Sherwood MAXIMUS SRB3600 User's Manual
Contents
1. 20 7 2 Parts Cleaning Recommendations 21 7 3 Commonly Used Cleaning Solutions 22 TA Handling TIPS 22 8 0 Two Year Warranty and Maintenance Information 24 8 1 Proper Procedure for Warranty Paperwork 24 8 2 Scheduled Maintenance 24 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 1 0 INTRODUCTION 1 This manual is written as a guide to the annual servicing and maintenance of the Sherwood Maximus SRB3600 regulator 2 This manual gives breakdowns of regulator parts equipment specifications servicing instructions troubleshooting recommendations and guidelines for proper care of these regulators The manual is intended for use only by persons specially trained and authorized to service Sherwood Scuba equipment 3 Anyone attempting to service or repair Sherwood Scuba regulators must have a thorough knowledge 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 outline2. TOOLS REQUIRED FOR SECOND STAGE SERVING 5 32 nut driver if you don t have a 5 32 nut driver use a 5 16 18 x 2 socket set screw 5 8 wrench 3 4 wrench 1 4 nut driver Slotted screwdriver Size 0 square drive screwdriver Such as a Channel Lock 51 0 10 Tom screwdriver Phillips screwdriver Side cutting pliers Sherwood Lever Height Adjusting Tool p n 4005 16 Red Loctite stud locking adhesive DISASSEMBLY Of SECOND STAGE To view the complete parts list of the second stage fold out the back cover of this manual 1 Remove the mouthpiece 4 by cutting the mouthpiece tie with side cutting pliers 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 Remove the two cover retaining screws Qusing a size 0 square drive screwdriver or a Phillips screwdriver NOTE Always remove these screws before peeling the cover off the case If you peel the cover off the case without removing these screws eventually the screw holes in the cover will elongate and no longer hold the screws This is not covered under warranty Roll the cover 2 off the top of the case 17 using your thumb and forefinger At this point the Sherwood logo on the purge button 2 can be changed to a different color See the parts list on t
3. Photo 1 Remove the yoke 0 and yoke nut 9 from the body NOTE If a Sherwood DIN adapter p n SAA5300 is installed in place of the normal yoke assembly remove it at this time See Sherwood Scuba Technical Bulletin 104 for servicing procedures for the SAAS300 DIN adapter Use a 5 32 Allen wrench to remove all remaining port plugs 076 the main body 02 Use 3 32 Allen wrench to remove the locking Allen screw from the main body see Photo 2 Photo 2 9 10 11 12 Use a regulator support handle and a 15 adjustable wrench or bench vise to remove the cap 6 and pressure adjusting ring 9 5 a unit from the main body Keep the wrench on the adjusting ring flats not on the cap flats for this operation This will ensure that the two units do not separate see Photo 3 Photo 3 Use a 15 adjustable wrench and a bench vise to separate the cap from the adjusting ring see Photo 4 Photo 4 Remove the piston 4 and spring 2 from the cap Remove the piston O rings and discard them Take care not to scratch the O ring grooves in the piston Remove the piston seat 3 by pushing through the stem with the Sherwood piston seat removal tool p n TL112 from the large end The seat will then pop out Discard the old seat CAUTION If any grease or oil gets on the flow control element assembly in the face of the piston the air flow will be impeded a Keep greasy fingertips
4. NOTE Do not allow lubrication grease on finger silicone overspray etc to get on the case 47 the diaphragm 48 or the retaining ring 49 This may cause these parts to slip or deteriorate THE FOLLOWING STEPS 13 18 MUST BE PERFORMED AFTER THE REGULATOR SECOND STAGE IS SET Up See Section 6 5 Set Up of Second Stage 13 14 15 16 17 Install the diaphragm finto the case 17 so that it sits evenly on the ledge Inspect the diaphragm retaining ring 19 You will see long tab and a short tab on the ring The short tab lines up with the short notch in the case when the ring is installed a If the diaphragm is blue the retaining ring must also be blue to give the proper fit b If you are replacing a white or black diaphragm with a new blue diaphragm the black retaining rings will not fit properly You must use a blue retaining ring These rings are available from your Sherwood Scuba distributor at no cost You should always have several on hand Install the proper diaphragm retaining ring into the case so that it holds the diaphragm in place Install the cover 7 onto the case by first hooking the bottom section over the exhaust valve area and then working the rest of the up and over the front section Work the cover around with your hands until everything is in place Using a size 0 square drive screwdriver or a Phillips screwdriver install the cover retaining screws 0 through the screw holes in t
5. away from the piston during servicing 13 14 15 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 A coating of grease or oil will interfere with the air flow through the flow control element the face of the piston see Photo 5 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 through the regulator upon descent 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 Photo 5 Place a 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 a pocket screwdriver to remove the star washer 2 that holds the filter 3 in place Most units used a star washer a flat disc washer with six outward facing legs Units made after 1997 use a wire retaining ring with a forward hook The only first stage bodies that can use this re useable ring have a groove machined into the area above the filter for the ring to fit snugly into Always discard the used filter and old style star washers newer style retaining rings are saved for reuse Remove the movi
6. by Ultrasonic with the manufacturer for strengths Cleaner Manufacturers and uses for their cleaners Some brand names of cleaning solutions Branasonic Micro Oakite 31 and Brex 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 Maximus SRB3600 regulator Pre Dive Checks 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 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 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 a thorough method for fully testing the function of the regulator 1 4 2 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 ar
7. has a SYA 5300 or SYA5200 DIN adapter instead of a standard yoke see the installation instructions given in Sherwood Technical Bulletin 104 for overhaul and installation instructions of the DIN adapter TESTING Of FIRST STAGE NOTE For safety always test the first stage regulator with at least one second stage installed The demand valve in the second stage acts as a relief valve in the event of a malfunction Before You Begin Testing 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 Install the first stage onto a tank valve and introduce 2700 3500 psig 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 5 4 2 Dry Air Bleed flow Test 13 2 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 The number and size of the bubbles may vary from regulator to regulator but the volume of air should be 13 25 cc per minute To check this use the following steps a Invert a small 25 cc capacity graduated cylinder filled with water over the underwater flow of bubbles The air entering the cylinder will gradually empty some of the water out of the cylinder b After exact
8. not need to polish the rough outer edge of the cone this is not a sealing surface Use compressed air to blow away any dust created by the polishing process ASSEMBLY OF FIRST STAGE Kit 4000 4 is the Annual Service Kit for the SRB3600 Maximus This kit contains the minimum parts to be replaced at every annual service interval Before installing new O rings on the piston and moving orifice lubricate the O rings with one of the recommended lubricants see Section 7 3 Installing the small O ring 2 on the piston will be easier if you use 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 Place the new piston seat 3on 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 Qand then the used backup washer onto the wider groove on the moving orifice Position 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 Using a greased soft
9. probe lightly lubricate the first 1 8 of the small bore in the body 05 where the small piston and moving orifice O rings seal 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 into the main body on top of the moving orifice Place the new star washer 2 from the service kiton top of the filter screen NOTE Replace domed screen P N 3601 16 with filter P N 1390 7 Some first stage bodies have a groove machined in the inlet for a filter retaining ring P N J2790056B For first stage bodies without the groove use a star washer P N 3504 6 Replace the lightly lubricated O ring Qonto the pressure adjusting ring 9 Lightly lubricate the piston bore in the pressure adjusting ring on the surface where the large piston O ring will seal Place the main spring over the piston stem Insert the main spring and piston with its clean lubricated new O rings and seat into the pressure adjusting ring Screw the cap C onto the pressure adjusting ring Use a 15 adjustable wrench and bench vise to snugly tighten the cap to the pressure adjusting ring see Photo 4 Do not overtighten Replace the lightly lubricated O ring 8 onto the main body Be sure to place the O ring into the groove right next to the threads not in the groove away from contact with the threads Lightly lubricate the bore in the pressure adjusting ring where the
10. A SHERWOOD w SCUBA REGULATORS SRB3600 Assembly amp Maintenance Guide FIRST STAGE MAXIMUS SRB3600 ITEM CATALOG DESCRIPTION SRB3601 First Stage Complete 5105 70 Handwheel Assembly 3504 6 Star Washer J2790056B Filter Retaining Ring 1390 7 Filter 29 3106 13A Moving Orifice Da e T bare no O rings 19 8010 8 Disc Spring 528774 007 Backup Ring for Moving Orifice GOO7A O ring for Moving Orifice 2 ea Bde tres hes 3801 20 Dust Cap Oi heck 1 1665 17 Yoke Nut TO 2 3801 4 Td aa 1 3105 6 L P Port Plugs i een eee ae GOFID O ring for L P Port Plugs RRR 3106 6 One Way Bleed Valve J07 S1024 08DB Locking Allen Screw 15 tive 2 3601 1 Main Body 90 O ring for port plug T7 1 3405 4 H P Port Plug 1 24 O ring fits on large end of Body 2 3601 7 Pressure Adjusting Ring 025 O ring fits on Pressure Adj Ring 3801 12B Main Spring GOO7A O ring for small end of piston 285 3601 5 Piston Seat 24 25 3601 13 Piston Bare no O
11. ITHOUT NOTICE Part Number S MAN2002
12. LATOR MODEL Sherwood SRB3600 Maximus AIR FLOW 32 cu ft min 850 liters min 1 atmosphere INHALATION RESISTANCE 1 1 w c 2 8 cm w c 1 atmosphere EXHALATION RESISTANCE 0 5 w c 1 3 cm w c max 1 atm RECOMMENDED LUBRICANT LTI Christo Lube MCG 111 Dow Corning 111 Compound Parker Super O Lube or equivalent First Stage Regulator SRB3601 TYPE Externally adjustable flow by piston with Moving orifice balancing and Positive Air Purge Dry Air Bleed U S Pat 4 226 257 WEIGHT 1 Ib 11 oz 8kg INTERSTAGE PRESSURE 120 150 psi 8 3 10 Bar MAXIMUM INLET PRESSURE 232 Bar for SRB3600CE Model POSITIVE AIR PURGE FLOW RATE 13 25 cc minute LOW PRESSURE PORTS 5 3 8 24 UNF HIGH PRESSURE PORTS 1 7 16 20 UNF MATERIALS Body CDA 360 Brass O rings Buna N Bleed Valve Ethylene Propylene Piston Seat Teflon Second Stage Regulator SRB3602 TYPE Downstream poppet diaphragm externally adjustable with underarm hose routing WEIGHT 8 oz 23 kg w o hose HOSE LENGTH 40 in 1 02 MATERIALS Cover Thermoplastic Triax Case Thermoplastic Triax Poppet Seat Buna N O Rings Buna N Diaphragm Tufel blue Exhaust Valve Thermoplastic Elastomer Wisdom Mouthpiece C Flex Maximum certified depth is 50m 3 0 O RINGS REFERENCE CHART 1 0 SPECIAL FEATURES OF THE MAXIMUS SRB3600 REGULATOR 4 1 FIRST STAGE FEATURES The ext
13. Ring Blue 20 spies J12C04045B Front Cover Retaining Screw ITEM CATALOG 21 3602 2 22 3602 5APK 3602 5ARD WS bee ate 3602 5AWH ata ted 3602 5 3602 5ANG 3602 5ARG 23 5 978 9BN 24 5 29 3602 18 25 0520 19 3602 29 26 9 3602 7 3602 20 28236 3602 9 2905 305 J11NO440BP 30 25 3602 22 rars 25 3602 21 2 a J113481874BARC 5016 20 41 SA GO10A GO11B DESCRIPTION Front Cover Logo Insert Pink Logo Insert Red Logo Insert White Logo Insert Yellow Logo Insert Green Logo Insert Orange Seat insert black Stem bare no seat Spring Lever Support Lever Washer white Adjusting Nut Fin dimpled end Fin plain end Screw for fins Hose Assembly 41 High Flow O ring hose outlet end O ring hose inlet end A SHERWOOD SCUBA 6204 Goodrich Road Clarence Ctr New York 14032 www sherwoodscuba com 2001 The Liberty Group Printed in the U S A on recycled paper amp Sherwood Scuba the SS symbol Oasis Blizzard Magnum Brut and Wisdom are trademarks of Sherwood Taylor Wharton Gas Equipment Division of Harsco Corp All other names are trademarks of their respective owners ALL PRODUCTS SUBJECT TO CHANGE W
14. ate of purchase by an authorized Sherwood dealer Failure to do so invalidates the warranty Even with infrequent use the regulator should be serviced annually to ensure proper performance and satisfy warranty requirements 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 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 SECOND STAGE MAXIMUS SRB3602 ITEM CATALOG DESCRIPTION 3602 16 for adjusting knob J12C04045B Screw 19 4006 17 Washer 3702 16C Adjuster Knob 3602 35 Cir Clip CP cores 1 3602 15 Nut 2 3602 14 Swivel Fitting Bae GOO6B O ring orifice small end cates 011 O ring orifice large end WO 29 3602 12 Orifice IT GO14C O ring orifice housing small end TZ GO15C O ring orifice housing large end TI ene 1 3602 13A Orifice Housing 14 3602 35 Mouthpiece Wisdom 3786 9W Mouthpiece Tie TO 3602 6 Exhaust Valve 17 3602 1 Case 18 25225 3602 4A Diaphragm 19 3602 17 Retaining
15. body O ring 8 will seal With 5 4 5 4 1 a greased soft probe lightly lubricate the first 1 8 of the small bore in the main body where the small piston O ring will seal Install the pressure adjusting ring cap assembly onto the body Hand tighten the assembly onto the body until it bottoms on the thread Lubricate the locking Allen screw A with silicone grease and place a small dab of grease onto the hole in the main body where the Allen screw is inserted Using a 3 32 Allen wrench screw the locking Allen screw into the main body until it lightly bottoms on the thread Do not tighten further Using your index finger install the clean and dry one way bleed valve into the body 09 No particular orientation is necessary NOTE If you use the bleed valve with the Sherwood logo molded into it P N 3106 6 you will notice molded near the right side of the logo Install the bleed valve with the dot oriented closest to the inlet of the regulator towards the yoke Lightly lubricate the body yoke nut threads with silicone grease and install the yoke 0 and the yoke nut 9 onto the body Using the regulator support handle p n 4700 15 in one of the LP pressure ports of the body and a 15 adjustable wrench tighten the yoke nut snugly see Photo 1 Lightly lubricate the threads of the handwheel with silicone grease and install the handwheel and dust 8 onto the yoke If the first stage
16. bove 140 psig 9 7 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 To raise the pressure to the desired final setting slowly turn the pressure adjusting ring in a counter clockwise direction as seen when looking down at the cap end of the regulator in 1 8 turn stages At the end of each 1 8 turn push the purge button several times to let the internal parts work into place to give a true reading If the pressure goes above the correct reading turn the pressure adjusting ring clockwise in 1 8 turn increments Between each 1 8 turn the purge button of the second stage must be depressed to allow the pressure to drop 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 Once the proper pressure has been set use the 3 32 Allen wrench to tighten the locking Allen screw 0 Tighten the screw clockwise only enough to stop the pressure adjusting ring from being moved by hand Do not overtighten Check the intermediate pressure one more time after you have tightened the Allen screw Never set the output pressure of the first stage above 150 psig 10 3 Bar 6 0 SECOND STAGE PROCEDURES 6 1 6 2
17. d 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 O ring onto piston tip Green colored p n 38 TL107 for installing first O ring onto moving orifice Black colored p n 29 TL108 for installing second O ring onto moving orifice Annual Service Kit 4000 4 Enriched Air Conversion Kit 4000 4N NOTE for more information on Sherwood tools and their uses see Sherwood s Tools Repair Kits and Accessories Assembly amp Maintenance Guide available from your authorized Sherwood distributor 5 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 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 Unscrew and remove the handwheel 1 Remove the dust cap 8 Install a Sherwood regulator support handle p n 4700 15 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 5 See Photo 1
18. d in this manual 4 The best source for current part numbers for any of the parts listed in this manual is your authorized Sherwood Scuba distributor 5 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 Scuba distributor or 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 6 Companion instructional VHS videotapes to this and other Sherwood Scuba repair manuals are available from your authorized Sherwood Scuba distributor at a nominal cost Ask your Sherwood Scuba sales representative for details 7 If you have any questions or need more information contact your Sherwood Scuba sales representative or Authorized Distributor 2 0 SPECIFICATIONS L l 2 2 23 GENERAL SPECIFICATIONS FOR THE SRB3600 MAXIMUS REGULATOR REGU
19. e case Lubricate and install new O rings 8 9 from the annual service kit onto the orifice Install the orifice back into the orifice housing 43 using your fingertip Use the ad usting knob 4 to turn the orifice counter clockwise until it stops Apply a drop of mild thread locker such as Locktite 242 or equivalent to the threads of the lever support 29 gt 10 11 12 Screw the orifice housing 13 the threads of the lever assembly Use a 3 4 wrench on the orifice housing to tighten them together snugly 70 lbs 7 8 nm Lubricate and install new O rings 1 42 from the annual service kit onto the orifice housing 3 Note that the larger of the two O rings goes on the end of the housing closest to the case 7 Lightly lubricate the inner bore of the swivel fitting with a recommended grease Install the swivel fitting onto the orifice housing While holding the orifice housing with a 3 4 wrench use a 5 8 wrench to install the retainer nut 6 onto the orifice housing thread Tighten the retainer nut snugly 70 lbs 7 8 Install the cir clip 6 onto the orifice Install the adjusting knob 4 onto the orifice 40 Install the washer 3 onto the screw 2 Place a small drop of locking adhesive onto the threads of the screw and install it snugly into the orifice using a size 0 square drive screwdriver or a Phillips screwdriver Install the cap 8 back onto the adjuster knob
20. e changed 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 25 cc min The system should be checked 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 air pressure is applied to the first stage have the regulator inspected 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 8 0 TWO YEAR WARRANTY AND MAINTENANCE 8 2 INFORMATION PROPER PROCEDURE FOR WARRANTY PAPERWORK For detailed information on the operation of the Sherwood Scuba Two Year Limited Warranty please refer to Sherwood Scuba Technical Bulletin 112 In most situations no paperwork will be necessary The customer w
21. e lever support depress the lever and turn the adjusting nut clockwise in 1 8 turn increments releasing the lever between turns to check for snugness and leaks b If the lever is snug against the lever support but air is hissing depress the lever and turn the adjusting nut counter clockwise in 1 8 turn increments releasing the lever between turns to check for snugness and leaks 7 When you find the point where the lever is snug against the lever support with no hissing turn the air on fully and depress the lever several times to work the parts in The regulator should not hiss after this working in If it does hiss repeat Steps 6a and 6b above 8 With the air on turn the adjusting knob 4 fully counter clockwise You should hear a slight hissing this is the long term storage position for the second stage The hissing should stop when you turn the knob clockwise about 1 8 turn 9 After setting the adjusting nut 9 check the relationship between the diaphragm wear plate and the tip of the lever assembly a Install the diaphragm and retaining ring The tip of the lever should just barely touch the diaphragm b Touch the diaphragm lightly with your finger If there is a significant gap between the lever tip and diaphragm then the lever is too low Remove the diaphragm and bend the lever slightly upward with Sherwood s Lever Bending Tool p n 4005 16 c If the regulator hisses slightly when the air is turned on but stops hissin
22. ernal adjustability of the first stage allows you to adjust the regulator output to match the type of diving being done Relatively low outlet pressure 120 psi 8 3 Bar helps the regulator resist freezing in cold water diving Medium outlet pressure 130 psi 9 Bar combines good breathing effort and durability Relatively high outlet pressure 150 psi 10 Bar maximizes flow rate for high work effort dives SECOND STAGE FEATURES The Maximus regulator s unique underarm hose routing protects the hose from snagging on obstructions during close quarters diving coral caves wrecks piers etc This routing also allows for better head movement thus lowering jaw fatigue caused by the hose pushing or pulling the second stage A longer hose and unique swivels make the regulator ideal in air sharing exercises The large high flow Wisdom mouthpiece and the oval exhaust valve provide comfort and lower breathing resistance The externally adjustable demand valve in the second stage allows the diver to custom tailor the regulator to the diving conditions and interstage pressure The knob can be backed off for extended storage periods of longer than three months eliminating the need for purge button lock down tabs To help prevent rapid pressure buildup in the first stage the Maximus allows you to leave the knob in the backed off counter clockwise position when the air is first turned on and then close the knob clockwise until the airflow jus
23. g when you remove the diaphragm then the lever is too high Use Sherwood s Lever Bending Tool to bend the lever slightly downward lt d 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 10 6 5 6 5 1 Return to Section 6 3 Step 13 of this manual Assembly Second Stage to complete assembly of the regulator TESTING Of SECOND STAGE Inhalation effort Check the inhalation effort of the second stage with a pan of water about five inches deep 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 3 2 cm at cracking It should drop to about 3 4 w 19 cm at one atmosphere and a moderate flow rate You can alter the inhalation effort within a certain range You can increase the inhalation effort by turning the adjusting nut 9 counter clockwise However discontinue counter clockwise adjusting when the lever becomes loose against the lever support 4 You can decrease the inhalation effort by turning the adjusting nut clockwise Discontinue clockwise adjusting when air begins to hiss past the second stage poppet 6 5 2 Exhalation Effort If you do not use instruments to check the exha
24. gaskets with little or no pressure across them The clean environment created by the Positive Air Purge System Dry Air Bleed makes this re use possible Clean the O rings carefully with a lint free rag and re lubricate lightly with LTI Christo Lube MCG 111 Dow Corning 111 Silicone grease Parker O ring Lube or equivalent If necessary clean all metal parts of the first stage except the piston in an ultrasonic cleaner or cleaning solution CAUTION Remove the O rings before cleaning any metal parts most cleaning solutions can damage the O ring material See Section 7 3 for recommendations on cleaning solutions Remove the regulator parts from the cleaning solution Blow all internal passageways dry with clean dry compressed air The piston O rings and the moving orifice O rings move in bores Inspect these bores 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 Inspect the moving orifice s sealing surface located at the top edge of the orifice cone Any 9 5 3 10 nicks scratches corrosion at the top of the cone can allow air pass which could result in creeping hose pressures Polish out the defects using a fine abrasive polishing stick When polishing apply a light pressure to prevent excessive wear on the cone You do
25. has entered through the inlet filter first make an attempt to clean it with a clean lint free cloth or a soft brush in a fresh soapy water solution If you must use a cleaning solution in an ultrasonic a 13 1 4 1 cleaner isolate the orifice from the side walls and all other parts Do this by placing the orifice individually in a plastic cup in the cleaning hopper This will help prevent mechanical damage to the sealing surfaces of the orifice Polish the orifice with a clean pencil eraser Blow off dust and debris after polishing Due to its unique stainless mesh design the inlet filter of the Sherwood SR3601 first stage can be cleaned in the ultrasonic cleaner Visually inspect the filter before and after cleaning Blow the filter dry with clean compressed air Check the strength of any cleaning solution by placing a spare chrome plated part in the bath for a few minutes longer than the time you expect to leave the parts in If visible damage to the chrome finish results then the solution is too strong COMMONLY USED CLEANING SOLUTIONS SOLUTION COMMENTS Soapy Water Good for plastic and silicone parts Vinegar and Water Ingredients easily available 15 Equal part solution minutes approx cleaning time 1000 cc Water Fast acting solution that should be 60 gr Sulfuric Acid made and used with care Use 60 gr Potassium Dichromate gloves and safety glasses Cleaning solutions Usually the best route to go Check recommended
26. he cover and into the holes in the case Do not overtighten These screws are threading into plastic which will hold well in service but is easily stripped if the screws are overtightened 18 Install the mouthpiece the new mouthpiece tie 5 from the service kit 6 4 SET UP OF SECOND STAGE For the following adjustments remove the exhaust tee cover and diaphragm 1 Turn the adjusting knob 4 out counter clockwise all the way and then in clockwise 1 8 turn 2 Use a 1 4 nut driver to turn the locking nut counter clockwise outward until the lever just loose enough so that the tip of the lever moves loosely and down about 1 16 3 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 186 and 240 Bar Install an intermediate pressure gauge into one of the low pressure ports 4 With the air off use a 1 4 nut driver to adjust the nut so that the lever dis just barely snugged against the lever support 5 Fully depress the lever with your thumb Slowly turn on the tank valve until you hear a slight hissing from the second stage lever area 6 Release the lever The air pressure will build up in the hose When the intermediate pressure gauge reads full and proper intermediate pressure you should hear no hissing and the lever should not be loose against the lever support a If the lever is loose against th
27. he foldout back cover for available colors If you are going to change the color follow the next five steps Otherwise go on to Item 5 in this section a Look at the tab inside the cover that holds the logo in place amp If the tab has a metal grip ring holding the logo into the cover grasp the ring with pliers so that squeezing the pliers causes the jaws of the grip ring to open Pull the grip ring off and then remove the logo by pulling it from the outside of the case If the logo has a plastic barb built into it instead of the grip ring then it is the newer style Simply pull the logo from the outside of the cover until it pops out d To install the new logo with a grip ring flatten the old grip ring with pliers until it has its original shape Then install the logo from the outside of the cover Slide the straightened grip ring 10 11 12 13 14 15 down the stem of the replacement logo until it bottoms Check the grip ring for tightness To install the new logo with a self holding barb push the new logo into the case from the outside until the barb is fully engaged inside the cover Using your thumbnail or a slotted screwdriver gently pry the diaphragm retaining ring out of the case see Photo 8 Gently remove the diaphragm 8 from the case Using a size 0 square drive screwdriver or a small Phillips screwdriver loosen and remove the screw 2 and washer 3 from the orifice adjust
28. ill 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 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 regional distributor for a Return Goods Authorization Number The color of the ring will determine the credit or type of service kit you will get in return 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 For 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 SCHEDULED MAINTENANCE To keep the owner warranty in effect your customers must have their regulators inspected and serviced annually within 6 weeks before or after the anniversary of the d
29. ing knob 4 Remove the adjusting knob from the end of the adjusting orifice Using a small slotted screwdriver remove the cir clip 5 from the adjusting orifice Holding the base of the orifice housing with a 3 4 wrench use a 5 8 wrench to remove the retainer nut 6 from the orifice housing 43 Remove the swivel fitting 7 from the orifice housing Inspect the inner sealing surfaces for scratches While holding the plastic case din your hand use a 3 4 wrench to remove the orifice housing from the lever support 26 The case is reinforced to withstand this operation Before removing the lever support 6 and assembly from the case look into the mouthpiece tube from the outside There are two plastic tabs in the mouthpiece tube against which the fins rest The fins should rest on the side of the tabs towards the orifice housing on the right side as you look into the mouthpiece tube from the outside Remember this placement when you reassemble the regulator Remove the lever support and assembly from the case with the heat transfer 6 still attached There is no reason to remove these fins from the lever support during a normal service interval If you do have to remove the fins use a 5 32 socket wrench to remove and replace the screws Normally only the poppet stem seat insert Z will need to be changed to restore the second stage to like new performance To change this stem seat insert leave the lever assembly together a Ca
30. is in the wrong groove you will see air leaking from between the module and the body instead of from the black one way bleed valve system 4 Repair any leaks 5 Check for the correct positive air purge flow rate See Section 5 4 Testing of First Stage for the proper method 7 0 HELPFUL HINTS 11 TROUBLESHOOTING REGULATORS POSSIBLE CAUSE HIGH INSTALLATION EFFORT AT DEPTH a Inlet filter clogged b No air flowing through the dry air bleed system c High pressure air supply insufficient d Second stage improperly adjusted FREE FLOWING a Intermediate pressure too high b Damaged or worn HP piston seat c Damaged or worn HP poppet stem seat d Nicked or corroded orifice sealing e Demand lever in second stage bent too high f Weak spring in second stage g Second stage improperly adjusted h Parts in the second stage have been severely chilled due to repeated purging and have shrunk allowing air to flow WET BREATHING a Improper clearing or diver diving in total head down position RECOMMENDED ACTION Replace the filter Check the flow rate coming out of the one way bleed valve If no or low air flow is detected clean the flow element in the piston or replace the piston Verify the supply air pressure Make sure the customer had the tank valve turned all the way on Repeat Steps 1 through 12 in Section 6 4 Set Up of Second Stage Adjust the first stage s out
31. lation effort the flow should feel smooth and unrestricted 2 If you use a water column it should not exceed 1 2 w c 1 3 cm at one atmosphere 3 Brand new Exhaust Valves will sometimes adhere slightly to the case causing a slight increase in inhalation effort This condition will disappear with use 6 5 3 Leak Test lee 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 3 Immerse the regulator until the water is 1 4 to 1 8 64 to 32 cm 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 leakage 6 5 4 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 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 the first stage Look particularly closely at the first stage area where the adjusting module meets the body If the module to body O ring
32. let pressure to below 150 psig Replace seat p n 3801 5 This also gives high intermediate pressure Replace seat p n 978 9BN Dress the orifices in the first and second stages with a polishing stick or replace the orifices Adjust or replace the lever Replace the spring Repeat Steps 1 through 12 in Section 6 4 Set Up of Second Stage Allow the second stage to warm up to room temperature This chilling will not occur in normal diving conditions Instruct the diver on proper clearing technique b Diaphragm improperly installed c Hole in the mouthpiece at tie area d Hole in the diaphragm e Damaged exhaust valve or edges of the exhaust valve not firmly seated on the case f Crack in case HUMMING OR BUZZING DURING INHALATION a Harmonic resonance between the springs and the mass of the piston NO AIR COMING FROM DRY AIR BLEED VALVE ON FIRST STAGE 1 2 a Piston flow element is plugged with grease b Body to module O ring in wrong groove body to groove between flange and threads PARTS CLEANING RECOMMENDATIONS Visually check position of diaphragm Replace the mouthpiece Replace the diaphragm Replace exhaust valve Replace case Refer to Section 5 2 in this manual 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 Replace piston Move O ring from groo
33. ly 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 25 cc If the reading is significantly higher than 25 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 to determine if it has been clogged by grease or other foreign matter If it is clogged the piston must be replaced 5 4 3 Intermediate Pressure Test 10 NOTE This test determmines the regulator s lock up pressure the pressure put out by the first stage during a no flow condition Attach any Sherwood second stage to one of the low pressure ports and the Sherwood intermediate pressure gauge TL119 to another low pressure port Plug all other ports with appropriate port plugs Attach the regulator to a tank valve giving a source pressure of between 2700 and 3500 psig 186 and 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 at about 120 psig 8 3 Bar when the pressure adjusting ring is screwed all the way in If the pressure gauge continues to rise a
34. ng orifice 4 from the body by pushing it with a soft plastic probe 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 see Photo 6 Carefully inspect the disc springs 6 for any cracks Replace all five disc springs if any cracks are found Photo 6 16 17 18 19 20 21 22 23 Remove the one way bleed valve 43 from the body using 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 This scratch may allow water to enter the first stage spring chamber during use 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 and polish the surface to remove deposits see Photo 7 Blow all residue from the body after polishing Photo 1 Remove the large O ring 8 from the body and the large O ring from the pressure adjusting ring Inspect all O rings other than those discarded because they were found in the Maximus annual service kit 4000 4 If you notice any cuts deformities or abrasion replace the damaged 0 rings Otherwise these static O rings can be reused in the first stage Most of the O rings not found in the service kit are non moving
35. refully remove the old seat insert from the poppet cavity using a pen knife or similar object b Put the new seat insert on a clean flat surface and lower the poppet cavity over it Install the black molded seat p n 978 9BN with the identifying Sherwood symbol facing outward amp 16 17 18 19 20 21 22 23 6 3 If you need to replace certain parts of the lever assembly stem spring lever etc you do this by temporarily screwing the orifice housing 03 with the orifice back onto the lever support and assembly without the plastic case With these parts screwed together the locking nut 9 can be removed without all of the components springing apart Remove the old part install the new part and re tighten the locking nut 9 Hold the orifice housing 3 in one hand Temporarily install the adjusting knob 9 and use it to turn the orifice clockwise until it comes out of the orifice housing Remove and discard the O rings on the orifice 8 Q and the orifice housing 0702 Grasp the oval exhaust valve 6 with your fingers and pull first one and then the other locking nipple out of the case Rinse all plastic and silicone parts in clean fresh water and then blow the parts dry with compressed air Inspect the case 17 for any cracks Look particularly closely at the area where the orifice housing and the lever support clamp down Replace the case if you find any cracks Squeeze marks and lines ca
36. rings or seat 25 G022A O ring for large end of Piston 2 3601 8 3601 15 Label TABLE OF CONTENTS Page 1 0 Introduction teaver ies eee oa teehee 1 2 0 Specifications 2 2 1 General 2 2 25 ISR OtAG eS eee dana aman 2 2 374 Second Stade n d Gs Janae Ae ea ARES SaaS ae ees 2 3 0 O rings Reference 3 4 0 Special Feature of the Maximus SRB3600 4 4 1 First Stage aoe a 4 4 2 Second Stage Features 4 5 0 First Stage Procedures 5 5 1 Tools Required for First Stage Servicing 5 5 2 Disassembly of First Stage 6 5 3 gt Assembly of First Stage 10 5 4 Testing Of First Stagen rire eee tad nee sae manang aT 11 6 0 Secoond Stage Procedures 13 6 1 Tools Required for Second Stage Servicing 13 6 2 Disassembly of Second Stage 13 6 3 Assembly of Second Stage 15 6 4 Set Up of Second Stage 17 6 5 Testing of Second Stage 18 TO Helpful Hints 20 7 1 Troubleshooting Regulators
37. t stops This is especially important when high 3500 psi 241 Bar tank pressures are used because it helps prevent rapid heat buildup at the piston seat The smooth hydrodynamic shape of the second stage is less resistant to forward motion through water thus lowering jaw fatigue The shape is also designed to resist free flowing caused by rapid initial immersion or forward motion With lower interstage hose pressure 120 psi 8 3 Bar the heat transfer fins become warmer during exhalation and transfer heat to the lever support area thus aiding in freeze resistance At high interstage hose pressures 135 150 psi 9 3 10 Bar the transfer fins become much colder causing condensation and moisture retention for the diver BEFORE YOU BEGIN Before you begin disassembly of the regulator test the first and second stages for output pressures and leakage Pretesting in this way will help you to pinpoint any specific areas requiring repair Make sure your work area is clean and well lighted with clean compressed air available to blow sand and dirt from parts 5 0 FIRST STAGE PROCEDURES 5 1 0015 REQUIRED FOR FIRST STAGE SERVICING Bench vise 3 32 Allen wrench 5 32 Allen wrench 6 or 8 adjustable wrenches 15 adjustable wrench Pocket screwdriver slotted 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 Sherwoo
38. used by compression of the case between the lever support and orifice housing are not a reason for changing the case Inspect the exhaust valve and the diaphragm for any tears or pin holes by stretching them gently as you hold them up to a light If you are repeatedly tearing diaphragms while inspecting you are applying too much force Inspect the orifice 0 for any nicks scratches or corrosion Polish out any corrosion or minor scratches using a fine grit rubberized polishing stick or a clean new pencil eraser Remember not to apply too much pressure when rotating the polishing stick Check frequently to see when the corrosion or scratch is gone and stop at that point Blow all dust and debris out of the orifice housing using clean compressed air Inspect all O ring grooves in the metal parts of the second stage Clean all O ring grooves with a lint free cloth NOTE Prior to this point you should have cleaned and inspected all parts following proper service procedures Do not continue until this has been done ASSEMBLY OF SECOND STAGE Install the exhaust valve into the case by inserting the two nipples into the small holes from the outside of the case Reach inside the case and pull each 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 Install the lever support 6 and assembly into the case setting it firmly between the guide ribs in th
39. ve between flange and Regulators which see heavy use particularly those used in salt water often need 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 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 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 If the first stage moving orifice p n29 3106 13A is corroded because salt water
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