OCTO SRB9150 SRB9350 BRUT MAGNUM SECOND STAGES SERVICE GUIDE

Transcription

1 SR9952 OCTO SRB9150 SRB9350 BRUT MAGNUM SECOND STAGES SERVICE GUIDE 1

2 INTRODUCTION The instructions set forth in this document are intended to guide the experienced scuba equipment repair technician through the standard service procedure for this Sherwood regulator. It is assumed that the technician possesses basic scuba equipment repair training, proper tools and the skill necessary to perform the service. If you have not received regulator service training provided by Sherwood Scuba specifically for this equipment, do not attempt to perform the service described in this document. Service parts for Sherwood equipment are sold only to Authorized Sherwood Dealers. Before attempting to perform service read this manual in its entirety. There are warnings and cautions contained in the manual that may affect your safety or the safety of the regulator user. If you are uncertain as to whether you are qualified to perform this service contact your regional Sherwood Scuba Distributor for technical assistance. USE OF WARNINGS, CAUTIONS AND NOTES WARNING: CAUTION: Indicates a potentially hazardous condition or situation which, if not avoided, may result in serious injury or death. Indicates a potentially hazardous condition or situation which, if not avoided, may result in minor injury. It may also be used to alert against unsafe practices. NOTE: Indicates an important point or reminder. REGISTRATION, INSPECTIONS AND SERVICES ON-LINE REGISTRY. All Sherwood regulators have to be registered right after purchase, either by the end consumer or the dive center where the item was acquired. If the dive center is not able to register the product for the end-consumer at the time of purchase, the sales associate form the dive center has to strongly encourage the end-consumer to register his/her product within 30 days after purchase. Effective immediately: recording inspections and services is required to ensure the proper continuity of the warranty process. Regardless of location, proper record keeping by the authorized dealer is required right after each inspection or service is performed. When the regulator is going to be used for recreational purposes a year or 150 dives after purchase an inspection is required; a year after such inspection or when the regulator has completed 300 dives a full service is required. Time frames may be different when the regulators are going to be used for public service, rental or instructional use. Please contact your local Sherwood Sales representative for additional information to discuss particular cases and usage. Recording information at our website: Go to & using your dealer credentials click on the Product Warranty tab and follow the instructions to record Inspection or Service. It is imperative that the Authorized Dealer record these events. 2

3 WHEN TO SERVICE Sherwood regulators are designed and tested to perform acceptably under typical recreational diving conditions up to 300 hours of use. This Sherwood regulator should be inspected at least annually to evaluate it s performance. In most cases a simple inspection, and if needed, minimal adjustment not requiring the replacement of parts will be sufficient for continued use If the regulator has been subjected to more than 300 hours of use or it has not received the benefit of careful post-dive cleaning and storage in a clean environment, a standard service overhaul is required. In any case the Sherwood regulator described in this manual should receive a standard service overhaul at least every two years to maintain optimal performance. The standard service overhaul includes disassembly, cleaning, inspection, replacement of seals, lubrication, reassembly and adjustments. Regulators that are used in extreme conditions, such as commercial, public service use or rentals require more frequent service overhauls of at least every 3 to 6 months. A qualified technician should be able to determine service frequency. Sherwood Scuba offers a standard service kit that contains the parts recommended to be replaced in connection with the standard service overhaul. PN# 9350PK covers 1st and primary 2nd stage Brut PRO SRB9150 and Magnum PRO SRB9350 & PN# 9952PK contains the parts to service Sherwood Octo SR9952 ANNUAL INSPECTION GUIDELINES 1. Visually inspect the first and second stage for signs of damage or deterioration. Mouthpieces with tears or other damage should be replaced. 2. Retract hose protectors and inspect the hose over its entire length for signs of damage including blisters, deep cuts or separation at the crimped fittings. If these signs are present the hose must be replaced and standard service overhaul is recommended. 3. Insert a soft probe through the exit port of the exhaust cover and lift the Exhaust Valve to inspect it for cuts, tears or contaminated surfaces. Perform this examination from both sides of the Exhaust Cover to observe the entire perimeter of the Exhaust Valve. If damage to the Exhaust Valve is found a complete overhaul is recommended. If the Exhaust Valve or the sealing surfaces on the Housing are contaminated with debris, the Exhaust Cover must be removed and the surfaces must be cleaned. Instructions for removing and replacing the Exhaust Cover appear in the Second Stage Service Guide. As a final check of the Exhaust Valve apply a moderate suction (approximately minus 5 inches of water, moderate inhalation effort) to the second stage mouthpiece with the air supply closed and the second stage purged. If leakage is detected a complete overhaul is recommended. 4. Inspect the first stage filter for evidence of contamination. Discolored filters indicate previous contact with contaminated air. If evidence of contamination is present it is recommended that a standard service overhaul be performed. In addition you should advise the customer that the regulator has been exposed to contamination and that previously used air cylinders used should be inspected. 5. Install an intermediate pressure gauge into one of the available LP ports. 6. Pressurize the regulator to approximately 500 psi and inspect for leakage. Note intermediate pressure. It should not be greater than 155 psi. If no leakage is detected increase inlet pressure to 3000 psi. Again check intermediate pressure. It should not exceed 155 psi. If intermediate pressure is out of range 145 +/- 10 psi or leakage is present a standard service overhaul is recommended. 7. Test the purge function. If there is not a strong surge of air, a standard overhaul is recommended. 8. Gently submerge the entire regulator and look for bubbles that indicate leakage. If leakage is present a standard service overhaul is recommended. 9. If a test bench is available perform an inhalation test. Inhalation effort should not be greater than 2.0 inches of water at opening and less than 5.0 inches of water at 15 SCFM. If a test bench is not available perform a subjective breathing test. When properly adjusted the regulator should provide smooth and easy inhalation. If difficulty with inhalation is suspected a standard overhaul is recommended. 3

4 GENERAL COMMENTS NOTE Read this section before attempting to perform service. 1. Read the entire set of procedures that follows before starting to service. Steps taken out of sequence or without the knowledge of the proper procedure could damage the regulator or otherwise complicate the service process. 2. Refer to the Illustrated Parts List while performing service. Each part is identified with an item number the first time it appears in the text. Parts that are to be replaced with new parts in conjunction with an overhaul have encircled reference numbers. 3. Do not attempt to reuse parts that are designated for replacement. Retain discarded parts to show to the customer to illustrate that a full overhaul service has been completed. 4. Work in a clean properly equipped area. Cleanliness is essential for all regulator servicing and is critical for regulators that will be exposed to enriched air mixtures (Nitrox). Do not attempt to service if all required tools and a clean work area are not available. 5. Work on one regulator at a time taking care not to mix parts from other regulators. Use only genuine Sherwood parts. Parts that appear similar may have different features that are not easy to detect and may cause poor performance. 6. Be careful to protect the finish on all surfaces of the regulator during the service procedure. When holding parts in a vise use soft or padded jaws to prevent defacing surfaces. 7. O-rings are classified by the service they perform and are identified as either static or dynamic. Dynamic O-rings are those that are subjected to movement and the effects of friction which tend to shorten the useful life of the O-ring. Static O-rings are used to create a seal between non-moving parts and are not subject to the same wearing effects. Static O-rings have a longer useful life and are not replaced unless they show signs of deterioration or brittleness. Careful inspection of these O-rings is required before they are returned to service. Lubrication of O-rings: a. All lubrication must be done with Tribolube 71 or Christolube MCG-111. b. General O-rings in most instances should receive only enough lubricant to ensure they are supple. A light coating of lubricant should present a surface that glistens but without a defined layer of lubricant visible. c. Ample When an ample application of lubricant is specified it generally applies to a dynamic O-ring subject to considerable motion or environmental conditions where a more generous application of lubricant might be beneficial. In this situation there should be a light film or layer of lubricant visible. General Ample 8. When removing O-rings use a plastic or a soft brass tool to lift the O-ring out of its groove. Do not use steel or other hard tools that might scratch sealing surfaces. 9. When instructed to use tools such as a hex key or a wrench, follow the standard convention to rotate clockwise to tighten and counterclockwise to loosen unless otherwise directed. 10. When instructed to tighten a part until snug, it means to apply torque just until the part stops moving freely and the torque requirement to advance it further rises markedly. When specific torque specifications are given there is a necessity to ensure that the part is tightened enough to retain position or to create a seal. Unless you are skilled at accurately estimating torque, a torque wrench should be used. Excessive torque may damage parts and require replacement. 4

5 ENRICHED AIR NITROX SERVICE The Sherwood regulator presented in this manual has been designed and manufactured to allow the use of Enriched Air Nitrox (EAN) gas with an oxygen component not to exceed 40%. In order to maintain this option the user must ensure that the regulator is protected from the introduction of hydrocarbons. The introduction of hydrocarbons into the regulator may increase the risk of fire when used with EAN. When servicing the regulator, the technician must be aware of this requirement and exercise caution not to contaminate the regulator with hydrocarbons. This requires a clean workplace, free of oil, grease, debris and other contaminants. Additionally in order to return the regulator to EAN service, the overhaul procedure must have a cleaning provision to remove all hydrocarbons before the regulator is reassembled. Do not substitute parts or use lubricants other than Tribolube 71 or Christo-Lube MCG 111. Silicone lubricants are not acceptable and increase the risk of a fire hazard. WARNING The introduction of hydrocarbons, lint, dirt and other contaminants into the areas of the regulator subjected to high pressures (greater than 500 psi) and EAN mixtures containing more than 40% oxygen may constitute a fire hazard and may subject the user to serious injury. FACILITY REQUIREMENTS The service facility is perhaps the most important asset of any professional dive store. It should be clean, well lighted, and stocked with a complete inventory of parts and manufacturer s specialty tools for the products your store sells. As a minimum requirement, your service facility should be equipped with the following items: Ultrasonic Cleaner - Select the right size model that can keep up with the volume of regulators that your store services. A built-in timer and heater will help control the cleaning time and temperature of the solution, since most solutions work best when heated. Bench Mounted Padded Vise - A vise is sometimes needed to hold the regulator secure especially when removing the first stage yoke retainer. Special care must be taken, however, to avoid damage that can result from improper use of this tool. Vise must be lined with soft material like rubber or wood. Be sure to follow the instructions provided in this manual. Magnification Lamp - Strong lighting and magnification are essential requirements for performing a thorough parts inspection - especially when locating the cause of a small leak. Quality Wrenches & Sockets - When working with chrome plated brass parts, it is especially critical to use the correct size wrench and to ensure that it fits properly over the part. The use of an adjustable wrench is very likely to cause damage to your customer s regulator, and should be strictly avoided at all times. Calibrated Inch-Pound Torque Wrench - it is important to follow the manufacturer s torque values whenever they are specified, in order to avoid over-tightening or under tightening a part. This is especially important for smaller parts and fittings, when over-tightening can easily damage the part. Calibrated Foot-Pound Torque Wrench - Torque wrenches that can be set for both inch-pound and foot-pound measurements generally tend to be less accurate than wrenches that are designed to measure torque within a specific range. Manufacturer s Specialty Tools - Specialty Tools are critically important to perform many of the steps during disassembly and reassembly according to each manufacturer s procedures. During the mentioned steps where the procedure clearly indicates the use of a specialty tool, Sherwood Scuba strongly discourages technicians the use of substitute or make-shift tools to perform such steps. Sherwood specialty tools required to perform service are listed on page 7. 5

6 SECTION SECOND STAGES RECOMMENDED TOOLS AND SUPPLIERS The specialty tools identified below may be purchased from your Sherwood Scuba Distributor. Common tools are available from several sources. Common Tools Open End Wrenches - 9/16, 5/8, 1/2 Hex Tool 5/32 Small Flat Blade Screw Driver - Wiha 260/3.5x60 Diagonal Pliers (wire cutters) Torque Wrenches 25 ft-lb and 60 in-lb (25 N-m and 10 N-m) Flashlight Compressed Air Gun O-ring picks, plastic or soft brass Magnifier or Stereoscopic microscope Specialty Tools Orifice Driver O-ring pick set, soft brass In-Line Adjustment Tool piece set Picks/ Flat Screw Drivers Balanced Poppet Insertion Tool

7 SECTION SECOND STAGES - DISASSEMBLY PROCEDURES 1. Retract hose protector (6) to expose the hose s swivel nut. 2. Use a 5/8" open end wrench to rotate the hose swivel fitting nut counterclockwise to separate the hose from the 2nd stage assembly. 3. Remove tie wrap (3) and mouthpiece (17, 17a or 17b). CAUTION When performing the next steps to remove the Purge Cover be careful to avoid placement of the probe or screwdriver between the Housing and the Diaphragm Retainer or prying up the tool rapidly. Incorrect tool placement or procedure increases the risk of damage to the Diaphragm and/or Diaphragm Retainer requiring replacement of the parts. 7

8 4. Locate notch at the bottom of the housing (9 or 9a) and start inserting the flat screwdriver Wiha 260/3.5 x 60 (contained in kit ) in between the lip of the purge cover and the housing 5. Carefully continue inserting the screw driver until it passes through one of the orifices at the top of the purge cover. Use that orifice area as a pivoting point for the next step. 6. While holding the cover with one or more fingers use the tool on a circular motion to facilitate the separation of the purge cover s lip from the regulator s housing. Holding the cover while separating it, prevents the cover from flying off the 2nd stage s housing. 8

9 7. After separating the purge cover we will have access to the diaphragm retainer (18 or 18a) and diaphragm (29 or 29a). Remove all those components and place them on a safe place for inspection & re-use. 8. Align the c-clip (4) with the housing molding mark shown to facilitate extraction. Use the same screw driver form step 4; and place its tip at the clip s notch. CAUTION Failure to extract the clip in an angle as indicated will increase the risk of breaking it. 9. Extract C-clip with an upwards and at-an-angle motion until it gets completely off the Venturi switch (10) or Access Plug (10a). 9

10 10. Extract Venturi Switch or Access Plug. 11. Remove the o-ring (16) from the Venturi Switch s or Access Plug s channel with a soft material pick. 12. Using a 11/16 wrench or a Crescent Wrench remove the retaining nut (23) by unthreading it counterclockwise and pull out the washer (22). It is likely that the nut will already be un-torque and lose after having removed the hose s swivel nut on a previous step. 13. Depress the demand lever (21) and carefully push the valve body assembly inwards. Make sure you collect the o-ring (16) that will likely fall off after it loses contact with the valve body assembly. 10

11 14. With the demand lever depressed continue removing the valve body assembly and valve flange (19). Be cautious not to press too hard to prevent deforming the demand lever. Place all the components on a safe place. 15. Rotate the Adjustable Balancing Chamber (27) counterclockwise to remove it. It is likely that the spring (26), Thrust Washer (14) and Poppet (25) washer will come out at the same time. Place those components aside. 16. Insert the driver side of a Poppet/Orifice Installation Tool ( ) through the threaded end of the valve body (20) and rotate orifice (11) counterclockwise until it has reached its last thread. 11

12 17. The o-ring (15) at the orifice will prevent the orifice assembly from been extracted completely even though the threads are not engaged; use the soft end of a Blunt Probe Pick ( Contained in kit) and push from the other end to carefully guide the orifice out of the valve body. 18. Using a soft material probe (brass or plastic) remove the o-ring from the orifice. 19. Go back to the components in step #14 & separate the Poppet (25), Thrust Washer (14), Spring (26) and Adjustable Balancing Chamber (27) and set them aside on a safe place for inspection and re-assembly. 12

13 20. Using a soft probe (brass or plastic) remove the o-ring (28) off the poppet (25) and discard it. 21. Remove and discard the LP seat (24) from the poppet and discard it. NOTE The following steps (22 24), to remove the Exhaust Tee and Exhaust Valve are only required when replacing the exhaust valve. These steps are not necessarily required on every single overhaul, only when regulator is excessively dirty or the exhaust valve is suspected to be damaged and needs to be replaced. Test Exhaust Valve consistency by pushing it against the housing. Only if it is losing resiliency it will fail to return to its original shape & will require to be replaced. 13

14 22. Locate Exhaust Tee Retaining Screws (2) inside the housing and with a Phillips screwdriver remove them by unthreading counterclockwise. Place screws on a safe place for inspection and reassemble. 23. Go to the opposite side & remove Exhaust Tee (13) by pulling it outwards. Put it in a safe place for inspection and re-assembly. 24. To remove the Exhaust Valve (1) pull evenly from both ends first; the insertion tip needs to be pulled slightly to facilitate its removal through the orifice, once this end has changed its shape slightly now pull the round valve end outwards. Once removed put Exhaust Valve on a safe place for inspection and re-assemble. 14

15 SECTION 2nd STAGES - GENERAL CLEANING AND INSPECTION PROCEDURES CLEANING: 25. Thermoplastic, silicone rubber and anodized aluminum parts, such as diaphragms, accent trim, adjustment knobs, static/ replaceable O-rings, and thermoplastic housings. a. Soak in a solution of warm water and ordinary liquid dish detergent. Scrub with a soft nylon bristle brush to remove deposits. b. Do not subject thermoplastic or rubber parts to ultrasonic cleaning or vinegar solutions. c. Rinse with fresh water and blow dry with clean low pressure compressed air. WARNING When heavy corrosion has developed, metallic parts will lose their chrome plating after time. The use of an ultrasonic cleaner may accelerate such loss and chrome peeling will develop. If the parts you are intending to clean present heavy mineral build up be cautious, and continue monitoring the parts immersed in the ultrasonic cleaner periodically. Start the process by using the ultrasonic cleaner for only 1-2 minutes, extract the part (s) and evaluate the chrome finish for peeling. 26. Chrome-plated Brass and Stainless Steel parts only Use a commercial grade Ultrasonic Cleaner with LFW (Lawrence Factor Wash). LFW should be used diluted at a concentration no higher than 1:4 LFW/Water ratio to ensure good penetration, mineral build up removal but also ensuring chrome plating protection. (Follow manufacturer s recommendations for your particular ultrasonic cleaner brand). The use of a heated ultrasonic cleaner will accelerate the cleaning process; most mineral buildup on heavily soiled metallic parts can be cleaned with a minute treatment with LFW diluted to 25% on a heated ultrasonic cleaner. WARNING If after a preliminary cleaning (1-2 min) metallic parts present heavy pitting and substantial damage particularly to sealing surfaces it is advisable to replace the whole part after the evaluation. Alternatively the use of household vinegar or warm water and a brush could be considered as a method to clean metallic parts but be mindful that such processes may not go to deeper ends of some metallic parts such as small inner threads, channels, sealing surfaces, etc, and corrosion build up may remain. The use of an ultrasonic cleaner proves valuable when sealing or friction surfaces can t be reached easily. Regardless of the method used, rinse all metallic parts right after the cleaning process thoroughly with fresh water and blow them dry with compressed air. 27. Hoses - a. Corrosion or mineral deposits on the metallic fittings on hoses may be cleaned using the procedure presented above provided that care is taken to dip only the metal fittings at each the end of the hose into the cleaning solution. Take care to prevent access of the solution into the hose inner conduit. b. Rinsing should include flushing the interior of the hose with fresh water followed by drying with compressed air. 15

16 INSPECTION: 28. Use a powerful magnifying glass or stereoscopic microscope if available to evaluate chrome plating at sealing surfaces. These surfaces must be free of scratches, blemishes or peeling to effectively seal against o-rings. Replacement of the whole part may be necessary if the mentioned imperfections are pronounced. 29. With magnifying glass or stereoscopic microscope if available, inspect orifice s sharp edge seating surface; this must be free of nicks, deep scratches and blemishes in order to seal properly. Replace if needed. 30. Inspect the integrity & flexibility of Diaphragm (29) and Exhaust Valve (1) by stretching them slightly, ensure they do not have cuts or deformities. Replace if needed. 31. Ensure you spend sufficient time during inspection and pay special attention to the physical integrity of all com ponents. Contact your regional distribution center s technical department if you have questions. SECTION 2nd STAGES - REASSEMBLY PROCEDURES NOTE If removal of Exhaust Tee and Exhaust valve was required follow steps 32 35; if not, skip to step Insert the tip of the Exhaust Valve (1) in the receiving orifice. 33. From the other end, pull the valve s insertion tip slowly until its tapered shape has come out all the way through the orifice. Light lubrication may help. 34. Ensure that the Exhaust Valve its placed correctly by slightly lifting it on various places, pushing down on it and by running a finger all around it. 16

17 WARNING Make sure not to apply too much torque when tightening the screws on the next step, otherwise the screw s threads will permanently deform the plastic from the housing. If that would to occur replacing the entire housing will be required. 35. Locate the Exhaust Tee (13) and the two Exhaust Tee Retaining Screws (2). Insert the Exhaust Tee applying low and even pressure by hand until it has reached its place; ensure its edges feel flush against the surface of the housing. Insert both screws and set them by hand first, then thread them in with a Phillips screw driver rotating clockwise until they bottom & feel secured; only low hand tight force is required. 17

18 36. Light lubrication to LP Seat s stem may be beneficial to facilitate insertion into poppet. 37. Insert the new LP seat (24) and ensure it sits flush against the poppet (25). 38. Amply lubricate a new o-ring (28) and install it at the outer channel on the poppet stem. 18

19 39. Using Poppet alignment tool insert poppet while demand lever (21) is lifted about 90 ; once pop pet is in, ensure that the poppet contact tabs have engaged with the Demand Lever cams properly by slightly and carefully rotating the tool and feeling where the poppet stops. If the poppet contact tabs have effectively engaged into the demand lever cams a slight resistance should be felt; if it rotates freely, it has not engaged correctly. Repeat step accordingly to ensure proper poppet placement in relationship with demand lever. 40. Carefully push the tool in and let it go to test transfer of movement; if the components have engaged correctly you d notice that by slightly pushing the tool inwards the demand lever will rise; letting the tool go, the demand lever will slowly fall. If transfer of movement is not effective do not move to the next step. NOTE If transfer of movement is not present or excessive resistance is felt, do not proceed to next steps. Correct as needed to ensure poppet is set correctly and transfer of movement is effective. 41. Extract tool. The Demand Lever should lay flat against the valve body at this point. 19

20 42. Locate Spring Bushing (14) and Spring (26). Before installing, ensure Spring Bushing s polished side is facing up to get in contact with spring s flat end coil. Insert Spring Bushing first and then Spring. 43. Lubricate the inside of the Adjustment Screw/ Balancing Chamber (27). 44. Start threading the Adjusting Screw (Balancing Chamber) clockwise. If previous steps were performed correctly, you d notice that while threading the demand lever will gradually rise and resistance to threading will increase; this will trans late in a gradual increased force applied to the spring that consequently will translate in higher breathing effort. Pre-set of the Adjusting Screw will be described on the following steps. 20

21 45. Test that the internal components of the Valve Body Assembly are operating properly by depressing the demand lever and letting it go repeatedly. A consistent and even resistance should be noticed throughout the demand lever s complete range of motion. 46. Once the Adjusting Screw/ Balancing Chamber (27) is flush against the edge of the valve body, thread one more turn inwards. That will be a good starting point to pre-set the spring force and Opening Effort. Calibration of the final O.E. using the Adjusting Screw will be described in Section Locate Valve Flange (19) and insert it in the right hand side of the 2nd stage s Housing (9 or 9a). 21

22 48. Ensure the Valve Flange square shape sits flush against the housing s square index feature. 49. Insert the Valve Body Assembly into the housing. Depress the demand lever carefully while the valve body gets inserted. 50. Continue guiding the Valve Body Assembly in slowly until it reaches the Valve Flange s end and both components square indexed features feel secured against the housing. All the threads of the Valve Body Assembly should be visible at the other end of the housing at this point. 22

23 51. Locate O-ring (16) and insert it over the Valve Body Assembly s threads all the way to the bottom. Proceed in the same fashion with the Washer (22). 52. Locate the nut (23) & by hand start rotating it clockwise over the Valve Body s threaded end until it bottoms against the washer. 53. Torque nut to 32 in lb. Apply torque rapidly to avoid thread deformation. 23

24 54. Locate Orifice (11) and install a new amply lubricated o-ring (15). 55. Insert the Orifice Assembly (sharp end first) through the threaded end of the Valve Body Assembly. 56. Using the driver end of a Poppet/Orifice Installation Tool ( ) thread the Orifice Assembly only 5 & 3/4 turns in. This pre-set will cause a free flow when the system gets pressurized. As a general precaution depress the demand lever to ensure the rotation of the orifice will never damage the surface of the seat in case more than 5 & 3/4 turns are applied. 24

25 57. Locate Ventury Switch (10) or Access Plug (10a) and install a generally lubricated o-ring (16), make sure it gets installed on the outer channel; (the inner channel is designated to receive the c-clip once the part is inserted into the housing). 58. Insert the Ventury Switch (10) on Magnum PRO or Access Plug (10a) on Octo or Brut PRO into the housing. 59. Locate the C-Clip (4) and install it securing the Venturi Switch or Access Plug (Octo & Brut PRO). When working on a Magnum PRO SRB9350, after installing C-Clip, test that the Venturi Switch (10) rotates freely within its range of motion. 25

26 60. Locate the Diaphragm (29 or 29a) and Diaphragm Retainer (18 or 18a). Before installing, locate the alignment marks on both and make sure they coincide before installing into the Housing (9). Assemble together. 61. Place Diaphragm w/ Diaphragm Retainer into the housing & aligning both their marks against one of the housing s molding marks. (The Housing s upper or lower molding marks will work just the same). 62. Locate Purge Cover (30, 30a or 30b) and ensure the Sherwood logo is aligned properly. 26

27 63. Start with one of the Purge Cover s ends engaged with the housing s plastic lip, (always start inserting purge cover at an angle with the housing). 64. Using both hands apply equal force sliding both thumbs over the Purge Cover at the same time until the bottom part of the cover s lip has met the Housing s channel completely. 65. Look all around the perimeter where the purge cover meets the housing and ensure it has engaged properly. Run your finger around the assembly to ensure an even fit. 27

28 SECTION 5 2nd STAGES - CALIBRATION PROCEDURES 66. Using an in-line adjuster and pressurized air supply proceed to test lever height and Opening Effort (O.E.). 67. Connect the 2nd stage to the in-line adjuster and the other end of the tool to a source of pressurized breathing air delivering 145 +/- 10 psi supply pressure; ensure the shaft of the tool has already engaged with the orifice s slot before starting the flow. WARNING If the orifice frictions against the LP seat this action will eventually cut the seat damaging it permanently requiring disassemble, replacement and re-calibration. Ensure the regulator purge is depressed every time the tool s adjustment wheel is rotated to prevent damaging the seat with the orifice s sharp edge. Purge 2nd stage prior & during each rotation. 68. Start the air flow. The original orifice s pre-set (Step #56) will produce a free flow. Use tool to adjust orifice (depressing purge every time tool s wheel is rotated) until leak stops but regulator is easy to purge. Cycle purge 20 to 30 times. Test lever height by purging the regulator one more time. If the purge is too sensitive (air flows immediately after barely touching the purge),re-calibrate orifice one more time as needed. NOTE There should be a reasonable gap in between the diaphragm s contact plate and the curved end of the demand lever; often this mentioned gap is noticeable (audible) by shaking the 2nd stage repetitively while pressurized, a very subtle rattle should be perceived indicating the presence of a small gap. If this gap is wider (louder rattle) the regulator will be difficult to purge. 69. Locate Mouthpiece (17, 17a or 17b) and install it evenly over the opening. 70. Secure the mouth piece with a Tie Wrap (3) and cut the excess. 28

29 71. De-pressurize the regulator assembly and remove the in-line Adjustment Tool from both the regulator and the hose. Install the hose assembly back to the 2nd stage and tighten the swivel nut to approximately 40 in lb. Push the hose protector (6) towards the housing to cover the hose fitting completely. 72. Cycle the regulator 30+ times by depressing and releasing the purge at regular intervals. 73. Using a Magnehelic gauge with a scale 0 3 inches of water measure initial opening effort. It should be between: OCTO PRO BRUT PRO MAGNUM PRO If the Opening Effort needs to be modified, remove the Port Plug (5) with a 5/32 hex key at the Venturi switch (10) on Magnum or Access Plug (10a) on Brut & Octo. All Sherood Octo, Brut and Magnum PRO models now require the use of a 7/32 hex key to access the Adjustment Screw/Balancing Chamber in order to increase or decrease the spring load. Clockwise rotation will increase the spring force and therefore increasing the Opening Effort (harder to breath from); counterclockwise rotation will decrease spring force, decreasing O.E at the same time (easier to breath from). WARNING Adjusting the opening effort lower than the recommended values will increase the risk of free flow; the 2nd stage could become too sensitive, unstable and prone to leak under real diving conditions. It is very important not to set O.E. lower than recommended. 75. If adjusting the initial Opening Effort was required, replace the Port Plug (5) at the Venturi Switch (Magnum PRO) or Access Plug; (Octo & Brut PRO) secure it hand tight only. Avoid over-torque & deforming threads. 76. Cycle the regulator again 30+ times as described in step # 68. Submerge the 2nd stage in water while pressur ized & inspect for air leaks or any other abnormalities, check O.E. again and troubleshoot if required. 77. Contact your local Sherwood distributor if additional technical assistance is required. THIS CONCLUDES THE SERVICE PROCEDURES FOR OCTO, BRUT AND MAGNUM PRO 2ND STAGES. 29

30 Magnum PRO, Brut PRO & Octo PRO SECOND STAGES a 30a ITEM PART # DESCRIPTION 1 SHV7006 EXHAUST VALVE 2 SHV7027 EXHAUST TEE RETAINING SCREWS 3 SHV7026 TIE WRAP 4 SHV7025 C CLIP 5 SHV7023 LP PORT PLUG 6 SHV7032 HOSE PROTECTOR, SHORT 7 SHV7031 HOSE PROTECTOR, LONG 8 SHV7530 HOSE ASSEMBLY 9 SHV6003 HOUSING WITH VANE 9a SHV7021 HOUSING (Brut/Octo) 10 SHV6002 VENTURI SWITCH, MAGNUM 10a SHV7022 ACCESS PLUG, BRUT/OCTO 11 SHV7016 ORIFICE O-RING 13 SHV7024 EXHAUST TEE 14 SHV7751 SPRING BUSHING O-RING O-RING 17 SHV5030 MAGNUM MOUTH PIECE (GREY) 17a SHV5035 BRUT MOUTH PIECE (BLACK) ITEM PART # DESCRIPTION 17b SHV5034 OCTO MOUTHPIECE (Yellow) 18 SHV6001 CHROME DIAPHRAGM RETAINER 18a SHV7012 BRUT/OCTO DIAPHRAGM RETAINER 19 SHV8350 VALVE FLANGE 20 SHV5062 VALVE TUBE 21 SHV5060 DEMAND LEVER 22 SHV8352 RETAINING WASHER 23 SHV8353 RETAINING NUT 24 SHV5065 LP SEAT POPPET SPRING 27 SHV5061 ADJUSTMENT SCREW (Balancing Chamber) O-RING 29 SHV7008 BLACK DIAPHRAGM (Magnum/Octo) 29a SHV7090 WHITE DIAPHRAGM (Brut) 30 SHV4475 MAGNUM PURGE COVER 30a SHV7009 BRUT PURGE COVER 30b SHV7009Y OCTO PURGE COVER *Circled parts included in service kit. 30