AP Diving APV300 User manual

AP Diving Ltd. APV300 Inflator Maintenance Manual
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APV300 Inflator
Maintenance Manual
Version 0.3
December 2015
Written by Tino de Rijk

AP Diving Ltd. APV300 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. APV300 inflator Exploded Diagram and Parts List............................... 5!
2.1 APV300 inflator Main Assembly .....................................................................5!
2.2 AP50 Inflator Hose Assembly.........................................................................6!
3. Service Kit Contents and Tools ............................................................ 7!
3.1 Service Kit Contents ....................................................................................... 7!
3.2 Special Tools needed .....................................................................................8!
3.3 Standard Tools needed ..................................................................................8!
4. Disassembly Instructions...................................................................... 9!
4.1 Remove stainless steel pin (if fitted) that holds the pull cord to the dumping
elbow ....................................................................................................................9!
4.2 Unscrew stem retainer from main body..........................................................9!
4.3 Remove inlet stem from main body .............................................................. 10!
4.4 Remove O-ring from inlet stem.....................................................................10!
4.5 Unscrew cap retainer from main body..........................................................10!
4.6 Remove blue button cap...............................................................................11!
4.7 Remove direct feed button from direct feed body.........................................11!
4.8 Remove direct feed body from main moulded body .....................................11!
4.9 Remove O-ring and mesh filter from direct feed body..................................12!
4.10 Unscrew core valve from direct feed body .................................................12!
4.11 Remove back end washer from stem ......................................................... 13!
4.12 Remove back end rubber from stem ..........................................................13!
4.13 Pull stem assembly out of moulded body ................................................... 14!
4.14 Remove spring from stem assembly ..........................................................14!
4.15 Unscrew stem with back end rubber from button .......................................14!
AP50 Medium Pressure (MP) hose disassembly ...............................................15!
4.16 Remove circlip from snap connector body .................................................15!
4.17 Remove sliding collar from snap connector body.......................................15!
4.18 Remove spring from snap connector body.................................................16!
4.19 Remove 4 ball bearings from snap connector body ...................................16!
4.20 Unscrew Schraeder valve from snap connector body ................................16!
4.21 Remove O-ring from snap connector body.................................................17!
5. Clean and Replace Service Parts ...................................................... 18!
5.1 Service kit contents ......................................................................................18!
5.2 Ultrasonically clean deposits from all metal parts.........................................19!
5.3 Replace all O-rings with new ones from the Service Kit...............................19!
6. Assembly Instructions ........................................................................ 20!
6.1 Screw new stem with new back end rubber into button ...............................20!
6.2 Fit spring to stem assembly.......................................................................... 20!
6.3 Push stem assembly into moulded body ...................................................... 21!
6.4 Push new back end rubber and back end washer onto stem.......................21!
6.5 Screw new core valve into direct feed body .................................................22!
6.6 Put new O-ring and mesh filter into direct feed body....................................22!

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6.7 Put direct feed body into main moulded body ..............................................22!
6.8 Put direct feed button into direct feed body ..................................................23!
6.9 Fit new blue button cap ................................................................................23!
6.10 Screw new cap retainer onto main body ....................................................24!
6.11 Put new O-ring onto inlet stem ...................................................................24!
6.12 Push inlet stem into main body...................................................................24!
6.13 Screw new stem retainer onto main body ..................................................25!
6.14 Refit stainless steel pin (if fitted) that holds the pull cord to the dumping
elbow ..................................................................................................................25!
AP50 hose assembly.......................................................................................... 26!
4.15 Fit new O-ring onto snap connector body...................................................26!
4.16 Screw new Schraeder valve into snap connector body..............................26!
4.17 Push 4 ball bearings back into snap connector body .................................26!
4.18 Put spring onto snap connector body .........................................................27!
4.19 Push sliding collar onto snap connector body ............................................27!
6.20 Refit circlip onto snap connector body........................................................27!
6.21 Test spring operation and hose sealing by pushing complete hose on and
off the Inflator unit............................................................................................... 28!
7. Testing Instructions ............................................................................ 29!
7.1 Test for leaks and proper operation..............................................................29!

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1. Introduction
1.1 Functional description
The APV300 low profile power inflator is derived from the original A.P.Valve. It has been
ergonomically restyled but continues to be an excellent BCD power inflator with a new very
low profile. The APV300 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, the AP200.
1.2 Servicing
Before servicing this APV300 inflator, you must receive instruction and certification in the
maintenance of this valve by AP Diving Ltd.
Without the correct training it is possible to configure the APV300 inflator incorrectly in an
unsafe manner. Factory or Dealer prescribed service for this valve is recommended at least
once annually.
WARNING: when servicing the APV300 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 valve 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
servicing action.
1.3 Warranty
This APV300 inflator is covered by APD’s 2-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.
© 2015 AP Diving Ltd.
APV300 inflator Maintenance Manual

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2. APV300 inflator Exploded Diagram and Parts List
2.1 APV300 inflator Main Assembly
NUMBER
DESCRIPTION
PART NUMBER
QUANTITY
1
Button
APV-100-31
1
2
Spring
AP-100-36
1
3
Stem
APV-300-2
1
4
Back end rubber
AP-100-38
2
5
APV300 moulded body
APV-300-1
1
6
Back end washer
AP-100-39
1
7
Stem retainer
APV-100-12
1
8
BS015 O-ring
BS-015-N70
1
9
Inlet stem
APV-200-10
1
10
BS010 O-ring
BS-010-N70
1
11
Mesh filter
AP-100-41
1
12
Direct feed body
AP-200-12-N
1
13
Core valve
APV-100-44
1
14
Direct feed button
AP-200-14N
1
15
Button cap
AP-100-14
1
16
Cap retainer
APV-100-13
1

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2.2 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 APV300 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 APV300 inflator has part number APV300A:
SERVICE KIT DESCRIPTION
PART NUMBER
APV300 Inflator Service Kit
This is the primary service kit with all parts that
should be replaced during regular service
APV300A

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3.2 Special Tools needed
When servicing the APV300 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 APV300 inflator valve.
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 APV300 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 APV300 inflator is recommended to avoid
rendering the APV300 inflator oxygen unclean due to human touch.

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4. Disassembly Instructions
4.1 Remove stainless steel pin (if fitted) that holds the pull cord to the
dumping elbow
- Push the stainless 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 Unscrew stem retainer from main body
- Unscrew counter-clockwise.
- This retainer needs to be replaced during service.

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4.3 Remove inlet stem from main body
- Pull it out straight.
4.4 Remove O-ring from inlet stem
- This O-ring needs to be replaced during service.
4.5 Unscrew cap retainer from main body
- Unscrew counter-clockwise.
- This retainer needs to be replaced during service.

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4.6 Remove blue button cap
- Just pull it off.
- The blue cap needs to be replaced during service.
4.7 Remove direct feed button from direct feed body
- Just pull it out.
4.8 Remove direct feed body from main moulded body
- Shake the main body a bit, and the feed body will drop out.

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4.9 Remove O-ring and mesh filter from direct feed body
- Both the O-ring and the mesh filter need to be replaced during service.
4.10 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.

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4.11 Remove back end washer from stem
- Use pliers to squeeze the split end of the stem together while simultaneously pushing
it down, out of the washer that is holding it in place.
- If this doesn’t work, use pliers to squeeze the split end together, and next push the
stem out of the washer, using a blunt tool like the handle of a small screwdriver.
- The stem needs to be replaced during service, as it will likely get slightly damaged
due to the removal action.
4.12 Remove back end rubber from stem
- Once the stem has been pushed through the hole in the washer, both the washer and
the white back end rubber can be pulled from the stem.

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4.13 Pull stem assembly out of moulded body
- Just pull it out.
4.14 Remove spring from stem assembly
- Take care not to damage the spring.
4.15 Unscrew stem with back end rubber from button
- Unscrew counter-clockwise.
- Both the stem and the white back end rubber fitted to it need to be replaced during
service.
This completes the disassembly of the APV300 inflator

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AP50 Medium Pressure (MP) hose disassembly
4.16 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.
4.17 Remove sliding collar from snap connector body
- Just pull it off.

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4.18 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.
4.19 Remove 4 ball bearings from snap connector body
- Use a small tray to catch the ball bearings to avoid loosing them.
4.20 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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4.21 Remove O-ring from snap connector body
- Carefully use a curved O-ring pick to remove this O-ring, taking care NOT to scratch
the bore of the O-ring groove or valve body.
- 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 APV300 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 APV300 inflator is exposed to, keep it in oxygen
service. Following the recommendations of the CGA (Compressed Gas Association), US
Navy, UK’s HSE and the EIGA (European Industrial Gas Association), breathing gasses
with an oxygen content of 23.5% or higher should be treated as 100% oxygen.
So only if you are absolutely sure that the APV300 will never be exposed to an oxygen
percentage of more than 23.5% can you disregard the rules of keeping equipment 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 APV300
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 APV300 inflator with the correct
tools. 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 APV300A Inflator Service Kit always
need to be replaced when servicing the APV300 inflator. The service kit contents are:
DESCRIPTION
PART NUMBER
QUANTITY
Stem
APV-300-2
1
Stem retainer
APV-100-12
1
Cap retainer
APV-100-13
1
Button cap
AP-100-14
1
White back end rubbers
AP-100-38
2
Mesh filter for direct feed body
AP-100-41
1
Core valves (direct feed body and
MP hose snap connector body)
APV-100-44
2
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
BS010 O-ring for direct feed body
BS-010-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.
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 ensure 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 hardness (degrees Shore).

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6. Assembly Instructions
WARNING: When assembling the APV300 inflator, use rubber gloves to avoid polluting
it while assembling, rendering it not oxygen-clean anymore.
For photographic clarity no rubber gloves are worn on the photos in this manual.
6.1 Screw new stem with new back end rubber into button
- Never reuse the old stem, as it is likely to have been slightly damaged in the removal
process.
- Push new white back end rubber onto the new stem, making sure it is pushed on all
the way.
oCheck this by rotating the white back end rubber on the stem.
- Next, screw the new stem with back end rubber into the grey button with the AP
Diving logo.
- Screw clockwise. Do NOT use tools or force, as it might damage the thread.
6.2 Fit spring to stem assembly
- Just push it on.