Page 1 TECHNICIAN SERVICE GUIDE 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. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012)
Page 2 SAFETY ..................................13 DIVING IN COLD WATER ............................13 REGULATOR FIRST STAGES ..........................15 PRISM 2 SERVICE & PARTS REPLACEMENT SCHEDULE .................. 20 PRISM 2 ASSEMBLIES DIAGRAM ......................... 22 PRISM 2 ASSEMBLIES DIAGRAM PARTS LIST ....................23 REBREATHER RECEIVING & FINAL INSPECTION FORM ................... 24 PRISM 2 ANNUAL SERVICE CHECKLIST ......................
Page 3 POSITIVE PRESSURE TEST (REPEATED) ......................80 NEGATIVE PRESSURE TEST..........................81 DISASSEMBLE & DISINFECT PARTS ..........................82 EXPLODED VIEW DIAGRAMS & PARTS LISTS ..................... 83 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-3 Doc. 12-4090 - r08 (8/9/2024)
Page 4 FINAL ADJUSTMENT .............................. 116 EXPLODED VIEW DIAGRAM & PARTS LIST (OXYGEN REG.) ................117 EXPLODED VIEW DIAGRAM & PARTS LIST (DILUENT REG.) ................119 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-4 Doc. 12-4090 - r08 (8/9/2024)
Page 5 VERSION 2 & 3 HUD ELECTRONICS SENSOR CALIBRATION ................154 WRIST DISPLAY ELECTRONICS SENSOR CALIBRATION ................156 EXPLODED VIEW DIAGRAM & PARTS LIST ....................... 158 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-5 Doc. 12-4090 - r08 (8/9/2024)
Page 6 REASSEMBLY PROCEDURE (SWITCH PLUG VER. 2 & 3 HUD ................. 180 DISASSEMBLY PROCEDURE (PIEZO SWITCH VER. 1 HUD) ................180 REASSEMBLY PROCEDURE (PIEZO SWITCH VER. 1 HUD) ................180 EXPLODED VIEW DIAGRAM ..........................182 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-6 Doc. 12-4090 - r08 (8/9/2024)
Page 7 DISASSEMBLY PROCEDURE (COMPLETE SERVICE) ..................193 REASSEMBLY PROCEDURE (COMPLETE SERVICE) ..................196 SOLENOID OPERATION CHECK .......................... 199 EXPLODED VIEW DIAGRAMS & PARTS LISTS ....................201 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-7 Doc. 12-4090 - r08 (8/9/2024)
Page 8 Salt Lake, UT 84116 INTRODUCTION This guide provides procedures for proper repair of the Hollis PRISM 2 Rebreather at the time of this writing. This guide does not replace proper instruction from a Hollis Service Seminar Instructor. Instructions contained within this guide are only to be performed by authorized and trained personnel. Before service, ensure with Hollis that this is the latest and most current revision of this guide.
Page 9 : partial pressure of oxygen Positive Pressure Check: a test that looks for leaks in the Breathing Loop when pressurized QD: quick disconnect WOB: work of breathing SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-9 Doc. 12-4090 - r08 (8/9/2024)
Page 10 ! WARNING: This Service Guide is not an instructional manual for operation of the PRISM 2. This guide only provides instructions on repairing the unit. No person should breathe from, or attempt to use in any way, a Hollis Prism 2 rebreather, or any component part thereof, without first completing an appropriate Hollis Certified user-training course.
Page 11 SERVICE GUIDE Notes: SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-11 Doc. 12-4090 - r08 (8/9/2024)
Page 12 Oxygen Service, it cannot subsequently be used with Nitrox breathing gases containing more than 40% oxygen by volume unless it is again prepared for Oxygen Service by a Qualified Hollis Dealer Facility who is certified in and follows Oxygen Service Procedures.
Page 13 COLD WATER AND BATTERIES PRISM 2 units are at the time of this writing shipped with (2) 9v alkaline batteries powering the solenoid. In tem- peratures lower than 40°F/4.4°C they must be replaced with 9v lithium batteries for proper function.
Page 14 Always pre-breathe (duration of 7 - 10 minutes) the PRISM 2 to start the endothermic reaction that will help to stabilize internal temperatures and check the system for proper operation before entering the water. Once the pre-breath is initiated, continue to breathe the unit until the dive is complete.
Page 15 PRISM First Stages are designed specifically to work with the Oxygen Solenoid used by the PRISM 2. DO NOT attempt to make changes to design or tune outside of recommended settings.
Page 16 PRIOR TO DISASSEMBLY • Ensure that you have the latest revision of this Service Guide and all Hollis Service Updates. Check the Hollis Technician Web Site or contact Hollis Customer Service to confirm.
Page 17 • 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 18 Repeat Steps 6 - 7, if necessary. Step 9. Oxygen Service Components require further cleaning and prep. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-18 Doc. 12-4090 - r08 (8/9/2024)
Page 19 • To ensure that the Parts do not become contaminated, assemble the components immediately after completion of Cleaning and Final Inspection. • Ensure that all Replacement Parts used are those specified in the Service Procedure(s) for use with the PRISM 2. Lubrication •...
Page 20 SERVICE GUIDE PRISM 2 SERVICE & PARTS REPLACEMENT SCHEDULE S = SERVICE, R = REPLACE PART AS NEEDED 24 MONTHS 5 YEARS Head to Inhalation Counter lung hose Head to counter lung hose connector O-rings Inhalation Counter lung (old style)
Page 21 SERVICE GUIDE PRISM 2 SERVICE & PARTS REPLACEMENT SCHEDULE S = SERVICE, R = REPLACE PART AS NEEDED 24 MONTHS 5 YEARS O2 Gas restrictors Diluent LP Hoses & QD Diluent HP Hose O2 Pressure gauge Diluent Pressure gauge Oxygen Solenoid...
Page 22 SERVICE GUIDE PRISM 2 ASSEMBLIES DIAGRAM SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-22 Doc. 12-4090 - r08 (8/9/2024)
Page 23 SERVICE GUIDE PRISM 2 ASSEMBLIES DIAGRAM PARTS LIST DIA. P/N DESCRIPTION NOTES 29174 HEAD ASSEMBLY W/PRED. 27755 SCRUBBER BASKET & CAP 27985 BUCKET ASSEMBLY 28224 NUT BAR 28680 MOUNTING TUBE 28217 MOUNTING POST 28681 COVER ASSY. 29229 H FRAME ASSY.
Page 24 SENSOR 2: ATTACH THE TESTING STICKER FROM ATTACH THE TESTING STICKER FROM THE PACKAGING. THE PACKAGING. SENSOR 3: ATTACH THE TESTING STICKER FROM THE PACKAGING. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-24 Doc. 12-4090 - r08 (8/9/2024)
Page 25 NOTES OR REV. UPDATES COMPLETED NOTE: Retain the original copy for store records. Provide a copy to the customer as proof of work completed. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-25 Doc. 12-4090 - r08 (8/9/2024)
Page 26 12. Batteries replaced (Battery Compartment) 13. Battery replaced (Handset) 14. New Oxygen Sensors (delivered to customer, SEALED IN ORIGINAL PACKAGING) 16. Oxygen Solenoid Function Tested 17. All Hollis mandated updates and firmware updates completed 18. Final Inspection Form completed WORK COMPLETED BY: DATE: SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com...
Page 27 Verify if it is time to replace schedule “B parts”. 6. To help find potential unit issues, work through the PRISM 2 Operational Checklist (doc. # 12-4097). It is free to download from www.HollisGear.com/support.asp, or it may be found within the PRISM 2 User Manual doc. # 12-4072.
Page 28 Breathing Loop c. disconnected LP hose e. PRISM 2 User Guide d. faulty ADV (replace) e. Counterlungs not positioned properly 5. Breathing Loop inflating a. stuck manual addition valve a. Breathing Loop while the electronics are shut off b.
Page 29 Battery Compartment b. stuck plunger b. Oxygen Solenoid c. wrong PO₂ setting or needs c. PRISM 2 User Guide calibration d. Wrist Display Computer Dis- play; Routing Board, Electrical d. faulty handset or routing Connectors, & Cables board 2.
Page 30 2. Manual Addition Valve does a. tank valve shut off a., b., c. PRISM 2 User Guide not function to inflate Breathing b. supply tank is empty d., e. Breathing Loop Loop c.
Page 31 2. Manual Addition Valve does a. tank valve shut off a., b., c. PRISM 2 User Guide not function to inflate Breathing b. supply tank is empty d. Breathing Loop Loop c. disconnected Diluent LP Hose d.
Page 32 SERVICE GUIDE SCRUBBER HEAD COMPLETE DIAGRAM 1 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-32 Doc. 12-4090 - r08 (8/9/2024)
Page 33 SERVICE GUIDE SCRUBBER HEAD COMPLETE DIAGRAM 2 TORQUE TO 9 1 in-lbs. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-33 Doc. 12-4090 - r08 (8/9/2024)
Page 34 SERVICE GUIDE SCRUBBER HEAD COMPLETE DIAGRAM 3 2 9 10 4 61 60 3 5 15 16 16 15 12 2 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-34 Doc. 12-4090 - r08 (8/9/2024)
Page 35 1 in-lbs. TORQUE TO 15 2 in-lbs. TORQUE TO 35/40 in-lbs. APPLY INSPECTION LACQUER 5 3 22 47 3 22 23 44 43 1 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-35 Doc. 12-4090 - r08 (8/9/2024)
Page 36 O-RING QTY: 2 28664 FOAM, BATTERY NEST Schedule B component that does not require annual service but should be replaced whenever it is disassembled. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-36 Doc. 12-4090 - r08 (8/9/2024)
Page 37 ELECTRICAL TERMINAL, 6 PIN USED W/ITEMS 63 & 64 * Schedule B componenet that does not require annual service but should be replaced whenever it is disassembled. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-37 Doc. 12-4090 - r08 (8/9/2024)
Page 38 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) SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-38 Doc. 12-4090 - r08 (8/9/2024)
Page 39 SERVICE GUIDE TROUBLESHOOTING The Breathing Loop (DSV/BOV, Breathing Hoses, Coun- ter Lungs; Scrubber Assembly) of the PRISM 2 is sensi- tive to wear and tear (Fig. 1). It should be thoroughly inspected during any service. The key failure to be looking for is a leak or a worn component that is about to fail.
Page 40 2. Rotate the OVER-PRESSURE VALVE (OPV) (40) body clockwise until it is fully closed. 3. Ensure the DSV/BOV (1) is closed. Fig. 5 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-40 Doc. 12-4090 - r08 (8/9/2024)
Page 41 2. Pull the HUD Display off of the DSV/BOV (1) (Fig. 6). Fig. 6 Set it aside carefully. Keep it out of the way so it is not damaged. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-41 Doc. 12-4090 - r08 (8/9/2024)
Page 42 ADV/MANUAL DILUENT ADDITION VALVE (52) (FIG. 10). Inspect mating surfaces and the RUBBER GASKET (53) for damage. Follow the PRISM 2 Service and Parts Replacement Schedule (Doc. 12-4092). See chapter "Swivel Style ADV" for service Fig. 10 instructions.
Page 43 NOTE: A thorough cleaning should rectify any Fig. 12 binding in the 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®.
Page 44 Valves and Service the DSV/BOV (1) as described in the DSV/BOV section of this service guide. 13. Clean and disinfect all components of the Breathing Loop with chemicals currently approved by Hollis before reassembly. REASSEMBLY 1. Place an O-RING (41) on the OVER-PRESSURE VALVE (OPV) (40), as shown (Fig.
Page 45 COUNTERLUNGS (30, 44) to the Counter- lung Mounting Yoke. 6. Lightly lubricate all BREATHING HOSE FITTING O-RINGS (15, 20, 24, 29, 37, 51) with Hollis approved lubricant. Then position them inside their respective O- ring grooves.
Page 46 NOTE: At the time of this writing, production units have a silver index mark for the correct orienta- tion of the fitting (28) (Fig. 23). SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-46 Doc. 12-4090 - r08 (8/9/2024)
Page 47 ! CAUTION: The captive O-ring, not torque, seals the fitting. Excessive torque will only serve to make the Hoses difficult to remove or even dam- age the Fitting. Fig. 26 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-47 Doc. 12-4090 - r08 (8/9/2024)
Page 48 0.22 ~ 0.23 PO₂. If the Oxygen Sensor readings start to drop back to 0.21 PO₂ after 1 minute, there is a positive pressure leak. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-48 Doc. 12-4090 - r08 (8/9/2024)
Page 49 BREATHING HOSES (13, 21, 31, 45) shortened, and the DSV/BOV (1) is still in your mouth, close the DSV/ BOV (1). 4. Allow the system to sit for one minute. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-49 Doc. 12-4090 - r08 (8/9/2024)
Page 50 1. Follow the proceeding subsection Disassembly to break down the Breathing Loop. 2. Clean the components with Steramine™ solution. 3. Drain the components, and hang them to dry. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-50 Doc. 12-4090 - r08 (8/9/2024)
Page 51 22-126 O-RING QTY: 2 29136 O-RING 27350 SCREW 27761 KNOB 22-010 O-RING 27031 MOUTHPIECE 21978 TY-STRAP 22-028 O-RING 27763 HOLDER, OUTLET 27765 MUSHROOM VALVE SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-51 Doc. 12-4090 - r08 (8/9/2024)
Page 52 25399 NUT, BOV VERSION for use w/BOV 28333 HOSE CLAMP QTY: 4 28364 COVER, HOSE CLAMP QTY: 2 27805 ELBOW ASSY., EXHALE 22-125 O-RING SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-52 Doc. 12-4090 - r08 (8/9/2024)
Page 53 25399 NUT, BOV VERSION not used w/BOV 28333 CLAMP QTY: 4 28364 COVER, HOSE CLAMP QTY: 2 27806 ELBOW ASSY., INHALE 22-125 O-RING SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-53 Doc. 12-4090 - r08 (8/9/2024)
Page 54 28992 RETAINING RING 29235 O-RING 27960 O2 ADDITION VALVE 219045 GASKET 24664 OPV, LP 22-125 O-RING 24558 HOLLIS LOGO, BUTTON 23237 ORAL VALVE, METAL SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-54 Doc. 12-4090 - r08 (8/9/2024)
Page 55 DILUENT ADD VALVE REPLACES P/N 27961 28080 GASKET 23237 ORAL VALVE, METAL This component assembly requires annual service. See chapter "Swivel Style ADV for service instructions. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-55 Doc. 12-4090 - r08 (8/9/2024)
Page 56 Tribolube 71 pure breathing gas supply P/N 220.9101 Christo-Lube MCG 111 snap ring pliers P/N TBD O-ring removal tool (plastic) O-ring pick valve core driver SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-56 Doc. 12-4090 - r08 (8/9/2024)
Page 57 3. Turning counterclockwise, remove the RETAINER (1) (Fig. 2). Inspect the RETAINER (1) looking for any Fig. 1 cracks, damage, or other deterioration. Discard if found. Fig. 2 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-57 Doc. 12-4090 - r08 (8/9/2024)
Page 58 While holding the HOUSING (5) and SWIVEL (8) sta- tionary, remove the VALVE CORE (3) with a valve core driver (Fig. 5). Fig. 4 Fig. 5 Fig. 6 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-58 Doc. 12-4090 - r08 (8/9/2024)
Page 59 11. Using an O-ring pick, remove the O-RING (9) from the QD NIPPLE (10) (Fig. 10). Inspect the O-RING (9) for signs of deterioration. Discard if found. Fig. 8 Fig. 9 Fig. 10 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-59 Doc. 12-4090 - r08 (8/9/2024)
Page 60 (3) clockwise (Fig. 13). Tighten to a torque of 7-10 in-lbs (0.8-1.1 N-m). DO NOT overtighten. 5. Slide a lubricated O-RING (7) over the SWIVEL (8) (Fig. 14). Fig. 12 Fig. 13 Fig. 14 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-60 Doc. 12-4090 - r08 (8/9/2024)
Page 61 HOUSING (5) (Fig. 17). Fig. 15 10. Place the PLUNGER (2), dome side up, inside the HOUSING (5) (Fig. 18). Fig. 16 Fig. 17 Fig. 18 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-61 Doc. 12-4090 - r08 (8/9/2024)
Page 62 HOUSING (5) (Fig. 20). 14. Install the ADV onto the Exhalation Counter lung. See the previous chapter "Breathing Loop" for instruc- tions. Fig. 20 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-62 Doc. 12-4090 - r08 (8/9/2024)
Page 63 PLUNGER 216748 VALVE CORE 29294 RETAINING RING 28361 HOUSING 28079 NUT, HOUSING 22-012 O-RING 28358 SWIVEL, VALVE 23-903 O-RING 219736 QD NIPPLE 28080 GASKET SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-63 Doc. 12-4090 - r08 (8/9/2024)
Page 64 Oetiker clamp pliers dowel or rounded tool handle STERAMINE™ cleaner P/N TBD 5/32" allen key P/N TBD Retaining Nut Tool P/N TBD O-ring removal tool (plastic) SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-64 Doc. 12-4090 - r08 (8/9/2024)
Page 65 If you can exhale through the assembly, check the MUSHROOM VALVE (12), O-RINGS (10, 20), FITTINGS (11, 21), CLAMPS (24), BODY (1), and HOSE (25) for damage. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-65 Doc. 12-4090 - r08 (8/9/2024)
Page 66 Fig. 3 10. Remove the O-RINGS (10, 18, 20) from the OUT- LET HOLDER (11), OUTLET ADAPTER (21) and INLET HOLDER (17). Discard. Fig. 4 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-66 Doc. 12-4090 - r08 (8/9/2024)
Page 67 Plastic components should be cleaned in Crystal Simple Green®. REASSEMBLY 1. Lubricate O-RINGS (3,4) with Hollis approved lubri- cant and install them into the Stainless Steel Barrel (Fig. Fig. 7 2. Lightly lubricate the internal walls of the BODY (1) with Hollis approved lubricant.
Page 68 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 INLET HOLDER (17), OUTLET HOLDER (11), and OUTLET ADAPTER (21).
Page 69 15. Repeat steps 12 - 14 for the exhalation side compo- nents. Fig. 14 16. Install the MOUTHPIECE (8) onto the DSV BODY (1) with a TY-STRAP (9). Fig. 15 Fig. 16 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-69 Doc. 12-4090 - r08 (8/9/2024)
Page 70 22-126 O-RING QTY: 2 29136 O-RING 27350 SCREW 27761 KNOB 22-010 O-RING 27031 MOUTHPIECE 21978 TY-STRAP 21978 O-RING 27763 HOLDER, OUTLET 27765 MUSHROOM VALVE SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-70 Doc. 12-4090 - r08 (8/9/2024)
Page 71 Not for use w/BOV 27764 HOLDER, INLET Not for use w/BOV 22-128 O-RING Not for use w/BOV 27765 MUSHROOM VALVE Not for use w/BOV SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-71 Doc. 12-4090 - r08 (8/9/2024)
Page 72 27768 ADAPTER, HOSE OUTLET Not for use w/BOV 27760 Not for use w/BOV 28364 COVER, HOSE CLAMP 28333 CLAMP QTY: 2 28330.14 HOSE, BREATHING SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-72 Doc. 12-4090 - r08 (8/9/2024)
Page 73 P/N 29124 Oetiker clamp pliers pure breathing gas supply P/N 220.9002 STERAMINE™ sanitizer O-ring Removal tool P/N 40.9308 Face Spanner TORX T15 Driver SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-73 Doc. 12-4090 - r08 (8/9/2024)
Page 74 BCD OPV spring. Lungs may slightly drupe during test or feel slightly softer than a BCD 5. Listen for any air escaping. Also look for any deflation of the COUNTERLUNGS SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-74 Doc. 12-4090 - r08 (8/9/2024)
Page 75 This is to ensure repairs have fixed the issue and no other leaks were hidden by the initial leak. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-75 Doc. 12-4090 - r08 (8/9/2024)
Page 76 Breathing Loop. Replace or make any repairs, as necessary. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-76 Doc. 12-4090 - r08 (8/9/2024)
Page 77 HOSE OUTLET ADAPTER (13). Then using the Oetiker clamp pliers engage the HOSE CLAMP'S on the hoses and reinstall the SILICONE HOSE CLAMP COVER. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-77 Doc. 12-4090 - r08 (8/9/2024)
Page 78 (22) or HOSE OUTLET ADAPTER (21). Then using the Oetiker clamp pliers engage the HOSE CLAMP'S on the hoses and reinstall the SILICONE HOSE CLAMP COVER. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-78 Doc. 12-4090 - r08 (8/9/2024)
Page 79 10. Install the two ADV SCREWS into the ADV INHALE TEE. 11. Install the DIAPHRAM, then the DIAPHRAM WASHER and finally screw the INAHLE TEE CAP into position. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-79 Doc. 12-4090 - r08 (8/9/2024)
Page 80 Positive Pressure tested again and pass before being returned to the customer. This is to ensure repairs have fixed the issue and no other SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-80 Doc. 12-4090 - r08 (8/9/2024)
Page 81 Sensor readings should drop to about 0.19 PO₂. If the Oxygen Sensor readings start to creep back up to 0.21 PO₂ after 1 minute, there is a negative pressure leak. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-81 Doc. 12-4090 - r08 (8/9/2024)
Page 82 Disassembly to break down the Breathing Loop. Clean the components with Steramine™ solution. Drain the components and hang them to dry Return items to Customer SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-82 Doc. 12-4090 - r08 (8/9/2024)
Page 83 BMCL Inhale Bladder V2 26200 INLET BODY 26201 INLET NUT 220.9504 BMCL OPV ASSEMBLY COURSE THREAD *item sold individually; quantity represents how many are used SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-83 Doc. 12-4090 - r08 (8/9/2024)
Page 84 SERVICE GUIDE INHALE TEE ASSEMBLY, BMCL SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-84 Doc. 12-4090 - r08 (8/9/2024)
Page 85 BLACK 28992 RETAINING RING 29235 O-RING 27765 MUSHROOM VALVE 2.128 O-RING 27766 NUT, MOUTHPIECE HOSE 26216 CE VERSION NUT, BREATHING HOSE, REVERSE THREAD, WHITE SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-85 Doc. 12-4090 - r08 (8/9/2024)
Page 86 SERVICE GUIDE EXHALE TEE ASSEMBLY, BMCL SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-86 Doc. 12-4090 - r08 (8/9/2024)
Page 87 NUT, BREATHING HOSE 29235 O-RING 28330.16 BREATHING HOSE, 16" 27768 ADAPTER, HOSE OUTLET 2.130 O-RING *item sold individually; quantity represents how many are used SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-87 Doc. 12-4090 - r08 (8/9/2024)
Page 88 P/N 7889 Tribolube 71 Dowel or rounded tool handle P/N 40.9308 Face Spanner 5/32" Allen key O-ring Removal tool Pin Wrench Wrenches of various sizes SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-88 Doc. 12-4090 - r08 (8/9/2024)
Page 89 Apply new O2 Label on the button valve. Install LP Hose to LP Coupling on inhalation Tee Assembly. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-89 Doc. 12-4090 - r08 (8/9/2024)
Page 90 Apply new O2 Label on the button valve. Install LP Hose to LP Coupling on inhalation Tee Assembly SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-90 Doc. 12-4090 - r08 (8/9/2024)
Page 91 O-RING *QTY. 3 3463 PORT PLUG, LP 26211 QD NIPPLE. ADV 28125.14 LP HOSE, 14" *item sold individually; quantity represents how many are used SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-91 Doc. 12-4090 - r08 (8/9/2024)
Page 92 PORT PLUG, LP V3.903 O-RING *QTY. 3 26211 QD NIPPLE. ADV 28125.14 LP HOSE, 14" *item sold individually; quantity represents how many are used SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-92 Doc. 12-4090 - r08 (8/9/2024)
Page 93 (for cleaning threads & basket) white vinegar 1 pair of rubber gloves paper towels 1 painter's or surgical mask lint free cloth or towel SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-93 Doc. 12-4090 - r08 (8/9/2024)
Page 94 1. While pressing the safety lock flush, release the LATCHES (9) (FIG. 1). 2. Pull the SCRUBBER BUCKET (1) straight off the Scrubber Head. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-94 Doc. 12-4090 - r08 (8/9/2024)
Page 95 Lift the HEAD PLATE (27) off the Scrubber Head. c. Remove the O-RING (26). d. Inspect the O-RING (26) for wear and deterioration. Discard if found. Fig. 3 Fig. 4 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-95 Doc. 12-4090 - r08 (8/9/2024)
Page 96 Discard the LOCKNUT (3). Inspect the SPRING (5) and SPRING PAD (4) for signs of decay, damage, or corro- sion. Discard if found. Fig. 5 Fig. 6 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-96 Doc. 12-4090 - r08 (8/9/2024)
Page 97 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. Fig. 10 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-97 Doc. 12-4090 - r08 (8/9/2024)
Page 98 4. Place the LOWER FOAM PAD (20) over the INNER BASKET (15). 5. Thread the SCRUBBER BASKET CAP (18) onto the SCRUBBER BASKET (15) until snug (Fig. 13). DO NOT over-tighten. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-98 Doc. 12-4090 - r08 (8/9/2024)
Page 99 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. Fig. 19 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-99 Doc. 12-4090 - r08 (8/9/2024)
Page 100 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 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-100 Doc. 12-4090 - r08 (8/9/2024)
Page 101 SCREW, BUTTON HEAD QTY: 12 28220 MOUNTING POST 24336 LOCKING NUT QTY: 6 224818 SCREW, BUTTON HEAD QTY: 2 224819 LOCKNUT QTY: 2 27982 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-101 Doc. 12-4090 - r08 (8/9/2024)
Page 102 NOTES 27749 SCRUBBER BASKET, OUTER 27751 SCRUBBER BASKET, INNER 22-133 O-RING 27756 SCRUBBER CAP 27869 FOAM PAD, UPPER 27908 FOAM PAD, LOWER 28977 DECAL SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-102 Doc. 12-4090 - r08 (8/9/2024)
Page 103 SCREW, BUTTON HEAD 29137 O-RING QTY: 2 22-153 O-RING 27809 HEAD PLATE 27810 SEAL, RED CO 27569 WASHER QTY: 4 24787 SCREW QTY: 4 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-103 Doc. 12-4090 - r08 (8/9/2024)
Page 104 NOTE: It may be necessary to partially or com- pletely remove the inner urethane bladder to positively identify the source of the leak SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-104 Doc. 12-4090 - r08 (8/9/2024)
Page 105 NOTE: Hollis USA offers replacement inner blad- ders for BCD wings sold with the PRISM 2. If the Bladder is cut, punctured, or damaged, the inner urethane bladder or the complete BCD Wing should be replaced.
Page 106 1. Following the above sections, remove the Airway As- sembly and Lower Over-Pressure Relief Valve. 2. Unzip the outer fabric. 3. Remove the Urethane Bladder. 4. Replacement is the reverse. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-106 Doc. 12-4090 - r08 (8/9/2024)
Page 107 BLADDER, CCR WING 208.1060.019 AIRWAY 19" without LPQD hose 208.1063 POWER INFLATOR RUBBER GASKET SOLO HARNESS YOKE, COUNTERLUNG SIDE STRAP ASSY. COUNTERLUNG LOWER STRAP ASSY., COUNTERLUNG SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-107 Doc. 12-4090 - r08 (8/9/2024)
Page 108 5/16” Allen Key ¼” Allen Key Soft Jawed Vise Magnifying Lens ¼” Drift Pin Punch 12 mm Open End Wrench surgical gloves (for oxygen service prep) SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-108 Doc. 12-4090 - r08 (8/9/2024)
Page 109 Air supply system, that is not rated for Oxygen Service, it cannot subsequently be used with Nitrox breathing gases containing more than 40% oxygen by volume unless it is again prepared for Oxygen Service by a Qualified Hollis Dealer Facility who is certified in and follows Oxygen Service Procedures.
Page 110 ! CAUTION: Tighten the vise only as needed to hold the first stage secure; DO NOT over tighten. Doing so will result in deformation of the parts, rendering them unusable. Fig. 3 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-110 Doc. 12-4090 - r08 (8/9/2024)
Page 111 ING BAND (9) for any signs of decay. Discard if found. Remove the VALVE PISTON (6) and VALVE SPRING (4) from the BODY (1). SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-111 Doc. 12-4090 - r08 (8/9/2024)
Page 112 DO NOT use impact to “drive” out Fig. 8 the HP SEAT (2). Discard the HP SEAT (2) and DO NOT attempt to reuse. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-112 Doc. 12-4090 - r08 (8/9/2024)
Page 113 Inspect all critical sealing surfaces for scratches or imperfections. ! WARNING: Use only genuine Hollis parts, subas- semblies and components whenever assembling Hollis products. DO NOT substitute any Hol- lis part with a part from another manufacturer, regardless of any similarity in shape, size or appearance.
Page 114 B. Place the loop end of the PROTECTOR CAP (N/S) over the BODY (1). C. Place the SPACER (16) over the PROTECTOR CAP (N/S). SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-114 Doc. 12-4090 - r08 (8/9/2024)
Page 115 11. Install the O-RING (26) onto the RESTRICTOR (26) (Fig. 15). 12. Press the RESTRICTOR (25) into the LP HOSE (24) fitting, as shown (Fig. 16). Fig. 15 Fig. 16 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-115 Doc. 12-4090 - r08 (8/9/2024)
Page 116 Hose into the High Pressure Port via an Fig. 17 adaptor. DANGER: Pressure Relief Valves (18) are required for the PRISM 2 application. DO NOT attempt to place into service first stage regulators without their Pressure Relief Valves (18) installed. FINAL ADJUSTMENT 1.
Page 117 SERVICE GUIDE PRISM OXYGEN REGULATOR FIRST STAGE DIAGRAM SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-117 Doc. 12-4090 - r08 (8/9/2024)
Page 118 Plug, LP O-RING 28843.41 HOSE, HP 204.2310 PRESSURE GAUGE, PSI 28285.38 QD HOSE, 38" 8125.23 LP HOSE, 38" RESTRICTOR, OXYGEN O-RING ORIFICE, OXYGEN PROTECTIVE CAP SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-118 Doc. 12-4090 - r08 (8/9/2024)
Page 119 SERVICE GUIDE PRISM DILUENT REGULATOR FIRST STAGE DIAGRAM SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-119 Doc. 12-4090 - r08 (8/9/2024)
Page 120 240.3001 OP VALVE ASSY. includes O-Ring 23463 Plug, LP 2V3-903 O-RING 28843.41 HP Hose 204.2310 PRESSURE GAUGE, PSI 28285.38 QD HOSE, 38" PROTECTIVE CAP SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-120 Doc. 12-4090 - r08 (8/9/2024)
Page 121 3/4” Open End Wrench P/N 240.9510 In-line Adjustment Tool 11/16” Open End Wrench 1/8" Allen Key 3/32" Allen Key Flat Blade (narrow) Jeweler's Screwdriver Cotton Swab (Q-Tip) SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-121 Doc. 12-4090 - r08 (8/9/2024)
Page 122 NOTE: To avoid internal corrosion and damage, NEVER submerge the BOV assembly in liquid with the LP Hose removed from the coupling (2). Fig. 2 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-122 Doc. 12-4090 - r08 (8/9/2024)
Page 123 (23). ONLY push on the outer edge. 7. Turn the BOV over and press out the EXHALATION VALVE HOLDER (22) in the same fashion as in step Fig. 5 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-123 Doc. 12-4090 - r08 (8/9/2024)
Page 124 NOTE: Be careful not to damage the sealing sur- Fig. 7 face of the inner metal spool (16) and BOV hous- ing (1). Fig. 8 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-124 Doc. 12-4090 - r08 (8/9/2024)
Page 125 SPOOL (16) into the BOV HOUSING (1) (Fig. 11). NOTE: Ensure that the holes for the installation of the lever (34) are aligned when installing the spool (16). Fig. 11 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-125 Doc. 12-4090 - r08 (8/9/2024)
Page 126 VALVE HOLDERS (22, 23) and properly seated (Fig. 14). DANGER: DO NOT put lubricant on the mushroom valves (26). Fig. 13 Fig. 14 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-126 Doc. 12-4090 - r08 (8/9/2024)
Page 127 (Fig. 16). Fig. 15 11. Using Oetiker style pliers reattach the Oetiker clamps (Fig. 17). Fig. 16 Fig. 17 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-127 Doc. 12-4090 - r08 (8/9/2024)
Page 128 (inhalation side) to diver's right (exhalation side) as shown by the arrow (Fig. 20). Fig. 20 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-128 Doc. 12-4090 - r08 (8/9/2024)
Page 129 LP port to eliminate the need for the swivel fitting. If the PRISM 2 is equipped with the swivel fitting, the O- rings should be replaced annually, as follows. 1. Using a 9/16" open end wrench, remove the LP hose counterclockwise from the swivel assembly (Fig.
Page 130 4. Tightening clockwise with a 9/16" open end wrench, install the LP hose end to the SWIVEL (38) to a torque of 35-40 in/lbs (4-4.5 N-m) (Fig. 24). Fig. 24 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-130 Doc. 12-4090 - r08 (8/9/2024)
Page 131 POPPET (6) shaft. Refer to 3. ORIFICE (3) incorrectly Tuning section. 2. Replace with new. adjusted. 3. Adjust ORIFICE (3) to cor- rect contact. Refer to Tuning section. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-131 Doc. 12-4090 - r08 (8/9/2024)
Page 132 (Fig. 22). Inspect the DIAPHRAGM (21) to ensure it is supple and free of any tears, corrosion, or other distortion. Discard if found. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-132 Doc. 12-4090 - r08 (8/9/2024)
Page 133 8. While tilting, lift the POPPET CHAMBER (4) and POPPET (6) assembly out of the BOV HOUSING (1) (Fig. 25). Fig. 24 Fig. 25 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-133 Doc. 12-4090 - r08 (8/9/2024)
Page 134 Ensure that all threading on the HOUSING (1) is in good condition. Discard either if any distortion or dam- age is found. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-134 Doc. 12-4090 - r08 (8/9/2024)
Page 135 Check to ensure that O-rings are clean and supple, and that every part and component has been thoroughly cleaned and dried. ! WARNING: Use only genuine Hollis parts, subas- semblies, and components whenever assembling Hollis products. DO NOT attempt to substitute another manufacturer’s part for a Hollis part,...
Page 136 NOTE: Using a srewdriver that is wider than the slotted end of the poppet (6) will damage the lock nut (11). SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-136 Doc. 12-4090 - r08 (8/9/2024)
Page 137 HOUSING (1) (Fig. 35). Set the INNER RING (32) in place over the DIA- PHRAGM (21). Ensure that it sits flush. Fig. 35 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-137 Doc. 12-4090 - r08 (8/9/2024)
Page 138 2. Pressurize the regulator with a pure air source of 3,000 PSI (206 BAR) and listen to determine that a slight air flow is initially present. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-138 Doc. 12-4090 - r08 (8/9/2024)
Page 139 Troubleshooting Section to determine possible cause and treatment. 7. Clean and disinfect the MOUTHPIECE (27) in warm, soapy water before returning the BOV equipment to the customer. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-139 Doc. 12-4090 - r08 (8/9/2024)
Page 140 SEAT 25391 POPPET 5074 SPRING 5117 POPPET WASHER 4587 LEVER 4335 SPACER 24336 LOCKING NUT 25398.07 PLUG, HOUSING 6326 EXHAUST VALVE 25397.07 EXHAUST COVER SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-140 Doc. 12-4090 - r08 (8/9/2024)
Page 141 28997 PURGE COVER 28998 INNER RING 29049 SCREW, LEVER 29053 LEVER, 2-POSITION 2.010 O-RING 22.130 O-RING QTY: 2 27768 HOSE ADAPTERS, BOV QTY: 2 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-141 Doc. 12-4090 - r08 (8/9/2024)
Page 142 SERVICE GUIDE BOV FIRST STAGE SWIVEL DIAGRAM DIA. CAT. DESCRIPTION NOTES 26769 POST, LP SWIVEL 22.012 O-RING QTY: 2 26768 LP SWIVEL 23.903 O-RING SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-142 Doc. 12-4090 - r08 (8/9/2024)
Page 143 Molykote 7 silicone O-ring pick P/N TBD O-ring removal tool voltmeter (plastic) 12mm socket driver P/N TBD Deoxit Gold® GN5 cleaner snap ring pliers’ dental tool SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-143 Doc. 12-4090 - r08 (8/9/2024)
Page 144 4. Remove the O-RING (11) in the groove of the LID (12) (FIG. 2). Inspect the O-RING (11) for any signs of wear or deterioration. Discard if found. Fig. 1 Fig. 2 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-144 Doc. 12-4090 - r08 (8/9/2024)
Page 145 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 of the Battery Fig.
Page 146 REASSEMBLY DANGER: DO NOT use 9V Alkaline batteries to power the Oxygen Solenoid in cold water. When using the PRISM 2 in water colder than 40°F/4.4°C you must use (2) 9V lithium batteries to power the Oxygen Solenoid. NOTE: If the internal over-pressure plug (2) was still intact upon Battery Housing (1) disassembly, skip step 1.
Page 147 BULKHEAD CONNECTOR, BAT. 29221 CABLE ASSY., BATTERY 28664 BATTERY NEST, FOAM 22-239.50 O-RING 22-235.50 O-RING 28990 COVER, ELECTRONICS 29048 OP VALVE ASSY. W/O-RING # 2V3-903 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-147 Doc. 12-4090 - r08 (8/9/2024)
Page 148 DOW CORNING® O-ring pick 7 silicone volt meter P/N TBD O-ring removal tool snap ring pliers (plastic) dental tool P/N TBD Deoxit Gold® GN5 cleaner SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-148 Doc. 12-4090 - r08 (8/9/2024)
Page 149 1. Sensors are expendable, the diver is not. The sensors from Hollis have a "DO NOT USE AFTER" date printed on the body. They should be removed from service at 12 months of use or 16 months from manufacture, whichever comes first. But regardless of the expect- ed sensor life, they must be taken out of service whenever they fail to operate properly.
Page 150 Fig. 1 stalled in position # 1, 2, and 3 respectively. This will provide the correct fit and placement of the wires. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-150 Doc. 12-4090 - r08 (8/9/2024)
Page 151 NOTE: The Oxygen Sensors (7) are interchange- able. Though for diagnostic reasons pay atten- Fig. 2 tion and note which sensor (7) corresponds to which readout position on the PRISM 2 HUD/Wrist Displays. READOUT ON 2 WIRE LEAD COLORS HUD/WRIST DISPLAY RED &...
Page 152 Hyperoxic Incident for the diver. REASSEMBLY NOTE: Any new sensors (7) must be delivered to the PRISM 2 User sealed in the packaging. The test data sticker inside the box must be adhered to the Hollis Rebreather Receiving and Final Inspection Form (found at the beginning of the PRISM 2 Technician Service Guide).
Page 153 SCRUBBER HEAD (1) and locking the 3 latches. RECOMMENDED SENSORS Hollis PRISM 2's require Hollis brand oxygen sensors (Fig. 4). Connector style: Molex MV Range: 8.5 - 14 mV (in air), 40 - 67 mV (in oxygen) Fig.
Page 154 Press and hold the Piezo Switch to turn the HUD off. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-154 Doc. 12-4090 - r08 (8/9/2024)
Page 155 PPO2 display. If all is well, turn off the HUD per the specific verion instructions. See the following page for a diagram of possible calibra- tion errors. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-155 Doc. 12-4090 - r08 (8/9/2024)
Page 156 See above for troubleshoot- LEDs on solid (1 column) sor #3 has failed. ing. Other columns normal DO NOT dive unless all sensors are functional. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-156 Doc. 12-4090 - r08 (8/9/2024)
Page 157 Cycle through the Menu with the left side button until "Turn Off" is displayed. Then press the right-side button to turn off the Wrist Display. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-157 Doc. 12-4090 - r08 (8/9/2024)
Page 158 RETAINING RING 22-113 O-RING QTY: 2 29224 BULKHEAD CON., OXYGEN 29222 CABLE ASSY., OXYGEN 28683 HOLDER, SENSOR QTY: 3 27946 OXYGEN SENSOR QTY: 3 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-158 Doc. 12-4090 - r08 (8/9/2024)
Page 159 ITEMS IF PROPERLY TRAINED, HAVE THE CORRECT TOOLS AND HAVE A PRESSURE CHAMBER OF SUFFICIENT IN SIZE TO TEST THE INTEGRTITY OF THE SEALS FOR THESE AREAS. Improperly servicing the items in this area of the Prism 2 can cause immediate failure of the computer electronic system and automatic oxygen control.
Page 160 5. bad Sensor Wiring Harness 3. verify issue with a good sen- sor, replace exhausted sensors as needed 4. clean/repair wiring 5. replace Sensor Wiring Har- ness SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-160 Doc. 12-4090 - r08 (8/9/2024)
Page 161 4 corner LED's flashing red 1. no DiveCAN® Communica- Check cables for defect or tions failure. (Ver. 2 & 3 HUD ONLY) SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-161 Doc. 12-4090 - r08 (8/9/2024)
Page 162 Valve section of this service guide for instruc- tions. NOTE: If the battery HOUSING (6) is removed during service, the PRISM 2 Scrubber Head As- sembly will need to be Wet Depth Tested to 200 FSW to complete the service. If you do not have the equipment to do this, you must send the Head Assembly back to the factory for service.
Page 163 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. Fig. 2 6.
Page 164 9. Using inspection lacquer, seal the retaining SCREW (7) or, if present, TAMPER RESISTANT SCREW (4) that is next to the LP oxygen solenoid fitting (diver side). SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-164 Doc. 12-4090 - r08 (8/9/2024)
Page 165 Valve section of this service guide for instruc- tions. NOTE: If the battery HOUSING (6) is removed during service, the PRISM 2 Scrubber Head As- sembly will need to be Wet Depth Tested to 200 FSW to complete the service. If you do not have the equipment to do this, you must send the Head Assembly back to the factory for service.
Page 166 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. Fig. 9 7.
Page 167 1. Using an electrical terminal tool, release the Electrical Terminals and pull them free of the Connector. See (Fig. 15 & 16). Fig. 15 Fig. 16 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-167 Doc. 12-4090 - r08 (8/9/2024)
Page 168 DO NOT over-tighten. Fig. 21 Fig. 22 5. Install the two O-RINGS (20, 21) onto the ADAPTER (19). 6. Align and install the Cable Assembly. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-168 Doc. 12-4090 - r08 (8/9/2024)
Page 169 2. Align and push the PORT PLUG (24) into place on the Scrubber Head. 3. Place the WAVE WASHER (22) over the PORT PLUG (24) end. Fig. 26 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-169 Doc. 12-4090 - r08 (8/9/2024)
Page 170 REASSEMBLY - o xygen ensor ulkhead 1. Lightly lubricate the O-RINGS (26) with Hollis ap- proved lubricant, and install them into the grooves of the BULKHEAD (25). 2. Press the BULKHEAD (25) into the HEAD ASSEM- BLY (27).
Page 171 Then slide the DiveCAN® strain releif sleave over the CABLE (15 or 16) fittings, as shown. 3. Secure the the DiveCAN® strain releif sleave with the two O-rings (Fig. 30). Fig. 30 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-171 Doc. 12-4090 - r08 (8/9/2024)
Page 172 CELL 3 PIN WIRE PREDATOR VIOLET WIRE) CELL 2 PREDATOR BROWN WIRE) WHITE CONNECTOR CELL 1 ORANGE FRONT VIEW PREDATOR GREEN WIRE) EMPTY GREEN BLACK SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-172 Doc. 12-4090 - r08 (8/9/2024)
Page 173 STRIPE EMPTY FRONT VIEW BLUE/ EMPTY WHITE STRIPE SENSOR COMMON SENSOR COMMON O₂ SENSOR 3 POS. O₂ SENSOR 2 POS. O₂ SENSOR 1 POS. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-173 Doc. 12-4090 - r08 (8/9/2024)
Page 174 RETAINING RING 22-014 O-RING QTY: 2 * Schedule B component that does not require annual service but should be replaced whenever it is disassembled. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-174 Doc. 12-4090 - r08 (8/9/2024)
Page 175 DIAGRAM TORQUE TO 4 1 in-lbs. DIA. CAT. DESCRIPTION NOTES 28363 WASHER QTY: 4 216510 SCREW QTY: 4 28622 ROUTING BOARD VER. 1 ELECTRONICS SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-175 Doc. 12-4090 - r08 (8/9/2024)
Page 176 27807 HEAD ASSEMBLY 27872 RETAINING RING * Schedule B component that does not require annual service but should be replaced whenever it is disassembled. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-176 Doc. 12-4090 - r08 (8/9/2024)
Page 177 Molykote 7 silicone inspection light P/N TBD O-ring removal tool O-ring pick (plastic) volt meter P/N TBD thin nut wrench P/N TBD Deoxit Gold® GN5 cleaner SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-177 Doc. 12-4090 - r08 (8/9/2024)
Page 178 2. failed calibration 4 corner LED's flashing red 1. no DiveCAN® Communica- Check cables for defect or tions failure. (Ver. 2 & 3 HUD ONLY) SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-178 Doc. 12-4090 - r08 (8/9/2024)
Page 179 (Fig. 1). 2. Press the SWITCH PLUG (1) out of the Scrubber Head with your finger. Fig. 1 3. Remove and discard O-RINGS (2, 3). SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-179 Doc. 12-4090 - r08 (8/9/2024)
Page 180 2. Press the PIEZO SWITCH (1) into place. 3. Install the WAVE WASHER (4) and thread the RE- TAINING NUT (5) clockwise. Fig. 4 Fig. 5 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-180 Doc. 12-4090 - r08 (8/9/2024)
Page 181 4. Tighten the RETAINING NUT (5) with a Thin Nut Wrench until the WAVE WASHER (4) flattens (Fig. 6). DO NOT over-tighten. Fig. 6 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-181 Doc. 12-4090 - r08 (8/9/2024)
Page 182 28212 THIN NUT 27807 HEAD ASSY. * Schedule B component that does not require annual service but should be replaced whenever it is disassembled. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-182 Doc. 12-4090 - r08 (8/9/2024)
Page 183 225367 SCREW 29233 29238 THUMB SCREW 29237 HUD BRKT ASSY., DSV VER. assembly, parts 7-13 29477 HUD BRKT ASSY., BOV VER. assembly, parts 7-13 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-183 Doc. 12-4090 - r08 (8/9/2024)
Page 184 Molykote 7 silicone O-ring pick P/N TBD O-ring removal tool (plastic) P/N TBD thin nut wrench P/N TBD Deoxit Gold® GN5 cleaner SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-184 Doc. 12-4090 - r08 (8/9/2024)
Page 185 ! CAUTION: DO NOT attempt to remove the cable from the Version 1 or 2 Wrist Display. It is sealed at the factory and is a factory service only item. If the cable needs to be replaced, contact Hollis Customer Service for a Return Authorization (RA) number.
Page 186 Be sure not to cross thread the battery cap’s threads. Tighten the battery cap until snug. Fig. 1 Do not over tighten the battery cap. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-186 Doc. 12-4090 - r08 (8/9/2024)
Page 187 See the Routing Board, Electrical Connectors, & Cables Fig. 5 section of this service guide for instructions on the instal- lation of the HUD Cable Assembly. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-187 Doc. 12-4090 - r08 (8/9/2024)
Page 188 (display set to medium brightness): 35 Hours Battery Operating Life (AA 1.5V Alkline) (display set to medium brightness): 100 hrs, 100 Hours 1 yr standby SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-188 Doc. 12-4090 - r08 (8/9/2024)
Page 189 (plastic) 9/16" open end wrench P/N TBD Deoxit Gold® GN5 cleaner 11/16" open end wrench P/N TBD thin nut wrench P/N TBD solenoid wrench SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-189 Doc. 12-4090 - r08 (8/9/2024)
Page 190 2. verify contents 2. Oxygen Supply Tank filled 3. Clean O injection port in Scrubber Head with incorrect gas 3. O₂ Injection Port clogged SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-190 Doc. 12-4090 - r08 (8/9/2024)
Page 191 DO NOT attempt to service for Oxygen use without proper knowledge and training. DANGER: Use ONLY Tribolube 71® or CHRISTO- LUBE® MCG 111 for lubrication and ONLY Hollis Parts to service the Oxygen Solenoid. Fig. 1 DISASSEMBLY - a...
Page 192 15 ± 2 in/lbs (1.69 ± 0.22 N-m) (Fig. 9). Then apply inspection laquer to one of the SCREW (17) heads. Fig. 8 Fig. 9 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-192 Doc. 12-4090 - r08 (8/9/2024)
Page 193 NOTE: If the Solenoid Compartment is serviced, the PRISM 2 Scrubber Head Assembly will need to be Fig. 11 Wet Depth Tested to 200 FSW (61 MSW) to complete the service. If you do not have the equipment to do this, you must send the Head Assembly back to the factory for service.
Page 194 Then turning counterclockwise, remove the COUPLING (19) with an 11/16" open end wrench Fig. 15 (Fig. 16). Temperarily, set the COUPLING (19) aside. Fig. 16 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-194 Doc. 12-4090 - r08 (8/9/2024)
Page 195 20. Turn the COUPLING (19) upside down so the FIL- TER (20) falls free (Fig. 21). Discard, DO NOT reuse. Fig. 19 Fig. 20 Fig. 21 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-195 Doc. 12-4090 - r08 (8/9/2024)
Page 196 Fig. 23 All Models 1. Lightly lubricate the Internal O-RING (7) with Hollis approved lubricant. 2. Place the Internal O-RING (7) into the groove of the SOLENOID FITTING (12 or 24), as shown (Fig. 25).
Page 197 55 to 60 in/ Fig. 28 lbs (6.2 to 6.8 N-m). DO NOT overtighten. Fig. 29 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-197 Doc. 12-4090 - r08 (8/9/2024)
Page 198 SERVICE GUIDE 12. Lightly lubricate the Solenoid O-RINGS (22, 23) with Hollis approved lubricant, and install the O-RINGS (22, 23) (Fig. 30). NOTE: It is easier to install the inboard O-ring (22) before the receiving end O-ring (23). This allows the O-ring (23) to slide right over the first O-ring (22) groove without seating.
Page 199 SERVICE GUIDE 20. Lightly lubricate the Solenoid O-RINGS (8, 9, 10, 11) with Hollis approved lubricant, and install the O-RINGS (8, 9, 10, 11). NOTE: The four O-RINGS (8, 9, 10, 11) are of slightly different sizes. Ensure each O-ring is in the correct groove before proceeding.
Page 200 27. Following the steps outlined in the Routing Board, Electrical Connectors, & Cables section of this service guide, replace the Battery Housing. Fig. 37 SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-200 Doc. 12-4090 - r08 (8/9/2024)
Page 201 O-RING 22-115 O-RING 22-116 O-RING 29464 O-RING 29448 SOLENOID FITTING 225595 FILTER, 10 MICRON brass color 22-010 O-RING 23-905 O-RING 29543 SOLENOID END BLOCK SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-201 Doc. 12-4090 - r08 (8/9/2024)
Page 202 26810 FILTER chrome color 22-010 O-RING * Schedule B component that does not require annual service but should be replaced whenever it is disassembled. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-202 Doc. 12-4090 - r08 (8/9/2024)
Page 203 O-RING 22-116 O-RING 27846 FITTING, SOLENOID * Schedule B component that does not require annual service but should be replaced whenever it is disassembled. SUPPORT: TOLL-FREE +1 (877) 598-5796 e-Mail: service@hollisrebreathers.com © Hollis (2012) PG-203 Doc. 12-4090 - r08 (8/9/2024)

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