.. .. beer; . . , .

T.l001 "PORPOISE" DIVING UNIT - SPORTSMAN MODEL 60 ASSEMBL Y - TESTI NG - AFTERCARE

1. ASSEMBLY AND TESTING

(0) Ensure that the canvos protective bog is stretched end fostened into position on the cylinder. (b) Unscrew eoch cylinder bond tension nut untiJ it is engaged by approximately three threads to a ll ow each bond to expand to its maximum. (e) Assemble the harness straps on to the top cylinder band end slide band into posi~ C.104 tion os shown-about 5" down fram the cylinder shoulder. This dimension will vary Qccording to yaur physique. Pa ss the harness straps t hrough the lewer band, positioning the plastic loops under the wire ond slide into the position shown­ about 1" up fram the lower cylinder shoulder.

(d) Position the harness straps, top end (h) Release the cylinder pressure graduolly­ bottam, about 2" apart ct ri ght ongles to until cylinder volve is fully open ot one the cylinder valve out let and cylinder band full turn. tension nuts - ti ghten the tension nuts - finger tight on ly. (j) Check the demand-valve by vigorously in­ haling and exhaling - ensuring that the (e) Release a smal l blast of ai r to clean the flow of air is sufficient and ceases after cylinder valve outlet-wipe the reducing­ eoch inhalation. valve coupling clean and screw into cylin­ der-tighten with the tension bar- med­ Note: ium pressure onl y-in the position shown. The demond-volve features- "VACUUM AS­ (f) Sc rew the demand-volve hose to the reduc­ SISTANCE" - which e utomatically operotes ing-valve outlet-fing er tight only-and os the air flow commences. When out of the position hose as shawn--ensuring that the water, 0 si ight knock on the valve may start hose passes over the right shoulder. the a ir fl ow ing- this can be stopped by plac­ ing 0 finger over the mouthpiece, or by put­ (9) Couple the oir hose to the demand-valve ting the mouthpiece in the mauth to create 0 --egein finger tight on ly. slight back pressure.

Respirlliory Engineers, Designers, Manufllcturers & Oislributors of: COUSTEAU_GAGNAN "AQUALUNG" 'nd " PORPOI5[" DIVING UNITS, IMDUSTRIAL 8REATHING EQUIPMENT, ACCUSORIU Memoer of the GrO

LA SPIItOTECHNIQUE, PARIS , fR ANCE • U. S. DIVEP~ LOS ANGEUS, U.S.A •• CRESSI·5UB, ITAL Y

(j) For fjnal check - immerse the cylinder­ Procedure valve, reducing-velve end demand-valve in water- with the pressure turned on, end ta) Immerse the valves in fresh water-Ieove exemine for leaks. immersed for 30 minutes or more to re­ move oll troces of solt-hang to dry, pro­ tected from sunlight. WARI'UNG: (bl Hose the cylinder end herness cerefully 00 not (eave the va.ves · unaer prellure with fresh water or totolly immerse if when not in use--c:lose the cylinder volve practicable. ond release air frem the circuit to relieve tension. Caution • 00 not allow the unit to remain overnight (k) Adjust the harness for ind ividual fitting without removing the solt, os excessive - positioning the cylinder so that the corrosion con take place. head, when thrown fuUy back will not touch it . • Da not fm the cylinder with oxygen-use (I) Prior to olvlng--check the cylinder pres· only pure breothing air, free of moisture sure-the slightest leok will empty the ond contaminotion. cylinder overnight. • Always stow the cylinder when not in use -in 0 vertical position-this enables any internal candensotion wh ich could corrode the thin eyfinder wolls, to remain in con­ tact with the thickened neck or base areal, 2. CARE AFTER DIVING which would not be weokened by normal eorrosion. The two main causes ot deterioration a re solt and strong sunlight. Immediately after leav. • Reod carefully the instructional booklet- lng the wa ter, dose the cylinder volve--re· 11 Aqua-lung Diving" I before ottempting lease the pressure from the circuit ond cover Jour first dive. the unit to protect it from strong sunlight. • Your "Porpoise" has the in-built sofety feature of "Vacuum Assisted Breothing", Wash your unit in fresh water os soon os pos­ the details of which ore contained in Tech­ sible ofter diving. nieol Sheet T.l007.

5 Rogion Street, North Melbou,nc Cable: " PORPOISE" Melbourne. Phone: 30. 3869 .. • • • •

T. l 002 " PORPOISE" DIVING UNIT - UNIVERSAL MODEL 60

ASSEMBL Y - TESTING - AFTER CARE

1. ASSEMBL Y AND TESTI NG

(0) Ensure thot the convas protective bog is stretched end fostened into position on the cylinder. (b) Unscrew each cylinder band tension nut until it is engaged by approximately three C, 102 threads, to ollow the bonds to expand to their maximum, end slide into the posi­ tion shown. T he top band about 5" down fram the shoulder of the eyfinder end the bottem band 1" up fram the tower ey lin­ der shoulder. The top band con be od­ jus ted up or down to suit the physique.

(c) Tighten the cylinder bond tension nuts­ you that your cylinder pressure is lew. If finger tight only with the harness " 0" you use excessive pressure in turning the cl ips towords you os shown. valve off - yau may have difficulty in (d) Release 0 small blast of air to clean the turning it on when your fingers are cold. cylinder volve outlet-wipe the reducing­ You will note thot the reserve supply verve coupling clean end screw into eyl· hondwheel turns freely when the oir pres· inder- tighten with the tension bar­ sure is low--ond tightens when the air medium pressure only-into the position pressure is high. This is to prevent a shown. knock from occidentolly opening the re· (e) Ensure that the "Reserve Supply" hand· serve unti I the cylinder pressure drops to wheel at the bose of the reducing·volve is the worning level-which voriest depend· turned "Off"-use finger pressure only ing on the depth end rote of respiration. - remember thot you must be oble to

Respir.Jlory Engineerl, O' l ion~s, Miinufil(lur.rs & Oislribulon 01 : CQUSTU.U·GAGNAN " AQUALUHG" illld " PORPOISE" DIVIHG UHITS, IHDUSTRIAL BUATHIHG EQUIPMEHT, AC:C:E$SORIE$ M.mber of the Grol.lp comprising: LA SPIROTECHNIQur, PARIS, FRAHCr • U. S. DIVERS, LOS ANGELES, U.S. ... . _ CRISSI-SUB, IT"'LY

(g) Couple the air hase ta the demand-valve 2 . CARE AFTER DIVING --ogoin, finger tight only. (h) Release the cylinder pressure gradually­ The two main causes of deterioration are until the cy li nder vo lve is fu lly open ct solt and strang sunlight. Immediotely after one fu ll turn. leaving the water, dose t he cylinder valve­ release the pressure from the circuit and (i) Check the demond verve by vigorously in ­ cover the unit to protect it from strong sun­ holing and exhaling-ensuring that the light. flow of air is sufficient ond ceoses after each exhalation. Wosh your unit in fresh woter os soon os possible after diving. Note: Procedure:- The demond-valve features - "VACUUM ASSISTANCE"-which automaticolly op­ (0) Immerse the volves in fresh water-Ieave erotes os the air flow commences. When immersed for 30 minutes or more to re­ move oll traees of salt--hang to dry, pro­ out of the woter, 0 slight knack on the velve moy start the oir flowing-this con tected from strang sunlight. be stopped by plodng a finger over the (b) Hose the eylinder a nd harness earefully mouthpiece, or by putting the mouthpiece with fresh woter or totolly immerse if in the mouth to create a slight bock pres­ practicoble. sure. Coution (j) For finol check - immerse the cylinder • 0 0 not ollow unit to remoin overnight with­ vo lve reducing-volve and demand-valve in out removing the solt, os excessive corro­ water - with the pressure turned on, sion con take ploce. cnd examine for lecks. • 0 0 not fil! the cylinder with oxygen-u •• only pure breothing air free of moisture ond contominotion. WARNING: • AlwoY5 stow thc cylinder, when not in use, in 0 verticol position- this enobles ony in­ 00 not leave the valve, under pressure ternol condensation wh ic h could corrode when not in use-.close the cylinder valve the thin cylinder walls, to remin in con­ and release air from the circuit to relieve toct with the thickened neck or base oreas, tension. which would not be weakened by no rm al corrosion. (k) Clip the harness into position and odjust • Reod corefully the instructionol booklct­ for individual fitting - positioning the " Aqua-Lung Oiving" - before ottempting cylinder so that the heod, when thrown you r first divc. fully bock will not touch it. • Your " Porpoise" hos the built-in sofety (I) Prior to diving-Breathing", sure-the slightest leak will empty the the details of wh ich are contoined in Tech­ cylinder overnight. nicol Sheet T.l007.

5 Rogion Street, North Melbourne C.ble: " PORPOISE" Melbourne. .. • • •

T.l 003 15 16 17 19

22 23 24 2S 26 \ I I \ I§:I§~'; ~[ I e1r- _. - ~

.,

/ / / 34 36 37 39...... 44 4S 46 47 ••

PARTS BREAKDOWN - "PORPOISE" SPORTSMAN MODEL 60

'nd.. P;.. , No. Duuiptlon 'ndeIl Part Ho. Ducrlptlon REDUCING VALVE AIR HOSE (Ist STAGE REGULATOR) 22. 0·' Snl "0" - Ring (2 off) I. CA·SMR.19 Lockscrew 23. U-Sl-C Tail - Coupllng (2 oft ) 2. CA-SMR-18 Filter - Spr ing alse 2<. U-SL.B Nut _ Coupllng (2 o ff) ,. CA-SMR-16 Spring • PI$lon 25. U-SL-D Ri f'l g • Cr lmplng (2 off) CA-SMR-20 Locks(rcw • Rollef Vilive 26. U-S l -A Hose - Air (H<»e Only) •S.• CA-SMR-15 Spring • Re h,f V.lvi CA-SMR-JO P'sloo Assembly - Relief Viii .... DEMAND VA LVE •• CA-$MR-25 PillOr'! Auembly (2nd ST AGE REGULATOR ) •• CA-SMR-Z Body • Val .... 27. CA-SMO-J Cover - Oiaphragm 10.•• CA-SMR-1 2 Union - Hose Tak.lI-off 28. CA-SMD-32 Diaphragm 11. CA.$MR·3 G!o~kel - Coupling Spindill 2 •. CA-SMD-7 Pres$Ure Plale • Diaphragm 12. CA-5MR-Z6 Seal Anembly _ High Pressu.e 30. CA.$MD-31 Mouthplec, IJ. CA-SMR-ZB Guide - Spring JI. CA-5MD-36 Lllver - F1.Ilcrum ,.. CA·SMR·l1 Spring - High Prenure Seat J2. CA-SMD -8 Pif'l • F1.IIcrum Lever IS. CA-SMR-S Locknut • Coupllng Spindie 0-11 Se,I - "0" - Ring [2 off) 16. CA-SMR-6 Nut _ Coupling ". CA-SMD-22 Cover - ExhauS! ValvII 17. CA-SMR-29 Filter A5sembly "J6.. CA-SMD-37 Valve Anembly - Ex haus! 18. CA-SMR.-7 Spindie - Coupling 37. CA-SMD-" Body • Dllmaf'ld Vilive I •. CA· SMR.8 Seal - Nase Coupling Spindie CA·SMO.14 Sirap A$SoIImbly _ Ne<:! .. 20. CA-SMR-22 Greaser - Piston ". CA-SMD-33 Follo .... e. _ Fulc.um lever 21 . O-IS Snl • "0 " - Ring .".1. 0·11 Seal - "0" - Ring

RespiralOfY Enginee.s, Desigf'll!'s, Manufllctu.ers & Distribulo.s 01; COUSTE AU.GAGNAN " AQUALUNG" . nd " PORPOISE" DIVING UNITS, INDUSTRIAL BRE ATHI NG EQUIPMENT, ACCESSOR IES Page 2 Member of the Gr ovp comprising: LA SPIRonCHHIQUI, PARIS, fRANCl _ U. $. DIVlR$, LOS ANGUn, U.S.A. _ CRUSI_SUB, ITALY

HARNESS <2 . CA-SMD-ll Hou5lng - Valva <3 . CA-SMD·l0 Loeknut - V. lve SM_Hol Strap A$sembly - Hamess - LH. SM-H-J Strap Assembly - Hftrnen _ R.H . CA-SMD-13 Gasket Retollin,ng S<:re"" ". - U_B6 Wir. Tenoion Band _ Cylinder

" PORPOISE" DIVING UNIT - SPORTSMAN MODEL 60 OVERHAUL .nd ADJUSTMENT

1. TO STRIP DOWN DEMAND-VALVE (bl Slip the diaphrogm 28 wi th its pressure (2nd STAGE REGU LATOR) plote 29 into posit ion - ol ign the slot in (0) Unscrew retoining 5c rew 48 end remove 29 at right a ngles to the bore and spring items 44, 45, 46 and 47--examine 44 the cover plate 27 into position, ensuring and 45 end remove embedded grit with e that the diaphragm rtm is accurately in hair brush - reploce 44 if domaged posit ion in its groove and thot the cover through overtension. Examine the rubber plate lugs mate with the slots in the valve sealing washer under the adjustment body 37_ screw head at rear of seot end ensure that (e) Ensure thot the folIower item 40 and it is intoct-however do not alter the "0" ring seal 41 a re occurately assembled scrcw sCHing unless the sealing washer into 42 and thot the fulcrum lever 31 has obvious ly bocn damogcd or thc seot swings freely, engaging the foliower in face needs re-focing_ the slot provided. Loosely screw retaining If the seat face is damaged it can be re­ screw 48 into 42 to provide a means to faced by grinding lightlyon the side of a hold on to, end holding the valve body fi ne emery wheel after the odj ustment verticol!y with the exhoust volve 34 point­ screw hes been removed. However the ing towords the ground-Iower the ful ­ screw setting must be re-set os explained crum lever 3 1 end its ossembly down into in 3 . Wosh items 46, 47 a nd 48 in clean­ the va lve body - ensuri ng that the ful­ ing spirit end re-coat with _C. 154 special crum lever assembly is facing the right lubricent. direction with the fulc rum pi n 32 towards the diaphragm 28. Watch through the (b) Unscrew knurl ed nut 43, end using item mouth port to ensure that the lever 31 48 loosely screwed in to grip upon, pullout engoges the slet in 29. Press the housing valve assembly 42 - wosh components in 42 into its position wi th the locating cleoning spirit and re-coat with C. 154 flats accurately mating wi th the flots lubricant. moulded into the valve body 37. Lock the (e) Remove cover plate 27 by springing the assembly in position with locknut 43 - retaining lugs individually - remove dia­ finger tight only. phragm assembly 28 and 29 and exomine (d) Ensure that the "0" ri ng seals 33 are in for deterioration. position in item 47 ond assemble 47, 48, (d) Remave exhaust valve cover 34 and pull­ taking care not to damage the "0" rings. out exhaust volve ossembly 36 - remove Insert the spring 46 into 48 and locate with 0 hair brush, any grit embedded on the seat 45 on to the spring. Locete the the volve seot or between the rubber valve gasket washer 44 into 42 end screw 48 plate ond meta I disc - saak in warm with its assembly into 42 and ti ghten with water if necessory to remove encrusted a screw driver applying moderate tension sa lt . only. Ensure that the sw ivel coupling 47 2. TO RE-ASSEMBLE pivots freely. (e) Couple the demand-valve to the unit and (a) Replace exha ust valve assembly 36 by release the air pressure slowly - ensure pressing into valve body 37 - ensure that the volve is not leoking. Inhale and thot it is ful ly home and accurotely lac­ exhale a few times to check that the air ated - no cement is requ ired. Replace flow is sufficient and ceoses at the end af the cover 34 by stretching into posit ion. each inhalation. 5 Roglon Street, North Melbourne Cable: " PORPOISE" Melhourne. Phone: 30-3869 Paga-:3

3. ADJUSTMENT PRDCEDURE ensure that it is intact. However do not after the screw seHing unless the sealing Ta obtain the best performance it is necessary washer has obviously been damaged. to accurately adjust the velve mechanism os (c) If the sc rew setting has not been altered follows:- then replace item 45 into positi on, re­ (0 ) Unscrew the retaining screw 48 end re­ assemble and test. If the leakage still move with its assembly. persists, then the mechanism may have (bl Remove the seet 45 e nd adjust its od­ lost its adjustment. lf so, proeeed to re­ justment screw until the 5crew end is odjust os outlined in 3. level with the seet face - then screw in s. MAINTENANCE TO AIR HOSE klockw ise) one eighth of 0 turn. (c) Re-ossemble end test - if the ve rve still Ensure that the hose bore is c1eor of dirt and continues to accurately close off the air wosh the couplings in methyloted spi rits, us­ suppJy, repeat the process - screwing ing a smoll brush to c; lean the "0" ring seats. the adjustment screw in one e ighth of 0 To repiace " 0" rings - remave with 0 turn each ti me until the vorve ceeses to needle, toking eore not ta damoge the meta I accurotely dose off the air fl ow end cam­ groove end slip new rings into position. Re- mences to discharge c t rest. greose with C.154 lubricent. . . (d) Finally remove the seet 45 once more end bock off (screw onti-clockwise) the adjust­ 6. TD STRIP DOWN REDUCING·VALVE ment 5c rew one-eighth of 0 turn. This will (1st STAGE REGU LATOR) ensure that the volve will be giving its maximum performance. (0) Unscrew item 1 end remove 2 ond 3 with piston ossembly 8 - wosh in c1eoning 4. TO CORRECT DEMAND·VALVE WHEN AIR· spirit and re-coot with C.1 54 lubricant. FLOW DOES NOT COMPLETEL Y SHUT OFF (b) Unscrew 4 from piston ossembly 8 end AFTER INHALATION extroct 5 and 6 ond replace rubber seot on 6 if necessory. Remave greoser 20 ond This con be 0 common occurrence if the volve is not woshed thoroughly in fresh water "0" ring 21 toking porticulor core not after use, or if not protected from dust ond to damage. Exomine 21 for defects ond reploee if necessary. Wash oll meta I ports grit, when not in use. However, it is 0 simple matter to rectify. in cl eoning spi ri t end re-eoat with C.154 lubrieant. (0) Before attempting to correct the volve - im merse in water - solt water will da - (c) Release lock-nut 15 ond unscrew spindie ollow it ta sook for 3 minutes end test it 18. Remave items 11, 12, 13 e nd 14. Un­ aga in . The leokoge moy only be caused serew a ir-fil ter 17 from inside spi ndie 18 by solt encrusted on the seet face of item ond clean gauze by wash ing in cleoning 45 wh ich can be simply removed in this spi rit ond blow clear with on a ir jet. manner. However, jf the trouble persists, Note: The air filter item 17 should be proceed os foll ows:- regularly cleaned to prov ide free air pas­ (b) Unscrew retaining screw 48 and remave sage--o semi-blocked fi lter will restriet the seat 45 - examine the seat face for the air flow censiderably, espeeiolly when embedded grit perticles, which can be re­ the cyJinder pressure is reduced to the lewer pressures. Do not remave 19 unJess moved wi th 0 hair brush or cloth. Exom ine rubber sealing was her under the adjust­ to replace. Exomine 11 earefully for dam­ ment screw head at rear of seat and age from over tension and replace If necesscry. Paga"

(d) Hone the face of sent 12 on 0 fine flot gauge to outlet 10. Open the cylinder carborundum stone with kerosene os a valve slowly end SCrew in retoining screw lubricant, using light finger pressure only. 1 until the gauge registers 95 p.s.i. Allow Hold the hone stotionary and rub the seot, to stand under pressure for 10 minutes face downward, backward and forward, end ensure thot the gauge needle does ocross the hone surfoce. Use 0 mognify­ not increose further than 10 p.s.i. - if ing gloss to examine the seot face - this occurs then the seot 12 should be hone until oll marks are removed. re-exomined. (e) Wosh oll metal parts in deaning spirit (b) With the out let pressure established ond and re-coot with C.154 lubricant. still under pressure - insert 0 screw through the hole in item 1 end en­ (f) Nase seal item 19 is pressed into position driver and can be twisted off with pi iers or by gage the adjustment screw 4. Back off holding the seal lightly in a vice. Replace­ (screw enti-dockwise) until air cam­ me nt seal is tapped into position and mences to discharge end then screw in pressed home, by screwing assembled one full turn. This will occurately set the coupling into the eylinder valve. relief volve to operote ot 150 to 200 p.s.i. {cl Unscrew item land place filter 2 in posi­ 7. TO RE-ASSEMBLE tion and re-assemble, agoin setting the out let pressure to 95 p.s.i. Co) Re-ossemble 4, 5 ond 6 into the piston 8, (dl Fine lly immerse the reducing volve in liberolly eoating the metal ports with water whiJe still under pressure to test for C. 154 lubrieont, ond toking eore to oe­ leokoge. eurately locote item 6 in position. Tem­ porarily odjust the spring tension by 9. TO CORRECT REDUCING-VALVE IF OVER- serewing the retoining serew in until the PRESSURE RELIEF-VALVE CONTINUES TO heod is flush with the end of the piston shoulder - for final setting see 8{b) . DISCHARGE (b) Reploee greoser 20 ond "0" ring 21 and The over-pressure relief-va lve item 6 situated apply C.154 lubrieant liberally to the out­ inside the piston assembly 8 relieves ony ex­ side surfoce of assembly 8, the inner sur­ cess pressure that may leok post the high face of 9, ond ossernble together. Tem­ pressure seot 12. This will be indicated, when porarily leove aside filter 2 and insert the the valve is immersed in water while under spring 3 ond retain in position with one pressure, by e continuous or intermittent turn of the adjustment screw 1. streom of bubbles emerglng from item 1. Ta {cl Carefully remove oll excess greose from correct, proceed as follows - iterns 13, 14 and 17 - keep grease away (0) Unlock the lock screw 15 ond unserew the from the face of item 12. Locote 12 oc­ spindIe ossembly 18. Remove the high curately on the spindie of 8 ond gosket pressure seot item 12 end re-hone the wosher 11 into the body 9. Assemble seat face os outlined in section 6(dl. Re­ items 13 to 18 ond screw into body 9 - assernble, toking core to use only moder­ opplying only moderate tension with 0 ate pressure when screwing horne spindie spanner on the nose of 18 (approx. 5 foot ossembly 18. pounds) and finally tighten lock-nut 15 (b) If the leok persists then remave items 1 firmly. end 2 - insert a screw driver and in­ B. ADJUSTMENT PROCEDURE AND TESTS creose tension of spring 5 by one full turn of odjusting screw 4. Reploce 1 end (0) Attoeh the reducin g volve to 0 fully 2 ond re-odjust pressure os outJined in charged cylinder - connect e pressure section 8(0)...... fw;p ~ • A '{)WV).1 Cc- ~. Lu. T. l 004 , , 10 12 2 • S • "

2· ~1 ------1

23

2-4 2S 26 27 28 29 30 31 33 3S 36

PARTS BREAKDOWN "PORPOISE" UNIVERSAL MODEL 60

Indu Part No. C",u lp lion I"du Part No. Descriptlon

REDUC ING VALVE 18. CA-SR-21 Spring - Reserve S.. pply (ht STAGE REGULATOR) 19. CA-BR-19 Screw - Re taining 1. CA-SR-J Seat Assembly 20. CA-SR-8A Washer - Spring Im.. lating 2. CA-BR-4 Washe. - High Pressu.e Seal 21. CA-B R-17 N .. t - Coupling 3. CA-BR-2 Bonnet - Reducing Val"e 22. CA-SR-12 Spindie - Coupling 4. CA-BR-24 Gland - Locknut 23. CA-SR-13 Sea! - Nose Coupl.ng Spindi.. 5. CA-BR-2J Lockn ut - Tube 24. CA-BR-16 Locknut - Coupling Spindie 6. CA_BR_9 Tube _ Spring Insulaling 25. CA-SR-14 Filter Anembly 7. CA-BR-7 Spr ing - Tension 26. CA-BR-15 W .. .ner - Coupling Spindie 8. CA-BR-BB Washe. - Spring Insulating 27. CA- BR-I Body - Reducing Valve 9. 0-3 Seal - "0" - Ring 28. CA-BR.37 Seal - ;>;Slon Assembly 10. CA-BR-S Piston & Diaphragm A$5(!mbly 29. 0-1 Seal - "0" - Ring 11. CA-BR-10 Piston Base 30. CA-aR-3B Piston - Safely Relief 12. 0-1 Seal - "0" - Ring 3 I. CA-BR-27 Spring - Safely Relie f 13. CA_8R_25 Elbow _ Take-off 32. CA- BR -29 Spindie - Reserve S.,pply 14. CA-BR-20 Washe, - Reserve Supply Housi ng 33 . CA-BR-26 Screw Re'aining - S~fe'y Relief 15. CA-BR-18 Housing Assembly - Reserve Supply 34. CA-BR-3l Lod

Respiratory Engineers, Designers, Manufaclurers 8. Distributors of: COUSTEAU-GAGNAN "AQUALUNG" '1II1d " PORPOISE" DIVING UNITS, INDUSTRIAL BREATHING EQUIPMENT, ACCESSORIES Me mber of the Group comprising: LA SPIROTECHNIQUE, PARIS, FR ANCE - U_ S. DIVERS , LOS ANGELES, U.S.A . _ CRESSI -SUB , ITALY

" PORPOISE" DIVING UNIT - UNIVERSAL MODEL 60 OVERHAUL and ADJUSTMENT

1. TO STRIP DOWN REDUCING VALVE shoulder of piston 10 and with "0" ring seal in position, insert the piston carefully into the bore of (1st STAGE REGULATOR) item 3. Inse rt the holding screws around the outer Ca) Unscrew retaining screw 36 and pull off the plastic flange and Ihrough the mating holes of the rubber hand-wheel 35 - unscrew Jocknut 34 and spindIe 32 diaphra gm, and then locate the whole assembly onto with "0" ring seal 29. Wash metal parts in clean­ the valve body 27. ing spirit and re-grease with special lubricant C. 154. (c) Ensure that the two ports for the tube assembly 1 5 Use only C.154 luhric:ant as normal gruses can are in alignment and then evenly tighten the screws cause an explosion when in contac:t with high pres­ around the valve bonnet 3, until they are al! firmly sure air. nipped up. (b) Unscrew adjusti ng screw 33 and extract spring 31 (d) RepJaee gasket washer 26, screw air filte r 25 lightJy and piston assembly 28 and 30. Wash metal parts into spindIe 22. Assemble 21 and 2 4 into position in cleaning spi rit and re-grease with C. 154. Examine and screw the assembly into the body 27. Tighten neoprene seat 28 for embedded grit and replace if with a small spanner on the hexagon collar of 22 - necessary. use only light tension Capprox. 5 foot pounds) to (c) Unlock the' lock-nut 24 and unscrew the spindie 22 avoid distorting 26, and lock the lock-nut 24 firmJy. complete with its assembled pa rts. Remove 24, 2 1 (e) Locate the end of tube 15 with the grand 4 in and unscrew air filter 25 from inside of spind!e. Do position and loosely screw the nut 5 into position. not remove 23 unless to repJace. Wash all metal Re-assemble items 19, 16, 15 and 14 - insert spring parts in cleaning spirit and regrease with C.154. 18 and press firmly home into 19. Balance the ball Blow the filter gauze on 25 dear with an air jet. 17 on top of the spring 18 and gently screw up into the valve body 27 - taking Care not to dis­ Note: The air filter item 25 shoutd be regularly lodge the ball. Tighten the grand nut 5 and retain­ deaned to provide tree ai r passage - a semi-blocked Ing screw 19 with a small spanner using moderate filter will restriet the air !low considerably - and will tension only (approx. 15 foot pounds). be especially noticcable when the cylinder pressure is reduced to the lower pressures. A blocked tilter (f) Assemble the over pressure relief valve items 30 and will reduce the reserve s\lppl y period, 31 - insert into valve body 27 and retain in posi. tion wi th adjustment screw 33. The valve is de­ (d) Replace gasket washer 26 if distorted through over­ signed to operate at 150 to 200 p.s.i. and the COf­ tension. reet spring tension can only bc applied by the pro­ (e) The nose seal item 23 is pressed into position and cedure outJined in 3{e) - however the outlet pres­ can be twisted off with pliers or by holding the seal sure musl be established first befote attempting to Jigh tly in a vice. Replacement seal is tapped into set the relief valve. Ta enable Ihis to be done, position and pressed home, by screwing assembled temporarily screw 33 in unlil the head is one­ coupling into the cylinder valve. eighth of an inch below the surface. (f) Loosen gland nut 5 and unscrew retaining screw 19 (g) Assemble items 29, 32, and 34 - insert into body - unscrew 5 and remave tube ilssembly 15. Extract 27 and tighten the lock nut 34 firmly - taking care spring 18 and ba ll 17. 00 not attempl to remove to ensure that 'he spindIe 32 is free 10 turn. At­ 'he nylon seal 4, unless to replace. To replace - tach handwheel 35 and lock retaining sc rew 36, ~ twist seal off with pliers and slip replacement seal into position. The new seal is compressed tightly on 3. ADJUSTMENT PROCEDURE AND TESTS to the tube when the lock-nut 5 is tightened. Wash metal parts in cleaning spirit and re-grease with (al The out let pressure of the reducing-vatve is adjusled C.154 lubricant. Examine the ball seat in 27 to see by adding washers item 2 under the head of the if ball has been seating correct!y. If the seat re­ high pressure seat housing 1. These washers are sup­ quires re-facing, it should be machined by a com­ plied in .010" thickness and each washer added in­ petent engineer without enlarging the bore diameter. creases the outl et pressure by 5 p.s.i. Gasket washers 14 and 16 should be replaced if (b) Screw the high pressure seat housing into posi- badly distorted or damaged. lion with one washer - tighten with moderate pres­ sure only. (g) Unscrew item 1, and remove one or more washers 2. Examine the seat face of item 1 and replace if (c) Attach apressure gauge 10 valve out leI 13 and badly grooved. Re-grease with C.154. coup!e the reducing valve 10 a full cyJinder of ilir - release the air pressure slowly and read the out­ (h) Loosen evenly and remove the holding screw5 around let pressure on the gauge. It should read 105 p.s.i. item 3 and remove piston assembly 10 with items 9, plus or minus 5 p.s.i. - adjust to the correct pres­ 8, 7, 6 and 20. Wash these parts wi th the excep­ sure by adding or subtracting washers and finally tion of the spring in mcthylated spirits only, and re­ lock ilem 1 firmly 10 ensure pressure tightness. grease -with C.154 lubricant. Examine "0" ring seal 9 and replace if badly warn. (d) Tes ~ the functioning of the valve - while still under pressure, and with pressure gauge still connected _ {il Extract piston base 11 trom valve body 27. Replace by allowing it to stand for al least 10 minutes. Dur­ "0" ring seal 12 if badly worn re-grease with ing this period the outlet pressure may slowly in­ C.154 lubricant. crease it the seat is a new one or an old one that (il Da not remove the take-off elbow 13 from body 2 7. has been disturbed, but should not exceed 115 p.s.i. Wash in cleaning spirit and re-grease internally with If this pressure is exceeded replace seat item 1. C. 154 lubricant. (e) To adjusl thc over pressure relief valve - after the 2. TO RE-A5SEMBLE out let pressure has been set and while still under pre ssure - unscrew the adiustment screw 33 unlil (a) Placc item 11 with its "0" ri ng seal 12 into posi­ air commences to discharge, then screw in one full tion into the valve body 27. turn and a quarter. (b) Place insulation washer 20, tube 6 and spring 7 (f) Finally immerse the reducing valvc in water to test into item 3. Loeate washer 8 onto the spi ndie for leaks whiJe stiJl under pressure.

5 Rogion $treet, North Melbourne Cable: " PORPOISE" Melbourne. Pho"e: 30·3869 .. • • •

T.l005

. \\'" .

, ,,- - --.,

PARTS BREAKDOWN "PORPOISE" UNIVERSAL MODEL 60

Illdex P,rt No. Dn crlptloll

DEMAND VALV E 20. CA-BO-27 Strap ASHmbly - Neck 21. CA-BD-J7 MO\.Ithpiec. (2nd STAGE REGULATOR ) AIR HOSE 1. CA-BO-28 Ring Clamp • meTa l 22. 0_3 Seal " 0 " - Ring (1 off) 2. CA_SO_. Ring Ctamp • rubber 23. 'U-SL-C Tail _ Coupllng (2 off) 3. CA-80-3 Plate • Cover 2-4. U-Sl-B Nut _ COUpll"Q (2 oft) 4. CA-80-1 6 Oiaphragm 2S. U-SL-D Ring - C,impll"lQ (2 off) 5. CA-80-S Pressure Plale O!aphragm 26. U-SL-A Hose -A ir (hMe 01'111') 6. CA-BO·' Body Assembly 7. CA -80-29 HARNESS • 30 Screw and Nul - Ring Clemp U_H_\-4 B.lt - Waist 8. CA-BD-9 FolIower - Fulcrum L.... r U-H-21 5t,ap Shoul

R.sp ! r~lory Eoginn's, Designers, M~nuf a clu'er. & Dislribulors of: COUSTEAU.GAGHAN " AQUALUHG" end " PORPOIS(" DIVING UHITS, INDUSTRIAL IREATHING IEQUIPMENT, ACCESSORlfS Member of the Group comprising : LA Sf'IROTECHNIQUf, PARIS, FRANCE • U. S. DIVERS, LOS ANGELES, U.S.A • • CRESSI·SUB, ITALY

"PORPOISE" DIVING UNIT - UNIVERSAL MODEL 60 OVERHAUL und ADJUSTMENT

1. TO STRIP DOWN DEMAND·VALVE with a screwdriver, using moderate pressure only. (2nd STAGE REGULATOR) (cl Before assembling further - couple the demand-valve (a) Remove metal ring clamp 1 and rubber ri ng clamp to the unit and apply ;ir p res~ ure - hold the valve 2. Wipe dean and grease screw thread with special so that the mouthpiece is pointing towards the lubricant C.154. g round and measure the distance the fulcrum lever (b) Remove cover plate 3 and dlaphragm assembly 4 17 protrudes through the slot in the body 6. T 0 and 5 by applYlng pressure to one slde and spring­ obtain the best performance it should measure fi ve­ ing them off their spigot. Wash in water and ex­ eighths of an inch - if it protrudes turther thi.lf1 this amine diaphrag.m 4 carefully for signs of hardening the valve will leak, or, if less, the valve will lose or cracking - replace it immediately it shows any same of its performance. The setting of the fulcrum sign of deterioration or 1055 of flexibility. Apply a le ver 17 is adjusted by altering the setting of the smear of C. 154 lubricant to 5 where the ful crum adjustment screw in item 12 _ by screwing dock· lever 17 contac:ts it, taking care to avoid applying wise the fulcrum lever wiJl protrude further, or anti­ Ihe grease where it can contac! the rubber dia~ cJockwise will reduce the amount of protrudance. phragm. One-eighth of a turn on the adjustment screw will (d Unscrew item 16, remove the spring 13 and low alter the position of fulcrum lever approximately one pressure seat 12. Examine the seating face of 12 and thirty·second of an inch. remove embedded grit with a hai r brush. Examine (d) Stretch the diaphragm 4 with its pressure plate 5 the rubber sealing washer under the adjustment into position on the locating spigot of 6 - press the screw head at rear of seat and ensure that it is in· cover plate 3 into position over 4 and finall y as­ tact - however do not alter the $crew $cHing uno semb!e 2 and 1 into position and tighten the sc:rew leu the sealing w.15her has obviously been damaged 7 wi th Ilentle pressure only. or the seat tal:e needs re-bcing. If the seat face is damaged it can be re-faced by grinding lightlyon 3. TO CORRECT DEMAND.VALVE WHEN AIR-FLOW DOES Ihe side of a fine emery wheel after the adiustment NOT COMPLETELY SHUT OFF AFTER INHALATION $C rew has been removed. However the screw setting This can be a c:ommon occurrence if the valve is not must be re·sel as explained in 2(C). Clear the fi lter washed thoroughly in fresh water after use, or jf not gauze 15 with an air jet and replace 14 if damaged protected from dust and grit, when not in use. How· through overtension. Re·grease 13 and 16 with ever it is a simple matter to rectify. C.154 lubricant. (a) Before attempting to correct the valve - immerse in (d) Unscrew knurled nut 11 and extract the assembly. water - sa lt water will do - allow it to soak for 3 Clean 11, 10, 8 and 17 in cleaning spi rit and re· minutes and test it again. The leakage may only be grease with C.154 !ubricant . Replac:e 9 if damaged caused by satt encrusted on the seat face of item through over-tension. 12, which can be simply removed in this manner. (e) Wash the vafve body 6 in warm water _ do not re­ However, if the trouble persists proceed as follows:- move the rubber parts 18, 19 and 21 unless to re­ (b) Unscrew retaining screw 16 and extract the seat 12 place. Ensure that grit is not embedded in the open­ - examine the seat face for embedded grit pa rticles, ing sUts of the e"haust valves 18. Re.coat the in_ ""hich can be removed with a ha ir brush er cloth. terior of the body and the externa! thread wi th C. 154 lubricant, taking care not to apply the grease Examine rubber seal ing washer under the adjustment whefe it could contact the rubber parts. screw head at rea r of seat and ensure that it is in· tact. However, do not alter the serew setting unless (fJ To replace the rubber exhaust valves 18 and mouth­ the sealing washer has obviollsly been damaged. piece 21 - coat the mating surfaces with rubber cement and slide into position. Allow cement to set (c) If the screw setting has not been altered, then replace and then wire bind for added security. Da not apply item 12 into posi ti on, re-assemble and test. If the excessive tension to the wire binding as it will only leakage still persists, then the mechanism may have distc rt the rubber - especiaJly on the exhaust valves, lost its adj ustment. If so, proceed to re-adjust as which could leak if distorted. outlined in 2(c). 2. TO RE·ASSEMBLE AND ADJUST 4. MAINTENANCE TO AIR HOSE {al Re·assemble items 17, 8, 9, 10 and 1 1 and insert En sure ,hat the hose bore is dear of dirt, and wash the into the valve body 6 tighten knurled nut 1 1 couplings in Methylated Spirits, using a small brush to finger tight only. clean the "0" ring seals. (b) Re-assemble Items 12, 13, 14 and 16 and screw Ta replace "0" rings.-Remove with a need!e, taking into valve hcusing 11 - fighten retalning screw 16 care not to damage the meta! groove and slip new rings into position.

5 Raglan Sheet, North Melbou,ne C.ble: " PORPOISE" Melbourne. Phone : 30-3869 T.1006

"PORPOISE" TWIN CYLINDER CONVERSION SET MODEL 60 FOR UNIVERSAL AND SPORTSMAN DIVING UNITS

3

l\IIo'!!!!I 4 C.113

3

1

1. CYLINDER

2. CANVAS CYLI NDER BAG

3. CYLINDER BANDS

4. SPACER

5. MANIFOLD

6. M A NIFOLD KEEPER PLUG

Respiratory Eng inecrs, Designer s, Manufacture rs & Distributors of: COUSTEAU-GAGNAN "AQUA-LUNG" .lind "PORPOISE" DIVING UNITS, INDUSTRIAL BREATHING EQUIPMENT, ACCESSORIES Member of the Group comprising: LA SPJROTECHp.jJQU~ , PARIS, FR AN CE _ U. S. DIVERS, LOS ANGELES, U.S.A. _ CRESSI-SUB, ITAL Y

INSTRUCTIONS TO CONVERT A SINGLE TO A TWIN CYLINDER " PORPOISE" UNIT - MODEL 60

{al Ensure the canvas cylinder bags ltem 2 are stretehed and tied into position.

(bl Conneet the two cylinders by screwing manifold 5 into position - do not fig hten at t his stage. Ensure the man;­ fold is positioned correctly as shown, with the keeper pl ug 6 facing outwa rd and reducer port upward.

(e) Unscrew the tension nut on cach cylinder band 3, until it is engaged by approximately three threads to all ow the cylinder band to expand to its maximum.

NOTE: For the "Sportsman" it wi ll be necessary to attach t he harness to the top eylinder bands and pass under­ neath the battom bands, before assembling - the "UnI· versal" ha rness can be si mply clipped onto the band SPORTSM AN after assembly. Id) Slide the two baUorn cyJinder bands into position - tighten the tension nuts with finger tension only. For the "Universal" the bands should be fitted with the '0' loops facing upwards, to enable the ha rness clips to be attached - fo r the "Sportsman" t he bands are reversed so t kat the '0' loops do not interfe re with the harness.

(e) Assemble the two top eylinder bands onto the spacer 4 and slide into posi tion, again with the '0' loaps positioned to suit the harness - tighten the bands, finger tight only.

(fl Serew the redueing-valve into the rnanifold 5, swing into position shown and tighten all three eoupling nuts with the tension bar supplied - da not use exeessive pressure.

(g) Finally attaeh the air hose - leading away from the redueing-valve as shown fo r eaeh model.

UNIVERSA L

541 King Street, West MeJbourne Cable: " PORPOISE" Melbourne. Phone: 30-4121 T.l007

"PORPOISE" UNIVERSAL AND SPORTSMAN DIVING UNITS

VACUUM ASSISTED BREATHING

Your "Porpoise" is designed ond produced to ollow you to dive with the utmost Confid­ ence ond Safety under All Conditions.

The beginner often commences the sport, thinking thot he only wishes to dive in shallow water, ond does not require equipment buHt to give the maximum performance - he does not understond - thot even in shallow woter, the maximum performance is required in circumstances created by psychologicol ond/or physical hordship, such os, ponic - poin - cold, etc.

Take the exomple of 0 diver becoming entangled or temporarily trapped ot depth - or even caught in astrang under-surfoce current. Unless he is an ext remely experienced diver with absolute controlover his emotions - he will experience same mental anguish - which will couse a rapid increose in the rote ond depth of his respiration. If ­ ot this instant the equipment could not meet the increased air flow demanded - ponie could result with on even further inereesed demond, end the diver would quickly lose eonsciousness. Here, you hove the major couse of diving eccidents.

Under extreme conditions the diver is in 0 similar circumstonce to 0 runner who pours out 0 terrific effort for a short distance - during this periad he will be suffering from on axygen lock with each lung full of air - becouse he connot fill hi s fungs fast enough ~ ond if he cantinued to maintoin his effort he would lose consciousness or at least be so distressed that he would be forced to stap and recover.

This effort is multi plied by depth - and, once you hove over-exerted yourself ot depth, it requires the utmost ski 11 end experience to recover.

Ta overcome the problem of over-exertion, "Vocuum Assistance" hos been built into the valve mechanism to ossist the diver to breathe-it relieves the diver af 60% af the breoth­ ing effart. A Venturi prineiple is built into the velve mechanism which ereates 0 partial vocuum and operates itself an being triggered by the inhalatian, ond stops when the vocuum i5 braken by 0 sl ight back pressure.

Respiratory Engineer., Designers, M/l nufaclurers & Dislribulors of: COUSTEAU-GAGNAN " AQUA_lUNG" "nd " PORPOISE" DIVIHG UNITS, INDUSTRIAL BREATHIHG EQUIPMENT, ACCESSORIES Membcr of the Group comprising : LA SPIROTECHNIQUE. PARIS, FRANCE _ U. S. DIVERS, LO S ANGELES, U.S.A. _ CRESSI-SUB, ITALY

A normal inhalation on sta nda rd equipment will require an inhalation effort to be held for approximately two seconds un til the lungs are f;lled - with "Porpoise" you wi ll fHI your lungs ten t imes faster - in two-tenths of a second - with only an in itial momentary effort.

While it gives a feeling af getting too much ai r - it actually is conserving it by con­ serving your energy - you da not waste air - you use onl y what you demend.

However, it requires a different breothing technique - instead of the slow inhalation normolly required, you need only apply sufficient effort to crock the velve open and it does the rest - as on experienced diver expressed it: "You breathe - like sipping 0 Martini" .

It will be necessory to practise breothing with your "Porpoise" unit, to become accust­ omed to the ropid delivery of ai r, especially if you ore already occustomed to using a standard type of apparatus.

It will be of vo lue to remember:- (0) The rapid discharge of air is much less noticeable when used in the water and any discomfort decreoses wit h depth and exertion.

(b) The Demand Valve out af the water will discharge with a slight knack, or when the varve is held ot the surfoce with the mauthport out of the water and diaphragm immersed.

(cl A discharge can also occur underwater when the Demand Varve is removed fram the mouth during an inhalation, ar wh ile the air is still flawing. In both instances the discharge can be stopped by placing 0 finger aver the mouthport to provide sufficient bock pressure to break the vocuum.

(d) The rapid discharge of air con be simply cantralled in use, by plocing the tip of the tongue over the mouthpart which will actually be between the front teeth. This provides sufficient back pressure ta eliminate the Vacuum Assistance.

Vacuum Assistance is built into both the Universal and Sportsman units for your per­ sonal safety ond hos been in constant use by Austra lian Navy Divers for aver twa yeors. Couple this unporolleled performance with the outstanding workmanship - the top quality materials - ond yau have - A Superior Diving Unit with Built-in Safety.

541 King Street, West Melbourne Cable: "PORPOJSE" Melbourne. Phone: 30-4121