®
REGULATORS
®
(SRB3300)
®
®
(SRB3400)
(SRB3500)
Includes
®
(SRB3200)
Assembly & Maintenance Guide
Download from Www.Somanuals.com. All Manuals Search And Download.
TABLE OF CONTENTS
Page
1.0
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.0
2.1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SRB3300 (Magnum II, SRB3400 (Oasis)
and SRB3500 (Oasis+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.0
O-ring Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
4.0
4.1
4.2
4.3
4.4
First Stage Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Tools Required for First Stage Servicing . . . . . . . . . . . . . . . .5
Disassembly of First Stage . . . . . . . . . . . . . . . . . . . . . . . . . .5
Assembly of First Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Testing of First Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
5.0
5.1
5.2
5.3
5.4
5.5
Second Stage Procedures . . . . . . . . . . . . . . . . . . . . . . . . .12
Tools Required for Second Stage Servicing . . . . . . . . . . . . . .12
Disassembly of Second Stage . . . . . . . . . . . . . . . . . . . . . . . .12
Assembly of Second Stage . . . . . . . . . . . . . . . . . . . . . . . . . .14
Set-Up of Second Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Testing of Second Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
6.0
6.1
6.2
6.3
6.4
Helpful Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Troubleshooting Regulators . . . . . . . . . . . . . . . . . . . . . . . . . .19
Parts Cleaning Recommendations . . . . . . . . . . . . . . . . . . . . .21
Commonly Used Cleaning Solutions . . . . . . . . . . . . . . . . . . .21
Handling Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.0
7.1
7.2
Two Year Warranty and Maintenance Information . . . . . . .23
Proper Procedure for Warranty Paperwork . . . . . . . . . . . . . .23
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
BEFORE YOU BEGIN.....
READ THESE INSTRUCTIONS COMPLETELY BEFORE YOU BEGIN SERVICING THE
REGULATOR.
THESE INSTRUCTIONS ARE INTENDED FOR PEOPLE WHO HAVE BEEN AUTHORIZED BY
SHERWOOD TO REPAIR SHERWOOD SCUBA EQUIPMENT. IF YOU ARE NOT SO
AUTHORIZED - STOP.
Download from Www.Somanuals.com. All Manuals Search And Download.
1.0 INTRODUCTION
1.
The procedures in this manual apply to the Sherwood Scuba MAGNUM II (SRB3300),
OASIS (SRB3400), and OASIS+ (SRB3500).
The most current part numbers can be obtained by calling your Sherwood Sales
Representative or Sherwood Scuba Customer Service.
WARNING
NEVER tighten the hose fitting to the first stage with more than 40 in. lbs. (4.5 Joules)
of torque. The inlet hose fitting can be weakened by overtightening.
All current Sherwood Scuba Regulators have service kits available which contain the parts
which must be changed at every annual service no matter what their condition. The standard
annual service kit for the Oasis, Oasis+, and Magnum is 4000-15. All other parts not contained
in this kit must be inspected by the technician and changed under warranty only if they have
failed due to problems with material or workmanship.
NOTE: Oxygen Enriched Air conversion kits are available for all current Sherwood regulators and valves.
The part number for the models covered in this manual is 4000-15N. These kits are to be installed into
properly cleaned and prepared regulators only by technicians trained by one of the major oxygen enriched
air training agencies.
2.
3.
This manual gives breakdowns of regulator parts, equipment specifications, servicing
instructions, troubleshooting recommendations, and guidelines for proper care of these
regulators. This manual is intended for use only by persons specially trained and authorized to
service Sherwood Scuba equipment.
Anyone attempting to service or repair Sherwood Scuba regulators must have a thorough
understanding of the principles of operation of scuba regulators and valves, as well as the
appropriate mechanical ability. The technician must be properly trained in the safe use of
compressed air and the various tools and cleaning solutions involved in the procedures
outlined in this manual.
4.
5.
The best source for current part numbers for any of the parts listed in this manual is your
current parts and price list from Sherwood.
Because of the many unique features found in Sherwood regulators, Sherwood conducts
seminars on a regular basis throughout North America to train technicians in proper service and
repair procedures for all current Sherwood regulators. In addition, all Sherwood dealers and
their staff members are encouraged to attend the seminars to gain an in-depth understanding
of the construction, special features and operation of Sherwood regulators. For information on
the dates and locations of upcoming Sherwood service seminars near you, contact your
Sherwood Sales Representative.
NOTE: You must be authorized by Sherwood to work on Sherwood Scuba equipment. You can obtain
proper authorization by attending all appropriate seminars given in your area. This is the only way you can
become an authorized Sherwood technician.
1
Download from Www.Somanuals.com. All Manuals Search And Download.
6.
7.
Companion instructional VHS videotapes to this and other Sherwood Scuba repair manuals are
available from Sherwood Scuba at a nominal cost. Ask your Sherwood Scuba Sales
Representative for details.
If you have any questions, or need more information, contact your Sherwood Scuba Sales
Representative or Sherwood Distributor.
2
Download from Www.Somanuals.com. All Manuals Search And Download.
2.0 SPECIFICATIONS
2.1
SPECIFICATIONS FOR THE SRB3300 MAGNUM® II, SRB3400 & SRB3500 OASIS®
REGULATOR MODELS:
Sherwood Magnum II SRB3300,
Oasis SRB3400 & SRB3500
AIR FLOW:
28-29 cu. ft. (793-821liters)/min. @ 1 atmosphere
1.1” (2.8 cm) w.c. @ 1 atmosphere
0.8” (2 cm) w.c. max. @ 1 atm.
LTI Christo-Lube®
INHALATION RESISTANCE:
EXHALATION RESISTANCE:
RECOMMENDED LUBRICANT:
A.
First Stage Regulator:
TYPE:
Flow-by piston with Moving Orifice Balancing and
Dry Air Bleed - U.S. Pat. # 4,226,257
1 lb. 3 oz. (.54kg)
WEIGHT:
INTERSTAGE PRESSURE:
MAXIMUM INLET PRESSURE:
135 -150 psi (9-10 bar)
232 Bar for SRB3300CE, SRB3900CE,
SRB3400CE & SRB3500CE Models
POSITIVE AIR PURGE
FLOW RATE:
13-27 cc/minute
# LOW PRESSURE PORTS:
# HIGH PRESSURE PORTS:
MATERIALS:
4 (3/8”-24 UNF)
2 (7/16”-20 UN)
Body - CDA-360 Brass
O-rings - Buna-N
Bleed Valve - Ethylene Propylene
Piston Seat - Teflon®
B.
Second Stage Regulator:
TYPE:
Downstream valve, diaphragm, Variable Fulcrum
- U.S. Pat. #3,991,785
WEIGHT:
7.6 oz. (.22 kg) ( w/o hose)
HOSE LENGTH:
MATERIALS:
31 in. (.79 m)
Cover - Thermoplastic Vinyl
Case - Thermoplastic Triax®
Poppet Seat - Buna-N
Poppet Seat - Buna-N
O-Rings - Buna-N
Diaphragm - Tufel® (black)
Exhaust Valve - Thermoplastic Elastomer (blue)
Mouthpiece - Liquid Silicone Rubber
Maximum certified depth is 50m
3
Download from Www.Somanuals.com. All Manuals Search And Download.
3.0 O-RINGS REFERENCE CHART
G007A
Moving orifice, small
end of piston
G907A
Seals second stage
orifice
to case
G0101A
Outlet end of hose
G022A
Large End of
piston
G011B
L.P. port plug, inlet end
of hose
G904A
Under filter in first stage
H.P. port plug
G122A
Seals cap to body
1.
2.
Before you begin disassembly of the regulator, test the first and second stages for output
pressures and leakage. Pre-testing in this way will help the technician to pinpoint any specific
problems requiring repair.
The work area must be clean and well lighted, with clean compressed air available to blow
sand and dirt from parts.
4
Download from Www.Somanuals.com. All Manuals Search And Download.
4.0 FIRST STAGE PROCEDURES
4.1
TOOLS REQUIRED FOR FIRST STAGE SERVICING
– Bench vise
– 3/32" Allen wrench
– 5/32" Allen wrench
– 6" or 8" adjustable wrenches
– 15" adjustable wrench
– Phillips screwdriver
– #10 Torx screwdriver
– Sherwood 50 cc Graduated Cylinder (p/n TL110)
– Sherwood Piston Seat Removal Tool (p/n TL112)
– Sherwood Plastic Probe (p/n TL111) to push out orifice
– Sherwood Regulator Support Handle (p/n TL113)
– Sherwood Intermediate Pressure Gauge (p/n TL119)
– Sherwood Inlet Filter Installation Tool (p/n TL115)
– Sherwood O-ring Installation Cones:
Brass-colored - p/n TL106 ( for installing small O-ring on piston tip )
Green-colored - p/n 38-TL107 ( for installing 1st O-ring onto moving orifice )
Black-colored - p/n 29-TL108 ( for installing 2nd O-ring onto moving orifice )
– Sherwood Oxygen Compatable Lubricant (Crystolube LTI) p/n SW-MS150
NOTE: For more information on Sherwood tools and their uses, see Sherwood’s Tools, Repair Kits and
Accessories - Assembly & Maintenance Guide, available from Sherwood.
4.2
DISASSEMBLY OF FIRST STAGE
To view all the parts used in the first stage, fold out the front cover of this manual. The
circled numbers below refer to the corresponding numbers on the drawing.
1.
Use 6” or 8” adjustable wrenches to disconnect all hoses from the first stage. Pull back the
hose protector from the inlet end of the hose. Inspect the hoses for wear. Pay particular
attention to the area where the metal ferrules meet the rubber hose material. Replace hoses if
necessary.
2.
3.
Unscrew and remove the handwheel 1 .
9
Remove the dust cap
.
5
Download from Www.Somanuals.com. All Manuals Search And Download.
14 16
4.
5.
Use a 5/32” Allen wrench, and a small adjustable wrench to remove all port plugs
hoses from the body.
and
10
Install a Sherwood regulator support handle (p/n TL113) into one of the low-pressure ports.
Use the support handle and a 15” adjustable wrench or bench vise to loosen the yoke nut
from the body
. See Photo #1.
12
Photo #1
NOTE: If a Sherwood DIN adapter (p/n SAA5200, or SAA5300) is installed in place of the more common yoke
assembly, remove it at this time. See Sherwood Technical Bulletin #104 for servicing procedures for the DIN
adapter.
6.
7.
Remove the yoke 11 and yoke nut
from the body.
10
Use the Sherwood regulator support handle and a 15” adjustable wrench or a bench vise to
25
remove the cap
from the main body.
8.
9.
Remove the spring
any shims
and the piston assembly 23 from the cap. Remove both
20
19
piston O-rings and discard them.
Remove the piston seat
by pushing through the stem with the Sherwood piston seat
22
removal tool (p/n TL112) from the large end. The seat will then pop out. Discard the old seat.
6
Download from Www.Somanuals.com. All Manuals Search And Download.
CAUTION
If any grease or oil gets on the piston flow control element, the air flow through the Dry
Air Bleed System will be impeded.
Photo #2
a. Keep greasy fingertips away from the flow element during servicing.
b. Use a clean, dry cloth to wipe the piston surface if it needs cleaning.
c. Do not put the piston in a cleaning solution or ultrasonic cleaner. If there is any oil on the
surface, it will coat the piston.
d. A coating of grease or oil will interfere with the air flow through the flow control element in
the face of the piston (see Photo #2). It may also cause the Dry Air Bleed System to cease
working. Although this is not dangerous to the diver, it may increase the difficulty of
breathing though the regulator upon descent.
e. If no air is bubbling from the one-way bleed valve, this is a good indication that the positive
air purge system is not working.
10.
Use a pocket screwdriver to remove the star washer 2 that holds the inlet filter 3 in place.
Most units used a star washer (a flat disc washer with six outwards facing legs) Units made in
1997 use a wire retaining ring with inward hook. The only first stage bodies that can use this re-
usable ring have a groove machined into the area above the filter for the ring to fit snugly into.
Always discard the used inlet filter. Old style star washers are discarded, newer style retaining
rings are saved for reuse.
11.
12.
Remove the moving orifice assembly 4 from the body by pushing it with the Sherwood
plastic probe (p/n TL111) from the large threaded end of the body. Catch the orifice assembly
in your hand as it comes out the yoke nut thread end of the body. Carefully inspect the disc
springs
for any cracks. Replace all five disc springs if any cracks are found.
6
15
Remove the one way bleed valve
from the body with your fingers or a soft plastic probe.
DO NOT use a metal screwdriver or blade since this will scratch the sealing surface against
which the bleed valve seals. A scratch may allow water to enter the first stage spring chamber
during use.
7
Download from Www.Somanuals.com. All Manuals Search And Download.
The sealing surface on the body where the one-way valve seals must be totally clean of
deposits. If any deposits remain on the sealing surface after initial cleaning, take a fine abrasive
polishing stick or a pencil with a new eraser and polish the surface to remove deposits (see
Photo #3).
Photo #3
13.
14.
15.
Blow all residue from the body after polishing.
18
Remove the large O-ring
from the body. This O-ring can usually be reused.
If necessary, clean all metal parts of the first stage except piston in an ultrasonic cleaner or
cleaning solution. Remove the O-rings before cleaning any metal parts; most cleaning
solutions can damage the O-ring material. See Section 6.3 for recommendations on cleaning
solutions. If major visible corrosion or deposits exist on parts, use a bristle brush, wooden, or
plastic stick to rub the deposits off. Allowing acidic cleaning solutions to do all of the work if
deposits are severe, will result in damage to internal chrome plating which will make parts even
more susceptible to future corrosion.
16.
17.
Remove the regulator parts from the cleaning solution. Blow all internal passageways dry with
clean, dry compressed air.
Inspect the bores in which the piston and orifice O-rings move for corrosion or wear. If the
bores are leaking air because of wear, replace the parts. If some corrosion deposits persist,
carefully wipe them away with a plastic scrubbing cloth. Blow any resulting dust out of the
regulator parts.
18.
Remove and discard the two black O-rings
from the moving orifice
. Save the white
7
4
backup washer; it can be reused. Inspect the moving orifice’s sealing surface (located at the
top edge of the orifice cone). Any nicks, scratches, or corrosion at the top of the cone can
allow air to pass, which will result in creeping hose pressures. Polish out the defects using a
fine abrasive polishing stick or pencil eraser. When polishing, apply a light pressure to prevent
excessive wear on the cone. Use compressed air to blow away any dust created by the
polishing process. You do not have to polish or smooth the relatively rough lower/outer edge of
the orifice cone. This is not a sealing surface.
8
Download from Www.Somanuals.com. All Manuals Search And Download.
4.3
ASSEMBLY OF FIRST STAGE
1.
The part number for each regulator kit can be found in Sherwood’s Tools, Repair Kit and
Accessories - Assembly & Maintenance Guide. The kits contain the minimumparts that must
be replaced at every annual service interval. The technician will also evaluate the condition of
all other parts to determine replacement needs. The kit number for the regulators covered in
this manual is 4000-15. The Nitrox kit for these models is p/n 4000-15N
2.
Before installing new O-rings on the piston and moving orifice, lubricate the O-rings with LTI
Crystolube (Sherwood p/n SW-MS150). Installation of the small O-ring 21 on the piston is
made much easier by using the brass-colored Sherwood O-ring installation cone (p/n TL106).
Place the cone over the tip of the piston. Slide the lubricated O-ring over the cone until it slips
into the piston groove.
3.
4.
Place the new piston seat on a clean piece of paper on a hard flat surface. Press the piston tip
firmly over the seat until it is fully installed. The piston is now rebuilt and ready for installation.
Use the Sherwood installation cones to prevent damage to the new O-rings during installation
onto the moving orifice. Use the black O-ring installation cone (p/n 29-TL108) to install first the
new O-ring 7 and then the used backup washer
onto the wider groove on the moving
8
orifice. Postion them so that the black O-ring is closest to the wide end of the moving orifice.
Use the green O-ring installation cone (p/n 38-TL107) to install the O-ring into the groove
closest to the pointed tip of the orifice.
5.
6.
Using a greased soft probe, lightly lubricate the first 1/8” of the small bore in the body
where the small piston and moving orifice O-rings seal.
13
With your finger, push the moving orifice assembly, pointed orifice end first, into the yoke end
of the main body as far as possible. Place the inlet filter 3 , rough side up, on top of the
moving orifice. Place the retaining ring or star washer 2 on top of the filter. Push the retaining
ring or star washer firmly into place with a dowel or screwdriver.
18
12
7.
8.
Replace the cleaned and lightly lubricated O-ring
on the body
.
Install the piston assembly 23 squarely into the cap
. If any shims were found when the
25
regulator was disassembled, place them over the piston stem. Then place the main spring 19
over the piston stem.
9.
Install the cap assembly onto the body. Hand-tighten the assembly as tightly as possible, then
install the Sherwood regulator support handle into one of the low pressure ports. Using a 15”
adjustable wrench or a bench vice to hold the cap, tighten the cap onto the body until it
bottoms on the thread. Do not tighten further.
10.
Using your index finger, install the clean and dry one-way bleed valve
into the body.
15
NOTE: If you use the bleed valve with the Sherwood logo molded into it P/N 3106-06 you will notice a
“dot” molded near the right side of the logo. Install the bleed valve with the “dot” oriented closest to the
inlet of the regulator (toward the yoke).
11.
12.
Lightly lubricate the body yoke nut threads with grease, and install the yoke
nut 10 onto the body.
and the yoke
11
Using the regulator support handle (p/n TL113) in one of the L. P. pressure ports of the body
and a 15” adjustable wrench, tighten the yoke nut snugly (see Photo #1).
9
Download from Www.Somanuals.com. All Manuals Search And Download.
13.
14.
Install the handwheel
and the dust cap
onto the yoke.
9
1
If the first stage has a SAA-5300 DIN adapter installed instead of a standard yoke, see the
installation instructions given in Sherwood Technical Bulletin #104 for overhaul and installation
instructions of the DIN adapter.
4.4 TESTING OF FIRST STAGE
NOTE: For safety, always test the first stage regulator with at least one second stage installed.The
demand valve on the second stage acts as a relief valve in the event of a malfunction.
A.
Before You Begin Testing
1.
Install an intermediate pressure test gauge (p/n TL119) into one of the low pressure ports of the
first stage. Plug any open outlet ports with suitable port plugs.
2.
Install the first stage onto a tank valve, and introduce 2700 - 3500 psig (186-240 bar) to the
inlet of the regulator. Flow air through the regulator by pushing the purge button on the second
stage several times to get all parts properly seated.
B.
1.
2.
Dry Air Bleed Flow Test
Submerge the first stage under several inches of water.
A small stream of bubbles should be escaping from the one-way bleed valve on the first stage
and nowhere else on the body (see Fig. 1). The number and size of the bubbles may vary from
regulator to regulator, but the volume of air should be 13 - 27 cc per minute. To check this, use
the following steps:
a. Invert a small (50 cc capacity) graduated cylinder (p/n TL110) filled with water over the
underwater flow of bubbles (see Fig. 1). The air entering the cylinder will gradually empty
some of the water out of the cylinder.
b. After one minute, remove the graduated cylinder from the air flow and raise the cylinder to
the surface so that the air/water dividing line inside the cylinder matches the water level
outside the cylinder. The measurement at this point should be between 13 and 27 cc.
c. If the reading is significantly higher than 27 cc, check the O-rings and sealing surfaces
mated to the piston. If the reading is below 13 cc, check the flow control element in the
piston (see photo 2) to determine if it has been clogged by grease or other foreign matter.
If it is clogged, the piston must be replaced.
Figure #1
10
Download from Www.Somanuals.com. All Manuals Search And Download.
C.
Intermediate Pressure Test
NOTE: This test determines the regulator’s lock-up pressure (the pressure put out by the first stage during
a no-flow condition).
1.
Attach any Sherwood second stage to one of the low pressure ports, and the Sherwood
intermediate pressure gauge (p/n TL119) to another low pressure port. Plug all other ports with
appropriate port plugs.
2.
3.
Attach the regulator to a tank valve giving a source pressure of between 2700 and 3500 psig
(186-240 Bar).
Turn the supply air on slowly while listening for any unusual air leaks. If any are heard, turn the
air off immediately and determine the source of the leak. If no leaks are found, watch the
pressure gauge reading rise as you continue turning the air on slowly. It should stop around
145 psig ( 10 bar).
4.
5.
6.
If the pressure gauge continues to rise above 155 psig (10.4 bar), turn the air supply off
immediately and inspect the regulator to determine the cause.
Once the air pressure stops rising, the internal parts should be worked into place by allowing
air to escape from the second stage several times by pushing the purge button.
If you have depressed the purge button several times and the pressure is below 135 psig
(9.3 bar), you can add shims
to increase the pressure. Do not use more than three shims.
20
7.
8.
If the pressure is too high, above 150 psig ( 10.3 bar), remove the necessary shims.
After the correct pressure has been reached, let the regulator sit for several minutes and then
depress the purge button again to check that the regulator returns to the proper pressure.
Never set the output pressure of the first stage above 150 psig (10.3 bar).
11
Download from Www.Somanuals.com. All Manuals Search And Download.
5.0 SECOND STAGE PROCEDURES
5.1
TOOLS REQUIRED FOR SECOND STAGE SERVICING
– Two good quality 6" or 8" (15 or 20 cm) adjustable wrenches
– #10 Torx screwdriver
– Small Phillips ACR Screwdriver
– Size 0 Square Drive (Robertson Head) screwdriver
– Side cutting pliers
– Sherwood In-line Adjusting Tool ( p/n TL102 )
– Sherwood Plastic Probe (p/n TL111) to push out orifice
– Sherwood Lever Height Adjusting Tool (p/n TL123)
5.2
DISASSEMBLY OF SECOND STAGE
WARNING
NEVER tighten the hose fitting to the first stage with more than 40 in. lbs. (4.5 joules) of
torque. The inlet hose fitting can be weakened by overtightening.
To view the complete parts list of the second stage, fold out the back cover of this manual.
1.
2.
Pull back the hose protector 27 from the inlet end ferrule. Remove the hose assembly 26
from the orifice housing
. Inspect the hose assembly for any cuts or cracks, especially on
22
the hose at the metal ferrules. Replace the hose assembly if any cuts or cracks are found.
Remove the mouthpiece 18 by cutting the mouthpiece tie 19 with side cutting pliers. Discard
the old mouthpiece tie. Examine the condition of the mouthpiece. Pay particular attention to
the area on top just behind where the old tie tightened. This is a prime area for small holes to
develop. If the mouthpiece is in good condition, it can be reused.
3.
4.
5.
Remove the exhaust tee retaining screw
with a Phillips or Square Drive screwdriver.
15
14
Remove the exhaust tee
from the case by pulling it back and off the top edge.
5
Remove the front cover
from the case by turning the bezel ring by hand. Some older units
(manufactured before 1986) have a metal bezel ring with a small metal locking tab in the
mouthpiece area. Remove this ring with a small slotted screwdriver.
A.
Purge Button Change:
only
NOTE: At this point, the purge button can be removed from the cover. This will be necessary
button travel is impeded by silt deposits, or if the logo
if the
1
is to be changed to a different color. If it is
necessary to remove the purge button, follow the next sub-steps A to E. Otherwise, go on to Step 6.
12
Download from Www.Somanuals.com. All Manuals Search And Download.
a. Place the cover assembly with the purge button logo face down on a clean flat surface.
b. From the inside of the cover assembly, push the four barbed tabs holding the purge button
assembly in place in towards each other. This will release the purge button
assembly from the cover.
NOTE: The purge button spring is located behind the purge button, with the wide end of the coil toward
the cover. Be sure to replace the spring with the wide end facing the cover.
1
c. If only the label insert
was purchased for installation, carefully remove the old label
with a thin flat-blade screwdriver, and install the new
insert from the purge button
2
colored label insert in its place.
d. Reverse the disassembly procedure to reassemble the case assembly with the new color
logo installed.
6.
7.
Gently remove the diaphragm
from the case. Hold the diaphragm up to a light source.
6
Gently stretch the diaphragm and look for tears or pinholes. If any are found, replace the
diaphragm. Otherwise, the diaphragm can be reused. If you are repeatedly tearing diaphragms
during this visual inspection, you are using too much force. You cannot return diaphragms torn
in this way for warranty credit.
Clamp the Sherwood modified 3/4” deep socket (p/n TL118) in a bench vise. Lower the lever
9
into the socket until the 3/4” hex of the lever support
10
13/16” wrench to loosen and remove the orifice housing
is engaged in the socket. Use a
.
22
NOTE: Some regulators (Oasis, Blizzard, Classic) will have heat transfer fins (10B) attached to the lever
support. The modified 3/4” socket will still fit onto the lever support with the fins attached. You can leave
the fins attached throughout your servicing. If the fins are damaged and need to be replaced, use the
Sherwood 5/32” drive socket to remove and replace the two 5/32” hex head screws (10A).
8.
Use the Sherwood in-line adjusting tool (p/n TL102) to back the adjusting orifice out of the
orifice housing until the threads disengage. Remove the in-line adjusting tool, and push the
adjusting orifice the rest of the way out of the orifice housing with the Sherwood Plastic Probe
(p/n TL111).
9.
Remove the O-ring
from the adjustable orifice.
23
10.
Before removing the exhaust valve
from the case, bend it over as far as it will go from the
16
top, bottom, left, and right sides. If it fails to snap back quickly, and does not lie perfectly flat
against the case, the valve should be replaced. If it does snap back satisfactorily, remove it and
inspect the sealing edges. If they appear smooth, and the locking tab on the nipple is good,
the valve can be reused.
21
11.
12.
Remove the spacing washer
, and the O-ring
from the threads of the lever support 10.
20
Remove the lever support from the inside of the case 17 .
Normally, you will simply need to change the poppet stem seat insert
to restore the second
13
stage to maximum performance. To change the stem seat insert 13, leave the lever assembly
together. With a penknife or similar object, carefully remove the old seat insert. Put the new
seat insert on a clean flat surface and lower the poppet cavity (from which the old seat insert
was removed) over the new seat insert. The new style black molded seat ( p/n 978-9BN)
should be installed with the identifying Sherwood symbol facing outward.
13
Download from Www.Somanuals.com. All Manuals Search And Download.
13.
If parts of the lever assembly (stem, spring, lever, etc.) need to be replaced, take apart the
assembly with the Sherwood stem socket tool (p/n TL124) Clamp the stem socket tool in a
bench vice. Insert the square head of the poppet stem into the tool. With a Phillips screwdriver,
or preferably a size 0 Square Drive (Robertson Head) screwdriver, loosen the screw
holds the assembly together.
that
7
NOTE:If only the lever
from under the washer
way out.
is to be replaced, do not totally remove the screw. You can remove the lever
by pushing the poppet into the lever support when the screw is almost all the
9
8
14.
15.
Rinse all plastic and silicone parts in clean fresh water, and then blow the parts dry with
compressed air to remove any sand and dust particles.
If necessary, clean all metal parts of the second stage in an ultrasonic cleaner or cleaning
solution. Remove the O-rings before cleaning any metal parts; most cleaning solutions are
damaging to the O-ring material. See Section 6.3 for recommendations on cleaning solutions.
22
NOTE: If you use an ultrasonic cleaner to clean the second stage adjustable orifice
, use a plastic
container to prevent the orifice from vibrating against other metal parts which could damage the orifice seal.
16.
17.
Inspect the case
for any cracks. Look particularly closely at the area where the orifice
17
housing and the lever support clamp down. Replace the case if any cracks are found.
Inspect the orifice sealing cone (where the poppet insert seals) for any nicks, scratches, or
corrosion. Corrosion or minor scratches can be polished out using a fine-grit rubberized
polishing stick or a clean new pencil eraser. Do not apply heavy pressure when rotating the
polishing stick. Stop polishing immediately after the corrosion or scratch disappears. An orifice
will not be accepted for warranty replacement simply because it is dirty or corroded. The
technician must clean the orifice sealing surface at every service interval.
18.
Blow all dust and debris out of the orifice housing with clean compressed air.
NOTE: Prior to this point, you should have cleaned and inspected all parts, following proper servicing
procedures. Do not continue until this has been done.
5.3
ASSEMBLY OF SECOND STAGE
1.
Re-install the cleaned and lubricated O-ring 23 onto the adjustable orifice 24. Install the
adjustable orifice back into the orifice housing. Push it in with your finger as far as it will go.
2.
Install the exhaust valve 16 into the case by inserting the nipple into the small hole from the
outside of the case. Reach inside the case and pull the nipple firmly with the fingers until you
hear or feel it “click” into place. Inspect the exhaust valve to see that it is properly seated.
3.
4.
Install the lever assembly into the case.
21
on the threads of the orifice housing. Install the spacing washer
20
Install the O-ring
around the outside of the O-ring.
NOTE: The spacing washer must be installed with the outer lip facing upward toward the orifice housing.
14
Download from Www.Somanuals.com. All Manuals Search And Download.
22
onto the threads of the lever assembly. With a 13/16” wrench on
5.
Screw the orifice housing
the orifice housing and a Sherwood modified 3/4” deep socket (clamped in a vise) on the hex
of the lever support 10 inside the case, tighten the orifice housing and the lever assembly
together snugly (70 in. lbs. / 8 Nm).
NOTE: Do not allow lubrication (grease on fingers, or silicone over-spray) to get on the case , the
17
diaphragm , or the exhaust valve 16 . This may cause slippage or deterioration of these parts.
6
NOTE: THE FOLLOWING STEPS (6 - 10) ARE INCLUDED HERE FOR CONTINUITY. THEY MUST BE
PERFORMED AFTER THE REGULATOR SECOND STAGE IS ADJUSTED (see 5.4 Setup of Second Stage).
6.
7.
Install the diaphragm
into the case so that it sits evenly on the ledge.
6
Install the cover 5 onto the case by sliding it carefully and firmly into place. Keep the cover
straight so that the cover vent holes and the purge button emblem are properly aligned. Install
the bezel ring
over the cover and tighten it firmly by hand onto the case.
4
14
onto the case flange by sliding it up from the bottom.
8.
9.
Install the exhaust tee
Install the retaining screw
through the screw hole in the exhaust tee and into the hole in the
15
case using a # 1 Phillips, or Size 0 Square Drive screwdriver.
DO NOT OVER-TIGHTEN
. This screw is threading into plastic, which will hold well in service but is
easily stripped if over-tightened.
10.
11.
Install a new mouthpiece 18 and mouthpiece tie 19.
Install one end of the hose into a serviced first stage, tighten snugly.
WARNING
NEVER tighten the hose with more than 40 in. lbs. (4.5 joules) of torque. The inlet hose
fitting can be weakened by overtightening.
5.4
SET- UP OF SECOND STAGE
For the following adjustments, remove the cover and diaphragm.
1.
Install Sherwood’s in-line adjusting tool (p/n TL102) between the orifice housing 22 and the
hose assembly 26 . Use the tool to screw the adjustable orifice
clockwise. Watch the end
24
as you do this. As soon as the tip of the lever begins to drop, stop turning the
of the lever
9
tool. The slight amount of friction this operation produces between the orifice and the stem
seat will not harm the stem seat.
2.
3.
Attach the in-line tool and the second stage to its accompanying overhauled and properly
adjusted first stage, and mount on an air tank filled to between 2700 and 3500 psig (186 and
240 bar).
Slowly turn on the tank valve. If you hear any leaks, determine the location of the leak, shut the
air off, and repair the leak as necessary.
15
Download from Www.Somanuals.com. All Manuals Search And Download.
24
counter-clockwise
4.
Turn on the air. Use the in-line adjusting tool to turn the adjusting orifice
until you hear a slight hissing. Then turn the adjusting orifice clockwise just enough to stop the
hissing. HINT: A slight clockwise turn past the point where the hissing just stops will reduce
wear and tear on regulators used heavily in rental or training situations.
5.
6.
Depress the lever assembly in the second stage five or six times to get the internal parts
seated in their proper positions. Listen for any hissing. Adjust if necessary.
After setting the adjusting orifice, check the relationship between the diaphragm wear plate and
the tip of the lever assembly. To do this, use the Sherwood lever height gauge and adjusting
tool (p/n TL123). Use the tool as a gauge by laying it across the top of the case as shown in
Photo #4.
Photo #4
7.
8.
Look across the case and gauge tool. The tip of the lever should be even with the bottom
surface of the gauge. If you are re-using the same major parts of the regulator, this
measurement will most likely be correct, and no adjustment will be needed. In fact bending the
lever should be avoided unless necessary to get the tip of the lever in the proper position.
If you have installed a new lever, and the lever tip is noticeably high, bend it lower by installing
the lever in the slot of the tool as shown in Photo #5.
Photo #5
9.
Holding the tool in one hand, with the tip of the lever toward the fingers, bend the lever
carefully. Do not hold on to the case when making this adjustment, as this can result in the
lever bending at the wrong area (near the lever support instead of at the mid-point of the lever).
If necessary, bend the lever upward using the same holding method.
10.
After the regulator is assembled, turn on the air. If the regulator hisses slightly, but stops
hissing when the diaphragm is removed, the lever is too high. Use the lever bending tool to
bend the lever slightly downward.
16
Download from Www.Somanuals.com. All Manuals Search And Download.
11.
12.
Replace the diaphragm. Continue to test the gap between the lever and the diaphragm after
each bending until the lever is in the correct position.
Return to Section 5.3.4 of this manual to complete assembly of the regulator.
5.5
A.
TESTING OF SECOND STAGE
Inhalation Effort
Check the inhalation effort of the second stage with a pan of water about five inches deep.
1.
2.
Slowly immerse the second stage with the front cover down and level. The regulator should
flow as soon as the diaphragm is a little deeper than level with surface of the water.
If you use a water column or water manometer to check inhalation effort, it should not exceed
1” w.c. (2.5 cm) at cracking. It should drop to about 3/4” w.c. (1.9 cm) at one atmosphere and a
moderate flow rate. You can alter the inhalation effort within a certain range.
3.
You can increase the inhalation effort by turning the adjusting orifice 22 clockwise.
However, discontinue clockwise adjusting when the lever
becomes loose against the lever
6
support
.
7
4.
5.
You can decrease the inhalation effort by turning the adjusting orifice counter-clockwise.
Discontinue counter-clockwise adjusting when air begins to hiss past the second stage orifice.
Install the second stage on the end of the hose. Use two wrenches to tighten the hose fitting
with 40 in. lbs. (4.5 Joules) of torque
B.
Exhalation Effort
1.
If you do not use instruments to check the exhalation effort, the flow should feel smooth and
unrestricted.
2.
3.
If you use a water column, it should not exceed 1/2” w.c.(.02 bar) at one atmosphere.
Brand new exhaust valves will sometimes adhere slightly to the case, causing a slight increase
in inhalation effort. This condition will disappear with use.
C.
1.
2.
3.
Leak Test
Disconnect the air supply. Purge the regulator of all positive air pressure.
Slowly immerse the second stage in a pan of water with the mouthpiece pointing straight up.
Immerse the regulator until the water is 1/4” to 1/8”( .64 to .32 cm ) from the lip of the
mouthpiece.
4.
5.
Hold the regulator in this position for one minute and then slowly raise it out of the water.
Tip the regulator mouthpiece downward and watch the inside of the mouthpiece tube. If any
water escapes from the mouthpiece tube, check for source of leakage.
17
Download from Www.Somanuals.com. All Manuals Search And Download.
D.
External Air Leaks
1
Attach the regulator first stage to a tank short enough to totally submerge the first and second
stage in your filling station cooling water.
2.
3.
With the tank valve still turned off, flood the second stage completely with water, and then
position it mouthpiece up.
Turn the tank air valve on slowly and then watch for any leaks in the first or second stage
(except for the normal flow of air from the one-way bleed valve on the first stage).
4.
5.
Repair any leaks.
Check for the correct positive air purge flow rate. See Section 4.4 “Testing of First Stage,” for
the proper method.
18
Download from Www.Somanuals.com. All Manuals Search And Download.
6.0 HELPFUL HINTS
6.1
TROUBLESHOOTING REGULATORS
POSSIBLE CAUSE
RECOMMENDED ACTION
A. High Inhalation Effort at Depth:
1. Inlet filter clogged.
Replace the filter.
2. No air flowing through the dry air bleed system.
Check the flow rate coming out of the
one-way bleed valve
. If no or low
15
air flow is detected, clean the flow
element in the piston, or replace the
piston.
3. High pressure air supply insufficient.
4. Second stage improperly adjusted.
Verify the supply air pressure. Make
sure the customer had the tank valve
turned all the way on.
Repeat Steps 1 through 6 in Section
5.4, “Set-Up of Second Stage.”
B. Free Flowing:
1. Intermediate pressure too high.
Adjust the first stage’s outlet pressure
to below 150 psig. Removing some 1st
stage shims
.
20
2. Damaged or worn H.P. piston seat.
Replace 1st stage seat (p/n 3801-5).
This also gives high intermediate
pressure..
3. Damaged or worn L.P. poppet stem seat.
4. Nicked or corroded orifice sealing.
Replace 2nd stage seat (p/n 978-9BN).
Dress the orifices in the first and
second stages with a polishing stick, or
replace the orifices.
5. Demand lever in second stage bent too high.
6. Weak spring in second stage.
Adjust or replace the lever.
Replace the spring.
7. Second stage improperly adjusted.
Repeat Steps 1 through 6 in Section
5.4, “Set-Up of Second Stage.”
8. Parts in the second stage have been severely
chilled due to repeated purging and have shrunk,
allowing air to flow.
Allow the second stage to warm back
up to room temperature. If the
regulator is to be used for Ice diving,
set the second stage up after cooling it
in Ice water. This will help prevent this
type of leakage from occuring due to
cold water conditions.
19
Download from Www.Somanuals.com. All Manuals Search And Download.
C. Wet Breathing:
1. Improper clearing, or diver diving in total
head-down position.
Instruct the diver on proper clearing
technique.
2. Diaphragm improperly installed.
3. Hole in the mouthpiece at tie area.
4. Hole in the diaphragm.
Check position of diaphragm visually.
Replace the mouthpiece.
Replace the diaphragm.
5. Damaged exhaust valve, or edges of
the exhaust valve not firmly seated on
the case.
Replace exhaust valve.
6. Crack in case.
Replace case.
D. Humming or Buzzing During Inhalation:
1. Harmonic resonance between the springs
and the mass of the piston.
Disassemble the first stage and flip the
main spring over. Change the position
of the piston in its bore. If
resonance is still present, install a new
piston and spring.
1. Harmonic resonance between the 2nd stage
lever assembly springs, and the mass of the
diaphragm.
This “honking” effect in the second
stage can be lessened by installing one
of Sherwoods new denser black
diaphragms shipped under the same
4006-13A part number as the older
blue diaphragm (available since 1997).
20
Download from Www.Somanuals.com. All Manuals Search And Download.
6.2
PARTS CLEANING RECOMMENDATIONS
Regulators which see heavy use, particularly those used in salt water, often require extra effort
to remove dirt and corrosion from the parts of the regulator. Some suggested cleaning solutions
are listed at the end of this section, and there are probably many others being used
successfully. Here are a few general suggestions we can make:
1. Don’t expect your cleaning solution to do all the work in a matter of seconds. If the solution
cleans extremely rapidly, it is probably too strong and is etching the finish on the parts. Use
a wooden or plastic stick or a soft bristle brush to help get rid of the thickest deposits. Take
special care not to damage orifice sealing areas. Dress the orifice sealing areas with a fine
grit polishing stick or pencil eraser after drying the parts.
2. Immerse only those parts which really need cleaning. With Sherwood’s Dry Air Bleed
System, the interior of the first stage is always clean and dry, so the piston and spring
should never need cleaning. Immersing the clean Sherwood piston in contaminated cleaning
solution can plug the flow control element in the face of the piston, which could slow or stop
the flow through the positive air purge system.
3. Many of the solutions used for cleaning metal parts can damage the nitrile compounds
found in O-rings. For this reason, remove all O-rings before placing parts in a cleaning bath.
6.3
COMMONLY USED CLEANING SOLUTIONS
SOLUTION
COMMENTS
Cleaning solutions recommended
by ultrasonic cleaner manufacturers
The preferred choice. Check with the
manufacturer for strengths and
recommended uses for their cleaners.
Soapy water
Good for plastic and silicone parts.
Vinegar and water (equal part solution)
Ingredients easily available. Approx. 15
minutes cleaning time. May damage
chrome finish.
1000 cc water
60 gr. sulfuric acid
60 gr. potassium dichromate
Fast-acting solution that must be made
and used with care. Use gloves and
safety glasses. Can damage chrome
finish.
21
Download from Www.Somanuals.com. All Manuals Search And Download.
6.4
HANDLING TIPS
How your customers treat their regulators will directly influence the unit’s function and
durability. Following are a few tips that you can pass on to your customers to help assure the
durability of their Sherwood Scuba regulator.
A.
Pre-Dive Checks
1.
Check the hoses and hose connections for cuts, abrasions or other signs of damage before
mounting the regulator on the tank valve. Slide the hose protectors back to inspect the areas of
the hose normally covered. Be sure all hose connections are tight.
2.
3.
4.
Too prevent a common source of internal corrosion and contamination of the Dry Air Bleed
System, ALWAYS turn the tank air valve on briefly before mounting the regulator. Many valve
contain contaminated water in the outlet because of rain or splashing.
After mounting the regulator first stage, but before turning on the tank air valve, check to make
sure that the yoke nut or DIN connection is tight and the regulator body is aligned properly, with
no kinks in the hoses.
Turn the tank valve on slowly and listen for leaks. If any leaks are found, replace or repair parts
as recommended.
5.
6.
Never lift the tank/BCD assembly by the regulator or hoses.
Surface-test the regulator by breathing lightly through the mouthpiece. Depressing the purge
button above the water’s surface is not meaningful an appropriate method for testing the func-
tion of the regulator.
B.
Post-Dive Care
1.
After the dive, blow all water out of the dust cap with clean dry air and place the cap securely
on the regulator inlet. On multiple tank dives, use great care to keep salt water out of the
regulator inlet when tanks are changed. Briefly release air from the valve before mounting the
regulator on the valve. Neglecting thesesimple procedures is the greatest cause of corrosion
and wear in scuba regulators. When used properly, Sherwood’s exclusive Dry Air Bleed System
keeps all other water-borne contamination out of the first stage body.
NOTE: A tiny stream of air bubbles escaping from a small black valve on the first stage indicates that the
Dry Air Bleed System is working. The amount of air used is negligible (13 - 27 cc/min.). Check the system
periodically (see Section 4.3B in this manual), particularly after servicing, to ensure that there is some air
escaping from the black one-way bleed valve. If no air is escaping from the valve when air pressure is applied
to the first stage, have the regulator inspected.
2.
3.
With the dust cap securely in place, rinse the first and second stages in clean fresh water.
DO NOT depress the purge button before or during rinsing since this may introduce water into
the second stage and the low pressure hose. Shake or blow all excess water from the second
stage and allow the entire regulator to air-dry before storing.
Store the regulator in a clean bag or storage box, away from sunlight, excessive heat and
humidity.
22
Download from Www.Somanuals.com. All Manuals Search And Download.
7.0 TWO YEAR WARRANTY AND MAINTENANCE
INFORMATION
7.1
PROPER PROCEDURE FOR WARRANTY PAPERWORK
1.
For detailed information on the operation of Sherwood Scuba Two Year Limited Warranty,
please refer to Sherwood Scuba Technical Bulletin # 112. You can also contact your Sherwood
Distributor if you still have questions about the warranty.
2.
3.
4.
In most situation no paperwork will be necessary. The customer will bring his or her regulator in
for one of its two annual servicings under the warranty. No parts other than those contained in
the standard annual service kits will be needed. Discard all old parts replaced by new kit parts.
Please do not return these used parts to Sherwood Scuba!
Remove one of the colored annual service rings from the main hose protector. When you have
collected several of these rings (25-50), contact your Sherwood Distributor for a Return Goods
Authorization Number. The color of the ring will determine the credit of type of service kit you
will receive.
If you replace parts other than those contained in the standard annual servicing kit, you will
have to submit paperwork. If the regulator meets the conditions of the two-year warranty, and
the warranty is still active fill out the Sherwood Warranty Replacement Parts Form. You must
describe the problem with the part you are returning in Part Five of the form. If this area is
blank, you will not receive credit for that part.
5.
In Sherwood Scuba regulators manufactured before Jan. 1, 1993 which still have a valid
Lifetime Limited Warranty you, the dealer, must send the white Warranty Service Form to
Sherwood. The information will be recorded by Sherwood to determine whether or not the
warranty on that particular regulator is still in effect.
7.2
SCHEDULED MAINTENANCE
1.
To keep the owner warranty in effect, your customers must have their regulators inspected and
serviced annually (within six weeks before or after the anniversary of the date of purchase) by
an authorized Sherwood Dealer. Failure to do so invalidates the warranty.
2.
3.
Even with infrequent use, the regulator should be serviced annually to ensure proper
performance and satisfy warranty requirements.
In Sherwood regulators manufactured before Jan. 1, 1993 which still have a valid Lifetime
Limited Warranty, you, the dealer, must send in the white Warranty Service Form in to
Sherwood. The information will be recorded by Sherwood to determine whether or not the
warranty on that particular regulator is still in effect.
23
Download from Www.Somanuals.com. All Manuals Search And Download.
SECOND STAGE REGULATOR - MAGNUM® II SRB3300, BLIZZARD® SRB3200, OASIS® SRB3400, OASIS® (SRB3500)
NOTE: Labels (Item 1 below) are also available in different colors.
ITEM #
CATALOG #
DESCRIPTION
1...................................3207-2..........................Label
2 ...............................3004-1 ............................Purge Button (no label insert)
3 ..........................19-4006-12 ..........................Purge Button Spring
4 ...............................3302-7 ............................Bezel Ring
5 ................................3302-6BK ........................Cover
6 ...............................4006-13A ........................Diaphragm (black Tufel®)
7..........................J12C04045B..........................Screw (combination Phillips/square drive)
8 ..........................19-4006-17 ..........................Washer
9 ..........................46-3302-20 ..........................Lever (for Blizzard)(black Teflon®-coated)
9 ................................3302-20 ..........................Lever (for Mag II, Oasis, Oasis+, Classic)
10...........................1-3004-8RH........................Lever Support (for Magnum II, no screw holes)
10 .........................1- 3106-17R ........................Lever Support (for Blizz.,Oasis,Oasis+,Classic)
10A....................J113481874BARC ..................Screws (2 needed)(for Blizz.,Oasis,Oasis+,Classic)
10B ......................25-3106-16 ..........................Fins (2 needed)(for Blizz.,Oasis,Oasis+,Classic)
11 .........................19-978-10 ..........................Spring
12 ..........................9-4006-18 ..........................Stem (no seat insert installed)
13............................978-9BN............................Seat Insert (for Stem)
14 .............................3302-2 ............................Exhaust Tee
15........................J12C04045B..........................Screw (combination Phillips/square drive)
16 .............................4006-15 ..........................Exhaust Valve
17 ............................3302R-1 ............................Case
18 ..............................3208-9S ..........................Mouthpiece
19 .............................3786-9W ........................Mouthpiece Tie
20 ............................G907A ..............................O-ring
21 ..........................1-3004-12 ..........................Spacing Washer
22 ..........................1-3004-4A ..........................Orifice Housing
23 ............................G010A ..............................O-ring (for adjustable orifice)
24 ........................43-4006-20 ..........................Adjustable Orifice (no O-ring)
25 ............................G010A ..............................O-ring (for hose outlet end)
26 .........................5016-20-31 ..........................Hose Assembly (31”)(includes hose protector)
27 .............................5100-27 ..........................Hose Protector
28 ............................G011B ..............................O-ring (hose inlet end)
Download from Www.Somanuals.com. All Manuals Search And Download.
6204 Goodrich Road
Clarence Ctr, New York 14032
Sherwood Scuba, the SS symbol, Oasis, Blizzard, Magnum, Brut and Wisdom
are trademarks of Sherwood, Harsco Corporation Gas and Fluid Control Group.
All other names are trademarks of their respective owners.
© 2001 The Liberty Group
ALL PRODUCTS SUBJECT TO CHANGE WITHOUT NOTICE.
Printed in the U.S.A on recycled paper
Part Number S-MAN2003
Download from Www.Somanuals.com. All Manuals Search And Download.
|