Aqua Lung CONSHELF XIV Technical Manual
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Aqua Lung CONSHELF XIV Technical Manual

First and second stage
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CONSHELF XIV
First and Second Stage
TECHNICaL MaNuaL
Rev 02/10

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Summary of Contents for Aqua Lung CONSHELF XIV

  • Page 1 CONSHELF XIV First and Second Stage TECHNICaL MaNuaL Rev 02/10...
  • Page 2 Military sales: ksilver@aqualung.com Trademark Notice Aqua Lung , is a registered trademark of Aqua Lung America, Inc. ® Warnings, Cautions, & Notes Pay special attention to information provided in warnings, cautions and notes that are accompanied by one of these symbols:...

  • Page 3: Table Of Contents

    TaBLE 5 - TORquE SpECIFICaTIONS ...........................29 TaBLE 6 - TEST BENCH SpECIFICaTIONS ........................29 pROCEDuRE a - CLEaNINg aND LuBRICaTION ......................30 FIRST STagE EXpLODED paRTS DRaWINgS ......................31 SECOND STagE EXpLODED paRTS DRaWINgS ......................32 CONSHELF XIV TOOL KIT ...............................33 REguLaTOR pRESS ................................34 MaINTENaNCE NOTES ..............................35...

  • Page 4: Change Record

    Conshelf XIV Technical Manual CHaNgE RECORD Change No. Date Title and/or brief description Change made by...

  • Page 5: Copyright Notice

    Read over the entire manual to become familiar with all procedures writing from Aqua Lung International. It may not be distributed through the before attempting to disassemble the product in this manual, and to internet or computer bulletin board systems without prior consent in writing learn which specialty tools and replacement parts will be required.

  • Page 6: Disassembly Procedure

    11/16” wrench. Remove and discard the adapter o-ring (21). Note: The Conshelf XIV Tool Kit (PN 108110) has all the tools re- quired for maintenance of all the Conshelf XIV configurations. The Conshelf XIV Tool Kit is described on pg. 33 of this manual.
  • Page 7 Use the vise mounting tool (PN100395) in the HP port or screw Conshelf (Supreme, External Fine Adjustment, EFA) an empty CO cartridge clockwise into one of the MP ports on Using the slotted tool (PN 081247) place the tool in the two slots the first stage body (16).

  • Page 8: Yoke Disassembly

    (34mm spring retainer dry kit) and flex 3/8” NOTE: If you are working on a Conshelf XIV Supreme (300 Bar wrench, turn the wrench counterclockwise and remove the spring DIN first stage), perform the disassembly instructions on p 9.

  • Page 9: Din Disassembly

    DIN Disassembly CauTION: The retaining ring (7) must be removed carefully as the components beneath it are under spring tension. Failure to place your finger over the sintered filter (9) while removing the Unscrew the threaded protector cap (45) and remove it from retaining ring may cause loss or damage of these parts.

  • Page 10: Second Stage Disassembly

    Conshelf XIV Technical Manual Diaphragm removal method #2 Second Stage Disassembly Using a #2 Phillips screwdriver (PN 9-47436), unscrew the Note: This method may only be performed after the High clamping screw (6) counterclockwise and remove it. Carefully Pressure side components have been removed.

  • Page 11: Assembly Procedure

    Conshelf XIV with port plug only: If the second stage has a Snip the mouthpiece clamp (23) with diagonal pliers (PN 9-45171) port plug (18), remove the port plug by turning it counterclock- and remove it. Next, pull off the mouthpiece (24).

  • Page 12: First Stage Assembly

    Lung product. ® DO NOT attempt to substitute an aqua Lung part with another ® manufacturer’s, regardless of any similarity in shape, size or appearance. Doing so may render the product unsafe, and could result in serious injury or death.
  • Page 13 Conshelf (Supreme, External Fine Adjustment, EFA) Note: There are four (4) different configurations of the MP side of first stage regulator. Read over Step 7 completely prior to reas- Insert the mainspring (28) into the spring retainer (31), ensure that sembly of the regulator to become familiar with which procedure the mainspring is centered over the spring pad (26) and then place the you should use.
  • Page 14 Conshelf XIV Technical Manual Now remove the first stage body from the vise, then remove Insert the seat spring (14), spring bock assembly (11) and the empty CO cartridge or vise mounting tool (PN 100395) spring (10) into the first stage body (16).

  • Page 15: Yoke Assembly

    Install the o-ring (51) onto the groove located inside the DIN adapter (50). Note: If you are working on a Conshelf XIV Supreme 300 Bar DIN first stage, perform the reassembly instructions in steps 19 - 24. Next, completely thread the yoke (6) clockwise onto the...

  • Page 16: Second Stage Assembly

    Conshelf XIV Technical Manual Install o-ring (46) into the groove of handwheel retainer Place the washer (19), radiused end up, spacer (21), and a (47) opposite the threads. Install o-ring (48) over the new locknut (22) onto the poppet. Turn the locknut clockwise threaded end of the handwheel retainer.
  • Page 17 Next, lightly lubricate the o-ring (12) and place it on the inlet Insert the new exhalation valve (10) into the box bottom (16) and fitting (11). To avoid marring the surface of the MP seat (13), pull on the stem of the valve until its barb passes through the depress the lever and screw the inlet fitting (11) clockwise into the hole into the box bottom.

  • Page 18: Attachment Of First Stage To Second Stage Regulators

    Conshelf XIV Technical Manual attachment of First Stage To Second Stage If not using a test bench, fit the mouthpiece (24) onto the box bottom, and fasten the mouthpiece in place with a new Regulators mouthpiece clamp (23). The lock tab on the mouthpiece clamp Install the two lubricated o-rings (25 &...

  • Page 19: Regulator Adjustment And Testing

    Table 5 - Test Bench Specifications, on page 29. In addition, all Note: If no test bench is available for testing the Conshelf XIV tests described must first be done at MP (500 psig) and then again at regulator, the following adjustment and testing procedures should service pressure (3000 psig).

  • Page 20: Environmental Kit Installation

    Conshelf (Supreme, External Fine Adjustment, EFA) Conshelf (Supreme) To complete the environmental conversion of a standard Conshelf XIV or reinstallation of environmental components To complete the environmental conversion of a standard on the Supreme EFA model, perform the following procedure Conshelf XIV or reinstallation of environmental components while the regulator is pressurized.

  • Page 21: Second Stage Adjustment And Testing Procedures

    Second Stage adjustment and Testing Conshelf (Dry kit) procedures To complete the environmental conversion of a standard Conshelf XIV or reinstallation of environmental components Note: Performing the second stage adjustment and testing, requires on the Dry Kit model, perform the following procedure while the the installation of the diaphragm, box top and ring clamp (8, 4 &...

  • Page 22: Second Stage With Port Plug (New Version)

    Conshelf XIV Technical Manual Second Stage adjustment and Testing: Install the clamp screw (6) using a #2 Phillips screwdriver (PN 9-47463). Tighten the screw hand tight until firm. A gap between Test Bench procedures the clamp ends of up to 1/8” is acceptable. Pressurize the regulator.

  • Page 23: Second Stage Adjustment And Testing: Manual Procedures

    Second Stage adjustment and Testing: Subjective Breathing Test Manual procedures In general, the properly overhauled and adjusted Conshelf XIV Before final reassembly of the second stage regulator and after regulator, upon breathing in and out of the mouthpiece slowly preliminary adjustment of the lever, the following procedures are and deeply four or five times, should deliver air to the user without recommended.

  • Page 24: Table 1 - First Stage Troubleshooting Guide

    Conshelf XIV Technical Manual Table 1: First Stage Trouble Shooting guide SyMpTOM pOSSIBLE CauSE TREaTMENT 1. HP Seat (15) is worn or damaged 1. Replace HP seat (15) 2. Machined seat orifice damaged 2. Replace body (16) High pressure Creep 3.

  • Page 25: Table 2 - Second Stage Trouble Shooting Guide

    Table 2: Second Stage Troubleshooting guide SyMpTOM pOSSIBLE CauSE TREaTMENT 1. Purge button (2) stuck open 1. Remove purge button and reseat 2. Turn locknut counterclockwise to 2. Lever (20) set too high adjust lever downward Second Stage air Leak or Free Flow 3.
  • Page 26 Conshelf XIV Technical Manual Table 3: List of Tools and Service Kits (additional Conshelf XIV Tools on page 32-33) paRT # DESCRIpTION appLICaTION MP Test 111610 Gauge Intermediate pressure testing 108362 Soft case O-ring Tool 944022 (Brass) O-ring removal & installation...
  • Page 27 8367A24 & installation Magnifier Inspection of parts 9-BA819008 Small Bent Shaft Screwdriver (Old Adjustment of second stage poppet (old style Conshelf XIV) Style Conshelf XIV) 1/4” Combination Wrench (Old Style Holding second stage locknut (old style Conshelf XIV) Conshelf XIV)
  • Page 28 Conshelf XIV Technical Manual Table 3: List of Tools and Service Kits (additional Conshelf XIV Tools on page 32-33) paRT # DESCRIpTION appLICaTION Seat Extractor HP seat removal, HP diaphragm removal 109437 10-102- O-ring tool Hose o-ring removal HP component assembly (See regulator press pg.33) 108112 Dowel, 1/2”...

  • Page 29: Table 5 - Torque Specifications

    Table 5: Torque Specifications paRT # DESCRIpTION / KEy ITEM # TORquE 105326 Spring retainer (27) 108851 Spring retainer (supreme) (31) 25 ±2 ft/lbs (33.9 Nm) 106317 Spring retainer (dry kit) (38) 100444 Second stage inlet fitting (11) 55 ±5 in/lbs (6.2 Nm) 090015 MP Hose fittings (26) 40 in/lbs (4.5 Nm)

  • Page 30: Procedure A - Cleaning And Lubrication

    Conshelf XIV Technical Manual procedure a: Cleaning and Lubricating aqua Lung Regulators Cleaning 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, household white distilled vinegar (acetic acid) in an ultrasonic cleaner will work well.

  • Page 31: First Stage Exploded Parts Drawings

    Conshelf XIV & XIV Supreme DIN Kit 25 ft/lbs 25 ft/lbs 25 ft/lbs 33.9 Nm 33.9 Nm 33.9 Nm 18 ft/lbs 24.5 Nm 40 in/lbs 4.5 Nm 20 ft/lbs 27 Nm 15 in/lbs 1.7 Nm Key # .Part # Description Key # .Part #...

  • Page 32: Second Stage Exploded Parts Drawings

    4.5 Nm 55 in/lbs 6.2 Nm NOTE: When replacing a Conshelf XIV box bottom manufactured before January ‘97 which does not feature an external lever height adjustment port, it is also necessary to order the exhaust Tee, port plug and o-ring. These four items (9,16,17 &...

  • Page 33: Conshelf Xiv Tool Kit

    • Made of 1000 Denier Cordura Nylon for toughness • This kit also contains tools to rebuild all u.S. Divers cylinder valves. • High quality tools • Every tool needed for Conshelf XIV and Conshelf Supreme XIV Note: Torque wrenches not provided 11.5”...

  • Page 34: Regulator Press

    Conshelf XIV Technical Manual REGULATOR PRESS for the CONSHELF XIV – PN 108105 Made in the U.S.A • Saves time, eliminates wasted effort • Frame is made of high quality, lightweight Aluminum, • only 5.2 lbs. Powder Coated flat black for durability •...

  • Page 35: Maintenance Notes

    Maintenance Notes...
  • Page 36 Conshelf XIV First and Second Stage 2340 Cousteau Court • Vista, CA 92081 Phone (760) 597-5000 • Fax (760) 597-4900 www.aqualung.com/militaryandprofessional ©2009 aqua Lung International Literature pN 108101 REV 02/10...

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