Apeks BLACK SAPPHIRE Maintenance Manual
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Apeks BLACK SAPPHIRE Maintenance Manual

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TECHNICAL SUPPORT
BLACK SAPPHIRE
REGULATOR
MAINTENANCE MANUAL
FOR
AUTHORISED TECHNICIANS
Issue 1
Document No. AP6209F
13/02/2015
APEKS MARINE EQUIPMENT LTD, NEPTUNE WAY, BLACKBURN, LANCASHIRE. BB1 2BT
Tel: +44 (0) 1254 692200 Fax: +44 (0) 1254 692211 E-mail: info@apeks.co.uk Web: www.apeks.co.uk

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  • Page 1 TECHNICAL SUPPORT BLACK SAPPHIRE REGULATOR MAINTENANCE MANUAL AUTHORISED TECHNICIANS Issue 1 Document No. AP6209F 13/02/2015 APEKS MARINE EQUIPMENT LTD, NEPTUNE WAY, BLACKBURN, LANCASHIRE. BB1 2BT Tel: +44 (0) 1254 692200 Fax: +44 (0) 1254 692211 E-mail: info@apeks.co.uk Web: www.apeks.co.uk...
  • Page 2 Amendments and approval of this document can only be carried out by the relevant people listed on the Approved list of signatures, which is listed in the Apeks Quality Manual. To instigate a change, a Task / Change request form, (Form No.

  • Page 3: Table Of Contents

    Black Sapphire Maintenance Manual Contents COPyRIGHT NOTICE ............................. 4 INTRODUCTION ..............................4 WARNINGS, CAUTIONS & NOTES ........................4 SCHEDULED SERvICE ............................4 GENERAL GUIDELINES ............................5 GENERAL CONvENTIONS ........................... 5 1ST STAGE DISASSEMBLy PROCEDURES ...................... 7 1ST STAGE REASSEMBLy PROCEDURES ....................... 9 1ST STAGE FINAL TESTING ..........................

  • Page 4: Copyright Notice

    Failure of step 8 requires replacement of the However, If you are at all unsure about the correct functioning Hose. of the Apeks Black Sapphire then it must be officially inspect- ed immediately. All service and inspection details need to be documented in the Regulator Service Record in the back of the Owner’s...

  • Page 5: General Guidelines

    Ring to create a during the cleaning procedure. protrusion. Grab Use only genuine Apeks parts provided in the 1st ‘O’ Ring or insert stage service kit (AP0241) and 2nd stage service kit (AP0219). DO NOT attempt to substitute an Apeks ‘O’...
  • Page 6 Black Sapphire Maintenance Manual Black Sapphire First Stage Servicing Procedure...

  • Page 7: 1St Stage Disassembly Procedures

    Black Sapphire Maintenance Manual Removal of hose Removal of Balance Plug Assembly 1. Using a 9/16” spanner, 6. Using a 6mm allen key unscrew the 5th Port (21) remove all of the hoses and remove.. from the first stage. Remove the ‘O’ Ring from inside the Hose Swivel.
  • Page 8 Diaphragm (9) towards the edge to cause it to lift. This will enable a pick to remove the Diaphragm without 9. Using the Black Sapphire Environmental End Cap Tool causing damage to any sealing surfaces. (PN AT89) unscrew the Environmental End Cap (1) and Clamp Ring (5).

  • Page 9: 1St Stage Reassembly Procedures

    16. To remove the HP Valve Seat (16) (visible between the two Black arrows) from the Black Sapphire Valve Body (11) locate the end of the HP Seat Tool (PNAT53) inside the small hole. Gently slide the tool into the hole, this will push the HP Valve Seat out of the bottom of the Valve Body (11).
  • Page 10 Black Sapphire Maintenance Manual Assembling and fitting of Yoke Connection Assembling and fitting of DIN Connection 1. Insert a new Disc Filter 4. Install a new ‘O’ Ring (25) with the smooth (27) into the face of the side out, into the Yoke Handwheel Connector Connector (24).
  • Page 11 Black Sapphire Maintenance Manual Fitting of the Dry Sealed Chamber 10. Press the Spring (18) onto the end of the 5th Port (21). Carefully insert a new H.P. Valve (17) into the H.P Balance plug assembly. 7. Drop the Valve Lifter (10) through the centre hole of the Valve Body (11).

  • Page 12: 1St Stage Final Testing

    Black Sapphire Maintenance Manual Adjusting the First Stage 4. Assuming there are no leaks, close the cylinder valve and depressurise the regulator by opening the gauge relief valve or by pressing the purge button of the second stage WARNING: Compressed air can be highly regulator.
  • Page 13 The Pour Moulded Hydrostatic Diaphragm Assuming that there are no leaks, close the cylinder (2) in the Black Sapphire does not need to be replaced valve and depressurise the regulator. Remove the first with a new one unless it is deemed damaged or worn stage from the valve and secure the Dust Cap (26) in by the technician.
  • Page 14 Black Sapphire Maintenance Manual Table 1A - Troubleshooting Guide (1st Stage) SyMPTOM POSSIBLE CAUSE TREATMENT 1. HP Valve (17) is worn or damaged. 1. Replace HP Valve. 2. Removable HP Valve Seat (16) is worn 2. Replace Removable HP Valve Seat.

  • Page 15: 1St Stage Table 1A - Troubleshooting Guide

    Black Sapphire Maintenance Manual Black Sapphire Second Stage...

  • Page 16: 2Nd Stage Disassembly Procedures

    Black Sapphire Maintenance Manual Removal of hose 4. Lift out the Dia- phragm Cover (4) and Diaphragm (5). Inspect 1. Using two 11/16” spanners, hold the Heat the Diaphragm. It Exchanger (11) stationary while turning the Hose should be supple and Swivel anticlockwise.
  • Page 17 Black Sapphire Maintenance Manual 8. Grasp the Venturi 12. Remove the ‘O’ Ring (30) from the Adjusting Lever (16 + 17) and pull Screw. Remove the Plug (25) from the Adjusting it out of the Case (6). Screw. Using a 5mm Allen key, unscrew the Spring Remove the ‘O’...
  • Page 18 Black Sapphire Maintenance Manual 15. Using a fingernail, remove the Silicone Seat (35) 19. To remove the Exhaust Tees (37) & (38), depress and small ‘O’ Ring (33) from the Shuttle Valve. the retaining button located in the centre (see picture) and slide the Left Hand Exhaust Tee (37) off the Case (6).

  • Page 19: 2Nd Stage Reassembly Procedures

    Black Sapphire Maintenance Manual Fitting Exhaust valve and Exhaust Tees Assembling and Fitting valve Assembly 1. If the Exhaust Valve (36) was removed, replace by 4. Install a new, threading the tail through the retaining hole on the lubricated ‘O’ Ring (20) outside of the Case (6) until the barb engages on the onto the Valve Spindle.
  • Page 20 Black Sapphire Maintenance Manual 8. If you removed the Lever (23), position the Valve 10. With the “feet” of the Shuttle Valve pointing Spindle (21) so that the Lever Hole is to the left of the downward (away from the Lever) and the Lever...
  • Page 21 Black Sapphire Maintenance Manual 12. Install the Adjusting Screw into the Valve Spindle. NOTE: The Arrow and line must be aligned There should now be spring tension on the Lever. to ensure that the two parts fasten together Continue to screw clockwise until the holes for the correctly.
  • Page 22 Black Sapphire Maintenance Manual 16. While depressing the Lever, insert the Valve 19. While holding the Spindle through the Venturi Lever and into the Case. rim of the case at eye Be sure that the two flats and the two Lever feet level, turn the seat engage in the tabs of the Blanking Piece.
  • Page 23 Black Sapphire Maintenance Manual Fitting Hose and Mouthpiece 25. After all testing has been completed, refit the Plug (25) (If 22. Add a new lubricated ‘O’ Ring to the male end of fitted) into the Adjusting the Hose. Install a new, lubricated ‘O’ Ring into hose Screw (29).

  • Page 24: 2Nd Stage Final Testing

    Black Sapphire Maintenance Manual Final Testing 6. Disconnect the second stage from the hose as shown in step 1 of the disassembly procedure. Using the Slotted Seat Warning: Compressed air can be highly Adjuster Tool (PN AT51) ,turn the seat (18) anti-clockwise explosive and is dangerous if misused.

  • Page 25: 2Nd Stage Converting To Left Hand Configuration

    (11) stationary while turning the Hose Swivel anti-clockwise. Using the Apeks XTX Tool (PN AT20F), unscrew the Case Cover (3). Lift out the Diaphragm Cover (4) and Diaphragm (5). Grasp the Venturi Lever (16) + (17) and pull it out of the Case.
  • Page 26 Black Sapphire Maintenance Manual Rotate the Venturi Ring (16) on the Venturi Lever Body Install lubricated ‘O’ Ring (14) onto the Blanking Piece (17). Align the Arrow on the Venturi Ring with the line (13). Point the Blanking Piece upward and insert it into on the Venturi Lever Body above the LEFT text.
  • Page 27 Black Sapphire Maintenance Manual Slide a lubricated ‘O’ Ring (12) down the threaded end Before fitting hose, carry out suction test by of the Valve Spindle. Screw the Heat Exchanger (11), holding thumb over valve Spindle (21) to seal and hexagon facing outward, onto the Valve Spindle until trying to breathe through mouthpiece outlet port.

  • Page 28: 2Nd Stage Table 1B - Troubleshooting Guide

    Black Sapphire Maintenance Manual Table 1B - Troubleshooting Guide (2nd Stage) SyMPTOM POSSIBLE CAUSE TREATMENT 1. Excessively high first-stage intermediate 1. Refer to first-stage pressure. Troubleshooting Guide. 2. Silicone Valve Seat (35) damaged or 2. Replace Rubber Seating. worn. 3. Reset Seat preliminary 3.

  • Page 29: 1St + 2Nd Stage Table 2 - Recommended Tool List

    Black Sapphire Maintenance Manual Table 2A - Recommended Tool List (1st Stage) PART NO. DESCRIPTION APPLICATION AP0430 I.P. test gauge Intermediate pressure testing AT79 ‘O’ Ring removal pick ‘O’ Ring removal AT30 C spanner Removal of Diaphragm Clamp & End Cap...
  • Page 30 Black Sapphire Maintenance Manual Table 3 - Recommended Lubricants & Cleaners LUBRICANT / CLEANER APPLICATION SOURCE Christo-Lube MCG-111 Lubrication Technologies All O ring seals ® (Lubricant). 310 Morton Street Jackson, OH 45640, USA (800) 477-8704, or Apeks Marine Equipment Ltd...
  • Page 31 Black Sapphire Maintenance Manual Table 4 - Torque Specifications PART NUMBER DESCRIPTION / KEy NUMBER TORqUE AP1471 Handwheel Connector (31) 20 Nm / 14.7 ft/lb AP1407 Yoke Connector 20 Nm / 14.7 ft/lb AP5309-5BS 5th Port 8 Nm / 5.9 ft/lb...

  • Page 32: Cleaning And Lubrication Procedure

    Black Sapphire Maintenance Manual Cleaning & Lubrication Procedure Cleaning Brass and Stainless Steel Parts If required, pre-clean in warm, soapy water* using a nylon bristle tooth brush. Thoroughly clean parts in an ultrasonic cleaner filled with a solution of household white distilled vinegar (Acetic Acid) mixed with fresh water (max 50% vinegar).

  • Page 33: 1St Stage Exploded Parts Drawing

    Black Sapphire Maintenance Manual Exploded Parts Diagram AP7308 Environmental End Cap AP1419 HP Valve AP7309 Environmental Decal AP1415 Spring AP1483 Hydrostatic Transmitter AP1299 BS006 O Ring AP1474 Spring Adjuster AP1300 BS151-16 O Ring AP7306 Clamp Ring AP5309-5BS 5th Port AP1473/1...

  • Page 34: 2Nd Stage Exploded Parts Drawing

    Black Sapphire Maintenance Manual Exploded Parts Diagram AP0624BS Black Sapphire Purge Button Assy AP6216 Reversible Spindle (incl spring) AP6222 XTX Spring AP6215 Reversible Spindle Collar AP7314 Black Sapphire Front Cover AP2035 Lever AP5802 Inner cover AP1151 Spring Pin AP5803 Diaphragm with Pad...
  • Page 35 TECHNICAL SUPPORT BLACK SAPPHIRE REGULATOR MAINTENANCE MANUAL AUTHORISED TECHNICIANS...

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