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CONSHELF XIV
First and Second Stage
Copyright 2004 Aqua Lung America, Inc. Rev. 7/2004
2 Conshelf XIV Service Manual
Contents
COPYRIGHT NOTICE...............................................................................................................................................3
INTRODUCTION .......................................................................................................................................................3
WARNINGS, CAUTIONS, & NOTES.........................................................................................................................3
SCHEDULED SERVICE............................................................................................................................................3
GENERAL GUIDELINES ..........................................................................................................................................3
GENERAL CONVENTIONS......................................................................................................................................4
DISASSEMBLY PROCEDURES...............................................................................................................................4
FIRST-STAGE DISASSEMBLY.............................................................................................................................................................. 4
SECOND-STAGE DISASSEMBLY ........................................................................................................................................................ 5
AUTHORIZED REGULATOR REASSEMBLY ..........................................................................................................6
First Stage Resassembly ..................................................................................................................................................................... 6
SECOND STAGE REASSEMBLY ......................................................................................................................................................... 8
AUTHORIZED REGULATOR ADJUSTMENT AND TESTING .................................................................................9
ATTACHMENT OF FIRST-STAGE TO SECOND-STAGE REGULATORS ............................................................................................ 9
FIRST-STAGE ADJUSTMENT AND TESTING.................................................................................................................................... 10
SECOND-STAGE ADJUSTMENT AND TESTING .............................................................................................................................. 11
SECOND-STAGE AIR FLOW TEST .................................................................................................................................................... 11
SECOND-STAGE OPENING EFFORT TEST ...................................................................................................................................... 11
SECOND-STAGE PURGE FLOW TEST.............................................................................................................................................. 11
OCTOPUS FLOW TEST ...................................................................................................................................................................... 11
OCTOPUS OPENING EFFORT TEST ................................................................................................................................................. 11
OCTOPUS PURGE FLOW TEST......................................................................................................................................................... 11
LEAKAGE TEST .................................................................................................................................................................................. 11
SUBJECTIVE BREATHING TESTING ............................................................................................................................................... 12
AUTHORIZED REGULATOR ADJUSTING AND TESTING: NON-FLOW BENCH PROCEDURES .....................12
SECOND-STAGE ADJUSTMENT AND TESTING .............................................................................................................................. 13
SECOND-STAGE AIR FLOW .............................................................................................................................................................. 13
OPENING EFFORT CHECK................................................................................................................................................................ 13
LEAKAGE TESTING ........................................................................................................................................................................... 13
SUBJECTIVE BREATHING TESTING ................................................................................................................................................ 13
APPENDIX A: DIN DISASSEMBLY AND REASSEMBLY PROCEDURES ...........................................................13
TABLE 1 - FIRST-STAGE TROUBLSHOOTING GUIDE.........................................................................................14
TABLE 2 - SECOND-STAGE TROUBLSHOOTING GUIDE ...................................................................................15
TABLE 3 - RECOMMENDED TOOL LIST ..............................................................................................................16
TABLE 4 - RECOMMENDED LUBRICANTS AND CLEANERS............................................................................17
TABLE 5 - TORQUE SPECIFICATIONS .................................................................................................................18
TABLE 6 - TEST BENCH SPECIFICATIONS .........................................................................................................18
PROCEDURE A - CLEANING AND LUBRICATION..............................................................................................19
SECOND-STAGE EXPLODED PARTS DRAWING ................................................................................................20
FIRST-STAGE EXPLODED PARTS DRAWING......................................................................................................21
3
GENERAL GUIDELINES
WARNINGS, CAUTIONS, & NOTES
1. In order to correctly perform the procedures outlined in
Pay special attention to information provided in warnings, this manual, it is important to follow each step exactly
cautions, and notes that are accompanied by one of these in the order given. Read over the entire manual to
symbols: become familiar with all procedures before attempting to
WARNINGS indicate a procedure or situation disassemble the first-stage, and to learn which specialty
tools and replacement parts will be required. Keep the
that may result in serious injury or death if
manual open beside you for reference while performing
instructions are not followed correctly. each procedure. Do not rely on memory.
CAUTIONS indicate any situation or tech- 2. All service and repair should be carried out in a work
nique that will result in potential damage to area specifically set up and equipped for the task.
Adequate lighting, cleanliness, and easy access to all
the product, or render the product unsafe if
required tools are essential for an efficient repair facility.
instructions are not followed correctly.
3. The regulator body will need to be secured in a vise
DISASSEMBLY PROCEDURES
F Note: Before performing any disassembly, refer to the
exploded parts drawing, which references 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 or brass o-ring
removal tool (PN 944022) when removing o-
rings to prevent damage to the sealing surface.
Even a small scratch across an o-ring seal-
7a. Standard Conshelf (Non-Supreme Model): Using a large
ing surface could result in leakage. Once an flat-bladed screwdriver, place the blade in the slot of the
o-ring sealing surface has been damaged, the adjustment screw (Item 31). Turn the screwdriver coun-
part must be replaced with new. DO NOT use a terclockwise and remove the adjustment screw. Lift out
dental pick, or any other steel instrument. the washer (Item 30). Next remove the mainspring (Item
29).
5
7B. Conshelf Supreme: Using the slotted tool (PN 081247) retaining ring (Item 5) from the groove on high-pressure
place the tool in the two slots of the secondary diaphragm inlet boss of the first-stage body. Then, turning the yoke
retaining ring (Item 34), turn the tool counterclockwise counterclockwise, unscrew and remove it from the first
and remove the retainer. Next, using your fingertips, stage.
lift upward on the secondary diaphragm (Item 33) and
CAUTION: The retaining ring (Item 7) must be
remove it. Remove the first-stage from the bench vise and
pour out and discard the silicone fluid. Finally, remount
removed carefully as the components beneath
the first-stage in the vise in its former orientation to com- it are under spring tension. Failure to place
plete the disassembly of the low-pressure side. Using a your finger over the sintered filter (Item 9)
large flat-bladed screwdriver, place the blade in the slot while removing the retaining ring will cause
on the adjustment screw (Item 31). Turn the screwdriver loss or damage of these parts.
counterclockwise and remove the adjustment screw. Lift
out the mainspring (Item 29). 15. With internal retaining-ring pliers, remove the retaining
ring and washer (Items 7 and 8) from the high-pressure
8. With a 1-inch crows foot and breaker bar, turn the inlet boss. Discard the used retaining ring and washer.
wrench counterclockwise and remove the spring retainer
(Item 28). Lift out the spring pad (Item 27) and the thrust 16. The sintered filter (Item 9) will pop out with the retaining
washer (Item 26). ring and washer. Remove and discard the sintered filter.
17. Lift out the spring (Item 10), spring block (Item 11), high-
CAUTION: DO NOT attempt to pry the dia-
pressure seat spring (Item 14), and the high-pressure
phragm out of the first-stage, as the diaphragm seat (Item 15). Discard the used seat.
seating shoulders in the first-stage will be
scratched, requiring replacement of the body CAUTION: Use EXTREME care when removing
(Item 16). O-rings from grooves. Even a small scratch
across an O-ring sealing surface will result in
9. Secure the dust cap (Item 3) in place by means of the leakage. Once an O-ring sealing surface has
yoke screw (Item 2). Using the low-pressure filtered air been damaged, the part must be replaced.
directed down through a low-pressure port on the first-
stage body (Item 16), blow out the primary diaphragm 18. Located inside the spring block (Item 11) is an O-ring and
(Item 25). (See Figure 2). Discard the used diaphragm. backup ring (Items 13 and 12). Remove and discard both
the O-ring and backup ring.
19. Remove the first-stage body from the vise. Remove the
CO2 cartridge from the body by turning the cartridge
counterclockwise.
20. Using a -inch wrench unscrew any remaining low-pres-
sure port plugs (Item 20). Remove and discard the port-
plug O-rings (Item 19).
This concludes the disassembly of the Conshelf First-Stage
Regulator.
Figure 2
SECOND-STAGE DISASSEMBLY
This concludes the disassembly of the Conshelf 4. Insert the pin support (Item 18) into the center hole of
the first-stage body.
Second-Stage Regulator.
5. Install a new primary diaphragm (Item 25) into the
first-stage body over the pin support by pushing its
Before starting reassembly, perform parts edges down into the supporting seat of the body. This
cleaning and lubrication according to the procedure can be completed by hand, or, if necessary,
procedures outlined in Procedure A, titled with the aid of a non-metallic flat-ended tool. The edges
of the diaphragm should be evenly and firmly positioned
Cleaning & Lubrication, on page 19. in the support seat.
AUTHORIZED REGULATOR 6. Place the gasket (Item 26) and, then, the spring pad
(Item 27) on the diaphragm. Place the spring retainer
REASSEMBLY (Item 28) over these two components and screw it clock-
wise completely onto the first-stage body to a torque
This subsection presents a detailed, step-by-step reassembly
of 20 2 foot-pounds using a 1- inch torque wrench.
procedure for the Conshelf 14 and Supreme Regulator Series.
Unless noted otherwise, this procedure applies to both the
Conshelf 14 and Supreme models. Specific references for the
Conshelf 14 and Supreme are indicated when necessary. It is
F NOTE: There are two (2) different configurations of
the low-pressure side of first-stage regulator. Read
over Step 7 completely prior to reassembly of the
important that the sequence be followed exactly in the order regulator to become familiar with which procedure
given.
you should use.
7
7A. Standard Conshelf (Non-Supreme Model) CAUTION: Use care when inserting the pin
Insert the mainspring (Item 29) into the spring retainer, into the first-stage body; do not allow the pin
ensuring that the mainspring is centered over the spring to contact the machined seating orifice of the
pad, and then place the washer (Item 30) on top of the first-stage body.
mainspring. Next, thread the adjustment screw (Item
31) clockwise over the mainspring and washer, then us- 10. While holding the small end of the new high-pressure
ing a large flat-bladed screwdriver, continue to turn the seat (Item 15) in one hand, insert the end of the pin
adjustment screw clockwise until it is flush with the end (Item 17) into the center of the seat. Then carefully
of the spring retainer (see Figure 4). insert the sub-assembly up into the center hole of the
first-stage body. Gently wiggle this sub-assembly, if
necessary, during this procedure to ensure that the end
of the pin is completely seated in the pin support (Item
4).
11. While holding the high-pressure seat and pin assembly
in place with one finger, turn the first-stage body over so
that its threaded inlet boss is facing upward.
12. Insert the seat spring (Item 14), spring block assembly
(Item 11) and spring (Item 10) into the inlet boss of the
first-stage body.
b. 2nd stage with port plug: 15. Second-stage with port plug only:
Insert the " nut driver portion of the Lever Height Ad- Install a new O-ring (item 17) onto the second-stage
justment Tool (LHAT) through the open port and hold the port plug (18). Thread the port plug into the second
locknut. Insert the screwdriver portion of the LHAT tool stage and tighten using a 4mm hex wrench.
throught the center of the nutdriver and insert it into the
end of the disc retainer. While holding the disc retainer
still with the the screwdriver, turn the nutdriver clockwise
F NOTE: Do not reinstall the diaphragm and box top
assembly (Items 8 & 4) until final adjustment of sec-
to correct the lever height or eliminate excessive free- ond-stage assembly is completed.
play. (See Figure 10)
AUTHORIZED REGULATOR
ADJUSTMENT AND TESTING
ATTACHMENT OF FIRST-STAGE TO
SECOND-STAGE REGULATORS
1. Install the two lubricated O-rings (Items 25 and 27) on
the intermediate-pressure hose (Item 26).
Figure 10
2. Attach the hose (Item 26) to one of the low-pressure
ports on the first-stage body (Item 16) using a -inch
torque wrench. Tighten the hose clockwise to a torque
10. Insert the new exhalation valve (Item 10) into the box of 40 inch-pounds.
bottom (Item 16) and pull on the stem of the valve until
its barb passes through the hole into the box bottom.
Using the wire cutters, trim the stem end of the valve F NOTE: If the Octopus Regulator is to be used, attach
the Octopus hose to the first-stage body as described
to above the barb. in Steps 1 and 2. Connection of additional hoses, such
11. Rotate the spring (Item 3), small-end first, onto the as the pressure gauge or low-pressure inflator hose,
purge button (Item 2). should not be done until after complete testing of the
12. Press the purge button (Item 2) sub-assembly through first and second stage(s). This will simplify trouble-
the box top (Item 4) and using external snap ring pliers, shooting leakage problems, if they occur.
install a new retaining ring (Item 41) into its groove on 3. Connect the first-stage regulator to a source of low-pres-
the purge button inside the box top. Ensure that the ra- sure (500 psig) breathing air. While firmly holding the
diused edge of the retaining ring faces toward the front free end(s) of the second-stage hose(s), carefully open
of the box top. the air source control valve allowing a small quantity of
13. Heat the exhaust tube (Item 9) in hot water at 200F; air to flow through the open hose(s). This will flush any
then stretch it over the flange of the box bottom (Item dust or debris from the interior of the hose(s).
16). Ensure that the locating lug on the exhaust tube 4. Close the air source control valve and attach the
is aligned with its notch in the flange of the box bottom. second-stage regulator(s) to the free end of the second-
Do not twist the exhaust tube over the flange or the stage hose(s). While holding the inlet fitting (Item 11)
locating lug will be damaged. with a -inch wrench, use an -inch torque wrench
14. Fit the mouthpiece (Item 24) onto the box bottom, and to tighten the swivel nut clockwise to a torque of 40 inch-
fasten the mouthpiece in place with a new mouthpiece pounds.
clamp (Item 23). The lock tab on the mouthpiece clamp
should be aligned with the air inlet boss of the box bot-
tom. Tighten with pliers and snip the extra length with
wire cutters.
10 Conshelf XIV Service Manual
FIRST-STAGE ADJUSTMENT AND TESTING setting, refer to the Troubleshooting Table 1on page 14
for corrective guidelines and specific procedures.
SECOND-STAGE ADJUSTMENT AND to drop below the intermediate pressure lock up, the
Magnehelic gauge should indicate an opening effort of
TESTING +0.6 of H2O to 1.5 of H2O. If the opening effort is not
within this range, refer to the Troubleshooting Table 2 on
page 15 for corrective guidelines and specific proce-
SECOND-STAGE AIR FLOW TEST dures.
3. Observe any bubbles streaming from the submerged 2. Thread the intermediate test pressure gauge (P/N
regulator over a one-minute period. This recommended 111610) onto the free end of the intermediate-pressure
time is necessary due to the lower bubble formation that hose. Make sure that the bleeder valve of the test pres-
occurs in cases of smaller leaks. Any bubbles noted in- sure gauge is open prior to pressurizing the regulator.
dicate leakage with the need to disassemble and check 3. Connect the first-stage regulator to a low-pressure
all sealing areas, assembly sequence and component air source (partially filled SCUBA cylinder - 500 psig).
positioning in order to correct the problem(s). Slowly turn on the air source control knob and pressur-
5. While holding the mouthpiece or exhaust tube (Items 24 2. To prevent the O-ring (42) from falling out during reas-
or 9), slowly submerge the second-stage regulator, box sebly, keep the bottom of the DIN adapter (41) facing
top facing downward and level, into a pan of clean water upward and screw the first stage body down into the
to a depth of about one inch above the diaphragm. DIN adapter until hand tight.
6. This submersion should cause the second-stage to free 3. Secure the vise mounting tool in a vise so the first stage
flow, indicating an acceptable, but approximate, opening stands vertical with the DIN adapter facing up. Attach
effort of one inch of water column. 1" (32mm) crow-foot to a torque wrench with and
tighten the DIN adapter to a torque measurement of 20
(2) foot-lbs.
LEAKAGE TESTING 4. Place the handwheel (40) over the top of the DIN
adapter with the male threads facing upward.
(See Page 9 for this procedure.)
5. Install both O-rings (37 & 39) onto the handwheel
retainer (38), and mate the male threads of the retainer
SUBJECTIVE BREATHING TESTING through the top of the handwheel and into the DIN
adapter. Turn the retainer clockwise by hand until snug.
(See Page 9 for this procedure.)
Attach a 6mm hex bit to a torque wrench and tighten the
handwheel retainer to a torque measurement of 15 (2)
This concludes the adjustment and testing proce- foot-pounds. Loosen the vise to remove the first stage,
and remove the vise mounting tool.
dures for the Conshelf Regulator Series.
6. Reattach the protector cap to the first stage, and install
it over the threads of the handwheel.
14 Conshelf XIV Service Manual
1. Cylinder valve not completely open 1. Open valve; check fill pressure
Restricted air flow or high inhala-
tion resistance through entire 2. Cylinder valve needs service 2. Switch to different cylinder
system
3. Filter (9) is clogged 3. Replace filter
15
1. Cylinder valve not completely open 1. Open valve; check fill pressure
Restricted air flow or high inhala-
SECOND STAGE
tion resistance through entire 2. Cylinder valve needs service 2. Switch to different cylinder
system
3. Filter (9) is clogged 3. Replace filter
3. Low pressure seat (13) damaged or worn 3. Replace low pressure seat
Hissing sound from second-
stage
4. HP leak 4. Overhaul first-stage
6. Purge flow adjustment screw (2) out too 6. Turn screw clockwise turn at a
far time and retest
101684 Lever Height Adjustment Tool (LHAT) Second-stage adjustment (newer style second-stage)
n/a Torque wrench, foot-pound First-stage Inlet fitting, spring retainer, HP Plug
n/a Breaker bar Sring retainer removal (used with 1 " crows-foot)
n/a " crows-foot LP hose installation (used with torque wrench)
n/a " crows foot Inlet fitting installation (used with torque wrench)
n/a 1 " crows-foot Sring retainer removal (used with breaker bar)
n/a Bent shaft, small blade screwdriver Lever height adjustment (older style second stage)
n/a 6mm hex bit DIN adapter installation (used with torque wrench)
17
Lubrication Technologies
310 Morton Street
Jackson, OH 45640
(800) 477-8704
Oakite #31 Acid bath for reusable stainless Oakite Products, Inc.
steel and brass parts. 50 Valley Road
Berkeley Heights, NJ 07922
White distilled vinegar (100 gr.) Acid bath for reusable stainless "Household" grade
steel and brass parts.
CAUTION: DO NOT use muriatic acid for the cleaning of any parts. Muriatic
acid, even when strongly diluted, can harm chrome plating, and may leave a
residue that is harmful to O-ring seals and other parts.
Liquid dishwashing detergent Degreaser for brass and stainless "Household" grade
(diluted with warm water) steel parts; general cleaning solu-
tion for plastic and rubber
18 Conshelf XIV Service Manual
Purge flow Inlet 2,500-3,000 (100) psig +5.0 SCFM (142 L.P.M.) Minimum
19
Procedure A
Cleaning & Lubrication
(All Aqua Lung Regulators)
Brass and Stainless Steel Parts
1. Preclean in warm, soapy water* using a nylon bristle tooth brush.
2. Thoroughly clean parts in an ultrasonic cleaner filled with soapy water. If there are stubborn deposits, houshold white distilled
vinegar (acetic acid) in an ultrasonic cleaner will work well. DO NOT place plastic, rubber, silicone or anodized aluminum parts
in vinegar.
3. Remove parts from the ultrasonic cleaner and rinse with fresh water. If tap water is extremely hard, place the parts in a bath
of distilled water to prevent any mineral residue. Agitate lightly, and allow to soak for 5-10 minutes. Remove and blow dry with
low pressure (25 psi) filtered air, and inspect closely to ensure proper cleaning and like-new condition.
CAUTION: Do not place plastic and rubber parts in acid solutions. Doing so my alter the physical prop-
erties of the component, causing it to prematurely degrade and/or break.
Hoses
If buildup of corrosion is severe, it is permissible to soak only the hose fittings in the ultrasonic cleaner as needed, and not allow
any solution to enter the hose. Rinse in fresh water and allow to dry with the cleaned ends hanging down. Blow filtered air through
them prior to installing onto the regulator.
*Soapy water is defined as "household" grade liquid dishwashing detergent diluted in warm water.
20 Conshelf XIV Service Manual
24
23
26
27 17 18
22
21
20
19
* 16
15 7
6
14
10
13
12
11
8a
9
5
*NOTE: When replacing a Conshelf XIV
box bottom manufactured before January
97 which does not feature an external 4 3
lever height adjustment port, it is also
necessary to order the port plug and O- 8b
ring (items 17 & 18). These three items
are available in kit form, PN 108535 2
1 25
3
2
26
7
4 8 27
9
5
10
11
12
13
6 14
28 32 32
15
29 29 29
16
21 30
31
19 20 35
31
33
36
22
17 34
23 34
18
24
www.aqualung.com
Rev. 7/2004