Aqua Lung Conshelf XIV User manual

CONSHELF XIV
First and Second Stage
TECHNICAL MANUAL
Rev 02/10

2 Conshelf XIV Technical Manual
COPYRIGHT NOTICE
©2010 AQUA LUNG AMERICA
CONSHELF XIV TECHNICAL MANUAL, P/N 108101
You can contact a Technical Adviser via e-mail at:
[email protected]
[email protected]
[email protected]
[email protected]
Military sales: [email protected]
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 format without prior
consent in writing from Aqua Lung America International, Inc.
A NOTE is used to emphasize important points, tips
and reminders.
AWARNING indicates a procedure or situation that,
if not avoided, could result in serious injury or death
to the user.
A CAUTION indicates any situation or technique that
could cause damage to the product, and could
subsequently result in injury to the user.
Warnings, Cautions, & Notes
Pay special attention to information provided in warnings, cautions and notes that are accompanied
by one of these symbols:
Trademark Notice
Aqua Lung®, is a registered trademark of Aqua Lung America, Inc.

3
CONTENTS
CHANGE RECORD ............................................................................................................................................................4
COPYRIGHT NOTICE .........................................................................................................................................................5
INTRODUCTION..................................................................................................................................................................5
WARNINGS, CAUTIONS & NOTES ..................................................................................................................................5
SCHEDULED SERVICE ......................................................................................................................................................5
GENERAL GUIDELINES ....................................................................................................................................................5
GENERAL CONVENTIONS ................................................................................................................................................5
DISASSEMBLY PROCEDURE............................................................................................................................................6
FIRST STAGE DISASSEMBLY ......................................................................................................................................6
YOKE DISASSEMBLY..................................................................................................................................................8
DIN DISASSEMBLY .....................................................................................................................................................9
SECOND STAGE DISASSEMBLY ...............................................................................................................................10
ASSEMBLY PROCEDURE................................................................................................................................................ 11
FIRST STAGE ASSEMBLY ..........................................................................................................................................12
YOKE ASSEMBLY......................................................................................................................................................15
DIN ASSEMBLY .........................................................................................................................................................15
SECOND STAGE ASSEMBLY .....................................................................................................................................16
ATTACHMENT OF FIRST STAGE TO SECOND STAGE REGULATORS..................................................................18
REGULATOR ADJUSTMENT AND TESTING .................................................................................................................19
FIRST STAGE ADJUSTMENT AND TESTING: TEST BENCH PROCEDURES ........................................................19
FIRST STAGE ADJUSTMENT AND TESTING: MANUAL PROCEDURES ...............................................................19
ENVIRONMENTAL KIT INSTALLATION.....................................................................................................................20
SECOND STAGE ADJUSTMENT AND TESTING PROCEDURES ..........................................................................21
SECOND STAGE WITHOUT PORT PLUG (OLD VERSION)....................................................................................21
SECOND STAGE WITH PORT PLUG (NEW VERSION) ..........................................................................................22
SECOND STAGE ADJUSTMENT AND TESTING: TEST BENCH PROCEDURES...................................................22
SECOND STAGE OPENING EFFORT TEST...............................................................................................................22
SECOND STAGE AIR FLOW TEST.............................................................................................................................22
SECOND STAGE PURGE FLOW TEST ......................................................................................................................22
OCTOPUS OPENING EFFORT TEST .........................................................................................................................22
OCTOPUS AIR FLOW TEST........................................................................................................................................22
OCTOPUS PURGE FLOW TEST .................................................................................................................................22
SECOND STAGE ADJUSTMENT AND TESTING: MANUAL PROCEDURES ............................................................23
SECOND STAGE AIR FLOW .......................................................................................................................................23
OPENING EFFORT CHECK.........................................................................................................................................23
SUBJECTIVE BREATHING TESTING.........................................................................................................................23
LEAKAGE TESTING ....................................................................................................................................................23
TABLE 1 - FIRST STAGE TROUBLESHOOTING GUIDE................................................................................................24
TABLE 2 - SECOND STAGE TROUBLE SHOOTING GUIDE..........................................................................................25
TABLE 3 - LIST OF RECOMMENDED TOOLS AND SERVICE KITS.............................................................................26
TABLE 4 - RECOMMENDED LUBRICANTS AND CLEANERS......................................................................................28
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

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

5
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
before attempting to disassemble the product in this manual, and to
learn which specialty tools and replacement parts will be required.
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 facility.
3. As the regulator is disassembled, reusable components should
be segregated and not allowed to intermix with nonreusable parts
or parts from other units. Delicate parts, including inlet ttings and
crowns which contain critical sealing surfaces, must be protected
and isolated from other parts to prevent damage during the cleaning
procedure.
4. Use only genuine Aqua Lung® parts provided in the overhaul
parts kit for this product. DO NOT attempt to substitute an Aqua
Lung® 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 counterclockwise.
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 illustration below) if possible, or use a brass or plastic o-ring
removal tool. Avoid using hardened steel picks, as they may dam-
age the o-ring sealing surface. All o-rings that are removed are
discarded and replaced with brand new o-rings.
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 Aqua Lung International. It may not be distributed through the
internet or computer bulletin board systems without prior consent in writing
from Aqua Lung International.
©2010 Aqua Lung America
Conshelf XIV Technical Maintenance Manual
INTRODUCTION
This manual provides factory prescribed procedures for the correct
service and repair of the Aqua Lung®Conshelf XIV regulator
described in this manual. 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 Authorized training through an Aqua
Lung Service & Repair Seminar. If you do not completely understand all
of the procedures outlined in this manual, contact Aqua Lung 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:
Scheduled Service
If the regulator is subjected to less than 50 dives per year, it is
permissible to overhaul it every other year with an inspection
procedure being performed on the “off” years. For example:
Year #1: Inspection
Year #2: Overhaul
Year #3: Inspection
Year #4: Overhaul, and so on.
Both Inspections and Overhauls need to be documented in the Annual
Service & Inspection Record in the back of the Owner’s Manual to keep
the Limited Lifetime Warranty in effect. If a regulator is subjected to more
than 50 dives per year, it should receive the complete overhaul.
An Ofcial Inspection consists of:
1. A pressurized immersion test of the entire unit to check
for air leakage.
2. Checking for stable intermediate pressure that is within
the acceptable range.
3. Checking for opening effort that is within the acceptable (bench
check) range.
4. A visual inspection of the lter for debris or discoloration.
5. A visual inspection of the exhaust valve to see that it is in
good shape and that it’s resting against a clean surface.
6. A visual inspection of the mouthpiece looking for tears
or holes.
7. Pulling back hose protectors and checking that the hoses
are secure in the hose crimps.
If a regulator fails item #1,2,3, the entire regulator should be overhauled.
If a regulator fails 4,5,6 or 7, it will be up to the technician’s discretion
whether or not a full overhaul is required.
NOTES are used to emphasize important points, tips and reminders.
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.
WARNINGS indicate a procedure or situation that may
result in serious injury or death if instructions are not
followed correctly.
4. The following acronyms are used throughout the manual: MP is
Medium Pressure; HP is High Pressure; LP is Low Pressure.
5. Numbers in parentheses reference the key numbers on the
exploded parts schematics. For example, in the statement,
“...remove the o-ring (13) from the spring block (11)...”, the number
13 is the key number to the spring block o-ring.
NOTE: A unit that receives heavy or frequent use, such as rental,
instruction, or commercial applications, should be serviced at least
twice a year - or more often - depending on the conditions of use
and the manner in which it is maintained. (Refer to the care and
maintenance procedures outlined in the Regulator Owner’s Manual.)
Pinch Method
Press upwards on sides of o-ring to
create a protrusion. Grab o-ring or
insert o-ring tool at protrusion.

6 Conshelf XIV Technical Manual
DISASSEMBLY PROCEDURE
NOTE: Before performing any disassembly, refer to the exploded
parts drawing, which references all mandatory replacement parts.
These parts should be replaced 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 brass o-ring removal tool (PN 944022)
or plastic (PN 103102) 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. DO NOT use a dental pick or any other steel
instrument, except where instructed.
First Stage Disassembly
1Using a 9/16” open end wrench, turn the wrench counterclockwise
and remove the MP hose (26) from the rst stage body (16). If
installed, remove the HP gauge hose with a 5/8” open end wrench
and, the MP inator hose with a 9/16” open end wrench. Remove HP
port plug with a 5/32” hex key or any remaining MP port plugs with
a 1/2” open end wrench or socket.
2 Remove the 2nd stage from the regulator by holding the inlet
tting (11) with a 3/4“ open end wrench, use an 11/16” open end
wrench to unscrew the swivel counterclockwise from the regulator
and remove the swivel end of the MP hose from the 2nd stage.
3 Remove and discard the o-rings (25 & 27) from the MP hose.
4 If the HP hose of the pressure gauge requires the use of the HP
adapter (22), remove the adapter by turning it c ounterclock wise, us-
ing an 11/16” wrench. Remove and discard the adapter o-ring (21).
5 Remove and discard all o-rings of the MP inator and/or the HP
hose of the pressure gauge.
CAUTION: NEVER attempt to secure the rst stage body by
direct clamping in a vise. This will result in damage to the
regulator body requiring replacement of this part.
CAUTION: Empty CO2 cartridge used for vise mounting should
not be an old rusty cartridge from a Buoyancy Control Device.
A new cartridge should be placed in a CO2 ring mechanism
and discharged.
NOTE: The Conshelf XIV Tool Kit (PN 108110) has all the tools re-
quired for maintenance of all the Conshelf XIV congurations. The
Conshelf XIV Tool Kit is described on pg. 33 of this manual.

7
6 Use the vise mounting tool (PN100395) in the HP port or screw
an empty CO2 cartridge clockwise into one of the MP ports on
the rst stage body (16). Mount the rst stage body in a bench vise,
mainspring side facing upward.
7 a Conshelf (Standard)
Using a large at blade screwdriver (PN 9-41586), place the
blade in the slot of the adjustment screw (30). Turn the screwdriver
counterclockwise and remove the adjustment screw. Next remove
the washer (29) and mainspring (28).
7 b Conshelf (Supreme)
Using the slotted tool (PN 081247) place the tool in the
two slots of the secondary diaphragm retainer (35), turn the tool
counterclockwise and remove the retainer. Next, using your
ngers, lift upward on the secondary diaphragm (32) and remove
it. Remove the rst stage from the bench vise and pour out and
discard the silicone uid in accordance with local directives.
Finally, remount the rst stage in the vise in its former orientation
to complete the disassembly of the MP side. Using a large at
bladed screwdriver, place the blade in the slot on the adjustment
screw (30). Turn the screwdriver counterclockwise and remove
the adjustment screw. Lift out the mainspring (28).
7d
Conshelf (Dry Kit)
Using the slotted tool (PN 081247) place the tool in the two
slots of the diaphragm retainer (44), turn the tool counterclockwise
and remove the retainer. Next, using your ngers, push the external
diaphragm (43) out of the diaphragm retainer (44). Remove the piston
(41) from the spring retainer (38). Finally, remount the rst stage in the
vise in its former orientation to complete the disassembly of the MP
side. Using a 6mm hex key, turn the adjustment screw (40) counter
clockwise and remove. Lift out the washer (29) and mainspring (39).
7 c Conshelf (Supreme, External Fine Adjustment, EFA)
Using the slotted tool (PN 081247) place the tool in the two slots
of the secondary diaphragm retainer (35), turn the tool counterclock-
wise and remove the retainer. Next, using a 5/32” hex key adapter (PN
5570A52), remove the external adjustment screw (34), secondary dia-
phragm (33) and spring (28) from the spring retainer (31). Remove the
rst stage from the bench vise and pour out and discard the silicone uid
in accordance with local directives. Separate the adjustment screw (34)
and secondary diaphragm (33). Discard the used diaphragm. Finally,
remount the rst stage in the vise in its former orientation to complete
the disassembly of the MP side.

8 Conshelf XIV Technical Manual
NOTE: If you are working on a Conshelf XIV Supreme (300 Bar
DIN rst stage), perform the disassembly instructions on p 9.
1 2 Unscrew the yoke screw (2) counterclockwise and remove
it from the yoke (6).
13
Disengage and remove the dust cap (3). Remove and discard
the o-ring (4).
11
Mount the rst stage in the bench vise with the yoke screw
facing up by means of the vise mount tool (PN 100395) or CO2
cartridge.
NOTE: This method uses LP ltered air to blow out the diaphragm. If
this method is not available, the diaphragm can be pushed out using
the seat installation tool using an alternate method described later in
this section on p. 10.
8 With a 1 3/8” crow foot (34mm spring retainer dry kit) and ex
wrench, turn the wrench counterclockwise and remove the spring
retainer (27) standard, (31) supreme, supreme EFA and (38) dry kit.
Lift out the spring pad (26) standard, supreme, supreme EFA, and
(37) dry kit and the thrust washer (25b).
NOTE: Depending on how rmly the diaphragm is retained on its
supporting “seat”, the MP port plugs (20) may have to be in place
when using LP ltered air to blow out the primary diaphragm.
1 0 Remove the rst stage from the bench vise. Lift out the pin
support (18) and pin (17).
9
Secure the dust cap (3) in place by means of the yoke screw
(2). Use LP ltered air directed down through a MP port on the
rst stage body (16), blow out the primary diaphragm (25a). Discard
the used diaphragm.
Diaphragm removal method #1
1 4 Using external retaining ring pliers (PN 111100), remove the
yoke retaining ring (5) from the groove on the HP inlet boss of
the rst stage body (16). Turn the yoke (6) counterclockwise to un-
screw and remove it from the rst stage. Discard the retaining ring.
Yoke Disassembly
CAUTION: DO NOT attempt to “pry” the diaphragm out of the
rst stage, as the diaphragm seating surface in the rst stage
will be scratched, requiring replacement of the body (16).

9
2 2 Located inside the spring block (11) is a back-up ring (12)
and o-ring (13). Remove and discard both the o-ring and
backup ring.
2 1 Dump out the spring (10), spring block (11), HP seat spring
(14), HP seat (15) and pin (17). Discard the used HP seat.
1 9 With internal retaining ring pliers (PN 111100), remove the
retaining ring (7) and washer (8) from the HP inlet boss.
Discard the used retaining ring and nylon washer. If the unit has a
steel washer, do not discard it.
2 0 The sintered lter (9) will pop out with the retaining ring and
washer. Remove and discard the sintered lter.
DIN Disassembly
15
Unscrew the threaded protector cap (45) and remove it from
the rst stage.
1 6 Secure the rst stage in the bench vice. Using a ex wrench (PN
9-44363) and 6mm hex key (PN 8367A24) to the handwheel
retainer (47), and turn it counterclockwise to loosen and remove. Re-
move and discard both o-rings (46 & 48).
17Lift the handwheel (49) off the DIN adapter (50), and closely
inspect the condition of the threads to ensure it is free of any
burrs or other damage that could prevent proper threading.
1 8 Apply a 1 1/4” (32mm) crow foot w/ ex wrench to the at sides at
the base of the DIN adapter (50), and turn it counterclockwise to
loosen and remove from the inlet boss of the rst stage body. Remove
and discard the o-ring (51) from inside the DIN adapter.
CAUTION: The retaining ring (7) must be removed carefully as
the components beneath it are under spring tension. Failure to
place your nger over the sintered lter (9) while removing the
retaining ring may cause loss or damage of these parts.
CAUTION: Use EXTREME care when removing o-rings from
grooves. Even a small scratch across an o-ring sealing surface
will result in leakage. Once an 0-ring sealing surface has been
damaged, the part must be replaced.

OLD DESIGN NEW DESIGN
10 Conshelf XIV Technical Manual
24
Remove the rst stage body (16) from the vise. Remove the
vise mount tool (PN 9 - 4 43 63) or CO2cartridge from the body
by turning counter-clockwise.
Second Stage Disassembly
1 Using a #2 Phillips screwdriver (PN 9-47436), unscrew the
clamping screw (6) counterclockwise and remove it. Carefully
remove the clamp ring (5).
2Lift off the box top (4) and remove the second stage diaphragm (8).
3 Using external snap ring pliers (PN 111100), remove the retain-
ing ring (7), purge button (2) and spring (3) from the box top (4).
Separate the spring from the purge button.
4 With the lever (20) depressed, use a 3/4” wrench (PN 5304A51)
to unscrew counterclockwise and remove the inlet tting (11).
Remove and discard the inlet tting external o-ring (12).
2 5 Using a 1/2 “ wrench or socket unscrew any remaining MP port
plugs (20). Remove and discard the port plug o-rings (19).
This Concludes the Disassembly of the First
Stage Regulator
2 3 Using the seat extraction tool (PN 109437), insert the small end
into the center of the HP side of the regulator very carefully, so not
to damage the HP crown. Push the seat extraction tool against the pin
support (18) and push the diaphragm (25a) out of the rst stage body.
Diaphragm removal method #2
NOTE: This method may only be performed after the High
Pressure side components have been removed.
CAUTION: During removal of the inlet tting (11) depress the
lever (20). Failure to keep the lever depressed could cause
damage to the sealing surface of the inlet tting (11).
CAUTION: The poppet assembly (14) is under spring ten-
sion. Care should be taken when removing these parts.
This will help prevent damage or loss of parts.
Before beginning assembly, perform parts cleaning
and lubrication in accordance with Procedure A:
Cleaning and Lubricating (p. 30).

11
5 Conshelf XIV with port plug only: If the second stage has a
port plug (18), remove the port plug by turning it counterclock-
wise with a ex wrench (PN 9-44363) 5/32” hex key adapter (PN
5570A52). Remove and discard the o-ring (17).
Before beginning assembly, perform parts cleaning
and lubrication in accordance with Procedure A:
Cleaning and Lubricating (p. 30).
ASSEMBLY PROCEDURE
NOTE: This section presents a detailed, step-by-step assembly
procedure for the Conshelf XIV ,Supreme. Supreme EFA and Dry
Kit Regulator Series. Unless noted otherwise, this procedure applies
to the Conshelf XIV, Supreme, Supreme EFA and Dry Kit models.
Specic references for the Conshelf XIV, Supreme, Supreme EFA
and Dry Kit are indicated when necessary. It is important that the
sequence be followed exactly in the order given.
11
Grasp the exhaust valve (10) and remove it from the box bottom
(16). Discard the used valve.
This Concludes the Disassembly of the
Second Stage Regulator
9 Snip the mouthpiece clamp (23) with diagonal pliers (PN 9-45171)
and remove it. Next, pull off the mouthpiece (24).
1 0 To remove the exhaust tee (9) from the box bottom (16), place
the second stage in hot water at 200°F until the exhaust tee
softens sufciently to pull off.
6 Fit the poppet wrench (PN 111003) over the disc end of the pop-
pet (14) and thread it into the box bottom. Hold the locknut (22)
with a 1/4” box end wrench (older version) or with the 1/4” nut driver
portion of the Lever Height Adjustment Tool (LHAT) inserted through
the open port (newer version). Turn the poppet wrench clockwise
and remove the locknut (22). Discard the used locknut.
7 Remove the spacer (21), lever (20) and washer (19) from inside
the box bottom.
8 Next, remove the poppet (14) and the spring (15) from the inlet
boss of the box bottom (16). Remove the MP seat (13) with the
o-ring tool (PN 10-102-400). Discard the used MP seat (13) that is
located in the large end of the poppet (14).
NOTE:Before performing any assembly, it is important to inspect all
parts, both new and those that are being reused, to ensure that every
part and component is perfectly clean and free of any dust, corrosion,
or blemishes. Before dressing each o-ring with Christo-Lube®, check
to ensure it is clean, supple, and free of any blemish.
CAUTION: Do not “twist” the exhaust tee (9) during its
removal, damage to the exhaust tee may occur.

12 Conshelf XIV Technical Manual
WARNING: Use only genuine Aqua Lung®parts, sub-assemblies,
and components whenever assembling any Aqua 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.
2 Lightly lubricate the port plug o-rings (19 & 21) and place them
on the corresponding rst stage port plug (20,23,24).
3 Install one of the MP port plugs (20) and HP port plug (23 or
24). Using a 1/2” crowfoot or socket attached to a in/lb torque
wrench, tighten the port plugs to 15 in/lbs (1.7 Nm).
First Stage Assembly
1 Screw an empty CO2cartridge or vise mounting tool (PN
100395) into one of the MP ports on the rst stage body (16).
Mount the rst stage body in a bench vise, mainspring side facing
upward, by the means of the CO2 cartridge or vise mounting tool.
NOTE: If the primary diaphragm (25a) displays a rough and
smooth side, place the smooth side down against the pin support.
6 Place the gasket (25b) and, then, the spring pad (26) standard,
supreme & supreme EFA, (37 dry kit) on the diaphragm. Place
the spring retainer (27 standard), (31 supreme & supreme EFA)
and (38 dry kit) over these two components and screw it clockwise
to completely onto the rst stage body to a torque of 25 ± 2 ft/lbs
(33.9 Nm) using a 1-3/8” crow foot and ft lb.torque wrench.
NOTE: Do not install remaining port plugs. Set it aside for later
installation. Leave the other two MP ports open for connection to
a test bench or MP test gauge (PN111610), and a second stage
hose during subsequent regulator adjustment and testing.
4 Insert the pin support (18) into the center hole of the rst
stage body.
5 Install a new primary diaphragm (25a) into the rst stage body
over the pin support (18) by pushing its edges down into the
supporting “seat” of the body. This procedure can be completed by
hand or if necessary, with the aid of a non-metallic at ended tool.
The edges of the diaphragm should be evenly and rmly positioned
in the support “seat”.
CAUTION: After torquing the spring retainer, wait 24 hours
and re-torque the spring retainer to 25 ± 2 ft/lbs (33.9 Nm).

13
7d
Conshelf (Dry Kit)
Insert the mainspring (39) into the spring retainer (38), en-
sure that the mainspring is centered over the spring pad (37) and
then place the washer (29) adjustment screw (40) over the protrud-
ing end of the mainspring. Next, using a 6mm hex key adapter (PN
8367A24), turn the adjustment screw clockwise until it is ush with
the end of the spring retainer. For the Conshelf Dry Kit, the piston
(41), external diaphragm (43) and diaphragm retainer (44) will be
installed after the MP adjustment is completed. Refer to “First Stage
Adjustment and Testing” on page 19.
7 c Conshelf (Supreme, External Fine Adjustment, EFA)
Insert the mainspring (28) into the spring retainer (31), ensure that
the mainspring is centered over the spring pad (26) and then place the
adjustment screw (34) over the protruding end of the mainspring. Next,
using 5/32” hex key adapter (PN 5570A52), turn the adjustment screw
clockwise until the bottom of the adjustment screw (34) is ush with the
top of the spring retainer (31). For the Conshelf Supreme, remember
that a new supply of silicone uid (36) will be poured into the spring
retainer (31) after the MP adjustment is complete. After the procedure
is nished, a new secondary diaphragm (33) and secondary diaphragm
retaining ring (35) will be reinstalled. Refer to “First Stage Adjustment
and Testing” on page 19.
NOTE: There are four (4) different congurations of the MP side
of rst stage regulator. Read over Step 7 completely prior to reas-
sembly of the regulator to become familiar with which procedure
you should use.
7 a Standard Conshelf (Non-Supreme Model)
Insert the mainspring (28) into the spring retainer (27), ensuring
that the mainspring is centered over the spring pad (26) and then place
the washer (29) on top of the mainspring. Next, thread the adjustment
screw (30) clockwise over the mainspring and washer, then using a
large at bladed screwdriver (PN 9-41586), continue to turn the adjust-
ment screw clockwise until it is ush with the end of the spring retainer.
Refer to “First Stage Adjustment and Testing” on page 19.
7 b Conshelf (Supreme)
Insert the mainspring (28) into the spring retainer (31), ensure
that the mainspring is centered over the spring pad (26) and then
place the adjustment screw (30) over the protruding end of the main-
spring. Next, using a large at bladed screwdriver (PN 9-41586), turn
the adjustment screw clockwise until it is ush with the secondary
diaphragm support shoulder of the spring retainer. For the Conshelf
Supreme, remember that a new supply of silicone uid (36) will be
poured into the spring retainer (31) after the MP adjustment is com-
plete. After the procedure is nished, a new secondary diaphragm
(32) and secondary diaphragm retaining ring (35) will be reinstalled.
Refer to “First Stage Adjustment and Testing” on page 19.

11
While holding the HP seat and pin assembly in place with one
nger, turn the rst stage body over so that it’s threaded inlet
boss is facing upward.
14 Conshelf XIV Technical Manual
13
Place the special high pressure block guide (PN 111000),
recessed end downward, over the inlet boss of the rst stage
body. Next, drop a new sintered lter (9) with rough side facing
upwards into the spring block guide. Place a new nylon washer
(8) on top of the sintered lter (9), followed by a new retaining ring
(7). Place the retaining ring in at side up.
14(1) Place the assembly into the regulator press and pull down
on the handle until the retaining ring snaps into place. (2) while
holding the block guide, with the retaining ring (9) centered over
the hole and on top of the washer (8) and lter (9), apply sufcient
pressure downward against the retaining ring (7), using the 1/2” at
end Delrin tool (PN 108112) to force the retaining ring through the
guide until it fully “locks” in its own groove in the inlet boss. Remove
the block guide and verify the retaining ring is correctly positioned.
At this point, the seat spring (14), spring block (11), spring (10) and
sintered lter (9) and nylon washer (8) should be correctly positioned
and “locked” in the inlet boss securely by the retaining ring (7).
Check this position carefully before proceeding.
1 2 Insert the seat spring (14), spring bock assembly (11) and
spring (10) into the rst stage body (16).
1 0 While holding the small end of the new HP seat (15) in one
hand, insert the end of the pin (17) into the center of the HP
seat. Then carefully insert the sub-assembly up into the center hole
of the rst stage body (16). 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 (18).
9 Install a new back up ring (12) and lightly lubricated o-ring
(13), in this order, into the open end of the spring block (11).
8 Now remove the rst stage body from the vise, then remove
the empty CO2 cartridge or vise mounting tool (PN 100395)
from the MP port.
CAUTION: Use care when inserting the pin into the rst
stage body; do not allow the pin to contact the machined
seating orice of the rst stage body.

15
17Install o-ring (4), unlubricated, into the dust cap (3) to com-
plete the dust cap assembly.
1 8 Wrap the nylon cord, tied to the dust cap, around one leg
of the yoke and pass the cap through the loop formed,
creating a “loose” knot. Place the dust cap on the inlet boss and
secure in place by turning the yoke screw down clockwise until
snug on the dust cap.
NOTE: If you are working on a Conshelf XIV Supreme 300 Bar DIN
rst stage, perform the reassembly instructions in steps 19 - 24.
15
Next, completely thread the yoke (6) clockwise onto the
inlet boss of the rst stage body: then secure by installing
a new yoke retaining ring (5) at side facing upwards on the inlet
boss using external snap-ring pliers (PN 111100).
1 6 Lightly lubricate the threads of the yoke screw (2). Reinstall
the yoke screw (2) by turning it clockwise into the yoke (6).
2 1 Secure the vise mounting tool (PN 100395) in a vise so
that the rst stage stands vertical with the DIN adapter (50)
facing up. Attach 1 1/4” (32mm) crow foot to a ft.lb. torque wrench
with and tighten the DIN adapter to a torque measure of 20 (±2)
ft/lbs (27Nm).
2 2 Place the handwheel (49) over the top of the DIN adapter
(50) with the male threads facing upward.
DIN Assembly
1 9 Install the o-ring (51) onto the groove located inside the
DIN adapter (50).
2 0 To prevent the o-ring (51) from falling out during reassem-
bly, keep the bottom of the DIN adapter (50) facing upward
and screw the rst stage body down into the DIN adapter until
hand tight.
Yoke Assembly

16 Conshelf XIV Technical Manual
2 3 Install o-ring (46) into the groove of handwheel retainer
(47) opposite the threads. Install o-ring (48) over the
threaded end of the handwheel retainer. Mate the male threads
of the retainer through the top of the handwheel (49) and into the
DIN adapter (50). Turn the retainer clockwise by hand until snug.
Attach a 6mm hex key adapter to a ft lb. torque wrench and
tighten the handwheel retainer to a torque measure of 18 (±2)
ft/lbs (24.5 Nm). Loosen the vise to remove the rst stage, and
remove the vise mounting tool (PN 100395).
24
Reattach the protector cap (45) to the rst stage and install
it over the threads of the handwheel (49).
2 Fit the disc and poppet with its spring onto the special disc
and Poppet wrench (PN 111003), and carefully insert into the
second stage box bottom (16). Screw the poppet wrench into the
box bottom so that the threaded stem of the poppet protrudes
into the interior of the box bottom.
Second Stage Assembly
1Insert the new disc (13) into the bore provided for it on the poppet
(14). Position the spring (15) over the stem of the poppet (14).
3 Place the washer (19), radiused end up, spacer (21), and a
new locknut (22) onto the poppet. Turn the locknut clockwise
until rst threads are engaged.
4Insert the lever (20) between the spacer and washer. Ensure that
the lever is properly aligned in its groove in the box bottom.
5 a 2nd stage without port plug:
While holding the locknut with the 1/4” box end wrench,
reinsert the poppet wrench (PN 111003) over the end of the poppet
(14). Do not compress the spring. Turn the poppet wrench clockwise
until about three threads of the poppet are visible beyond the head
of the locknut. Remove the poppet wrench and 1/4” wrench from the
box bottom.
5 b 2nd stage with port plug:
Insert the 1/4” nut driver portion of the Lever Height Adjust-
ment Tool (LHAT) through the open port plug and hold the locknut.
Insert the poppet wrench (PN 111003) over the end of the poppet
(14). Do not compress the spring. Turn the 1/4” nut driver por-
tion of the Lever Height Adjustment Tool (LHAT) until about three
threads of the retainer are visible beyond the head of the locknut.
Remove the poppet wrench and LHAT tool from the box bottom.
This Concludes the Assembly of the First
Stage Regulator. Testing of the First Stage
Regulator Will Follow Assembly of the
Second Stage.

17
6 Next, lightly lubricate the o-ring (12) and place it on the inlet
tting (11). To avoid marring the surface of the MP seat (13),
depress the lever and screw the inlet tting (11) clockwise into the
inlet boss of the box bottom using a 3/4” crow foot or socket and
in lb. torque wrench, tighten the inlet tting to a torque of 55 ± 5 in/
lbs (6.2 Nm).
7a
2nd stage with port plug:
Insert the 1/4” nut driver portion of the Lever Height Adjust-
ment Tool (LHAT) through the open port and hold the locknut. Insert
the screwdriver portion of the LHAT tool through the center of the nut
driver and insert it into the end of the poppet. While holding the pop-
pet still with the screwdriver, turn the nut driver to correct the lever
height or eliminate excessive “free-play”.
7 At this point, the top of the lever (20) should be approximately
ush with the top surface of the box bottom (16). Lay a straight
edge or “sight” across the top surface of the box bottom to conrm
correct lever height. If the top of the lever is below the top surface
of the box bottom, or if there is excessive “free play” or “op” in the
lever, use the following procedure:
7b
2nd stage without port plug:
Hold the poppet stem with a small, bent shank screw-
driver and turn the locknut (22) with a 1/4” open end wrench.
Adjust only far enough to correct the lever height or eliminate
excessive “free-play”.
1 0 Press the purge button (2) sub-assembly through the box top
(4) and using external snap ring pliers (PN 111100), install a
new retaining ring (6) into its groove on the purge button inside the
box top. Ensure that the at edge of the retaining ring faces up.
8 Insert the new exhalation valve (10) into the box bottom (16) and
pull on the stem of the valve until its barb passes through the
hole into the box bottom. Using the diagonal pliers (PN 9-45171),
trim the stem end of the valve 1/8” to 1/4” above the barb.
9 Rotate the spring (3), small end rst, onto the purge button (2).
11
Heat the exhaust tee (9) in hot water at 200°F; then stretch it
over the ange of the box bottom. Do not “twist” the exhaust
tee over the ange or the locating lug will be damaged.

18 Conshelf XIV Technical Manual
1 2 If not using a test bench, t the mouthpiece (24) onto the
box bottom, and fasten the mouthpiece in place with a new
mouthpiece clamp (23). The lock tab on the mouthpiece clamp
should be aligned to the side air inlet boss of the box bottom. Tighten
with pliers and snip the extra length with wire cutters. If using a test
bench, do not t the mouthpiece to the box bottom.
Attachment of First Stage To Second Stage
Regulators
13
Second stage with port plug only:
Install a new o-ring (17) onto the second stage port plug
(18). Thread the port plug into the second stage and tighten with
a in.lb torque wrench and 5/32” hex key adapter (PN 5570A52)
to 15 in/lbs (1.7 Nm).
NOTE: If you do not have the port plug box bottom, do not reinstall
the diaphragm and box top (8 & 4) until nal adjustment of second
stage assembly is completed.
1 4 Install the diaphragm (8), box top (4) and ring clamp (5). In-
stall the clamp screw (6) using a #2 Phillips screwdriver (PN
9-47436). Tighten the screw hand tight until rm. A gap between
the clamp ends of up to 1/8” is acceptable.
4 Close the air source control valve and attach the second stage
regulator(s) to the free end of the second stage hose(s). While
holding the inlet tting (11) with a 3/4” wrench, use an 11/16” crow
foot and in/lb torque wrench to tighten the swivel nut clockwise to a
torque of 40 in/lbs (4.5 Nm).
3 Connect the rst stage regulator to a source of MP (500 psig)
breathing air. While rmly holding the free end(s) of the second
stage hose(s), carefully open the air source control valve allowing
a small quantity of air to ow through the open hose(s). This will
ush any dust or debris from the interior of the hose(s).
NOTE: Before placing the Conshelf regulator back in service, the following
sequence of adjustments is necessary. The use of a ow test bench is the
preferred method to insure the quality of your adjustments. This will enable
the service technician to check critical performance requirements of the
regulator series more precisely. If no test bench is available to the service
technician, use of a SCUBA cylinder, the less preferred testing procedure
will follow this section.
2 Attach the hose (26) to one of the MP ports on the rst stage body
(16) using a 9/16” crow foot and in/lb. torque wrench. Tighten
the hose clockwise to a torque of 40 in/lbs (4.5 Nm).
1 Install the two lubricated o-rings (25 & 27) on the MP hose
(26). O-ring (25) is in the 2nd stage kit and o-ring (27) is in the
1st stage kit.
This Concludes the Assembly of the Second
Stage Regulator.

19
3 The optimum lockup pressure is 140±5 psig for the standard Con-
shelf XIV, and 125±5 psig for the Conshelf XIV Supreme, Supreme
EFA, Dry kit and 300 Bar DIN versions. To increase the MP, turn the
adjustment screw (30) standard & supreme, (34) supreme EFA and
(40) dr y kit “in” or clockwise; to decrease the MP, turn the adjustment
screw “out” or counterclockwise. Turn the adjustment screw using
a large at bladed screwdriver or 5/32 hex key adapter (supreme
EFA) . Turn the screw no more than 1/8 turns at a time, then purge
the second stage several times and observe the adjustment’s MP
increase. Repeat this process until the proper MP is set.
4 If the acceptable range cannot be achieved by varying the
adjustment screw (30) standard & supreme, (34) supreme EFA
and (40) dry kit, refer to the Troubleshooting Table 1 on page 24
for corrective guidelines ad specic procedures.
5 With the correct MP achieved, depress the purge button (2)
several times, release and observe the test bench MP gauge 5
seconds to 15 seconds after purging. The MP indicated must not
“creep” or slowly increase more than 5 psig within this time. If the
MP pressure will not stabilize at one pressure setting, refer to the
Troubleshooting Table 1 on page 24 for corrective guidelines and
specic procedures.
CAUTION: While adjusting the MP, be sure to “cycle” the regulator
by pushing the purge button (2) at least ten (10) times after turning
the adjustment screw (30) standard & supreme, (34) supreme
EFA and (40) dry kit. Failure to “cycle” the regulator can result
in a false reading of the rst stage MP “lock-up”.
First Stage Adjustment and Testing:
Test Bench Procedures
1 With the rst stage regulator mounted on the test bench HP valve
block adapter, attach a spare MP hose (26) to the open MP port
on the rst stage regulator. Attach the free end of this hose to the
male tting provided for it on the test bench.
NOTE: In conjunction with this subsection, the technician should refer
to Table 5 - Test Bench Specications, on page 29. In addition, all
tests described must rst be done at MP (500 psig) and then again at
service pressure (3000 psig).
2 While watching the MP gauge on the test bench, slowly pressurize
the bench and regulator to 500 psig. The MP gauge should indicate
a “lockup” pressure of 120-160 psig. If the gauge pressure increases
beyond 160 psig, turn the air source off immediately. This indicates a
failure of the rst stage regulator to achieve “lockup” pressure. Refer
to the Troubleshooting Table 1 on page 24 for corrective guidelines
and specic procedures. If the MP is not greater than 160 psig but
there is an audible leak or freeow from the second stage regulator(s),
adjustment of the lever (20) will be required before nal adjustment of
the rst stage MP can be completed. To adjust the lever see “Second
Stage Adjustment and Testing”, on p. 21 & 22.
Regulator Adjusting and Testing:
Manual Procedures
1 After attaching the rst and second stage (see Attachment of
First-stage to Second-stage Regulators, steps 1 through 4,
on page 18) unscrew one of the MP port plugs (20) and attach
a spare MP hose (26). Attach this hose to one of the open MP
ports on the rst stage body (16).
NOTE: If no test bench is available for testing the Conshelf XIV
regulator, the following adjustment and testing procedures should
be followed.
2 Thread the MP test pressure gauge (PN111610) onto the free
end of the MP hose. Make sure that the bleeder valve of the
test pressure gauge is open prior to pressurizing the regulator.
3Connect the rst stage regulator to a HP air source (partially lled
SCUBA cylinder - 500 psig). Slowly turn on the air source control
knob and pressurize the regulator. Once the regulator is pressurized,
slowly close gauge bleeder valve while watching the test gauge.
The gauge should indicate “lockup” pressure of 120-160 psig. If the
gauge pressure continues beyond 160 psig, immediately open the
gauge bleeder valve and close the air source control valve. Such a
steadily increasing gauge pressure beyond 160 psig indicates failure
of the rst stage regulator to achieve “lockup” pressure. Refer to the
Troubleshooting Table 1, on page 24 for corrective guidelines and
specic procedures.
4If the MP is not greater than 160 psig but there is an audible leak or
freeow from the second stage regulator(s), adjustment of the lever
(20) will be required before nal adjustment of the rst stage MP can be
completed. To adjust the lever see page 21 & 22 “Second Stage Adjust-
ment and Testing” for corrective guidelines and specic procedures.
5 The optimum lockup pressure is 140±5 psig for the Standard
Conshelf XIV, and 125±5 psig for the Conshelf XIV Supreme,
Supreme EFA , Dry kit and 300 Bar DIN versions. To increase
the MP, turn the adjustment screw (30) Standard & Supreme, (34)
Supreme EFA and (40) Dry Kit “in” or clockwise; to decrease the
MP, turn the adjustment screw “out” or counterclockwise. Turn the
adjustment screw using a large flat-bladed screwdriver or 5/32” hex
key adapter. Turn the screw no more than 1/8 turn at a time, then
purge the second stage several times and observe the adjustment
MP increase. Repeat this process until the proper MP is set.
6With the correct MP achieved, depress the purge button (2) sev-
eral times, release and observe the MP gauge 5 seconds to 15
seconds after purging. The MP indicated must not “creep” or slowly
increase more than 5 psig within this time. If the MP will not stabilize,
at one pressure setting, refer to the Troubleshooting Table 2, page
25, for corrective guidelines and specic procedures.
7 After stabilizing the MP repeat Steps 3 through 7 at 3000
psig, service pressure.
NOTE: For the Conshelf Supreme, Supreme EFA and Dry Kit:
See page 20 for reinstallation of environmental components on
the Supreme & Dry Kit Models.
CAUTION: If an adjustment of MP is required, be sure to
“cycle” the regulator (10 times) by pushing the purge button
(2) after turning the adjustment screw (30) standard & su-
preme, (34) supreme EFA and (40) dry kit). Failure to “cycle”
the regulator can result in a false reading of the rst stage
MP “lockup”.
Regulator Adjustment and Testing
8
Install the MP port plug (20) back into the rst stage body (16).
Using a 1/2” crow foot or socket attached to a in/lb torque
wrench, tighten the port plug to 15 in/lbs (1.7 Nm).

20 Conshelf XIV Technical Manual
Pressurized
Not Pressurized
Conshelf (Supreme, External Fine Adjustment, EFA)
1b
To complete the environmental conversion of a standard
Conshelf XIV or reinstallation of environmental components
on the Supreme EFA model, perform the following procedure
while the regulator is pressurized.
i While the regulator is still pressurized with 3000 PSI (206 BAR),
pour silicone uid into the spring retainer until the level reaches
within 1/8” below the top of the retainer.
iiPlace the secondary diaphragm (33) on to the EFA adjustment
screw (34) with the outer, raised lip pointing up. The diaphragm
must be covered with silicone to function properly.
iii
Air bubbles underneath the secondary diaphragm (33) must be
removed by smoothing the diaphragm with the ngernail.
iv
Using the square, slotted tool, screw the secondary dia-
phragm retaining ring (35) clockwise into the spring retainer.
Hand tighten rmly.
v Verify that the MP has not changed after the conversion or re-
installation procedure. Refer to the subsection of the rst stage
adjustment as required.
vi When the regulator is depressurized, the secondary dia-
phragm will appear to be “sucked” in. When the regulator
is pressurized, the secondary diaphragm returns to its normal
shape.
viiRecheck the MP to conrm there has been no change.
CAUTION: Performing this procedure while the rst stage is
unpressurized results in incorrect MP pressure and excessive
strain on the secondary diaphragm.
Pressurized
Not Pressurized
i While the regulator is still pressurized with 3000 PSI (206 BAR),
pour silicone uid into the spring retainer until the level reaches
within 1/8” below the top of the retainer. Ensure all air bubbles have
been removed.
ii
Insert the secondary diaphragm (32) into the spring retainer (31)
with the outer, raised lip pointing up. The diaphragm must be
covered with silicone to function properly.
iii
Air bubbles underneath the secondary diaphragm (32) must be
removed by smoothing the diaphragm with the ngernail.
iv
Using the square, slotted tool, screw the secondary diaphragm
retaining ring (35) clockwise into the spring retainer (31). Hand
tighten rmly.
v Verify that the MP has not changed after the conversion or re-
installation procedure. Refer to the subsection of the rst stage
adjustment as required.
vi
When the regulator is depressurized, the secondary diaphragm
will appear to be “sucked” in. When the regulator is pressur-
ized, the secondary diaphragm returns to its normal shape.
viiRecheck the MP to conrm there has been no change.
CAUTION: Performing this procedure while the rst stage is
unpressurized results in incorrect MP pressure and excessive
strain on the secondary diaphragm.
Conshelf (Supreme)
1aTo complete the environmental conversion of a standard
Conshelf XIV or reinstallation of environmental components
on the Supreme model, perform the following procedure while
the regulator is pressurized.
Environmental Kit Installation