Legend 1 st Stage. Please Turn Off The Cell Phones

Legend 1st Stage

Please Turn Off The Cell Phones

4

This program 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

©2007 Aqua Lung International, Inc. Legend Series First Stage Service Program

Copyright notice

O-ring Removal (Pinch Method)

P/n 944022

• Pinch Method: Using fingers, push on opposite sides to create protrusion

• Use only brass or plastic pics to remove o-rings, this will protect delicate seating surfaces

• Never reuse o-rings

Product Features

Go directly to Disassembly

Features

• Models

• Over-Balanced Diaphragm Design

• Dry Chamber (Environmentally Sealed)

• Air Turbo System

• Available In 300 Bar DIN

• Polyurethane Sheath

Features

• Easy Access To HP Seat

• Hose Configuration

• High Pressure Seat

• Conical Filter

• Nitrox Compatible

Features (Models)

• Five Models

– Legend LX

– Legend LX Supreme

– Legend

– Legend Supreme

– Legend Glacia

Features (Diaphragm Mechanism)

• Proven high performance design• Small components reduce friction compared

to large piston• Moving parts protected from environment• Peak performance regardless of tank

pressure or depth• Easy to set the medium pressure externally

Features (Over-Balanced Design)

• Balanced First Stage

– Medium pressure remains constant at 135 psi plus ambient

• Legend First Stage

– Medium pressure increase at a rate faster than ambient

– Increases by two atmospheres by 165 feet

– Helps compensate for denser air at depth

Features (Dry Chamber)

• Protects main spring from freeze-up

• Keeps spring chamber free of contamination & corrosion

• No messy oil

Features (Air Turbo System)

• Shortcut between MP reservoir and diaphragm chamber

• Diaphragm reacts faster to pressure drop

• Reg becomes more responsive to air demand

Features (Yoke Or DIN)

3365 psi yoke (232 Bar)

4351 psi DIN (300 Bar)

Features (Polyurethane Sheath)

• Provides shock resistance

• Covers entire brass body

• Enhances cosmetics of first stage

• Replacement sheaths can “dress up” used regs

Features (Easy Access)

• End plug also balancing chamber

• Eliminates spring block and spring

Features (Hose Configuration)

• Can be mounted with diaphragm up or down

• Two HP ports for redundancy and versatility

• Four MP ports to accommodate drysuit hose

Features (High Pressure Seat)

• Best in industry!

• Operates up to 4500 psi

• Resilient to deep coining

• Forgiving of contaminants

Features (Conical Filter)

• More porous than previous filters

• Greater surface area

– Better filtration

– Better flow

• Same filter used in yoke or DIN configuration

Features (Nitrox Compatible)

• The Legend is nitrox (EAN) compatible to 40% out of the box

• Built with a high level of cleanliness

• EAN compatible components and lubricants

• Have passed required adiabatic compression testing to ensure their safety and compatibility

Features (Nitrox Compatible)

• Responsibility of the owner to maintain the cleanliness of the regulator

• If regulator will be used interchangeably with breathing air, the air should be oxygen-compatible or “hyper-filtered” whereas the condensed hydrocarbons do not exceed 0.1 mg/m3

• Grade E air does not necessarily meet this criterion

• Hydrocarbons found in Grade E air can pose a risk in the presence of elevated oxygen content

Features (Nitrox Compatible)

• Hydrocarbons build up over time along the passageways of the equipment

• When hydrocarbons come in contact with high-pressure oxygen enriched air, they can pose a very real hazard that can lead to combustion

• If a regulator has had use with Grade E breathing air, it should receive a standard overhaul, including ultrasonic cleaning with a detergent solution, that removes hydrocarbons, prior to being put back into nitrox service

Features (Nitrox Compatible)

• Although second stage components are not exposed to high pressure EAN, Aqualung recommends that the same cleaning procedures be followed for the complete regulator

• This prevents the possibility of cross contamination and guarantees the cleanliness of the entire regulator

Disassembly

Remove One HP Port Plug

• 4mm hex key

Remove Cap

• 8mm hex key

Remove Ribbed Washer

Remove Secondary Diaphragm

Remove Piston

Remove Spacer

Remove Adjustment Screw

• 8mm hex key

• Remove washer

Remove Main Spring

Install Vise Mounting Tool• Vise mounting tool (p/n

100395)

CAUTION: If using a CO2 cartridge, use a HP adapter so threads don’t break off in 1st stage port!

• Or discharged CO2 cartridge w/HP adapter

Remove Spring Retainer

• Install vise mount tool into bench vise

– 32mm wrench

– 17mm hex key for Glacia

CAUTION: NEVER mount 1st stage directly in vise!

Remove Spring Pad

Remove Thrust Washer

NOTE: Pull thrust washer to one side and rotate

Remove Diaphragm

• Recommended method:

– Keep finger over diaphragm

– Use a quick blast of LP air

– Alternate method to follow

Remove Pin Support & Pin

Remove HP Plug

• 8mm hex key

Remove HP Seat & Spring

Remove HP Seat & Spring

NOTE: Pin will come out during this class because diaphragm is still installed

Remove Diaphragm (Alternate)

• Push out with seat extraction tool (p/n 109437)

Remove HP Plug O-ring

Remove HP Plug O-ring & Backup Ring

!CAUTION: Care must be taken not to scratch the inside wall of the balance chamber or a leak could result

Remove Crown Orifice

• Work over padded surface

– Use extraction tool

– Insert tool at an angle

Remove Crown O-ring

Disassemble ACD Yoke (Auto-Closure Device)

Click here Non-ACD Legend

Click here Legend

ACD (DIN)

Disassemble ACD (Yoke)

• Mount in vise

– Remove yoke screw & dust cap

– 15” adj. wrench

– Remove yoke retainer

Remove O-ring & Filter

Loosen Yoke Shutter Valve• Install yoke retainer back into yoke

– Install dust cap & yoke screw

– Snug down yoke screw

Turn Clockwise• Carefully clamp yoke retainer in vise by the

wrench flats

– Use 3mm hex key

– Turn clockwise to loosen yoke shutter valve

Remove Yoke Screw

• Remove from vise

– Remove yoke screw & dust cap

Remove ACD From Yoke

• Separate ACD components

Remove Shutter Valve O-ring

• Push shutter valve out of shutter crown

• Remove o-ring first

Remove Shutter Crown O-ring

• Remove o-ring from inside groove of shutter crown

Yoke ACD Components

Click here move to next step

Disassemble ACD DIN

• Remove dust cap

Install DIN To Yoke Converter

• DIN to yoke converter (p/n 125237)

Remove Shutter Valve

• Remove DIN shutter valve

• Secure 1st stage into vise

– 4mm hex key

NOTE: Early versions require a 3mm hex key

Remove DIN To Yoke Converter

• Remove shutter crown

Remove Shutter Crown O-rings

Remove Spring

Remove DIN Screw

• 7/16” or 11mm deep socket

Remove DIN Screw O-ring

Remove Handwheel

Remove Filter Holder

• 17mm wrench

Remove Filter & O-ring

• Seat extraction tool

DIN ACD Components

Remove All Port Plugs

• Remove body from vise

– Remove vise mounting tool

– 4mm hex key

Remove Sheath

This Concludes Disassembly

Cleaning & Lubrication

Go directly to Reassembly

Cleaning Procedures

• Brass and Stainless Steel Parts

– Pre-clean in warm soapy water; nylon bristle brush

– Ultrasonically clean with soapy water; vinegar OK on tough corrosion

– Rinse in fresh water; use distilled water if tap water is “hard”

– Blow dry with hydrocarbon free gas (for EAN use)

Cleaning Procedures

• Aluminum, Plastic & Rubber Parts

– Soak in warm, soapy water

– Use soft nylon bristle brush to remove deposits

– Rinse with fresh water

– Blow dry with LP hydrocarbon free gas (for EAN use)

CAUTION: DO NOT soak plastic parts in acidic solutions !

Cleaning Procedures

• Regulator Hose

– Hose fittings - Ultrasonically clean with soapy water; vinegar OK on tough corrosion

– Can run soapy water through hose if needed

– Thoroughly rinse with fresh water

– Blow out hose before installing

Lubrication Procedures

• Lubrication

– Christo-lube MCG 111

– Light film only

– Remove visible excess

– If regulator will be used with EAN, you should wear powderless, latex gloves (or equivalent) when lubricating and handling o-rings

Reassembly

Install Sheath

Install Port Plugs

• 4mm hex key

– Leave out 1 MP and 1 HP plug

• Install port plug o-rings

Inspect Crown Orifice

• Critically inspect the crown orifice under magnification

– Confirm it is acceptable for reuse

Sealing area

O-ring groove

Install Crown O-ring

Install Crown Orifice

• Use seat installation tool

– Place crown against plastic handle

– Push crown into the body

– Make sure crown is seated evenly

Install Backup Ring In HP Plug

• Concave side facing out; fits up against o-ring

Install HP O-ring

Install HP Plug O-ring

Install HP Seat & Spring

Install HP Plug

• 8mm hex key

– Compress & turn simultaneously

Torque HP Plug

• 8mm hex key adapter

– In/lb torque wrench

– 45 in/lbs (4.9 Nm)

Torque: 45 in/lbs 4.9 Nm

Install Pin & Pin Support

• Press down several times, should feel spring loaded

Install Diaphragm & Thrust Washer

• Press edges to ensure it’s evenly seated

• Either side faces up

– Press edges to ensure it’s evenly seated

Install Spring Pad

Click here for Legend Glacia

Install Main Spring & Washer

Install Adjustment Screw

• 8mm hex key

– Capture first few threads

– DO NOT thread all the way in

Install Spring Retainer• Main spring fits into adjustment

screw

Torque Spring Retainer• Install vise mount tool into body, mount

in vise

– Use Legend spring retainer socket (p/n 122152) & ft/lb torque wrench w/ 3” ext.

– Torque to 18 ft/lbs (24.5 Nm)

• Optional: 32mm crow-foot

Torque: 18 ft/lbs 24.5 Nm

Preset Adjustment Screw

• 2-3 threads showing above inside rim

Assemble ACD Yoke (Auto-Closure Device)

Click here Non-ACD Legend

Click here Legend ACD

(DIN)

Assemble ACD (Yoke) • Install o-ring into shutter

crown

– Use seat installation tool to help guide o-ring

Shutter Valve Into Shutter Crown

Install Shutter Valve O-ring

Set Spring In Spring Retainer

Set Shutter Crown On Spring

Place Sub-Assembly In Yoke

Install Dust Cap & Yoke Screw

• Compress the spring by tightening the yoke screw until snug

Tighten Counter-Clockwise

• 3mm hex key

– Tighten shutter valve counter-clockwise 3-full turns

Tighten Yoke Screw Snug

Tighten Counter-Clockwise• Carefully clamp yoke retainer in vise by

wrench flats

– 3mm hex key adapter and in/lb torque wrench

– Torque to 18 in/lbs (2 Nm)

Torque: 18 in/lbs 2 Nm

Remove Yoke Retainer

Measure Shoulder

1.5mm

Install Unlubricated O-ring & Filter

Install Inlet Fitting• Pass inlet fitting thru yoke

– Keep filter facing up; prevents o-ring from falling out

Torque Inlet Fitting

• Inlet socket (p/n 111001)

– Ft/lb torque wrench & 3” extension

– Torque to 18 ft/lbs (24.5 Nm)

Torque: 18 ft/lbs 24.5 Nm

Install Yoke Screw• Dust cap over threads w/Aqua Lung

logo facing out

– Remove 1st stage from vise

– Remove vise mount tool

Click here move to

next step

Assemble ACD (DIN)

Install O-rings In Shutter Crown

• Install “unlubricated” face o-ring

Install DIN Screw O-ring

Insert Filter Holder Into Handwheel

Install DIN Screw• Thread DIN screw into

filter holder

– 7/16” or 11mm deep socket

– Tighten DIN screw hand-tight

Assemble ACD (DIN)

• Install filter

• Install “unlubricated” o-ring into filter holder

Install DIN Adapter• Hold 1st stage inlet side down

– 7/16” or 11mm deep socket

– Thread DIN adapter “up” into body until snug

Torque DIN Screw

• Mount 1st stage in bench vise

– Ft/lb torque wrench & 7/16” or 11mm deep socket

– Torque to 18 ft/lbs (24.5 Nm)

Torque: 18 ft/lbs 24.5 Nm

Install Spring & DIN Crown

Install DIN To Yoke Converter

Insert DIN Shutter Valve

Torque DIN Shutter Valve

• In/lb torque wrench

– 4mm hex key adapter

– Torque to 18 in/lbs (2 Nm)

NOTE: Early versions require a 3mm hex key

Torque: 18 in/lbs 2 Nm

Remove DIN To Yoke Converter

• Remove 1st stage from vise

– Remove vise mounting tool

Adjusting & Final Assembly

Adjusting Medium Pressure (MP)• Install MP gauge (p/n 111610)

into 1st stage MP port

– If gauge lacks over-pressure relief valve, attach properly adjusted 2nd stage as relief valve in case of HP leak

Adjusting Medium Pressure (MP)• Attach Legend to fully charged cylinder

3000 psi (206 bar)

WARNING!

If the pressure gauge rapidly exceeds 145 psi (10 bar), there is a HP leak. Quickly close the cylinder valve and purge the regulator. Failure to do so may cause a rupture to the MP hose and/or MP gauge which, in turn, can lead to personal injury

Adjusting Medium Pressure (MP)

• With relief valve open on gauge, slowly open cyl. valve & pressurize the 1st stage

Adjusting Medium Pressure (MP)

• Close the relief valve

– If MP rapidly exceeds 145 psi (10 bar), open relief valve & shut off cylinder valve

– This means there is a HP leak

Adjusting Medium Pressure (MP)

• Using an 8mm hex key

– Turn adjustment screw clockwise in 1/8 turn increments to increase the MP

– Turn Adjustment screw counter-clockwise to decrease the MP

Adjusting Medium Pressure (MP)

• Using the relief valve on the gauge

– Cycle the reg several times after each adjustment

– Set the MP to: Legend Std. 130-145 psi (9-10 bar)

– Legend Supreme 116-130 psi (8-9 bar)

Legend Std. MP Settings: 130-145 psi 9-10 bar

Legend Sup. MP Settings: 116-130 psi 8-9 bar

Adjusting Medium Pressure (MP)• Let the regulator

stand for several minutes. Check that MP remains stable

– If MP rises more than 5psi (0.3 bar), it indicates a leak

– Close valve, purge line & pressurize again

– Confirm MP is stable

Legend Std. MP Settings: 130-145 psi 9-10 bar

Legend Sup. MP Settings: 116-130 psi 8-9 bar

Install Spacer & Ribbed Washer

• Spacer flats face upward, align flats w/spring retainer flats

Install Piston (Load Transmitter)

• Dry chamber parts must be installed while under pressure

Install Diaphragm

• Cup side faces down

– Diaphragm edge fits into outer groove

– Work edges with finger

Torque Cap

• Mount 1st stage in bench vise

– In/lb torque wrench

– 8mm hex key adapter

– Torque to 35 in/lbs (3.9 Nm)

Torque: 35 in/lbs 3.9 Nm

Testing

Recheck MP

• MP should still be in proper range

– 130-145 psi for Std. (9-10 bar)

– 116-130 psi for Supreme (8-9 bar)

– Readjust if necessary

Legend Std. MP Settings: 130-145 psi 9-10 bar

Legend Sup. MP Settings: 116-130 psi 8-9 bar

Immersion Test

• With Legend still pressurized

– Submerge in bath of water

– Look for streaming bubbles; don’t mistake trapped air for leaks

– Note leak source; refer to troubleshooting table in Technical Maintenance Manual

This Concludes Service Of Legend 1st Stage

Rev 07/10/07Rev 07/10/07