Hollis Prism 2 User'S & Service Manual Download Page 9

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Doc. 12-4091 - r01 (9/12/12)

PG-9

SERVICE

GUIDE

SUPPORT: TOLL-FREE 888-383-DIVE │ FAX 510-729-5115 │ E-MAIL [email protected]

2002 DESIGN

(

2012)

SAFETY

WARNING:

The CO₂ absorbent material used in the Scrubber is caustic alkaline material. Take steps to protect your-

self and your working environment from the effects of airborne dusting of absorbent, eye, and skin con-

tact. Good protection would include gloves, eye protection, and a dust mask. See Material Safety Data

Sheets for the absorbent material for further safety recommendations before working with the Scrubber

Bucket Assembly.

PRIOR TO PERFORMING SERVICE:

EXTERNAL INSPECTION

• Visually inspect the Regulator First Stage Cone Filters for any visible residue present.

• Closely examine all metal parts for any signs of external corrosion.

• If the metal parts have a chrome finish, check closely for any flaking or chipping. DO NOT clean any Parts found

to be flaking or chipping chrome in an ultrasonic cleaner.

PRIOR TO DISASSEMBLY

• Ensure that you have the latest revision of this Service Guide and all Hollis Service Updates. Contact Hollis

Customer Service to confirm.

• Be certain to perform the Initial Inspection and Troubleshooting Procedures of each section of this Service Pro-

cedure Guide prior to beginning any Section's Disassembly. Doing so will provide clues as to which Internal Parts

may be worn.

• Review the complete Disassembly and Reassembly sections provided in this Service Procedure Guide for the

specific Assemblies being serviced.

• Ensure that you are equipped with all of the Tools and Parts needed.

DO NOT

attempt to perform the Service if

not equipped with the proper Tools and Parts.

• Perform the outlined steps in the order given, without exception. The Reassembly Procedures have been

outlined with the assumption that you first followed the Disassembly Procedures as outlined.

• Before reusing or scrapping any parts during service, refer to the Parts Replacement Schedule and Letter Codes

(a, b, c) that follow the Exploded View Diagram Numbers.

DO NOT

allow old parts to be reused.

• O-rings are classified as being either dynamic or static. Dynamic O-rings are mounted directly on a moving Part,

or they create a Seal against a moving Part. Static O-rings create a Seal between two non-moving Parts. Since

Dynamic O-rings sustain friction and movement, they are to be discarded and replaced during every Service,

regardless of age or appearance. Static O-rings are less subject to wear and after passing close Inspection may

sometimes be reused, although this is not necessarily recommended. Always follow the Service & Parts Replace-

ment Schedule Outlined in the following section.

Summary of Contents for Prism 2

Page 1: ...29 5115 E MAIL info hollisgear com This PRISM 2 Service Procedure conveys a list of components and service procedures that reflect the PRISM 2 as it was configured at the time of this writing 9 12 12 USER SERVICE GUIDE Doc 12 4091 r01 9 12 12 ...

Page 2: ...RECOMMENDED CHEMICALS LUBRICANTS 8 OXYGEN USE 8 SAFETY 9 SERVICE SCHEDULE ASSEMBLIES 1 SERVICE PARTS REPLACEMENT SCHEDULE SCHEDULE 13 2 PRISM 2 ASSEMBLIES DIAGRAM DIAGRAM 15 AMBIENT PRESSURE 1 BREATHING LOOP TOOLS 17 TROUBLE SHOOTING 18 INITIAL INSPECTION 18 POSITIVE PRESSURE TEST 19 DISASSEMBLY PROCEDURE 20 REASSEMBLY PROCEDURE 23 POSITIVE PRESSURE TEST REPEATED 26 NEGATIVE PRESSURE TEST 27 DISAS...

Page 3: ...HECKS 36 DISASSEMBLY PROCEDURE 37 REASSEMBLY PROCEDURE 38 EXPLODED VIEW DIAGRAMS PARTS LISTS 41 3 SCRUBBER BUCKET SCRUBBER BASKET TOOLS 44 TROUBLE SHOOTING 45 DISASSEMBLY PROCEDURE 45 REASSEMBLY PROCEDURE 49 EXPLODED VIEW DIAGRAMS PARTS LISTS 52 BATTERIES OXYGEN SENSORS 1 BATTERY COMPARTMENT TOOLS 55 TROUBLE SHOOTING 56 DISASSEMBLY PROCEDURE 56 REASSEMBLY PROCEDURE 58 EXPLODED VIEW DIAGRAM PARTS L...

Page 4: ...DIVE FAX 510 729 5115 E MAIL info hollisgear com 2002 DESIGN 2012 2 OXYGEN SENSORS TOOLS 60 TROUBLE SHOOTING 61 DISASSEMBLY PROCEDURE 62 MILLIVOLT LINEARITY TEST CLEANING 63 REASSEMBLY PROCEDURE 64 RECOMMENDED SENSORS 65 CALIBRATION 65 EXPLODED VIEW DIAGRAM PARTS LIST 67 ...

Page 5: ...replace proper instruction from a PRISM 2 Instructor Instructions contained within this guide are only to be performed by persons trained to dive and assemble the PRISM 2 Before service ensure with Hol lis that this is the most current revision of this guide If you do not completely understand the instructions given in this manual lack the correct tools or lack the appropriate level of mechanical ...

Page 6: ...eathing Loop parts of the rebreather that breathing gas circulates within Diluent a gas used for breathing volume and to reduce the fraction of oxygen in the Breathing Loop DSV dive surface valve FO2 fraction of oxygen HP high pressure IP intermediate pressure LP low pressure Negative Pressure Check a test placing the Breathing Loop under a vacuum condition to check for leaks OC open circuit OPV o...

Page 7: ...Certified user training course DO NOT modify or change the Breathing Loop components with any after market parts Doing so could dangerously effect the breathing dynamics of the system and lead to serious injury or death ONLY USE Hollis brand Oxygen Sensors Ensure any BCD used with the unit provides adequate lift capacity If a Hollis alternate inflator regulator is removed or not installed an ad eq...

Page 8: ...al connectors have thin precious metal plating DO NOT scrape corrosion from contacts with a hard sharp object DO NOT use abrasives petroleum distillates silicone based cleaners erasers combust able chemicals or any other harsh cleaners Hollis recommends the use of DeoxIT Gold GN5 for cleaning the electrical contacts OXYGEN USE WARNING The Hollis PRISM 2 oxygen critical components are prepared for ...

Page 9: ...vice Pro cedure Guide prior to beginning any Section s Disassembly Doing so will provide clues as to which Internal Parts may be worn Review the complete Disassembly and Reassembly sections provided in this Service Procedure Guide for the specific Assemblies being serviced Ensure that you are equipped with all of the Tools and Parts needed DO NOT attempt to perform the Service if not equipped with...

Page 10: ...ill be needed for rinsing For blow drying parts and components a clean oil free low pressure air supply is to be used DISASSEMBLY Again prior to beginning Disassembly perform the Inspection and Troubleshooting Procedures at the beginning of each of this Guide s sections Disassemble the different PRISM 2 components in accordance with the disassembly section provided in this Service Procedure Guide ...

Page 11: ...n Tips Use a bright inspection light and magnifying glass to aid seeing damage and defects in the dark colored plastic Fig 1 Follow the O ring grooves with a toothpick end of a paintbrush handle or other such device that can not scratch the plastic This will help you to identify defects you can not see PRE ASSEMBLY To ensure that the Parts do not become contaminated assemble the components immedia...

Page 12: ...Y Assemble the PRISM 2 Components according to the Reassembly Procedures described in each section of this Service Procedure Guide Refer to the PRISM 2 User Manual for instructions on how to assemble all Compo nents together into a complete and working PRISM 2 unit Perform any and all Testing as described in each section of this Service Guide ...

Page 13: ...Hose S R R DSV O rings 3 S R R Exhalation mushroom valve S R R Exhalation mushroom valve seat S R R Exhalation hose S R R Exhalation counterlung S R Manual O2 Addition Valve S R R OPV R R Head to Enhalation Counterlung hose S R R Exhaust Plenum O Ring Not Gasket S R R Red CO Seal S R R Scrubber basket S R Basket Spring S R O2 cell holders S R R O2 cell wiring harness S R R Battery Cap sealing O ri...

Page 14: ...TOLL FREE 888 383 DIVE FAX 510 729 5115 E MAIL info hollisgear com 2002 DESIGN 2012 PART AS NEEDED 12 MONTHS 36 MONTHS 5 YEARS Diluent LP Hoses QD S R S R Diluent HP Hose S R R O2 Pressure gauge S R S Diluent Pressure gauge S R S Oxygen Solenoid S R S R ...

Page 15: ...4091 r01 9 12 12 PG 15 SERVICE GUIDE SUPPORT TOLL FREE 888 383 DIVE FAX 510 729 5115 E MAIL info hollisgear com 2002 DESIGN 2012 9 8 10 3 2 4 14 13 6 5 12 1 11 7 13 16 17 19 18 15 2 PRISM 2 ASSEMBLIES DIAGRAM ...

Page 16: ...5 28680 MOUNTING TUBE 6 28217 MOUNTING POST 7 28681 COVER ASSY 8 29229 H FRAME ASSY 9 29228 SCREW NYLON 10 27270 REG ASSY OXYGEN Doc 12 4096 Technician only 11 27271 REG ASSY DILUENT Doc 12 4096 Technician only 12 28834 WASHER 13 28832 SCREW 14 24819 LOCK NUT 15 28764 COUNTERLUNG INHALATION Doc 12 4094 16 28729 COUNTERLUNG EXHALATION Doc 12 4094 17 29225 HOSE ASSY EXHALE Doc 12 4094 18 29226 HOSE ...

Page 17: ...012 Tools Required 1 BREATHING LOOP Specialty Tools P N 220 9102 Tribolube 71 P N 220 9101 Christo Lube MCG 111 P N TBD Oetiker clamp pliers P N TBD STERAMINE sanitizer P N TBD Thin Nut Wrench P N TBD SI TECH attachment tool P N TBD O ring removal tool plastic Standard Tools magnifying lens inspection light pure breathing gas supply ...

Page 18: ...Work Of Breathing WOB to an unsafe level or cause other safety risks The Breathing Loop has been heavily tested by Hollis for many conditions of use Technicians are not equipped nor authorized to perform the proper testing to evaluate the suitability of after market or modification parts The technician MUST assemble the PRISM 2 to current factory standards and configuration If there is any questio...

Page 19: ...htness by gripping the COUNTERLUNG 30 Flange with one hand and turning the OXYGEN ADDI TION VALVE 38 Fitting Nut clockwise until snug DO NOT overtighten Fig 4 Visually inspect the valve for cracks or breakage anything that may cause a leak See Manual Oxygen Addition Valve section for further service procedures for this item 7 Rotate the OVER PRESSURE VALVE OPV 40 open and closed You should feel a ...

Page 20: ...st NOTE Be aware that if the ambient temperature and introduced gas temperature are not matched the unit may falsely fail the Positive Pressure Test Avoid this by allowing the unit and breath ing gas supply tanks to reach room temperature before performing the test 9 If the Breathing Loop has failed this test repair re place any leaking component found during this test Re peat the test as necessar...

Page 21: ...o the Counterlung Mounting Yoke as Shown In spect the Quick Releases and Velcro Fasteners for wear and damage repair and replace as needed NOTE The Quick Releases and Velcro Fasten ers are sewn in place In the field the COUNTER LUNGS 30 44 and Counterlung Mounting Yoke can only be replaced If shipment to the factory is possible contact Hollis Customer Service for possible repairs of the existing C...

Page 22: ...he rotation of the OPV 40 At the time of this writing Hollis is using a SI TECH valve identical to those commonly used on Dry suits If the valve needs further service besides cleaning refer to service procedures and or recommendations from SI TECH You may also simply replace the valve with a new one available from Hollis if you so choose 9 Visually inspect the BREATHING HOSES 13 21 31 45 HOSE CLAM...

Page 23: ... one must never dive with COUNTER LUNGS 30 44 that show signs of excessive wear ordamage SinceCOUNTERLUNG 30 44 integrity failure during a dive would cause immediate and catastrophic flooding of the Breathing Loop NOTE If the DRAIN VALVES 43 54 do not leak due to heavy corrosion damage or need to be replaced skip step 11 11 ONLY if replacing remove and discard the DRAIN VALVES 43 54 Grip the drain...

Page 24: ...ng of the Left Side COUNTERLUNG 44 Then align the index of the VALVE 52 to orient the hose fitting pointing upwards as shown Continue threading the PLASTIC NUT 52 until tight while hold ing the VALVE 52 in place Fig 18 DO NOT over tighten NOTE If the Drain Valves were not removed skip step 4 4 Insert the barbed fitting of the DRAIN VALVE 43 54 into the drain spout and push it into the drain spout ...

Page 25: ... the Scrubber Head Thread the FITTINGS 34 49 into their ports clockwise until hand tight Fig 21 DO NOT over tighten CAUTION ThecaptiveO ring nottorque sealsthe fitting Excessivetorquewillonlyservetomakethe hosesdifficulttoremoveorevendamagethefitting WARNING Ensure that the BREATHING HOSE 21 with the INHALE DIAPHRAGM CAGE 22 has the 6 sided hex ELBOW FITTING 28 See the sec tion on BOV DSV in this ...

Page 26: ...re not already installed on the DSV BOV after service of the DSV BOV do so now Otherwise skip steps 10 and 11 10 Thread the Forward EXHALATION BREATHING HOSE COUPLING 16 clockwise onto the BOV DSV 1 Arrow Head Side Ensure the BOV DSV 1 is ori ented as shown Fig 25 Then tighten hand tight DO NOT over tighten CAUTION ThecaptiveO ring nottorque sealsthe fitting Excessive torque will only serve to mak...

Page 27: ...r any deflation or loss of COUNTERLUNG 30 44 fullness 7 Any escaping air or deflation means the breathing loop has failed The Positive Pressure Test NOTE The Shearwater Secondary can be used as a digital gauge to verify pressure loss With positive pressure applied and the DSV closed the Oxygen Sensor readings should raise to about 0 22 0 23 PO If the Oxygen Sensor readings start to drop back to 0 ...

Page 28: ... pres sure from the Breathing Loop Squeeze any additional volume from the COUNTERLUNGS 30 44 removing as much gas as possible 2 With the DSV BOV 1 in your mouth inhale with your mouth and exhale from your nose Repeat this until no more gas is present in the Breathing Loop and the COUNTERLUNGS 30 44 are fully collapsed 3 While the Breathing Loop is fully collapsed with the BREATHING HOSES 13 21 31 ...

Page 29: ... pressure equalizes with ambient pressure Non occurrence is a sure sign that there is a leak 7 If the Breathing Loop has failed this test repair re place any leaking component found during this test Re peat the test as necessary to find the source of failure DISASSEMBLE AND DISINFECT PARTS 1 Follow the proceeding subsection Disassembly to break down the Breathing Loop 2 Clean the components with S...

Page 30: ... 2012 8 9 5 7 6 1 2 4 11 10 12 3 3 DIA CAT P N DESCRIPTION NOTES 1 c 27762 BODY DSV 2 c 27760 BARREL 3 a 22 126 O RING QTY 2 4 a 29136 O RING 5 c 27350 SCREW 6 c 27761 KNOB 7 a 22 010 O RING 8 b 27031 MOUTHPIECE 9 a 21978 TY STRAP 10 a 22 028 O RING 11 c 27763 HOLDER OUTLET 12 a 27765 MUSHROOM VALVE DIVE SURFACE VALVE DSV DIAGRAM ...

Page 31: ...2002 DESIGN 2012 20 19 18 17 15 14 16 18 17 13 DIA CAT P N DESCRIPTION NOTES 13 b 28330 14 HOSE BREATHING 14 c 27768 ADAPTER HOSE OUTLET 15 a 22 130 O RING 16 c 27766 NUT CHROME 17 c 28333 HOSE CLAMP QTY 4 18 b 28364 COVER HOSE CLAMP QTY 2 19 c 27805 ELBOW ASSY EXHALE 20 a 22 125 O RING EXHALATION HOSE ASSEMBLY DIAGRAM ...

Page 32: ...IGN 2012 23 24 22 25 27 21 27 29 28 26 26 DIA CAT P N DESCRIPTION NOTES 21 b 28330 14 HOSE BREATHING 22 c 27764 HOLDER INLET 23 a 27765 MUSHROOM VALVE 24 a 22 128 O RING 25 c 27765 NUT CHROME 26 c 28333 CLAMP QTY 4 27 b 28364 COVER HOSE CLAMP QTY 2 28 c 27806 ELBOW ASSY INHALE 29 a 22 125 O RING INHALATION HOSE ASSEMBLY DIAGRAM ...

Page 33: ...RIPTION NOTES 30 c 28133 COUNTERLUNG EXHALE 31 b 28330 14 HOSE BREATHING 32 c 28333 CLAMP QTY 4 33 b 28364 COVER HOSE CLAMP QTY 2 34 c 27813 NUT CHROME 35 c 27770 ADAPTER HOSE 36 c 28992 RETAINING RING 37 a 29235 O RING 38 a 27960 O2 ADDITION VALVE 39 a 219045 GASKET 40 c 24664 OPV LP 41 b 22 125 O RING 42 c 24558 HOLLIS LOGO BUTTON 43 c 23237 ORAL VALVE METAL EXHALATION COUNTERLUNG ASSEMBLY DIAGR...

Page 34: ... 49 50 51 54 DIA CAT P N DESCRIPTION NOTES 44 c 28134 COUNTERLUNG INHALE 45 b 28330 14 HOSE BREATHING 46 c 28333 CLAMP QTY 4 47 b 28364 COVER HOSE CLAMP QTY 2 48 c 28992 RETAINING RING 49 c 27813 NUT CHROME 50 c 27770 ADAPTER HOSE 51 a 29235 O RING 52 a 27961 DILUENT ADD VALVE 53 a 28080 GASKET 54 c 23237 ORAL VALVE METAL INHALATION COUNTERLUNG ASSEMBLY DIAGRAM ...

Page 35: ...2 DESIGN 2012 Tools Required 2 DIVE SURFACE VALVE DSV Specialty Tools P N 220 9102 Tribolube 71 P N 220 9101 Christo Lube MCG 111 P N TBD Oetiker clamp pliers P N TBD STERAMINE cleaner P N TBD Retaining Nut Tool P N TBD O ring removal tool plastic Standard Tools magnifying lens inspection light dowel or rounded tool handle ...

Page 36: ...hing gas flows through the Breathing Loop Func tional Mushroom Valves ensure that all exhaled gas passes through the Scrubber to remove CO2 before it is breathed again The following is a description of a Mushroom Valve Test that will help you evaluate and diagnose any problems before disassembly of the DSV and Hose Assembly 1 Clean and disinfect the DSV and HOSES 13 25 2 Set the DSV to surface mod...

Page 37: ...5 Inspect the HOSE NUT 16 22 threads for damage Clean and or replace them as needed 6 Pull the HOSE INLET HOLDER 17 and HOSE OUTLET ADAPTER 21 straight out of the DSV Fig 3 7 With the rounded handle of a screw driver similar hand tool or dowel press the OUTLET HOLDER 11 from the DSV Fig 4 8 Inspect the seating surface on the OUTLET HOLDER 11 and INLET HOLDER 17 The surfaces should be smooth and pr...

Page 38: ...s found the BARREL 2 must be replaced 15 Snip the plastic TY STRAP 9 that holds the MOUTHPIECE 7 and remove the MOUTHPIECE 8 Inspect the condition of the MOUTHPIECE 8 to ensure that it is supple and free of any tears or damage Dis card if found 16 Clean all DSV Assembly parts and inspect for cracks and other damage NOTE Metal DSV Assembly parts may be cleaned in a sonic bath Plastic components sho...

Page 39: ...re not to place damaging stress on the VALVE HOLDER 11 17 7 If removed replace the MUSHROOM VALVES 12 19 by gently pulling the Retainer Stem through the VALVE HOLDERS 11 17 until the Retaining Flange is completely inside the Valve Holders and properly seated Fig 11 8 Lightly lubricate the HOLDER O RINGS 10 18 20 with Hollis approved lubricant and install the O RINGS 10 18 20 in the grooves of the ...

Page 40: ...ther on their correct sides 11 Thread the DSV NUTS 16 22 clockwise onto the BODY 1 and tighten DO NOT over tighten 12 Install the INHALATION HOSE 13 onto the INLET VALVE HOLDER 17 until the nodes seat in the first corrugation ring as shown Fig 14 13 Install two HOSE CLAMPS 14 with hose clamp pliers Fig 15 14 Slide the Silicone Hose Clamp Cover 15 over the HOSE CLAMPS 14 Fig 16 15 Repeat steps 12 1...

Page 41: ...IGN 2012 8 9 5 7 6 1 2 4 11 10 12 3 3 DIA CAT P N DESCRIPTION NOTES 1 c 27762 BODY 2 c 27760 BARREL 3 a 22 126 O RING QTY 2 4 a 29136 O RING 5 c 27350 SCREW 6 c 27761 KNOB 7 a 22 010 O RING 8 b 27031 MOUTHPIECE 9 b 21978 TY STRAP 10 a 21978 O RING 11 c 27763 HOLDER OUTLET 12 a 27765 MUSHROOM VALVE DIVE SURFACE VALVE DSV DIAGRAM ...

Page 42: ... 5115 E MAIL info hollisgear com 2002 DESIGN 2012 19 18 17 16 15 13 14 DIA CAT P N DESCRIPTION NOTES 13 b 28330 14 HOSE BREATHING 14 c 28333 CLAMP QTY 2 15 b 28364 COVER HOSE CLAMP 16 c 27766 NUT 17 c 27764 HOLDER INLET 18 a 22 128 O RING 19 a 27765 MUSHROOM VALVE INHALATION HOSE DIAGRAM ...

Page 43: ...FAX 510 729 5115 E MAIL info hollisgear com 2002 DESIGN 2012 20 21 22 23 24 25 DIA CAT P N DESCRIPTION NOTES 20 a 22 130 O RING 21 c 27768 ADAPTER HOSE OUTLET 22 c 27760 NUT 23 b 28364 COVER HOSE CLAMP 24 c 28333 CLAMP QTY 2 25 b 28330 14 HOSE BREATHING EXHALATION HOSE DIAGRAM ...

Page 44: ...isto Lube MCG 111 P N TBD STERAMINE cleaner P N TBD O ring removal tool plastic Standard Tools magnifying lens inspection light 1 16 Allen driver 3 8 socket driver 5 64 Allen driver 3 8 open end wrench nylon brush for cleaning threads basket white vinegar 1 pair of rubber gloves paper towels 1 painter s or surgical mask lint free cloth or towel Specifications Torques P N 28084 Screw Latch Keeper 9...

Page 45: ... 1 bad O RINGS 25 2 damaged sealing surface of the SCRUBBER BUCKET 1 1 replace O RINGS 25 2 Inspect the SCRUBBER BUCKET 1 sealing surface for scratches grooves and dings If found replace the SCRUBBER BUCKET 1 DISASSEMBLY WARNING The CO2 absorbent material used in the Scrubber is caustic Take steps to protect yourself and your working environment from the effects of airborne dusting of the material...

Page 46: ...f found If twelve months or more old discard the RED CO SEAL 28 5 Inspect the RED CO SEAL 28 groove in the HEAD PLATE 27 for any scratches or damage to the mating surface If damaged remove and discard Removing Head Plate a Turning counterclockwise remove the RETAINING SCREWS 30 and WASHERS 29 with a 1 16 Allen driver Fig 4 b Lift the HEAD PLATE 27 off the Scrubber Head c Remove the O RING 26 d Ins...

Page 47: ...ING 5 and SPRING PAD 4 for signs of decay damage or corro sion Discard if found NOTE The LATCH KEEPER 23 only needs to be removed if damaged If it is in good condition skip step 7 7 Turning counterclockwise remove the SCREWS 24 using a 5 64 Allen driver Fig 7 The LATCH KEEPER 23 should slide free easily NOTE The RETAINER BAND ASSEMBLY 7 only needstoberemovedifdamagedorbadlycorroded If it is in goo...

Page 48: ...nsethepartwithfreshwatertoremovethevinegar CAUTION Never use a screwdriver to clean the caked absorbent from the SCRUBBER BASKET 15 threads Doing so may lead to damage of the mesh if the screwdriver slips 13 Remove the UPPER FOAM PAD 19 and inspect it for deterioration Discard if Found 14 Inspect the OUTER SCRUBBER BASKET 15 and INNER BASKET 16 mesh for tears Then inspect the O ring sealing surfac...

Page 49: ... the INNER BASKET 15 5 Thread the SCRUBBER BASKET CAP 18 onto the SCRUBBER BASKET 15 until snug Fig 13 DO NOT over tighten NOTE If the Spring Assembly was not removed skip step 6 6 Place a SPRING 5 STRIKE PLATE 4 and WASHER 2 over the Center Stud of the BUCKET 1 Tighten a LOCKNUT 3 onto the Center Stud of the BUCKET 1 turning clockwise with a 3 8 driver Tighten until only one thread is exposed Fig...

Page 50: ...ved skip steps 11 12 and 13 11 Slide the RETAINING BAND ASSEMBLY 7 over the SCRUBBER BUCKET 1 12 Place both SCREWS 13 through the holes in the RETAINING BAND ASSEMBLY 7 13 Thread the LOCKNUTS 14 onto the SCREWS 13 clockwise Tighten them with a 3 8 open end wrench Fig 19 DO NOT over tighten 11 Lightly lubricate and install the two O RINGS 25 into the grooves on the SCRUBBER HEAD 22 Fig 20 NOTE It i...

Page 51: ...02 DESIGN 2012 13 Place the SCRUBBER BASKET 15 into the SCRUBBER BUCKET 1 Ensure to align the centering hole with the Spring Assembly Fig 21 14 Being careful not to pinch the O RINGS 25 seat the SCRUBBER BUCKET 1 over the O RINGS 25 and SCRUBBER HEAD 22 15 Latch the 3 LATCHES 9 to the LATCH KEEPER 23 Fig 22 Fig 21 Fig 22 ...

Page 52: ...CAT P N DESCRIPTION NOTES 1 c 27986 BUCKET STUD ASSY 2 c 224817 WASHER 3 c 224819 LOCKNUT 4 c 28354 PAD SPRING 5 c 28355 SPRING BUCKET 6 b 29227 SPONGE PAD 7 c 27983 BAND ASSY W LATCHES HARDWARE 8 c 27984 BAND BUCKET 9 c 27980 LATCH QTY 3 10 c 28847 SCREW BUTTON HEAD QTY 12 11 c 28220 MOUNTING POST 12 c 24336 LOCKING NUT QTY 6 13 c 224818 SCREW BUTTON HEAD QTY 2 14 c 224819 LOCKNUT QTY 2 15 c 2798...

Page 53: ... info hollisgear com 2002 DESIGN 2012 18 20 19 16 17 15 21 DIA CAT P N DESCRIPTION NOTES 15 c 27749 SCRUBBER BASKET OUTER 16 c 27751 SCRUBBER BASKET INNER 17 a 22 133 O RING 18 c 27756 SCRUBBER CAP 19 a 27869 FOAM PAD UPPER 20 a 27908 FOAM PAD LOWER 21 c 28977 DECAL SCRUBBER BASKET ASSEMBLY DIAGRAM ...

Page 54: ...GN 2012 25 23 24 2 TORQUE TO 9 1 in lbs 2 28 27 26 29 30 22 2 DIA CAT P N DESCRIPTION NOTES 22 c 27807 HEAD ASSEMBLY 23 c 27816 KEEPER LATCH 24 c 28084 SCREW BUTTON HEAD 25 a 29137 O RING QTY 2 26 b 22 153 O RING 27 c 27809 HEAD PLATE 28 a 27810 SEAL RED CO2 29 c 27569 WASHER QTY 4 30 c 24787 SCREW QTY 4 SCRUBBER O RINGS DIAGRAM ...

Page 55: ...SSURE RELIEF VALVE Specialty Tools P N TBD Dow Corning Molykote 7 silicone P N TBD O ring removal tool plastic P N TBD Deoxit Gold GN5 cleaner Standard Tools magnifying lens inspection light O ring pick volt meter 12mm socket driver snap ring pliers dental tool Specifications Torques P N 29048 OP Valve 35 40 in lbs 4 4 5 N m P N 216748 Screw Latch 9 in lbs 1 02 N m ...

Page 56: ...oded or damaged BATTERY CABLE ASSEMBLY 8 3 flooded compartment 1 replace battery 2 clean or replace BATTERY CABLE ASSEMBLY 8 3 See above for causes and treatment DISASSEMBLY 1 Lift the LATCHES 5 while pressing the safety locks flush Fig 1 2 With the LATCHES 5 released lift the LID 12 straight off of the HOUSING 1 3 Remove and disconnect the batteries from the BAT TERY CABLE ASSEMBLY 8 4 Remove the...

Page 57: ...OT use abrasives petroleum distillates silicone based cleaners erasers combust able chemicals oranyotherharshcleaners Hollisrecommendsthe useofDeoxITGold GN5forcleaningtheelectrical contacts of the BATTERY CABLE ASSEMBLY 8 and BULKHEAD CONNECTOR 7 NOTE It is not necessary to remove the PRES SURE RELIEF VALVE 13 during regular service It may simply be rinsed with water It is designed to relieve int...

Page 58: ...batteries to the BATTERY CABLE ASSEMBLY 8 Then ensuring that the wiring is not twisted or contorted place the batteries into the cutout in the FOAM INSERT 9 NOTE If the PRESSURE RELIEF VALVE 13 on the LID 12 was not removed for replacement skip step 5 5 Using a torque driver and 12 mm socket tighten the PRESSURE RELIEF VALVE ASSEMBLY 13 clockwise to a torque of 35 to 40 in lbs 4 to 4 5 N m Fig 7 D...

Page 59: ...lbs 4 DIA CAT P N DESCRIPTION NOTES 1 c 28675 HOUSING ELECTRONICS 2 c 216823 PRESSURE PLUG 3 c 22 003 O RING 4 c 27651 SCREW QTY 4 5 c 27979 LATCH QTY 2 6 c 22 113 O RING QTY 2 7 c 29223 BULKHEAD CONNECTOR BAT 8 c 29221 CABLE ASSY BATTERY 9 c 28664 BATTERY NEST FOAM 10 a 22 239 50 O RING 11 a 22 235 50 O RING 12 c 28990 COVER ELECTRONICS 13 c 29048 OP VALVE ASSY W O RING 2V3 903 BATTERY HOUSING AS...

Page 60: ...ollisgear com 2002 DESIGN 2012 Tools Required 2 OXYGEN SENSORS Specialty Tools P N 220 9102 Tribolube 71 P N 220 9101 Christo Lube MCG 111 P N TBD O ring removal tool plastic P N TBD Deoxit Gold GN5 cleaner Standard Tools magnifying lens inspection light O ring pick volt meter snap ring pliers dental tool ...

Page 61: ... bub ble wrap when travelling Alternately leave the OXYGEN SENSORS 7 installed in their SENSOR HOLDERS 6 to insulate against shock Then carry the SCRUBBER HEAD 1 inside the supplied Blue Box when travelling by air to further insulate the SCRUBBER HEAD 1 and OXYGEN SENSORS 7 from shock 5 Touching and contaminating the Teflon membrane face of the sensor can cause reduction in the signal output or de...

Page 62: ... There are three OXYGEN SENSORS 7 located on the underside of the Scrubber Head To access the un derside of the Scrubber Head the Scrubber Bucket and Scrubber Basket will need to be removed 2 Begin by unlatching the 3 Neilson Sessions Latches that hold the scrubber bucket to the Scrubber Head 3 Pull the Bucket Assembly off of the Scrubber Head Set it aside 4 The SENSORS 7 are held in place with SI...

Page 63: ...n the PRISM 2 unit must pass this Millivolt Linearity Test TECHNICIANS ONLY NOTE Any opened SENSORS 7 must have serial numbers date of testing and mV reading data re sults documented for the customer on a copy of the Hollis Rebreather Receiving and Final Inspection Form You should retain the original copy for your records WARNING The SENSORS 7 must be installed in the PRISM 2 tested and pass the F...

Page 64: ...1 0 ATA PRESSURE 1 6 ATA PRESSURE AIR 8 5 14 mV N A 100 OXYGEN 40 6 66 9 mV 65 107 mV REASSEMBLY 1 Connect the WIRE HARNESS 5 to the BULKHEAD CONNECTOR 4 on the underside of the SCRUBBER HEAD 1 2 Install a clean OXYGEN SENSOR 7 with sufficient remaining service life or a new OXYGEN SENSOR 7 into one of the SILICONE RETAINER SLEEVES 6 CAUTION Lubricant on the plastic sides of the OXYGEN SENSOR 7 ma...

Page 65: ...en open the DSV BOV just long enough to allow the Breathing Loop to settle to ambient pressure With the DSV BOV now closed press the Piezo Switch three times within one second without lifting your finger off the button Fig 4 CELL CALIBRATION ACCEPTED If calibration of all three cells has been accepted the Primary Display will illuminate all three LEDs in red for 5 seconds without blinking If any c...

Page 66: ... oxygen The valid millivolt range for calibration is 30 70 mV This scales with percentage of oxygen and barometric pressure Pressing the Menu Button will prevent the calibration Pressing SELECT will calibrate the sensor displays The displays should now all read 98 If any display shows FAIL the calibration has failed because the mV reading is out of range Fig 7 The system defaults to a calibration ...

Page 67: ...sgear com 2002 DESIGN 2012 4 3 2 1 6 5 7 DIA CAT P N DESCRIPTION NOTES 1 c 27807 HEAD ASSEMBLY 2 c 27872 RETAINING RING 3 c 22 113 O RING QTY 2 4 c 29224 BULKHEAD CON OXYGEN 5 c 29222 CABLE ASSY OXYGEN 6 c 28683 HOLDER SENSOR QTY 3 7 a 27946 OXYGEN SENSOR QTY 3 not shown SCRUBBER HEAD SENSOR COMPONENTS DIAGRAM ...

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