AP Diving APV200 User manual

AP Diving Ltd. APV200 Inflator Maintenance Manual
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APV200 Inflator
Maintenance Manual
Version 1.2
March 2017
Written by Tino de Rijk

AP Diving Ltd. APV200 Inflator Maintenance Manual
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Table of Contents
1. Introduction...........................................................................................4!
1.1 Functional description.....................................................................................4!
1.2 Servicing .........................................................................................................4!
1.3 Warranty .........................................................................................................4!
1.4 Copyright and Applicable Law ........................................................................4!
2. APV200 inflator Exploded Diagram and Parts List ...............................5!
2.1 APV200 inflator Main Assembly .....................................................................5!
2.2 APV200 Breathing Module .............................................................................6!
2.3 AP50 Inflator Hose Assembly .........................................................................7!
3. Service Kit Contents and Tools ............................................................8!
3.1 Service Kit Contents .......................................................................................8!
3.2 Special Tools needed .....................................................................................9!
3.3 Standard Tools needed ..................................................................................9!
4. Disassembly Instructions....................................................................10!
4.1 Remove steel pin (if fitted) that holds the pull cord to the dumping elbow....10!
4.2 Remove stem retainer and inlet stem from main body .................................10!
4.3 Remove O-ring from inlet stem.....................................................................11!
4.4 Unscrew cap retainer from main body ..........................................................11!
4.5 Remove blue button cap...............................................................................11!
4.6 Remove direct feed button from direct feed body.........................................12!
4.7 Remove direct feed body from main body ....................................................12!
4.8 Remove O-ring and mesh filter from direct feed body ..................................12!
4.9 Unscrew core valve from direct feed body....................................................13!
4.10 Unscrew module cap from APV200 body ...................................................13!
4.11 Remove breathing module from APV200 body ..........................................14!
4.12 Pull back end washer and back end rubber from stem assembly ..............14!
4.13 Remove stem assembly from breathing module ........................................15!
4.14 Remove O-ring from breathing module ......................................................15!
AP50 Medium Pressure (MP) hose disassembly ...............................................16!
4.15 Remove circlip from snap connector body..................................................16!
4.16 Remove sliding collar from snap connector body .......................................16!
4.17 Remove spring from snap connector body .................................................17!
4.18 Remove 4 ball bearings from snap connector body ...................................17!
4.19 Unscrew Schraeder valve from snap connector body ................................17!
4.20 Remove O-ring from snap connector body.................................................18!
5. Clean and Replace Service Parts.......................................................19!
5.1 Service kit contents.......................................................................................19!
5.2 Ultrasonically clean deposits from all metal parts.........................................20!
5.3 Replace all O-rings with new ones from the Service Kit ...............................20!
5.4 How to lightly grease O-rings........................................................................20!
6. Assembly Instructions.........................................................................22!
6.1 Fit new O-ring onto breathing module ..........................................................22!
6.2 Push stem assembly with spring into breathing module...............................22!
6.3 Put new back end rubber and back end washer onto stem assembly..........23!
6.4 Push breathing module into APV200 body ...................................................23!
6.5 Screw module cap onto APV200 body .........................................................24!
6.6 Screw new core valve into direct feed body .................................................24!

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6.7 Fit new O-ring and mesh filter into direct feed body .....................................25!
6.8 Push direct feed body into main body...........................................................25!
6.9 Push direct feed button into direct feed body ...............................................25!
6.10 Fit new blue button cap...............................................................................26!
6.11 Screw cap retainer onto main body ............................................................26!
6.12 Fit new O-ring onto inlet stem.....................................................................26!
6.13 Push inlet stem into main body and screw stem retainer on ......................27!
6.14 Refit steel pin (if fitted) that holds the pull cord to the dumping elbow........27!
AP50 hose assembly ..........................................................................................28!
6.15 Fit new O-ring inside snap connector body ................................................28!
6.16 Screw new Schraeder valve into snap connector body ..............................28!
6.17 Push 4 ball bearings back into snap connector body .................................28!
6.18 Put spring onto snap connector body .........................................................29!
6.19 Push sliding collar onto snap connector body ............................................29!
6.20 Refit circlip onto snap connector body........................................................29!
7. Testing Instructions ............................................................................30!
7.1 Test spring operation and hose sealing by pushing complete hose on and off
the Inflator unit ....................................................................................................30!
7.2 Test for leaks and proper operation..............................................................30!

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1. Introduction
1.1 Functional description
Developed from the original A.P.Valve, the APV200 has been ergonomically restyled but
continues to offer the combined functions of a BCD power inflator and emergency jacket
breathing valve. The APV200 is a replacement part for post-2007 (BUDDY and AP Diving)
BCD’s.
N.B. If you require a replacement for pre-2007 BUDDY BCD’s, you need the
previous version of this inflator, the AP200.
1.2 Servicing
Before servicing this APV200 inflator, you must receive instruction and certification in the
maintenance of this breathing valve/inflator by AP Diving Ltd.
Without the correct training it is possible to configure the APV200 inflator incorrectly in an
unsafe manner. Factory or Dealer prescribed service for this gas isolator is recommended at
least once annually.
WARNING: when servicing the APV200 inflator 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 breathing valve/inflator in the disassembly and assembly
process. Please don’t try to save money by re-using parts that really should be replaced
during a proper service.
1.3 Warranty
This APV200 inflator is covered by APD’s 1-year warranty against defects in materials or
workmanship. This warranty is only extended to the original purchaser, and is not
transferable. For more information, be sure to read the warranty section of the user manual,
and the purchaser should save the sales receipt.
A copy of the receipt must be presented whenever obtaining warranty service.
1.4 Copyright and Applicable Law
This Maintenance Manual is 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 Ltd.
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 Ltd.
APV200 inflator Maintenance Manual

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2. APV200 inflator Exploded Diagram and Parts List
2.1 APV200 inflator Main Assembly
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
Mouth piece
AP-18
1
2
Ty-rap
AP-21
1
3
APV200 body
APV-200-1
1
4
Mesh filter
AP-100-41
1
5
BS010 O-ring
BS-010-N70
1
6
Inlet stem
APV-200-10
1
7
BS015 O-ring
BS-015-N70
1
8
Stem retainer
APV-100-12
1
9
Direct feed body
AP-200-12-N
1
10
Core valve
AP-100-44
1
11
Direct feed button
AP-200-14N
1
12
Button cap
AP-100-14
1
13
Cap retainer
APV-100-13
1
14
Breathing module
APV-200-3
1
15
Module cap
APV-100-10
1

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2.2 APV200 Breathing Module
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
Back end washer
AP-100-39
1
2
Back end rubber
AP-100-38
1
3
BS 18.1 x 1.6 O-ring
BS18.1+1.6-N70
1
4
Body
AP-100-37
1
5
Spring
AP-100-36
1
6
Stem
AP-100-35
1
7
Washer
AP-100-34
1
8
Diaphragm
AP-200-33
1
9
Diaphragm washer
AP-100-32
1
10
Button
APV-100-31
1

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2.3 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

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3. Service Kit Contents and Tools
3.1 Service Kit Contents
WARNING: When replacing O-rings, next to the size, the hardness of the O-rings
(declared in degrees Shore, and indicated by the suffixes N70 or N90) is ESSENTIAL for
proper operation. AP Diving deliberately chooses the N70 hardness of the
O-rings for the APV200 inflator.
If, against our recommendation, you choose to select your O-rings to come from another
source than AP Diving Ltd., make sure you select the right type in size AND hardness AND
material (composition).
The main service kit for the APV200 inflator has part number APV200A:
SERVICE KIT DESCRIPTION
PART NUMBER
APV200 Inflator Service Kit
This is the primary service kit with all parts that
should be replaced during regular service
APV200A

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3.2 Special Tools needed
When servicing the APV200 inflator, the following special tool is needed:
DESCRIPTION
PART NUMBER
Tool for removing/replacing the core valve and Schraeder valve
AP50E
AP50E
3.3 Standard Tools needed
Besides the special tools mentioned above, there are no special tools needed for servicing
the APV200 inflator gas isolator.
Normal tools needed are:
- Pliers;
- O-ring picking tools;
- Oxygen-compatible or Silicon grease (depending on the gas the inflator is exposed to)
osee chapter 5 for remarks about when you need to keep this device in oxygen
service;
- (Access to) an ultrasonic bath for cleaning the metal parts.
WARNING: Do NOT use aggressive chemicals. They might damage the metal plating of
the APV200 inflator. 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 APV200 inflator is recommended to avoid
rendering the APV200 inflator oxygen unclean due to human touch.

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4. Disassembly Instructions
4.1 Remove steel pin (if fitted) that holds the pull cord to the dumping
elbow
- Push the steel pin out of the main body.
oThe pin can be just pushed out. It is not screwed in; it is held in place by
friction.
4.2 Remove stem retainer and inlet stem from main body
- Unscrew the stem retainer counter-clockwise.
- Pull the inlet stem out straight; no need to rotate.

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4.3 Remove O-ring from inlet stem
- This O-ring needs to be replaced during service.
4.4 Unscrew cap retainer from main body
- Unscrew counter-clockwise.
4.5 Remove blue button cap
- Just pull it off.
- The button cap needs to be replaced during service.

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4.6 Remove direct feed button from direct feed body
- Just pull it out.
4.7 Remove direct feed body from main body
- Shake the main body a bit, and the feed body will drop out.
4.8 Remove O-ring and mesh filter from direct feed body
- Both the O-ring and the mesh filter need to be replaced during service.

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4.9 Unscrew core valve from direct feed body
- Use tool AP50E tool or equivalent to unscrew the core valve out of the feed body.
- Unscrew counter-clockwise.
- The core valve needs to be replaced during service.
4.10 Unscrew module cap from APV200 body
- Unscrew counter-clockwise.

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4.11 Remove breathing module from APV200 body
- Gently pry the breathing module out.
- It might help a bit to also give the backside of the module a gentle push with your
finger, pushing through the big hole of the corrugated hose inlet.
- Make sure you pull it out straight: if you allow it to make an angle with the main body
it will get stuck. In that case push it back in all the way and start again.
4.12 Pull back end washer and back end rubber from stem assembly
- The end of the stem is split. You can wiggle the back end washer a bit and just pull it
off.
- After having removed the washer, the white back end rubber can just be taken off.
- The white back end rubber needs to be replaced during service.

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4.13 Remove stem assembly from breathing module
- The stem can now just be taken out.
- Make sure you don’t lose the spring.
4.14 Remove O-ring from breathing module
- This O-ring needs to be replaced during service.
This completes the disassembly of the APV200 inflator

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AP50 Medium Pressure (MP) hose disassembly
4.15 Remove circlip from snap connector body
- Use small pliers to remove the circlip from the snap connector body.
- Take care not to widen the circlip, as it will otherwise not be usable again during
assembly.
4.16 Remove sliding collar from snap connector body
- Just pull it off.

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4.17 Remove spring from snap connector body
- Just pull it off.
- Make sure you do not inadvertently let the ball bearings drop out in the process.
4.18 Remove 4 ball bearings from snap connector body
- Use a small tray to catch the 4 ball bearings to avoid losing them.
4.19 Unscrew Schraeder valve from snap connector body
- Use the AP50E tool or equivalent to unscrew the Schraeder valve from the body.
- Unscrew counter-clockwise.
- This Schraeder valve needs to be replaced during service.

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4.20 Remove O-ring from snap connector body
- Use a curved O-ring pick to remove this O-ring.
- This O-ring needs to be replaced during service.
This completes the disassembly of the AP50 Medium Pressure hose.

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5. Clean and Replace Service Parts
The servicing of the APV200 inflator contains 4 “action groups”:
1. Removing and binning all parts that should be replaced. This includes all O-rings.
2. Depending on the gas content the APV200 inflator is exposed to, keep it in oxygen
service. The CGA (Compressed Gas Association), US Navy, UK’s HSE and the EIGA
(European Industrial Gas Association) all recommend that breathing gasses with an
oxygen content of 23.5% or higher should be treated as 100% oxygen. However, some
technical training agencies still use 40% as the maximum percentage that is allowed for
equipment that is not in oxygen service.
AP Diving advises to err on the side of safety, and to use the value of 23.5% as the
cutoff percentage beyond which the equipment must be in oxygen service.
If in doubt: keep it in oxygen service, as that only takes a little bit more effort.
3. Ultrasonic-cleaning of all disassembled metal parts. This is mandatory if the APV200
inflator is to be kept in oxygen service, but recommended in all other servicing situations.
4. Lightly grease new parts, fit them, and re-assemble the APV200 inflator with the correct
tools and the correct torques. Use oxygen-compatible grease, and avoid contaminating
the metal parts after cleaning. Use the smallest amount of grease possible.
5.1 Service kit contents
As described in chapter 3.1, all the parts included in the APV200A Inflator Service Kit always
need to be replaced when servicing the APV200 inflator. The service kit contents are:
DESCRIPTION
PART NUMBER
QUANTITY
Button cap
AP-100-14
1
White back end rubber
AP-100-38
1
Mesh filter for direct feed body
AP-100-41
1
BS010 O-ring for direct feed body
BS-010-N70
1
Core valves (direct feed body and MP hose
snap connector body)
AP-100-44
2
BS 18.1 x 1.6 O-ring for breathing module
BS18.1+1.6-N70
1
BS015 O-ring for inlet stem
BS-015-N70
1
BS011 O-ring on inside of snap connector
body of MP hose
BS-011-N70
1

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5.2 Ultrasonically clean deposits from all metal parts
Clean deposits from all metal parts, like chalk and salt.
WARNING: Do NOT use aggressive chemicals. They might damage the metal plating.
Use an ultrasonic cleaning bath with a suitable cleaning fluid instead. A 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 APV200 is highly recommended to avoid
rendering the APV200 unclean due to human touch.
For photographic clarity no rubber gloves are worn on the photos in this manual.
5.3 Replace all O-rings with new ones from the Service Kit
WARNING:
- Replace all O-rings: do NOT re-use old ones.
- ONLY use original parts from APD, to make sure the O-rings:
oAre the exact size;
oAre of the correct material (especially important in a high oxygen content and
overpressure environment);
oAre of the correct stiffness (degrees Shore).
5.4 How to lightly grease O-rings
When greasing O-rings, make sure NOT to use too much grease.
Especially O2 compatible grease has the potential to become stiffer over time, which may
cause a hardened clot of grease to become a source for leaking.
The best way to grease O-rings is using a simple “grease bag”.
A grease bag is a clean and clear plastic bag, into which you put a small amount of grease.
Optionally you can make two bags: one with O2 compatible grease, and one with normal
silicone grease. Make sure you label them properly to avoid mixing them up! Also put a date
on it, so you know how old your grease bag is. Don’t use them longer than a year.
A nice advantage of using a grease bag is that you use only a tiny amount of grease for
greasing many O-rings, so there is little waste.
We recommend that you use resealable bags, e.g. the ones with a plastic zipper, typically
used for airtight food storage. This allows you to zip up the bag after use, keeping the
contents clean for repeated use.
The simple steps are as follows:
- Take a plastic bag and deposit a SMALL amount of grease in it.