Sherwood SRB3108 User's Manual
Contents
1. Hold the case in one hand and use a 3 4 wrench to loosen and remove the orifice housing from the lever assembly The case is strengthened at the lever support area to withstand the turning forces of the lever support when this is done 7 Use the Sherwood in line adjusting tool p n TL102 to back the adjusting orifice Item 18 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 TL 111 8 Remove the O ring Item 19 from the adjustable orifice e 9 Before removing the exhaust valve Item 12 from the case bend it over as far as it will go from the 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 10 Remove the lever support from the inside of the case Item 13 11 Normally you will simply need to change the poppet stem seat insert Item 9 to restore the second stage to maximum performance To change the stem seat insert Item 9 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 from2. 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 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 TESTING INHALATION EFFORT Check the inhalation effort of the second stage with a pan of water about five inches deep 1 Slowly immerse the second stage with the inlet hose pointed straight up Since this is an octopus regulator no air should flow before the water floods into the mouthpiece This type of setting assures that the regulator will not be prone to free flowing while it is out of the mouth during the dive 2 If you use a water column or water manometer to check inhalation effort it should not be less than 1 5 2 w c at cracking You can alter the inhalation effort within a certain range 3 You can increase the inhalation effort by turning the adjusting orifice Item 18 clockwise Discontinue clockwise adjusting when the lever assembly Item 5 becomes loose against the lever support Item 6 4 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 EXHALATION EFFORT If you do not use instruments to check the exhalation effort the flow should feel smooth and unrestricted If you use a water column it shou
3. lift the tank BCD assembly by the regulator or hoses b Surface test the regulator by breathing lightly through the mouthpiece Depressing the purge button above the water s surface is not an appropriate method for testing the function of the regulator 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 keep salt water out of the regulator inlet when changing tanks Neglecting these simple 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 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 you apply air pressure to the first stage have the regulator inspected 2 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 e
4. A SHERWOOD SCUBA REGULATORS MINIMUS SHADOW SRB3108 SRB3209 Assembly amp Maintenance Guide TABLE OF CONTENTS Page Topic Number Mtrod ction uui ira od NE c E aa d bd Soc OR LI a VO ROCA E eue as 1 SPECINCATONS MN PP 1 Tools Required for Servicing 2 Disassembly aN a eres BRL DEOR E AIO 2 PISSED YE n sea nS a e aede d I fr e i ot le pee TER 3 SO urea Sa aera aac Ras fL ut dot etae nares 4 TOSUNG xis d ehh e E eh e eds d eee e nee bees 5 THOUBISSHOOUING DD 6 Parts Cleaning Recommendations 7 Maintenance amp Handling Tips 8 IMPORTANT Read all instructions and procedures in this manual carefully before servicing the regulator Parts have changed cosmetically over the years but newer style parts can usually be used in place of older parts The most current part numbers can be obtained by calling your authorized Sherwood Distributor If you have any questions contact your Sherwood Sales Representative or authorized Sherwood Distributor INTRODUCTION This manual is a guide for the annual servicing and maintenance of the Sherwood SR3108 Minimus and SR3209 Shadow regulators It gives breakdowns of regulator parts equipment specifications servicing instructions troubleshooting recommendations and guidelines for proper care of t
5. ever 9 3108R 9 Lever Support right hand version 9 3108L 9 Lever Support left hand version amp Shadow ARS 19 3602 29 Spring Bue 9 3108 18 Stem no seat insert installed 978 9BN Seat Insert for stem 10 3801 8 Exhaust Grill 11 4006 15 Exhaust Valve 12 3702 5 uix ius Screw for Cover 4 required Case right hand version nyc sri Case left hand amp Shadow version THE HOUSING AND SWIVEL PARTS IN FIGURE 1 ARE UNIQUE TO THE SR3209 SHADOW THEY REPLACE ITEM 16 FOUND IN THE SR3108 MINIMUS TAE Lxx 15 s 16 d nsus 18 19 5 20 21 22 13455 43 4006 20 3809 50 36 3602 27 GO11B G01 OA G01 OA Mouthpiece Tie Mouthpiece Orifice Housing for Minimus version O ring for adjustable orifice Adjustable Orifice no O ring O ring for hose outlet end Hose Assembly with hose protector 36 Hose Protector O ring hose inlet end Note The following parts are unique to the Shadow 23 24 s 25 44 See Fig 1 1 3209 7 2 3209 12 3208 30 38 Orifice Housing for Shadow version O ring larger of the two for the Swivel O ring smaller of the two for the Swivel Swivel fitting Hose assembly with quick disconnect A SHERWOOD wi SCUBA 6204 Goodrich Road Clarence Ctr New York 14032 www sherwoodscuba com 2001 The Liberty Group Prin
6. exhaust valve to see that it is properly seated 3 Snap the exhaust grid Item 10 back into its slots Make sure it is properly seated 4 Install the lever assembly into the case b Screw the orifice housing Item 16 onto the threads of the lever assembly Hold the case Item 13 in one hand Use a 3 4 wrench on the orifice housing Tighten the orifice housing and the lever assembly together snugly 70 in Ibs Note Do not allow lubrication grease on fingers or silicone over spray to get on the case Item 13 the diaphragm Item 2 or the exhaust valve Item 11 as it may cause slippage or deterioration of these parts Note If the unit is SR3209 Shadow the O rings Items 24 amp 25 should now be lubricated and replaced onto the orifice housing Item 23 The larger of the two O rings goes on closest to the case Item 13 Install the short hose assembly onto the swivel Item 26 Lubricate the inner bore of the swivel Re install the swivel back onto the orifice housing Note The following steps 5 8 are included here for continuity They must be performed after the regulator second stage is adjusted see Set Up of Second Stage page 4 6 Install the diaphragm Item 2 into the case so that it sits evenly on the ledge 7 Install the cover Item 1 onto the case by sliding it carefully and firmly into place 8 Install the four screws Item 12 that hold the cover onto the case using a 10 Torx screwdrive
7. g a 3 4 and a 5 8 wrench Inspect the hose assembly for any cuts or cracks especially on the hose at the metal ferrules Replace the hose assembly if any cuts or cracks are found 2 Remove the mouthpiece Item 15 by cutting the mouthpiece tie Item 14 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 Pry out the exhaust grid Item 10 with a small screwdriver 4 Use a 10 Torx or small slot screwdriver to remove the four screws Item 12 holding the front cover Item 1 in place b Gently remove the diaphragm Item 2 from the cover Hold the diaphragm up to a light source Gently stretch the diaphragm and look for tears or pinholes If any are found replace the diaphragm Otherwise the diaphragm can be reused Note If the unit is a SR3209 Shadow at this point you should pull off the swivel Item 26 Fig 1 from the orifice housing Item 23 Inspect the inner bore of the swivel for any scratches that may have caused air leakage Remove and inspect the O rings Items 24 amp 25 from the orifice housing Replace them if any wear or deformation of the O rings is found Remove the short hose assembly Item 27 from the swivel using a 9 16 wrench Inspect the hose for kinks and bulges 6
8. h 2 Damaged or worn L P poppet stem seat 3 Nicked or corroded orifice sealing 4 Demand lever bent too high 5 Weak spring in second stage 6 Second stage improperly adjusted manual entitled Set Up 7 Parts in the second stage have been severely chilled due to repeated purging and have shrunk allowing air to flow RECOMMENDED ACTION First stage should be putting out 130 psig minimum Repeat Steps 1 through 4 in the section of this manual entitled Set Up First stage should be putting out 150 psig maximum Replace seat p n 978 95 Dress the orifice with a polishing stick or replace the orifice ice Adjust or replace the lever Replace the spring Repeat Steps 1 through 4 in the section of this Allow the second stage to warm back up to room temperature this chilling will not occur in normal diving WET BREATHING 1 Improper clearing or diver diving Instruct the diver on proper clearing head technique in total down position 2 Diaphragm improperly installed Check position of diaphragm visually 3 Hole in the mouthpiece at area Replace the mouthpiece 4 Hole in the diaphragm Replace the diaphragm 5 Damaged exhaust valve or edges ofthe Replace exhaust valve exhaust valve not firmly seated on the case 62 Crack INCASE 7 s prd EE Bea We Replace case PARTS CLEANING RECOMMENDATIONS Regu
9. hese regulators This manual is intended for use only by persons specially trained and authorized to service Sherwood Scuba equipment Because of the many unique features found only 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 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 For information on the dates and locations of upcoming Sherwood service seminars near you contact your Sherwood Distributor or Sherwood Sales Representative IMPORTANT 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 also 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 SPECIFICATIONS REGULATOR MODEL Sherwood SR3108 Minimus amp SR3209 Shado
10. lators 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 First 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 may be 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 seal ing areas Dress the orifice sealing areas with a fine grit polishing stick or pencil eraser after drying the parts 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 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 SOME EXAMPLES OF COMMONLY USED CLEANING SOLUTIONS SOLUTION COMMENTS Soapy Water Sd du gabe a
11. ld not exceed 1 2 w c at one atmosphere Brand new exhaust valves will sometimes adhere slightly to the case causing a slight increase in exhalation effort This condition will disappear with use LEAK TEST 1 Disconnect the air supply Purge the regulator of all positive air pressure 2 Slowly immerse the second stage in a pan of water with the mouthpiece pointing straight up V 3 Immerse the regulator until the water is 1 4 to 1 8 from the lip of the mouthpiece 4 Hold the regulator in this position for one minute and then slowly raise it out of the water 5 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 EXTERNAL AIR LEAKS leakage 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 With the tank valve still turned off flood the second stage completely with water and then position it mouthpiece up 3 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 4 Repair any leaks the first stage TROUBLESHOOTING POSSIBLE CAUSE HIGH INHALATION EFFORT AT DEPTH 1 Interstage pressure too low 2 Second stage improperly adjusted FREE FLOWING 1 Intermediate pressure too hig
12. ns 5 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 e 6 After setting the adjusting orifice check the relationship between the diaphragm wear plate and the tip of the lever assembly If you are reusing the same major parts of the regulator this measurement will most likely be correct and no adjustment will be needed To check this relationship temporarily install the diaphragm Item 2 With the diaphragm properly seated along its edges use the finger to tap the wear plate against the tip of the lever If a slight gap between the wear plate and the lever tip is detected the lever is too low If no gap is felt and no air begins hissing when the cover is installed the height of the lever is OK If air does begin to hiss only when the cover is installed the lever is too high 7 If no adjustment to the lever height is needed proceed to step 8 If adjustment either up or down on the lever is needed use Sherwood s lever height adjusting tool p n TL123 Install the lever in the slot of the tool Refer to Sherwood s Tools Repair Kits and Accessories Manual page 8 for instructions on the use of the TL 123 tool 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
13. ntire regulator to air dry before storing 3 Store the regulator in a clean bag or storage box away from sunlight excessive heat and humidity SCHEDULED MAINTENANCE To keep the owner warranty in effect your customers must have their regulators inspected and serviced annually within 30 days before or after the anniversary of the date of purchase by an authorized Sherwood Dealer Failure to do so invalidates the warranty Even with infrequent use the regulator must be serviced annually to ensure proper performance and satisfy warranty requirements Companion instructional VHS videotapes to this and other Sherwood repair manuals are available from your authorized Sherwood distributor at a nominal cost Ask your Sherwood sales representative or authorized Sherwood distributor for details NOTE Part numbers and specifications are subject to change without notice Changes will be announced by technical bulletins You the repair technician should have ready access to these bulletins Your authorized Sherwood distributor is your most current source of correct part numbers and information MINIMUS 583108 AND SHADOW SR3209 ITEM CATALOG DESCRIPTION T es 3108R 6 Cover right hand version Ti ak hes 3108L 6 Cover left hand amp Shadow version 2 unm 3108 13 Diaphragm blue Tufel J12CO4045B Screw combination Phillips square drive 4 19 4006 17 Washer D aeu 3108 3 L
14. r Sherwood Tool TL117 or a small slotted screwdriver CAUTION DO NOT OVER TIGHTEN These screws are threading into plastic which will hold well in service but can be stripped if over tightened 9 Install the mouthpiece Item 15 and mouthpiece tie Item 14 SET UP NOTE For the following adjustments remove the cover and diaphragm 1 Install Sherwood s in line adjusting tool p n TL102 between the orifice housing Item 16 and the hose assembly Item 20 Use the tool to screw the adjustable orifice Item 18 clockwise Watch the end of the lever Item 5 as you do this As soon as the tip of the lever begins to drop stop turning the tool NOTE The slight amount of friction this operation produces between the orifice and the stem seat will not harm the stem seat 2 Attach 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 3 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 4 Turn on the air Use the in line adjusting tool to turn the adjusting orifice Item 18 counter clockwise until you hear a slight hissing Then turn the adjusting orifice clockwise just enough to stop the hissing NOTE 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 situatio
15. rse bee E Bae qne eas Good for plastic and silicone parts Vinegar and water Ingredients easily available Approx 15 min equal part solution cleaning time 1000 cc water Fast acting solution that must be made and used gr sullutib eR Soc HC with care Use gloves and safety glasses 60 gr potassium dichromate Cleaning solutions recommended The preferred choice Check with the manufacturer by ultrasonic cleaner manufacturers for strengths and recommended uses for their cleaners CUSTOMER MAINTENANCE amp HANDLING TIPS How your customers treat their regulators will directly influence the unit s function and durability Here are a few tips that you can pass on to your customers to help ensure the durability of their new Sherwood octopus 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 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 3 Turn the tank valve on slowly and listen for leaks If any leaks are found replace or repair parts as recommended 4 Never
16. ted in the U S A on recycled paper 5 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 ALL PRODUCTS SUBJECT TO CHANGE WITHOUT NOTICE Part Number S MAN2007
17. use an ultrasonic cleaner to clean the adjustable orifice Item 18 use a plastic container to prevent the orifice from vibrating against other metal parts which could damage the orifice seal 16 Inspect the case Item 13 for any cracks Look particularly closely at the area where the orifice housing and the lever support clamp down Replace the case if any cracks are found 17 Inspect the orifice s Irem 18 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 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 ASSEMBLY 1 Re install the cleaned and lubricated O ring Item 19 onto the adjustable orifice Item 18 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 Item 12 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
18. w AIRFLOW a 29 cu ft min 1 atmosphere INHALATION RESISTANCE 1 5 w c 1 atmosphere EXHALATION RESISTANCE 0 8 w c max Q 1 atm RECOMMENDED LUBRICANTS LTI Christo Lube 1110 Dow Corning 111 Compound Parker Super O Lube or equivalent cospe eee s der Benes ott Downstream valve diaphragm with Variable Fulcrum U S Pat 3 991 785 WEIGHT Ies AREE RI 4 2 oz octopus w o main hose 8 1 oz Shadow w o main hose HOSE LENGTH 36 in MATERIALS Cover Thermoplastic Triax Case Thermoplastic Triax Poppet Seat Liquid Silicone Tm Rubber O rings Diaphragm Tufel Blue Exhaust Valve Thermoplastic Elastomer Mouthpiece C Flex TOOLS REQUIRED FOR MINIMUS amp SHADOW SERVICING 10 Torx Screwdriver Sherwood Tool TL117 Phillips screwdriver 3 4 wrench 5 8 wrench 9 16 wrench 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 TL123 Sherwood Stem Socket Tool p n TL124 DISASSEMBLY To view the complete parts list of the second stage fold out the front cover of this manual 1 Pull back the hose protector Item 21 from the inlet end ferrule Remove the hose assembly Item 20 from the orifice housing Item 16 usin
19. which the old seat insert was removed over the new seat insert 12 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 loosen the screw Item 3 that holds the assembly together two turns only 13 Re install the orifice housing onto the lever support without the case turning the two parts together firmly by hand This will cause the poppet Item 8 to be pushed out farther than normal by the orifice This in turn will cause the lever to go limp NOTE If only the lever Item 5 is to be replaced do not totally remove the screw You can now remove the lever from under the washer and replace it with a new lever If other parts such as the spring Item 7 are to be replaced remove the screw Item 3 fully Then remove the orifice housing from the lever assembly to get these parts out 14 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 15 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 page 7 for recommendations on cleaning solutions NOTE If you
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