regulator cover P 3 Install diffusor N and stop ring M 4 Lubricate the piston shaft with silicone lubricant and fit O ring L onto the piston 5 Lubricate the control spring set or control spring K with silicone lubricant and fit it them to the shaft of the piston 6 Lubricate the piston location in the regulator hous ing 7 Hold the regulator with the anti freezing cap side up and place protective pin on piston L Push the Protective pin and the piston up into the regulator housing 8 Turn over the regulator and place it in the regula tor fixture with the piston facing up 9 Fit cover P and tighten to a torque of 15 Nm with a 21 mm torque wrench 10 Place protective pin in piston L place on of the back up washers I on protective pin and press it down well with help of the punch tool 11 Place O ring I and the other back up washer on the protective pin and press them firmly down once more with help of the punch tool Remove the Protective pin and the punch tool 21 SERVICE AND REPAIR MANUAL DIVATOR 1 12 F it spring over the piston shaft 13 Fit O ring G to valve seat 14 Lubricate the entire valve seat including the sealing s
17. h the hose bend protection back over the hose ends 33 4 1 3 THE RELIEVING LOOP gt Replacement of the relieving loop gt gt Tools Mounting tool 88 233 51 U spanner 10 13 mm 460 190 774 U spanner 24 mm 99 519 51 Torque wrench adapter 13 15 mm 460 190 852 Torque wrench assy 5 50 Nm 336 190 478 gt Spare part Relieving Loop Kit 96 726 51 gt Mounting the relieving loop Unpack the two relieving loops and straighten them out Relieving loop shall be mounted on the umbili cal following the instruction below css RISSET ss conical end with an opening 1 Guide the high pressure hose through the opening in the conical end of the braided film Open the braided film approx 7 cm from the end and lead out the hose Continue to stitch the hose through the braided film with approx 7 cm space until two inserts has been done Open the braided film 7 cm from the last insert and guide the hose into the braided film 7 1 7 1 7 1 T 1cm 2 Guide high pressure hose same way as above through the front part of the relieving loop Start with the first insert approx 34 cm from the loop A Open the braided film approx 7 cm from the end and lead out the hose Continue to stitch the hose through the braided film with approx 7 cm space until two inserts has been done N J SERVICE AND REPAIR MANUAL DIVATOR DP1 Open the braided film 7 cm from the
18. he following subassemblies gt Surface supply panel with valve block pressure gauge warning whistle hose and cylinder connec tions gt Divinghosewith reliving loops and P regulator with anti freezing unit SERVICE AND REPAIR MANUAL DIVATOR 2 ANNUAL SERVICE This chapter describes everything that needs tobe done during annual service provided thatthe equipment isnotdamaged For damaged equipment repair work can bedone accordingtochapter Repair Year This chapter is divided into the following parts which should be carried out in chronological or der gt External cleaning of regulator unit with hoses gt Checks of cylinder connection pressure gauge and hoses gt Replacement of anti freezing cap inlet filter and O ring in high pressure connection gt Full functional test 2 1 TOOLS amp CONSUMABLES TOOLS PART NO Fixture regulator 460 190 855 Screwdriver slotted 5 5 x 100 460 190 767 Hexagonal key 5mm 460 200 008 Spong Washing brus Vice CONSUMABLES PARTS PART NO NOTES Clocking compund 460 190 846 Silicone lubricant 331 900 269 Curacid PSA Rinse 1 L 336 921 330 or hand detergent low pH Lint free cloth SERVICE AND REPAIR MANUAL DIVATOR 2 2 SERVICE KITS All service kits and service parts listed below shall be replaced during service SURFACE PANEL PART NO NOTES O rings amp filter for high pressure connections 1 unit 460 190 701 DP1 REGULATOR P
19. he nipple with 13 mm and 19 mm U spanners 3 Remove and discard the O ring from the connection nipple SERVICE AND REPAIR MANUAL DIVATOR 1 Disassemble the P regulator ie Screw off the regulator cover P including the quick coupling using a 21 mm U spanner or the 21 mm torque wrench adapter R Remove and discard O ring O from the regula tor cover Remove the diffusor M and the stop ring M Place the bottom part of the piston extractor tool on top of the open regulator Screw the upper part of the piston extractor tool into the piston Pull the piston out by screwing the bottom part The piston may offer some resistance because of the back up washers 4 Take out control spring set or control spring K depending on regulator version Remove and discard O ring L from the piston Turn over the regulator in the regulator fixture Using the awl remove and discard the sealing plate Using a screwdriver unscrew adjustment screw F turn over the regulator and take out and dis card the valve seat with O ring G save the spring H Use the protective pin to press out the back up washers and O ring I from the top of the regula tor and discard them 10 Check the adjustment screw for damages move old Loctite residues from the adjusting screw and in the re
20. into the connection nip ple The filter shall be centred so that the point of the nipple fits into the hole in the filter Screw in and tighten the nipple by hand to stop using a 5 mm hexagonal wrench gt A Check that the threaded connections A not are damaged gt Replace the O rings 1 Unscrew and remove the nipples in both ends with help of a 5 mm hexagon wrench 2 Remove and discard the O rings B from the nip ples and clean the threads from locking compound residue from 3 Apply a thin later of silicone lubrication on two new O rings and attach them in the groove on each nipple ends 4 Apply two drops of locking compound on the threads of the nipple 5 Fit the nipples into the connection nipples Tighten the nipples gently by hand torque 1 Nm 2 5 2 ANTI FREEZING CAP gt Important about the anti freezing cap Moisture can penetrate into the regulator from the air supply damaged hoses fittings or via the anti freezing cap This moisture can lead to a risk of internal freezing but also cause corrosion inside the regulator It is important to regularly inspect the antifreeze bladder with respect to moisture The antifreezing capshall be replaced when perform ing the annual maintenance Antifreezing cap also functions as a pressure relief valve in case of a leak from the regulator It is therefore important to frostskyddshattan and its protective cover is moun
21. l 9 Remove and discard inner O ring C2 the with the O ring tool 7 10 Remove and discard two outer O rings D on the shuttle insert housing gt Assemble the shuttle insert 1 Lubricate the new O rings C2 with a small amount of silicone lubricant 2 Fit one O ring onto a new seats C1 3 Fit the seat into shuttle insert with help of the punch tool Push the seat down to the bottom 4 Lubricate the new O rings D with a small amount of silicone lubricant 5 Thread the assembly tool on to the shuttle insert and then place one O ring D on the tool 6 Push by hand the O ring D over the assembly tool and down into the inner groove in the whistle insert 23 gt gt gt SERVICE AND REPAIR MANUAL DIVATOR 1 7 Fit the other O ring to the outer groove in the same way 8 Lubricate the O rings F with a small amount of silicone lubricant 9 Fit the new O rings F on the connection nipple of the hoses 10 Screw one hose into the shuttle insert and tighten to 15 Nm using a 13 mm torque wrench Put coun ter force with a 24 mm U spanner 11 Fit the shuttle insert with the mounted hose in the valve block 12 Secure the shuttle insert with the locking clip B and retaining ring A Check that the grips of the locking clip B fit into the recesses in the retaining ring A 13 F it the
22. l in a vice To easy the mounting soapy water on the hose to make the bend restrictor to slip on Make sure that the nut of the hose fitting i vis ible to make mounting of the hose possible Remove the mounting tool Connect the hose to the P regulator hose con nector or valve block what ever applies Tighten the hose to 15 Nm with a 13 mm torque wrench and put counter force with a U spanner that fits 4 1 5 TESTING gt Testing in a test unit The DIVATOR DP1 must be tested with Interspiro test equipment at every annual or six year inspection and after repair at a service workshop For a general description of and operating instruc tions for the test unit see the user manual for the test equipment Tests must be done in accordance with test protocol for DIVATOR DP1 gt Logging of test results and comments Test results must be logged according to the instruc tion for the specific test equipment 36 SERVIGE AND REPAIR MANUAL DIVATOR DP1 SERVICE AND REPAIR MANUAL DIVATOR 9 STORAGE All parts made of rubber or parts containing rubber components should be stored in a cool dry and dark place and in a sealed plastic bag 37 CENTRAL EUROPE NORTH amp SOUTH AMERICA AUSTRIA INTERSPIRO GesmbH www interspiro de Feldbacher Str 3 A 8200 GLEISDORF AUSTRIA TEL 43 0 311 236 133 FAX 43 0 311 236 133 22 E MAIL info interspiro de GERMANY INTERSPIRO G
23. last insert and guide the hose into the braided film pass the loop A by guiding the hose out of and in to the braid under the loop Guide out the hose approx 10 cm before the end loop B and pull out minimum 50 cm of the high pressure hose 6 ans 1cm 1 1 71 cm an 1 34 cm braided film before Hnountening 50 1 cm alt 100 1 cm KR SARS gt 7 QK R TASTA 3 Make a whipping with the waxed line part no 96 739 at point b in Fig 4 See the Whipping instruction in the chapter below Whipping and tape 4 Attach the carbine hook to loop B and fasten it to a fixed point Pull back the braided film along the high pressure hose so that it fits tight around the hose Use a pair of protective gloves to avoid injuries see Fig 5 Secure the end of the braided film with a whipping at point a Fig 4 5 Apply the whipping according to the instruction below 6 Repeat step 1 4 above to attach the relieving loop at the other end of the high pressure hose gt Whipping instruction Preparations In order to tighten the whipping enough wind the waxed line around a wooden pin or similar and use it as a handle when pulling the line 1 The whipping is tied by laying a loop of the waxed whipping line along the rope see illustration A B Tie the whipping line hard 10 15 t
24. mbH www interspiro de Postfach 1220 D 76691 FORST BADEN GERMANY TEL 49 0 7251 8030 FAX 49 0 7251 2298 E MAIL info interspiro de SWITZERLAND INTERSPIRO AG www interspiro de GiiterstraBe 47 CH 4133 PRATTELN SWITZERLAND TEL 41 61 827 99 77 FAX 41 61 827 99 70 E MAIL info interspiro ch THE NETHERLANDS amp BELGIUM INTERSPIRO BV www interspiro nl Operetteweg 35 NL 1323 VK ALMERE NETHERLANDS TEL 31 0 36 5363103 FAX 31 0 36 5384809 E MAIL infobv interspiro com INTERSPIRO Inc www interspiro us com 10225 82nd Avenue PLEASANT PRAIRIE WI 53158 5801 USA TEL 1 262 947 9901 FAX 1 262 947 9902 E MAIL sales interspiro us com UNITED KINGDOM amp IRELAND INTERSPIRO Ltd www interspiro com 7 Hawksworth Road Central Park TELFORD Shropshire TF2 9TU UNITED KINGDOM TEL 44 0 1952 200 190 FAX 44 0 1952 299 805 E MAIL infouk interspiro com SCANDINAVIA ASIA PACIFIC amp MIDDLE EAST SWEDEN NORDIC amp EXPORT SALES DIVISION www interspiro com Box 10060 S 181 10 LIDING SWEDEN TEL 46 8 636 51 00 FAX 46 8 636 51 99 E MAIL info interspiro com MALAYSIA NORDIC amp EXPORT SALES DIVISION www interspiro com 305 amp 305A Lorong Perak Taman Melawati 53100 KUALA LUMPUR MALAYSIA TEL 60 3 4105 8122 FAX 60 3 4105 3122 E MAIL asiapacific interspiro com www interspiro com mmy PART NO 31957A01
25. n international standard requirements as well as on Interspiro s ex periences and tests ServiceintervalsaredefinedintheServiceandTestSchedule in the user manual Thetechnicians performing any service orrepair workon any Interspiro breathing apparatus must be trained and certified by Interspiro on the specific apparatus The manual is divided into three chapters describ ing gt Annual Service including the operations to be performed and service parts to be replaced at an annual service gt Six year Service including the operations to be performed and service parts to be replaced at six year service gt Repair set out instructions for the dismantling and assembling of the repairable assemblies Each chapter describes what needs to be done during service provided that the equipment is not damaged For such equipment repair work can be done accord ing to chapter Repair SERVICE AND REPAIR MANUAL DIVATOR DP1 1 1 GENERAL SERVICE STEPS gt Cleaning before any service or repair it is recommended to completely clean the equipment according to the user manual gt Service certain parts need to be replaced to ensure a high degree of safety gt Checking certain parts listed in each section need to be checked gt Testing service and or repair work on equipment shall always be completed by a full functional test 1 2 THE SURFACE SUPPLY UNIT The Surface supply unit consists of t
26. nd tapings are intact Check that the free end of the supply hose connected to the MKII P regulator i minimum 50 cm 20 inch loong meassured from connection nipple to the releav ing loop eye according to illustration below M gt 50 Ne 1 Safety carbine hook a A A Check the seams and check for corrosion on the hooks Check that the hooks run easily on the safety belt and that it locks Check the seams and check that the belt has not suffered chemical attack nor changed colour or shape Check the carbine hook for mechanicalwear and changes of shape gt Connection R5 8 N Check thread and air holes mechanical wear and deposits gt P regulator AB pbRelief valve Check that the protective band B on the relief valve is not damaged Check the safety valve for mechani cal wear gt gt Quick coupling Check that the quick coupling A is undamaged and clean Check for mechanical wear Check that the quick coupling cover C is intact SERVICE AND REPAIR MANUAL DIVATOR DP1 2 4 2 INSPECTING THE SURFACE UNIT gt Surface panel box NG 1 Check that the surface panel box A is undamaged and that the instruction label Check points B can be read 2 Check that the OPEN ring and the pressure relief handle D is present Valve block
27. ng to an agreement between Interspiro and the user Check that there are no deposits If there are remove them and resume inspection under them Check that there are no discolorations caused by chemical attack for instance Chemical attack may weaken the hose If the hose is used in environments where it may be subject to chemical attack keep a detailed log gt gt Even equipment was cleaned as described in Section 2 3 contamination by chemicals may still harm the person servicing the equipment Make sure that the hose has been thoroughly decontaminated and neutralized Special training in decontamination and neutralizing is needed SERVICE AND REPAIR MANUAL DIVATOR DP1 If you suspect that the hose has been affected by chemicals or that chemicals have penetrated the outer sheath the hose should be replaced The lifetime of the high pressure hose is eight 8 years from when the hose was completely manufactured The year of manufacture is determined by the date for the pressure test stamped on the hose connection nipples in the format P YY The eight 8 year life time applies only under the conditions that the hose is handled and inspected in accordance with safety bulletin 31574B01 Divator DP1 Supply Hose Lifeline gt Relieving loops N A Ne J Check the relieving loops A of the diving hose for wear and mechanical damage Check that the whip pings a
28. or from the air supply damaged hoses fittings or via the anti freezing cap This moisture can lead to a risk of internal freezing but also cause corrosion inside the regulator It is important to regularly inspect the antifreeze bladder with respect to moisture Theantifreezingcapshallbereplacedwhenperformingthe annual maintenance Antifreezingcapalsofunctionsasa pressurereliefvalvein case of a leak from the regulator Itisthereforeimportanttofrostskyddsh ttananditsprotec tive cover is mounted in the right way NOTE A leaking anti freezing cap not only increases the risk of freezing it makes the regulator work less ef ficiently Oxides and salt deposits inthe regulator may adversely influence the high levels of performance associated with Interspiro products gt gt Remove the anti freezing cap 1 Remove the hose clamp from the anti freezing cover A with a screwdriver 2 Open the hinged anti freezing cover and remove the anti freezing cap B from the groove on the regulator housing Discard the antifreezing cap 25 SERVICE AND REPAIR MANUAL DIVATOR DP1 3 Check that no water has leaked in to the regulator If water has leaked in the regulator must be blown dry completely gt Remove the connecting hose 1 Secure the regulator fixture and the regulator in the vice so that the coupling is facing upwards 2 Pull back the hose bend restrictor and remove the hose not t
29. s described in Section 2 3 contamination by chemicals may still harm the person servicing the equipment Make sure that the hose has been thoroughly decontaminated and neutralised Special training in decontamination and neutralising is needed 15 SERVICE AND REPAIR MANUAL DIVATOR DP1 If you suspect that the hose has been affected by chemicals or that chemicals have penetrated the outer sheath the hose should be replaced The lifetime of the high pressure hose is eight 8 years from when the hose was completely manufactured The year of manufacture is determined by the date for the pressure test stamped on the hose connection nipples in the format P YY The eight 8 year life time applies only under the conditions that the hose is handled and inspected in accordance with safety bulletin 31574B01 Divator DP1 Supply Hose Lifeline gt Relieving loops v A NG 27 Check relieving loops of diving hose for wear and mechanical damage Check that the whip pings and tapings are intact Check that the free end of the supply hose connected to the MKII P regulator i minimum 50 cm 20 inch loong meassured from connection nipple to the releav ing loop eye according to illustration below gt 50 4 D gt Safety belt carbine hook a on 52 Check the seams and check for corrosion the hooks Check that the hook
30. s run easily on the safety belt and that it locks Check the seams and check that the belt has not suffered chemical attack nor changed colour or shape Check carbine hook for mechanical wear and changes of shape gt Connection R5 8 1 2 J Check the thread and air holes for mechanical wear and deposits gt P regulator gt Relief valve Check that the protective band B on the relief valve is not damaged Check the safety valve for mechani cal wear gt gt Quick coupling Check that the quick coupling is undamaged and clean Check for mechanical wear Check that the quick coupling cover C is intact 16 SERVICE AND REPAIR MANUAL DIVATOR DP1 3 4 2 INSPECTING THE SURFACE UNIT gt Surface panel box JE NG 1 Check that the surface panel box A is undamaged and that the instruction label Check points B can be read 2 Check that the OPEN ring and the pressure relief handle D is present Valve block Check that the valve block has no mechanical damage bPressure gauge Check that the pressure gauge is free from scratches and other mechanical damage gt gt Whistle insert Check the whistle insert Check that the retaining ring and locking clip F are in place gt gt Shuttle insert Check the shuttle insert G for deposits and me chanical damage Check that the shuttle ins
31. secure it with the screw Note the position of the two white gliding cases Apply a drop of locking compound to the end of the screw and attach the nut and tighten it firmly using a 10 mm U spanner and a5 mm hexagonal wrench 9 Push the hose bend restrictors back over the hose ends 6 Punch in the screw form the outside of the lid and fit the spacer Apply a drop of locking compound at the end of the screw and fit it in the valve block Tighten the screw firmly by hand using a 3 mm hexago nal wrench 31 4 1 2 PRESSURE GAUGE gt Replacement of the pressure gauge gt gt Tools U spanner 10 13 mm 460 190 774 Hexagonal key 5 mm 460 200 008 Hexagonal key 3 mm 460 200 522 U spanner 14 15 mm 460 190 769 U spanner 12 mm 31 236 51 U spanner 24 mm 99 519 51 Manifold fixture 95 927 01 gt Consumable Locking compound 460 190 846 gt Dismounting the valve block Pull back the hose bend protector on the left side of the valve block Loosen and unscrew the left hose with 13 mm and 24 mm U spanners Remove and discard the O ring at the end of the hose Remove by hand the retaining rings on the shuttle valve as well as on whistle Remove with help of a circlip pliers also the lock ing clips from the shuttle insert and the whistle Disconnect the whistle and the shuttle valve from the valve block Remove the valve block from the surface unit case
32. shuttle into the shuttle insert 14 Fit the O ring C2 onto the second seat C1 Fit the seat into the shuttle insert using punch tool Push the seat down to the bottom 15 Screw the second hose into shuttle insert in the valve block 16 Tighten the hose to 15 Nm with a 18 mm torque wrench and put counter force with a 24 mm U spanner 17 Push the hose bend protection back over the hose ends 24 SERVICE AND REPAIR MANUAL DIVATOR DP1 3 5 4 VENTING INSERT I 4 gt Removing venting insert 2 NG 1 Remove the retaining rings A 2 Remove the locking clips B with the circlip pli ers 3 Pull the venting inserts out of the connecting manifolds 4 Remove and discard O rings Fitting the venting insert 1 Lubricate the O rings with thin coating of silicone lubricant 2 Thread the assembly tool on to the venting insert and thread one O ring over tool and puch the O ring by hand down into the grove 3 Fit the other O ring to the outer groove in the same way 4 Fit the venting insert into the connection mani folds 6 Fit locking clips B and retaining rings A gt gt NOTE Check that the grips of the locking clip 2 fitinto the recesses in the retaining ring 1 3 5 5 P REGULATOR Important about the anti freezing cap Moisture can penetrate into the regulat
33. ted in the right way NOTE A leaking anti freezing cap not only increases the risk of freezing it makes the regulator work less ef ficiently Oxides and salt deposits in the regulator may adversely influence the high levels of performance associated with Interspiro products 11 SERVICE AND REPAIR MANUAL DIVATOR DP1 gt Remove the anti freezing cap 1 Remove the hose clamp C from the anti freezing cover A with a screwdriver 2 Open the hinged anti freezing cover and remove the anti freezing cap B from the groove on the regulator housing Discard the antifreezing cap 3 Check that no water has leaked in to the regulator If water has leaked in the regulator must be blown dry completely gt Dry blowing Blow dry compressed air into one of the two air ducts that connect the underside of the regulator piston to the anti freezing cap until no moisture comes out of the opposite air duct gt gt Mount the anti freezing cap 1 Pull the new anti freezing cap B carefully over the flange on the regulator Gently pull on the lower edge of the anti freezing cap then release so that it is completely filled with air There should now be a gap of about 1 mm for the anti freezing cover A 2 Fit the anti freezing cover A over the anti freez ing cap and secure it with the hose clamp C with help of a screwdriver Make sure that the plastic halves do not pinch the anti freezing cap
34. the valve block from the outside of the case lid Remove the valve block and attach it to mani fold fixture Loosen and unscrew the connection nipple C us ing a 19 mm socket fitted in the torque wrench NOTE Do not dismount the inlet filter Unscrew the connection nipple Remove and dis card the O ring B SS 10 Clean the threads in the valve block and on the connection nipple from locking compound residuals with the barrel brush SERVICE AND REPAIR MANUAL DIVATOR 1 ASSEMBLING 1 Lubricate a new O ring B with a thin layer of silicone lubricant and fit it to the end of the con nection nipple 2 Slide the new hand wheel A over connec tion nipple C Apply a small amount of locking compound in three threads at the end of the connection nipple and screw it in to the regulator manifold 7 Reinstall the whistle and the shuttle valve with its hoses gt gt gt Check that the grips of the locking clip fits into the recesses in the retaining ring 3 Tighten the connection nipple with 20 Nm using 19 mm socket and the torque wrench assy 5 50 8 Tighten the hose to 15 Nm with a 13 mm torque wrench and put counter force with a 24 mm U spanner 4 Remove the valve block from the fixture and at tach it to the bracket in surface panel lid 5 Refit the valve block to the bracket in the surface unit case and
35. ting piston F Remove the O rings D E and G tun Je Shake out the spring H Tap the whistle insert cylinder P insert firmly against the workbench to extract the piston F Remove the and sealing cone K the O ring M and the spring N from the piston L gt Fitting the whistle insert 1 Check that all parts have been cleaned and degreased Make sure that all remains of the old sealing label J has been removed Lubricate piston and both ends of spring N with a thin coating of silicone lubricant Thread the spring c spring retainer b with its guide collar against the spring and fit a new O ring a on to piston d a N b 9 2 Insert a new sealing into piston 1 In sert the unit into the whistle insert cylinder P Place the whistle insert cylinder P in the plug in whistle fixture and secure the fixture in the vice Screw in the whistle cylinder A and tighten it with a 20 mm torque wrench to a torque of 20 Nm Check that the sealing cone K has been cen tred Keep the whistle insert cylinder P in the whistle fixture until step 13 so that the cone does not get into the wrong position Lubricate the final turn of the spring H with a thin layer of silicone lubricant Lubricate two new O rings and with a thin coating of silicone lubricant Thread the O rings on to the regulating piston
36. urface 15 The valve seat with O ring G must be fitted with the chamfered side facing in towards the sealing tip of piston L 16 Set the adjustment screw F approximately by screwing it in until its back edge is flush with the thread entry of the regulator housing gt Checking and adjusting the P regulator 1 Connect the regulator in the Interspiro test equipment For a general description of and operating instructions for the test unit see Functional Description for the test equipment 2 Adjust the secondary pressure according to the test instruction for Divator DP1 surface supply 3 After adjustment secure the adjustment screw F with a drop of locking compound on the thread entry gt gt gt NOTE Make sure that the locking compound does not cover the hole in adjusting screw F 4 Fit a new sealing plate E over the adjustment screw F Tap lightly with the flat side of the ball hammer until it is flush with the regulator hous ing Then use the ball side of the hammer to lock the sealing plate gt Installing anti freezing cap a N dei 1 Install the new anti freezing cap B by carefully pulling it over the flange on the regulator Gently pull on the lower edge of the anti freezing cap then release so that the anti freezing cap is completely filled with air There should now be a gap of about 1 mm so that the anti freezing cover A can grip without pinching the anti freezing cap
37. urns around the rope over the loop The whipping will be approx 5 mm wide 0 20 inch Stick the working end through the loop see illustra tion C Haul the loop end back under the whipping so that booth ends of the whipping line are secured in the centre of the whipping Trim both ends as short as possible see illustration D Strip the protective foil on the vulcanizing tape Wrap under tension so the width of the tape will be reduced from 19 mm to approx 6 mm starts vulcanizing 7 Wrap 4 6 turns so that the whipping is fully cov ered Whipping NN on 9 Vulcanizing 1 35 SERVICE AND REPAIR MANUAL DIVATOR DP1 4 1 4 HOSE BEND RESTRICTOR gt Replacement of the hose bend restrictor gt Tools Mounting tool 88 233 51 U spanner 10 13 mm 460 190 774 U spanner 18 19 mm 460 190 775 U spanner 24 mm 99 519 51 Torque wrench adapter 13 15mm 460 190 852 Torque wrench assy 5 50 Nm 336 190 478 gt Spare part Hose bend restrictor kit 460 190 917 gt Remove the old hose bend restrictor 1 Disconnect the high pressure hose from the P regulator hose connector or valve block what ever applies Pull off the old hose bend restrictor from the hose gt Mounting the new hose bend restrictor 1 Connect the hose end to the mounting tool 2 Pull the new hose bend restrictor over the mounting tool and secure the open end of the too
Download Pdf Manuals
Related Search