AP Diving AP50 User manual

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
Page 1 of 38
Medium Pressure
and
Convoluted Hose
Shortening Instructions
Version 1.1
February 2017
Written by Tino de Rijk

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
Page 2 of 38
Table of Contents
1. Introduction...........................................................................................4!
1.1 Reason for these instructions .........................................................................4!
1.2 About “MP” and “HP” hoses............................................................................4!
1.3 Servicing .........................................................................................................4!
1.4 Copyright and Applicable Law ........................................................................5!
2. Exploded Diagrams and Parts Lists .....................................................6!
2.1 AP50 Inflator Hose Assembly .........................................................................6!
2.2 EV50 Auto Air Hose Assembly (new model with standard hose) ...................7!
2.3 AP150 Auto Air Hose Assembly (old model with bigger bore hose)...............8!
2.4 RB07B/01 Scrubber Canister Exhale Hose Assembly – New Ty-wrap version
..............................................................................................................................9!
2.5 RB07B/02 Scrubber Canister Inhale Hose Assembly – New Ty-wrap Version
............................................................................................................................10!
2.6 RB07B/03 Mouthpiece Inhale Hose Assembly – New Ty-wrap Version.......11!
2.7 RB07B/04 Mouthpiece Exhale Hose Assembly – New Ty-wrap Version .....12!
2.8 RB07/01 Scrubber Canister Exhale Hose Assembly – Old Clamped Version
............................................................................................................................13!
2.9 RB07/02 Scrubber Canister Inhale Hose Assembly – Old Clamped Version
............................................................................................................................14!
2.10 RB07/03 Mouthpiece Inhale Hose Assembly – Old Clamped Version .......15!
2.11 RB07/04 Mouthpiece Exhale Hose Assembly – Old Clamped Version ......16!
3. Tools...................................................................................................17!
3.1 Special Tools needed ...................................................................................17!
3.2 Standard Tools needed ................................................................................18!
4. Shortening Medium Pressure (AP50) hoses (NOT Auto Air) .............19!
4.1 Mark where you want to cut the MP hose.....................................................19!
4.2 Unscrew the 3/8”UNF hose end from the hose collar...................................19!
4.3 Unscrew the hose collar from the MP hose ..................................................20!
4.4 Use the hose cutter to cut the hose ..............................................................20!
4.5 Screw the shortened MP hose back into the hose collar..............................21!
4.6 Screw the 3/8”UNF end back into the hose collar ........................................22!
4.7 Shortening the hose on the snap connector end ..........................................22!
4.8 Shortening the ADV and OCB hoses on the latest screw connector end
(AP300)...............................................................................................................23!
5. Shortening Auto Air Medium Pressure (MP) hoses............................24!
5.1 Important notice: beware: TWO types of hoses and connectors! .................24!
5.2 How to distinguish the two types of hoses and connectors ..........................25!
5.3 Shortening the hoses on 3/8”UNF end .........................................................26!
5.4 Shortening the hose on the snap connector end ..........................................27!
6. Shortening convoluted hoses – new Ty-wrap type.............................28!
6.1 Pull the curved Ty-wrap cover down the convoluted hose ...........................28!
6.2 Cut the two Ty-wraps....................................................................................28!
6.3 Pull the convoluted hose from the swivel stem.............................................29!
6.4 Cut the convoluted hose to the desired length .............................................30!
6.5 Push the convoluted hose back onto the swivel stem ..................................30!
6.6 Fit two new Ty-wraps onto convoluted hose.................................................31!
6.7 Push curved Ty-wrap cover back over the Ty-wraps....................................32!

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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7. Shortening convoluted hoses – old split ring type ..............................33!
7.1 Hold the convoluted hose end with RBTOOL12 for better grip.....................33!
..........................................................................................................................33!
7.2 Unscrew outer hose clamp from split inner hose clamp halves....................33!
7.3 Remove the two split inner hose clamp halves from convoluted hose .........34!
7.4 Pull the convoluted hose from the swivel stem.............................................34!
7.5 Cut the convoluted hose to the desired length .............................................35!
7.6 Push the convoluted hose back onto the swivel stem ..................................35!
7.7 Refit the two split inner hose clamp halves onto the hose............................36!
7.8 Screw outer hose clamp back onto the split inner hose clamp halves .........37!
7.9 Updating the clamping System .....................................................................38!
8. Testing Instructions ............................................................................38!
8.1 Test for leaks and proper operation..............................................................38!
8.2 Visual inspection...........................................................................................38!

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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1. Introduction
1.1 Reason for these instructions
When you have finished reading these instructions you will no doubt agree with us that
shortening AP hoses is indeed simple, BUT “the devil is in the details”:
- Get the details (and tools) right, and you end up with a shorter hose that functions
perfectly and is also safe;
- Get them wrong and you end up with a hose that might detach from its end fitting, or
burst due to it becoming weak through using an incompatible / faulty combination of
parts.
1.2 About “MP” and “HP” hoses
The abbreviation “MP” used in these instructions stands for “medium pressure”. ONLY MP
hoses and convoluted hoses can be shortened “in the field” (i.e. outside the factory).
High Pressure (HP) hoses CANNOT be shortened “in the field”. This is only possible in
the factory, as it requires crimping the end fittings, which requires specialised factory-based
equipment.
- “Medium pressure” is pressure typically in the working range of around 10 bar.
MP hoses are typically used for inflators and regulators (between 1st and 2nd stage).
The EN250:2014 norm (paragraph 5.8.4 and 5.8.6) specifies that the burst pressure of
medium pressure hose assemblies shall withstand four times the rated working pressure
or at least 100 bar, whichever is the higher, without leakage or burst.
- “High pressure” is pressure typically in the working range of 200 to 300 bar.
HP hoses are typically used for high pressure gauges or filling whips, used for
monitoring the remaining gas supply in diving cylinders or for filling diving cylinders.
The EN250:2014 norm (paragraph 5.8.3 and 5.8.5) specifies that high pressure hose
assemblies shall withstand a pressure of four times the rated working pressure without
leakage or burst.
1.3 Servicing
Before servicing AP medium pressure or convoluted hoses you must receive instruction and
certification in hose shortening and end fitting maintenance by AP Diving.
Without the correct training it is possible to shorten hoses or service end fittings in an unsafe
manner.
The Inspiration range of closed circuit rebreathers’ CE certification to EN14143 is unaffected
by properly shortened hoses, provided that the shorter hoses do not affect the operation (e.g.
reachability of key components like inflators) or gas throughput and breathing resistance of
the rebreather in any way.
The AP hoses meet the requirements of the Personal Protective Equipment Directive
89/686/EEC – CE certification when fitted to an AP Diving rebreather.
They also meet the requirements as specified in European norm EN250:2014.
WARNING: when servicing AP hoses it is VERY important that all parts that may suffer
wear and tear get replaced. It is also very important that the correct tools are used to avoid
damaging any part of the hoses in the disassembly and assembly process.

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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Please don’t try to save money by re-using parts that really should be replaced during a
proper servicing action.
BThe numbers between brackets after the part names in the disassembly and assembly
chapters correspond to the sequence numbers in the diagrams in chapter 2.
1.4 Copyright and Applicable Law
These instructions are copyrighted, all rights reserved. It may not, in whole or in part, be
copied, photocopied, reproduced, translated, or reduced to any electronic medium (including
the Internet) or machine-readable form without prior consent in writing from AP Diving.
All products are sold on the strict understanding that only English Law applies in cases of
warranty claims and product liability, regardless of where the equipment is purchased or
used. Should a claim be made then the venue for this would be in Truro, England.
© 2017 AP Diving.
Medium Pressure and Convoluted Hose Shortening Instructions

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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2. Exploded Diagramsand Parts Lists
2.1 AP50 Inflator Hose Assembly
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
Collar circlip
AP-50-P6
1
2
Sliding collar
AP-50-P1
1
3
Spring
AP-50-P5
1
4
O-ring
BS-011-N70
1
5
Schraeder valve
AP-100-44
1
6
Ball bearing
AP-50-P7
4
7
Snap connector body
AP-50-P2
1
8
Hose collar
AP-50-P3
2
9
Oxygen heat shrink (optional)
HS-01
1
10
Hose
AP-50-C
1
11
3/8” UNF hose end
AP-50-P4
1
12
O-ring
BS-903-N70
1
AP50 hoses are used on the rebreather manual inflators, AP400 dry suit inflator and the
AP200 BCD inflator (not the Auto Air).

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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2.2 EV50 Auto Air Hose Assembly (new model with standard hose)
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
O-ring
BS-903-N70
1
2
3/8” UNF end
AP-50-P4
1
3
Hose collar
AP-50-P3
2
4
LP hose
AP-50-C
1
5
Coupling body
RB-70-30
1
6
Blue moulded washer
AP-150-18
1
7
Spring
AP-150-11
1
8
Sliding collar
AP-150-12
1
9
O-ring
BS-5.6x2.4-N70
1
10
Funnel seat
AP-150-05
1
11
Spring
AP-150-08
1
12
Valve float
AP-150-6B
1
13
O-ring
BS-109-N70
1
14
Guide washer
AP-150-10
1
15
Valve sleeve
AP-150-14
1
16
Ball bearing
AP-150-13
4
This hose is used on:
- All AP Evolution and Inspiration EVO rebreathers since 2005,
- All AP Evolution Plus and Inspiration EVP rebreathers,
- All AP Inspiration and Inspiration XPD rebreathers since 2008, and
- All AP BCD’s and wings fitted with an Auto Air since February 2009.

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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2.3 AP150 Auto Air Hose Assembly (old model with bigger bore hose)
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
O-ring
BS-903-N70
1
2
3/8” UNF end
AP-150-01
1
3
Hose collar
AP-150-02
2
4
LP hose
AP-150-C
1
5
Coupling body
AP-150-04
1
6
Blue moulded washer
AP-150-18
1
7
Spring
AP-150-11
1
8
Sliding collar
AP-150-12
1
9
O-ring
BS-5.6x2.4-N70
1
10
Funnel seat
AP-150-05
1
11
Spring
AP-150-08
1
12
Valve float
AP-150-6B
1
13
O-ring
BS-109-N70
1
14
Guide washer
AP-150-10
1
15
Valve sleeve
AP-150-14
1
16
Ball bearing
AP-150-13
4
This hose was used on:
- All AP Evolution rebreathers until 2005,
- All AP Inspiration rebreathers until 2008, and
- All AP BCD’s and wings fitted with an Auto Air until February 2009.

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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2.4 RB07B/01 Scrubber Canister Exhale Hose Assembly – New Ty-wrap
version
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
O-ring BS-027-N70
BS-027-N70
4
2
Swivel stem – modified
RB12-04-M
1
3
Canister locking ring
RB12-05
1
4
Curved Ty-wrap
RBCT1
4
5
Curved Ty-wrap cover
RB12-02-A
2
6
Exhale hose cover
RB08-B
1
7
Convoluted hose
RB07B
1
8
Exhale locking ring
RB12-03
1
9
Swivel stem
RB12-04
1

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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2.5 RB07B/02 Scrubber Canister Inhale Hose Assembly – New Ty-wrap
Version
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
O-ring BS-027-N70
BS-027-N70
4
2
Swivel stem
RB12-04
2
3
Inhale locking ring - square
RB12-03-IN
1
4
Curved Ty-wrap
RBCT1
4
5
Curved Ty-wrap cover
RB12-02-A
2
6
Inhale hose cover
RB08-A
1
7
Convoluted hose
RB07B
1
8
Exhale locking ring
RB12-03
1

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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2.6 RB07B/03 Mouthpiece Inhale Hose Assembly – New Ty-wrap Version
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
O-ring BS-027-N70
BS-027-N70
1
2
Mouthpiece swivel stem
RB02-06
1
3
Mouthpiece locking ring
RB02-09
1
4
Curved Ty-wrap
RBCT1
4
5
Curved Ty-wrap cover
RB12-02-A
2
6
Convoluted hose
RB07B
1
7
Counterweight
RB50-01
1
8
Hose indicator
RB40-05
2
9
HUD hose clip
RB80-06A
4
10
Inhale locking ring – square
RB12-03-IN
1
11
Swivel stem
RB12-04
1
12
O-ring BS-027-N70
BS-027-N70
2
13
HUD clip
RB80-05M
1

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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2.7 RB07B/04 Mouthpiece Exhale Hose Assembly – New Ty-wrap Version
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
O-ring BS-027-N70
BS-027-N70
1
2
Mouthpiece swivel stem
RB02-06
1
3
Mouthpiece locking ring
RB02-09
1
4
Curved Ty-wrap
RBCT1
4
5
Curved Ty-wrap cover
RB12-02-A
2
6
Counterweight
RB50-01
1
7
Convoluted hose
RB07B
1
8
Exhale locking ring
RB12-03
1
9
Swivel stem
RB12-04
1
10
O-ring BS-027-N70
BS-027-N70
2

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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2.8 RB07/01 Scrubber Canister Exhale Hose Assembly – Old Clamped
Version
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
O-ring BS-027-N70
BS-027-N70
4
2
Swivel stem
RB12-04
2
3
Canister locking ring
RB12-05
1
4
Hose clamp inner
RB12-01
4
5
Hose clamp outer
RB12-02
2
6
Exhale hose cover
RB08-B
1
7
Convoluted hose
RB07B
1
8
Exhale locking ring
RB12-03
1

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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2.9 RB07/02 Scrubber Canister Inhale Hose Assembly – Old Clamped
Version
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
O-ring BS-027-N70
BS-027-N70
4
2
Swivel stem
RB12-04
2
3
Inhale locking ring - square
RB12-03-IN
1
4
Hose clamp inner
RB12-01
4
5
Hose clamp outer
RB12-02
2
6
Exhale hose cover
RB08-A
1
7
Convoluted hose
RB07B
1
8
Exhale locking ring
RB12-03
1

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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2.10 RB07/03 Mouthpiece Inhale Hose Assembly – Old Clamped Version
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
O-ring BS-029-N70
BS-029-N70
1
2
Mouthpiece swivel stem
RB02-06
1
3
Mouthpiece locking ring
RB02-09
1
4
Hose clamp inner
RB12-01
4
5
Hose clamp outer
RB12-02
2
6
Convoluted hose
RB07B
1
7
Counterweight
RB50-01
1
8
Hose indicator
RB40-05
2
9
HUD hose clip
RB80-06A
4
10
Inhale locking ring – square
RB12-03-IN
1
11
Swivel stem
RB12-04
1
12
O-ring BS-027-N70
BS-027-N70
2
13
HUD clip
RB80-05M
1

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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2.11 RB07/04 Mouthpiece Exhale Hose Assembly – Old Clamped Version
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
O-ring BS-029-N70
BS-029-N70
1
2
Mouthpiece swivel stem
RB02-06
1
3
Mouthpiece locking ring
RB02-09
1
4
Hose clamp inner
RB12-01
4
5
Hose clamp outer
RB12-02
2
6
Convoluted hose
RB07B
1
7
Counterweight
RB50-01
1
8
Exhale locking ring
RB12-03
1
9
Swivel stem
RB12-04
1
10
O-ring BS-027-N70
BS-027-N70
2

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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3. Tools
3.1 Special Tools needed
When shortening MP and Convoluted hoses, the following special tools are needed:
- Hose cutting tool.
This generic tool can be found on the Internet on various places when entering the
search string “nylon tube hose cutter up to 12 mm”.
It is amongst others for sale at Amazon.co.uk for around GBP 5,--.
- Cable Tie tension gun.
This tool can be found amongst others at http://www.rapidonline.com/Cables-
Connectors/Cable-Ty-Tension-Gun-85-0285). This tool is needed for the proper
tensioning and cutting of the special rounded Ty-wraps that are used in the new type of
convoluted hose ends, as shown below:

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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- RBTOOL12 convoluted hose end holding tool.
This tool can be bought from AP Diving. However it is only needed for shortening
convoluted hoses with the old type of convoluted hose ends (pre 2009) that use locking
rings and split rings, as shown below. These can be easily changed for the new Ty-wrap
fittings RB12-02-A Hose Coupling Cover and RBCT1 Cable Ties that are also available
from AP Diving. See chapter 6 for details on this new type of fitting.
3.2 Standard Tools needed
Besides the special tools mentioned above, the following standard tools are needed:
- 17, 19 and 22 mm wrenches
- 5 mm Allen key
- O-ring picking tools
- (Access to) an ultrasonic bath for cleaning the metal parts.
WARNING: Do NOT use aggressive chemicals. They might damage the metal plating of
the hose ends. Use an ultrasonic cleaning bath with a suitable cleaning fluid. A very good
cleaning fluid is Biox “O2” immersion fluid. See WWW.BIOXINT.COM for further information
and distributors.
The use of rubber gloves while re-assembling the hoses is recommended to avoid rendering
them unclean due to human touch.

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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4. Shortening Medium Pressure (AP50) hoses (NOT Auto
Air)
4.1 Mark where you want to cut the MP hose
4.2 Unscrew the 3/8”UNF hose end from the hose collar
- Using 2 x 17 mm spanners, unscrew the hose end from the hose collar
- Unscrew anti-clock-wise.

AP Diving Ltd. Medium Pressure and Convoluted Hose Shortening Instructions
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4.3 Unscrew the hose collar from the MP hose
WARNING: This has a Left Hand Thread, so in order to unscrew it, you need to unscrew
clock-wise, NOT anti-clock-wise!
- Using a 17 mm spanner, unscrew the hose collar from the MP hose
- Unscrew clock-wise.
4.4 Use the hose cutter to cut the hose
- Use the hose cutter to cut the hose to the desired length.
- Use the indication you applied earlier as your guide.
- If you use a knife instead of a hose cutter make every effort to guarantee a “straight”,
90 degree cut.