Apeks BLACK SAPPHIRE User manual

TECHNICAL SUPPORT
APEKS MARINE EQUIPMENT LTD, NEPTUNE WAY, BLACKBURN, LANCASHIRE. BB1 2BT
Tel: [phone] Fax: [phone] E-mail: [email protected] Web: www.apeks.co.uk
MAINTENANCE MANUAL
FOR
AUTHORISED TECHNICIANS
Document No. AP6209F
Issue 1
13/02/2015
BLACK SAPPHIRE
REGULATOR

2
Black Sapphire Maintenance Manual
AMENDMENTS RECORD:
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.
‘DESI/10002’), must be completed and passed to the relevant person(s) for approval which are listed on the Approved List of
Signatures. When approval has been granted and recorded this table can then be completed and the document up issued.
Change
No.
Change
Request No.
Description & Comments: Change
Date
New Issue
No.
Changed
By:
Approved
By:

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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 .............................................................................................................................. 12
1ST STAGE TABLE 1A - TROUBLESHOOTING GUIDE .................................................................................. 15
2ND STAGE DISASSEMBLY PROCEDURES......................................................................................................16
2ND STAGE REASSEMBLY PROCEDURES......................................................................................................19
2ND STAGE FINAL TESTING...............................................................................................................................24
2ND STAGE CONVERTING TO LEFT HAND CONFIGURATION.....................................................................25
2ND STAGE TABLE 1B - TROUBLESHOOTING GUIDE...................................................................................28
1ST + 2ND STAGE TABLE 2 - RECOMMENDED TOOL LIST.......................................................................... 29
TABLE 3 - RECOMMENDED LUBRICANTS AND CLEANERS ...................................................................... 30
TABLE 4 -TORQUE SPECIFICATIONS .............................................................................................................. 31
TABLE 5 - TEST BENCH SPECIFICATIONS ..................................................................................................... 31
CLEANING AND LUBRICATION PROCEDURE.................................................................................................32
1ST STAGE EXPLODED PARTS DRAWING ..................................................................................................... 33
2ND STAGE EXPLODED PARTS DRAWING..................................................................................................... 34

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Black Sapphire Maintenance Manual
4
COPYRIGHT NOTICE
This manual is copyrighted, all rights reserved. It may not,
in whole or in part, be copied, photocopied, reproduced,
translated, or reduced to any electronic medium or machine
readable form without prior consent in writing from Apeks
Marine Equipment Ltd. It may not be distributed through the
internet or computer bulletin board systems without prior
consent from Apeks Marine Equipment Ltd.
©2014 Apeks Marine Equipment Ltd.
Black Sapphire Regulator Maintenance Manual
(AP6209F Issue 1)
INTRODUCTION
This manual provides factory prescribed procedures for the
correct maintenance and repair of the Apeks Black Sapphire
regulator. It is not intended to be used as an instructional
manual for untrained personnel. The procedures outlined
within this manual are to be performed only by personnel
who have received factory authorised training through an
Apeks Service & Repair Seminar. If you do not completely
understand all of the procedures outlined in this manual,
contact Apeks to speak directly with a Technical Advisor
before proceeding any further.
WARNINGS, CAUTIONS & NOTES
Pay special attention to information provided in warnings,
cautions, and notes that are accompanied by one of these
symbols:
WARNINGS indicate a procedure or situation
that may result in serious injury or death if
instructions are not followed correctly.
CAUTIONS indicate any situation or
technique that will result in potential damage
to the product, or render the product unsafe if
instructions are not followed correctly.
NOTES are used to emphasise important points,
tips, and reminders.
SCHEDULED SERVICE
It is recommended that the Apeks Black Sapphire regulator
should be serviced annually regardless of usage.
However, If you are at all unsure about the correct functioning
of the Apeks Black Sapphire then it must be ofcially inspect-
ed immediately.
All service and inspection details need to be documented
in the Regulator Service Record in the back of the Owner’s
Manual to keep the Limited Lifetime Warranty in effect.
A First Stage Ofcial Inspection consists
of:
1. A pressurised immersion test of the entire unit to
check for air leakage.
2. Checking for stable medium pressure that is within
the acceptable range.
3. Checking that all parts are tightly fastened together
and that no parts are loose.
4. A visual inspection of the Environmental Diaphragm
looking for tears or holes and checking the general
condition.
5. A visual inspection of any lters for debris or dis-
colouration.
6. Pulling back hose protectors and checking that the
hoses are secure in the hose crimps.
If a regulator fails steps 1,2, or 3 the entire regulator
should be serviced. If a regulator fails 4 or 5 it will be up
to the technician’s discretion whether or not a full service
is required. Failure of step 6 requires replacement of the
Hose.
A Second Stage Ofcial Inspection
consists of:
1. A pressurised immersion test of the entire unit to
check for air leakage.
2. Checking for stable medium pressure that is within
the acceptable range.
3. Checking for opening effort that is within the
acceptable range.
4. Checking for smooth operation of the control knob
and venturi switch.
5. A visual inspection of any lters for debris or dis-
colouration.
6. A visual inspection of the exhaust valve(s) to see
that they are in good condition and that it is seating
against a clean and undamaged surface.
7. A visual inspection of the mouthpiece looking for
tears or holes and checking the general condition.
8. Pulling back hose protectors and checking that the
hoses are secure in the hose crimps.
If a regulator fails steps 1,2,3 or 4 the entire regulator
should be serviced. If a regulator fails 5,6 or 7 it will be up
to the technician’s discretion whether or not a full service
is required. Failure of step 8 requires replacement of the
Hose.

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Black Sapphire Maintenance Manual
GENERAL GUIDELINES
1. In order to correctly perform the procedures outlined
in this manual, it is important to follow each step
exactly in the order given. Read over the entire
manual to become familiar with all procedures and
to learn which specialty tools and replacement parts
will be required before commencing disassembly.
Keep the manual open beside you for reference while
performing each procedure. Do not rely on memory.
2. All service and repair should be carried out in a work
area specically set up and equipped for the task.
Adequate lighting, cleanliness, and easy access to all
required tools are essential for an efcient repair facil-
ity.
3. During disassembly, reusable components should be
segregated and not allowed to intermix with non-
reusable parts or parts from other units. Delicate
parts, including inlet ttings and valve seats which
contain critical sealing surfaces, must be protected
and isolated from other parts to prevent damage
during the cleaning procedure.
4. Use only genuine Apeks parts provided in the 1st
stage service kit (AP0241) and 2nd stage service kit
(AP0219). DO NOT attempt to substitute an Apeks
part with another manufacturer’s, regardless of any
similarity in shape or size.
5. Do not attempt to reuse mandatory replacement
parts under any circumstances, regardless of the
amount of use the product has received since it was
manufactured or last serviced.
6. When reassembling, it is important to follow every
torque specication prescribed in this manual,
using a calibrated torque wrench. Most parts are
made of either marine brass or plastic, and can be
permanently damaged by undue stress.
GENERAL CONVENTIONS
Unless otherwise instructed, the following terminology and
techniques are assumed:
1. When instructed to remove, unscrew, or loosen a
threaded part, turn the part anti-clockwise.
2. When instructed to install, screw in, or tighten a
threaded part, turn the part clockwise.
3. When instructed to remove an ‘O’ Ring, use the pinch
method (see gure below) if possible, or use a brass,
aluminium or plastic ‘O’ Ring removal tool. Avoid using
hardened steel picks, as they may damage ‘O’ Ring
sealing surfaces. All ‘O’ Rings that are removed are
discarded and replaced with brand new ‘O’ Rings.
4. The following acronyms are used throughout the
manual: MP is Medium Pressure; HP is High Pressure;
PN is Part Number.
5. Numbers in parentheses reference the key numbers
on the exploded parts schematics. For example, in the
statement, “...remove ‘O’ Ring (11) from...”, the number
11 is the key number to the Blanking Piece ‘O’ Ring.
DISASSEMBLY PROCEDURES
NOTE: Before performing any disassembly,
refer to the exploded parts drawing, which refer-
ences all mandatory replacement parts. These
parts should be replaced with new, and must not
be reused under any circumstances - regardless
of the age of the regulator or how much use it
has received since it was last serviced.
CAUTION: Use only a plastic, brass or
aluminium ‘O’ Ring removal tool (PN AT79)
when removing ‘O’ Rings to prevent damage
to the sealing surface. Even a small scratch
across an ‘O’ Ring sealing surface could
result in leakage. Once an ‘O’ Ring sealing
surface has been damaged, the part must
be replaced with new. DO NOT use a dental
pick, or any other steel instrument.
Pinch Method
Press upwards
on sides of ‘O’
Ring to create a
protrusion. Grab
‘O’ Ring or insert
‘O’ Ring tool at
protrusion.

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Black Sapphire Maintenance Manual
Black Sapphire First Stage
Servicing Procedure

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Black Sapphire Maintenance Manual
Removal of hose
Removal of Blanking Plugs
1. Using a 9/16” spanner,
remove all of the hoses
from the rst stage.
Remove the ‘O’ Ring from
inside the Hose Swivel.
Exercise caution not
to scratch the ‘O’ Ring
groove. Remove the ‘O’
Ring from the Hose Nut
end of the Hose.
2. Pull back the two Hose
Protectors and inspect
the Hose Crimps. If either
Crimp is damaged or the
Hose is pulling out of the
crimp then the Hose must
be replaced.
3. Using a 5mm Allen key remove all of the MP and HP
blanking plugs including 5th Port
4. Remove all of the ‘O’
Rings (13,14) from the
Blanking Plugs.
5. Using the First Stage
Work Handle (PN AT48)
clamp the regulator in a
vice.
Removal of Balance Plug Assembly
6. Using a 6mm allen key unscrew the 5th Port (21)
and remove..
7. Separate the 5th port
assembly by
pulling on each end.
8. Remove ‘O’ Rings
(14,19,20) from the 5th
Port (21), taking care not
to scratch the ‘O’ Ring
grooves.
NOTE: See page 16 for
second stage removal from
hose.

8
Black Sapphire Maintenance Manual
NOTE: If the First Stage has a DIN Connection, go to
step 13: if it has a Yoke Connection follow step 14.
Removal of Din Connection
NOTE: The thickness of the spanner must not exceed
11mm or it will not t between the thread and the
ange. The correct spanner can be purchased from
Apeks (PN AT47)
10. Remove the Load Transmitter (3) and using a 34mm
open ended spanner unscrew the Diaphragm Clamp (6).
11. Remove the Spring (7) & Spring Carrier (8). Press down
on the Diaphragm (9) towards the edge to cause it to lift.
This will enable a pick to remove the Diaphragm without
causing damage to any sealing surfaces.
12. Remove the Valve
Lifter (10) from the Valve
Body (11).
13. Using a 6mm Allen key, unscrew the DIN Connection
Assembly and separate into four pieces. Remove the ‘O’
Ring (27) from the end of the Handwheel connector (31).
Use a thin dowel or Allen key to remove Conical Filter (29)
and O Ring (14).
9. Using the Black Sapphire Environmental End Cap Tool
(PN AT89) unscrew the Environmental End Cap (1) and
Clamp Ring (5). Separate Environmental Decal (2) from
End Cap (1).
Removal of Dry Sealed Chamber
CAUTION: Ensure
Environmental End
Cap tool (PN AT89)
is seated correctly
onto End Cap and an
even force is applied
downwards to avoid
slipping.
NOTE: The Spring Adjuster (4) can be left in the
Diaphragm Clamp (6) for cleaning and re assembly.

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Black Sapphire Maintenance Manual
Removal of Yoke Connection
14. Unscrew the Yoke
Knob (28) and remove the
Dust Cap (26) from the
Yoke Clamp (23). Using a
3/4” A/F spanner, unscrew
the Yoke Connector (24)
and Yoke Clamp.Remove
the ‘O’ Ring from the Yoke
Connector (14).
15. Insert a dowel through
the open end of the Yoke
Connector (24) and push
out the Disc Filter (25).
Removal of Removable HP Valve Seat
CAUTION: Before proceeding, make sure you are
working over a padded work surface: otherwise,
the Removable HP Valve Seat (16) may be
damaged during removal.
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).
Removable
HP Valve Seat XTX200 HP
Seat Tool
(PN AT53)
17. Remove the ‘O’ Ring
(14) from the HP Valve
Seat (16).
This Ends Disassembly
REASSEMBLY PROCEDURES
Fitting of Removable HP Valve Seat
1. Install a new lubricated ‘O’ Ring (14) onto the Removable
HP Valve Seat (16). Locate the Removable HP Valve Seat
onto the end of the HP Seat Tool (PN AT53). Ensure that
the seating face of the Valve Seat is against the Seat Tool.
Firmly push the Seat Tool into the Valve Body (11) until the
Removable HP Valve Seat is located at the bottom of the
bore.
WARNING: The regulator will not operate if the
Removable HP Valve Seat is inserted into the Valve
Body incorrectly.
NOTE: A slot on the at face of the HP valve seat has
been added to identify the way of assembly
NOTE: Before starting reassembly perform parts
cleaning and lubrication according to the procedures
outlined in ‘Cleaning & Lubrication’ on page 32.

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Black Sapphire Maintenance Manual
NOTE: Ensure that the ‘O’ Ring is retained in the
Connector after the Conical Filter has been tted.
Assembling and tting of DIN Connection
CAUTION: If the Handwheel Connector Assembly
is not held vertically whilst it is screwed into
the Valve Body, the ‘O’ Ring in the end of the
Handwheel Connector may not remain in the
correct position.
4. Install a new ‘O’ Ring
(27) into the face of the
Handwheel Connector
(31). Install a new
lubricated ‘O’ Ring (14)
into the opposite end of
the Connector. Install the
Conical Filter (29) into the
Connector, through the ‘O’
Ring.
5. Insert the threaded
end of the Handwheel
Connector (31) through
the threaded end of the
Handwheel (30), with the
Valve Body held so that
the inlet connection port
points down, screw the
Handwheel Connector into
the Valve Body (11) until
nger tight.
6. Secure the Valve Body
(11) back into the vice
using the First Stage Work
Handle (PN AT48). Tighten
the Handwheel Connector
(31) using a 6mm Allen key
bit in a torque wrench to
20 Nm.
3. Secure the Valve Body
(11) back into the vice
using the First Stage Work
Handle (PN AT48). Tighten
the Yoke Clamp Connector
using a 3/4” A/F spanner
to 20Nm (14.7 ft/lb).
Install the Protective Cap
(26) with the logo facing
outwards, onto the Yoke
Clamp (23). Screw the
Yoke Knob (28) back into
the Yoke Clamp (23), until
the Protective Cap (26) is
retained in place.
CAUTION: If
the Yoke Clamp
Assembly is not
held vertically
whilst it is screwed
into the Valve Body,
the ‘O’ Ring in the
end of the Yoke
Clamp Connector
may not remain in
the correct position.
2. Insert the Yoke Clamp
Connector (24) through the
Yoke Clamp (23). With the
Valve Body held so that the
inlet connection port points
down, screw the Yoke
Clamp Connector into the
Valve Body (11) until nger
tight.
1. Insert a new Disc Filter
(25) with the smooth
side out, into the Yoke
Connector (24). Install a
new lubricated ‘O’ Ring
(14) into the end of the
Connector.
Assembling and tting of Yoke Connection

11
Black Sapphire Maintenance Manual
Fitting of the Dry Sealed Chamber
7. Drop the Valve Lifter (10) through the centre hole of the
Valve Body (11). Press a new Diaphragm (9) into the Body.
Run your nger around the edge of the diaphragm to make
sure it is properly seated.
8. Place the spring carrier (8) and Spring (7) centrally onto
the diaphragm (9).Thread the Diaphragm Clamp (6) onto the
Valve Body (11), making sure that the Spring (7) remains
on the Spring Carrier (8), until hand tight. Using a 34mm
Spanner (PN AT47) tighten the Diaphragm Clamp (6) to
30Nm (22.1 ft/lb).
9. Fit new Lubricated ‘O’
Rings (14 & 20) onto the
5th Port (21). Install a new
lubricated ‘O’ Ring (19)
into the end of the 5th Port.
Ensure that the ‘O’ Ring is
ush.
This Ends Re-assembly
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.
11. Insert the 5th Port (21) into the Valve Body (11) ensuring
the H.P. valve locates onto the lifter and tighten using a
6mm allen key to a torque value of 8 Nm.

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Black Sapphire Maintenance Manual
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
regulator. Adjust the medium pressure by turning the Spring
Adjuster (4): Turning in the Spring Adjuster (clockwise)
increases the MP; Turning out the Spring Adjuster (counter
clockwise) decreases the MP. Turn the Spring Adjuster in
1/8th turn increments and purge the relief valve several
times after each adjustment. When the MP is between 9 and
10 bar , purge the relief valve on and off 10-15 times. After
cycling, watch the gauge needle. The rst stage MP should
“lock-up” between 9 and 10 bar. Make any adjustments
as necessary. Allow the rst stage to stay pressurised for
several minutes and check the MP again to make sure it
remains “locked-up” between 9 and 10 bar. If the MP creeps
upward more than 0.25 bar, then there is a leak. Refer to the
troubleshooting table for possible causes.
5. Close the cylinder valve and depressurise the regulator
by opening the gauge relief valve or by pressing the purge
button of the second stage regulator. Close the relief valve
and repressurise the system. The MP should still read
between 9 and 10 bar. If the pressure reading is different
than the original setting, repeat steps 3 and 4 until the MP is
stable.
CAUTION: If the pressure gauge rapidly exceeds
11 bar, then there is a HP leak. Quickly close the
cylinder valve and purge the regulator. Refer to the
troubleshooting table for the causes of the leak.
3. Attach a MP test gauge
(0 - 20 bar) to a medium
pressure hose and thread
the hose into a MP port.
If your test gauge does
not have an over pressure
relief valve, you must also
attach a properly adjusted
second stage to the rst
stage to act as the relief
valve in case of a HP leak.
Make sure Blanking Plugs
are installed in any open
ports.
2. Install new lubricated
‘O’ Rings (13,14) on all of
the Blanking Plugs (12,15).
Using a 5mm Allen key,
install all of the Blanking
Plugs into the Valve Body.
1. Attach the rst stage
(with no Blanking Plugs
tted) to a fully charged
232 or 300 bar cylinder.
Slowly open the cylinder
valve, this will remove any
particles or contaminants
from the rst stage.
Adjusting the First Stage
WARNING: Compressed air can be highly
explosive and is dangerous if misused. Ensure
cylinder valve is opened slowly. Use Eye and
Ear Personal Protective Equipment when
performing any tests involving Compressed
air.
This Ends Adjustment

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Black Sapphire Maintenance Manual
Final Assembly
NOTE: The Pour Moulded Hydrostatic Diaphragm
(2) in the Black Sapphire does not need to be replaced
with a new one unless it is deemed damaged or worn
by the technician.
1. With the regulator still
pressurised, insert the
Load Transmitter (3) into
the Diaphragm Clamp (6).
Press a new Hydrostatic
Diaphragm (2) into the
Environmental End Cap (1)
(If required).
Immersion Test
With the Blanking Plugs and at least one properly
adjusted second stage installed, slowly open
the cylinder valve and pressurise the rst stage.
Completely Submerge the rst stage in fresh water
and check for leaks.
NOTE: Do not confuse bubbles from trapped air with
a true air leak. If there is an air leak, bubbles will come
out in a steady constant stream.
Assuming that there are no leaks, close the cylinder
valve and depressurise the regulator. Remove the rst
stage from the valve and secure the Dust Cap (26) in
place with the Yoke Clamp Knob (28). If the regulator
has a DIN connection replace the Protective DIN Cap
(32).
If a leak is detected, note the source of the leak and
refer to the troubleshooting table on page 14 for
possible causes and corrective actions.
This Ends Testing
This Ends Reassembly
2. Thread the Environmental End Cap (1) and Clamp Ring
(5) onto the Diaphragm Clamp (6) until hand tight. Using
the End Cap Tool (PN AT89), tighten the Environmental End
Cap (1) until there is metal to metal contact. Re-check the
medium pressure, making sure that it is still between 9 and
10 bar.
NOTE: Lightly press the diaphragm whilst
tightening the end cap, once the rst stage has been
depressurised the diaphragm will assume a concaved
positioning for added protection.
3. Close the cylinder valve and depressurise the regulator.
Remove the test gauge and reinstall the Blanking Plug.
CAUTION: Ensure Environmental End Cap tool is
seated correctly onto End Cap and an even force is
applied downwards to avoid slipping.
CAUTION: Ensure Environmental End Cap (1) and
Clamp Ring (5) are engaged together by the location
lugs.

14
Black Sapphire Maintenance Manual
SYMPTOM POSSIBLE CAUSE TREATMENT
High Pressure Creep
(also causes second stage leaks)
1. HP Valve (17) is worn or damaged. 1. Replace HP Valve.
2. Removable HP Valve Seat (16) is worn
or damaged. 2. Replace Removable HP Valve Seat.
3. ‘O’ Ring on Removable HP Valve Seat
(14) is damaged or worn. 3. Replace ‘O’ Ring.
4. 5th Port internal wall damaged. 4. Replace 5th Port.
5. ‘O’ Ring (19) inside 5th Port (21) is
damaged or worn. 5. Replace ‘O’ Ring.
6. ‘O’ Ring (14) on 5th Port (21) is
damaged or worn. 6. Replace ‘O’ Ring.
External air leakage
or
Secondary diaphragm distended
or burst
1. Blanking Plug ‘O’ Rings (13,14) are worn
or damaged. 1. Replace ‘O’ Ring.
2. Diaphragm (9) worn or damaged. 2. Replace diaphragm.
3. Diaphragm seating surface damaged. 3. Replace Valve Body.
4. Connector ‘O’ Ring (14) worn or
damaged. 4. Replace ‘O’ Ring.
5. Diaphragm Clamp (6) loose. 5. Tighten Diaphragm Clamp.
6. ‘O’ Ring on 5th Port (20) worn or
damaged. 6. Replace ‘O’ Ring.
Restricted air ow or high inhalation
resistance through entire system
1. Cylinder valve not completely open. 1. Open valve, check ll pressure.
2. Cylinder valve requires servicing 2. Switch to different cylinder.
3. Conical Filter (29) or Disc Filter (25) is
clogged. 3. Replace lter.
4. Very Low Medium Pressure. 4. Adjust Medium Pressure to
between 9 and 10 bar.
Table 1A - Troubleshooting Guide (1st Stage)

15
Black Sapphire Maintenance Manual
Black Sapphire Second Stage

16
Black Sapphire Maintenance Manual
NOTE: Ensure that the tool is rmly pressed
against the Case Cover whilst unscrewing.
Removal of hose
Removal of diaphragm
1. Using two 11/16” spanners, hold the Heat
Exchanger (11) stationary while turning the Hose
Swivel anticlockwise. Remove the ‘O’ Ring from
inside the Hose Swivel. Exercise caution not to
scratch the ‘O’ Ring groove. Remove the ‘O’ Ring
from the male end of the Hose.
2. Pull back the two
Hose Protectors and
inspect the Hose
Crimps. If either Crimp
is damaged or the
Hose is pulling out
of the crimp then the
Hose must be replaced.
3. Using the Apeks
Front Cover Tool (PN
AT20F), unscrew the
Case Cover (3).
NOTE: The Front Cover (3) and Purge Button (1)
should be cleaned complete. It is not necessary
to remove the purge button when servicing.
Removal of valve assembly
4. Lift out the Dia-
phragm Cover (4) and
Diaphragm (5). Inspect
the Diaphragm. It
should be supple and
be free from damage.
If it looks good, there
is no need to replace it
and it may be reused.
If there is any sign of
deterioration, it should
be replaced.
5. Using an 11/16”
spanner, remove the
Heat Exchanger (11).
6. Press the Lever (23) against the Valve Spindle
(21). While keeping the Lever depressed, grasp the
Knob and pull the Valve Spindle assembly out of the
Case (6). Remove the Blanking Piece (13) from the
opposite side of the case.
7. Remove the two ‘O’ Rings (12) & (14) from the
Blanking Piece (13).

17
Black Sapphire Maintenance Manual
NOTE: The Venturi Lever may have come out
with the valve Spindle in step 6. If this is the
case, depress the Lever and slide the Venturi
Lever off.
8. Grasp the Venturi
Lever (16 + 17) and pull
it out of the Case (6).
Remove the ‘O’ Ring
(15) from the Venturi
Lever.
9. It is NOT necessary
to separate the Venturi
Lever into its two
separate parts unless
the regulator is being
converted to a different
hand conguration. To
separate them grasp
the Venturi Lever (16 +
17) as shown and push
the Venturi Ring (16) off
the Venturi Lever Body
(17).
10. Turn the Adjusting Screw (29) clockwise (inward)
one turn. The Spring Pin (24) should drop out. If the
Pin remains in the Valve Spindle, use a 1/16” dowel
or punch to push it partially out, then use needle nose
pliers to completely remove it from the valve body.
11. Unscrew the Adjusting Screw (29) and completely
remove it from the Valve Spindle (21).
12. Remove the ‘O’ Ring (30) from the Adjusting
Screw. Remove the Plug (25) from the Adjusting
Screw. Using a 5mm Allen key, unscrew the Spring
Adjuster (27) and press the spring adjuster out.
Remove the two ‘O’ rings (26 & 28) from the Spring
Adjuster.
13. Remove the ‘O’
Ring (20) from the
Valve Spindle.
14. Insert a small 1/8” wooden dowel into the
threaded end of the Valve Spindle and push out the
Shuttle Valve assembly (31-35). Separate the Shuttle
Valve assembly by pulling on each end.

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Black Sapphire Maintenance Manual
15. Using a ngernail, remove the Silicone Seat (35)
and small ‘O’ Ring (33) from the Shuttle Valve.
16. Using a Slotted
Seat Adjuster (PN
AT51), turn the Seat
(18) six to seven full
turns anti-clockwise.
As the Seat is ‘O’
Ring sealed, it will not
completely unscrew
from the Valve
Spindle. Insert the seat
extraction tool (109437)
into the opposite
end and push the
Seat completely out.
Remove the ‘O’ Ring
(19) from the Seat.
17. To remove the
Spindle Collar (22),
push both edges of the
collar as shown.
NOTE: It is not necessary to remove the Spindle
Collar under normal servicing circumstances,
unless it is deemed relevant by the service
technician, for example if it is damaged or dirty.
18. The Lever (23)
should be inspected for
deterioration, it is NOT
necessary to remove it
from the Valve Spindle.
If the Lever is to be
removed, carefully pull
one of the legs out of
the Valve Spindle and
then ease the second
leg out.
This Ends Disassembly
Before starting reassembly, perform parts
cleaning and lubrication according to the
procedures outlined in ‘Cleaning & Lubrication’
on page 32.
NOTE: If the
Exhaust Valve (36)
is to be removed,
pinch edge of
Exhaust Valve and
pull tail through
hole in Case (6).
Inspection and Removal of Exhaust Valve
Removal of Mouthpiece
19. To remove the Exhaust Tees (37) & (38), depress
the retaining button located in the centre (see picture)
and slide the Left Hand Exhaust Tee (37) off the Case
(6). Then Slide the Right Hand Exhaust Tee (38) off
the case.
20. Fold back the edges of the Exhaust Valve (36)
and inspect underneath. The seating surface should
be clean and free of damage. Inspect the Exhaust
Valve. It should be supple and have well dened
edges. If it looks good, there is no need to remove
it and it may be reused. If there is any sign of
deterioration, it should be replaced.
21. Using side
cutters, snip the
Zip Tie (7) taking
care not to damage
the Mouthpiece
(8). Remove the
Mouthpiece (8).

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Black Sapphire Maintenance Manual
Fitting Exhaust Valve and Exhaust Tees
WARNING: Flooding may occur if the tail of
the valve is not fully pulled through. Check
that barb has engaged on inside of Case.
1. If the Exhaust Valve (36) was removed, replace by
threading the tail through the retaining hole on the
outside of the Case (6) until the barb engages on the
inside. If the Exhaust Valve is new, cut off the excess
stem with side cutters leaving approximately 5mm of
the tail behind.
2. Check that the
Exhaust Rib (39) is
rmly located in the Left
Hand Large Exhaust
Tee (38).
3. Align the Left Hand Exhaust Tee (38) guide with
the slots on the Case (6). Slide the Exhaust Tee
onto the Case until the retaining button is positioned
centrally over the Exhaust Valve (36). Align the Right
Hand Exhaust Tee (37) with the Case and slide into
position, until the retaining button clips underneath
the Left Hand Exhaust Tee (38).
Assembling and Fitting Valve Assembly
NOTE: Ensure Silicone Seat has been tted
ush with Shuttle Valve.
4. Install a new,
lubricated ‘O’ Ring (20)
onto the Valve Spindle.
(21).
5. Press a new, lubricated ‘O’ Ring (33) onto the stem
of the Shuttle Valve (34). Press a new Silicone Seat
(35) into the front of the Shuttle Valve.
6. Fit the Valve Spring (32) onto the leading edge of
the Counterbalance Cylinder (31). Carefully guide the
stem of the Shuttle Valve through the Spring and into
the Counterbalance Cylinder.
7. If the Spindle Collar (22) was removed during the
disassembly process replace the Collar using a set of
circlip pliers. Spread the Collar (22) and push it onto
the Valve Spindle (21). Ensure that the arrow points
towards the lever.
CAUTION: Do not overstretch the Spindle
Collar when replacing doing so may cause
the Spindle collar to crack and break.

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Black Sapphire Maintenance Manual
CAUTION: Ensure that Lever is not twisted
and that legs are parallel. Lever should
appear as that shown on the left, not as
shown on the right. If necessary, gently
squeeze legs together to straighten.
WARNING: Ensure that the spindle collar is
set in the correct position. Failure to do so
will result in a substantial loss of breathing
performance.
CAUTION: Ensure that the Spindle Collar
clicks rmly into position and that the entire
Valve Spindle Hole is visible.
8. If you removed the Lever (23), position the Valve
Spindle (21) so that the Lever Hole is to the left of the
centre line and the Dimple is to the right of the centre
line with the threaded end facing you. (See photo
below left). Insert the lever so that it points to the right
of the Valve Spindle, as shown below.
9. Ensure that the Spindle Collar (22) is rotated to the
correct position for the required Hose conguration.
NOTE: Ensure that the Lever has a full range
of movement and does not catch on the Valve
Spindle. Ensure that the spring can be seen
through the Valve Spindle Hole.
10. With the “feet” of the Shuttle Valve pointing
downward (away from the Lever) and the Lever
pointing straight up (perpendicular to the Valve
Spindle), insert the Valve assembly into the Valve
Spindle. Using your nger, press the Shuttle Valve
assembly all the way into the Valve Spindle.
11. Install a new, lubricated ‘O’ Ring (30) onto the
Adjusting Screw (29). Install new, lubricated ‘O’
Rings (26 & 28) onto the Spring Adjuster (27). Using
an Allen key, thread the Spring Adjuster into the
Adjusting Screw (29) until it is ush with the end of
the screw, then screw in six full additional revolutions.
LEFT HANDED RIGHT HANDED