Authorized Technician TECHNICAL MAINTENANCE MANUAL LEGEND FIRST STAGE Copyright ©2000 Aqua Lung America, Inc. Rev.
Legend First Stage Service Manual Contents COPYRIGHT NOTICE...............................................................................................................................................3 INTRODUCTION .......................................................................................................................................................3 WARNINGS, CAUTIONS, & NOTES...............................................................................................................
COPYRIGHT NOTICE An Official Inspection consists of: 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 America. It may not be distributed through the internet or computer bulletin board systems without prior consent in writing from Aqua Lung America. ©2002 Aqua Lung America, Inc. Legend First Stage Service Manual 1.
5. 6. Legend First Stage Service Manual 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. When reassembling, it is important to follow every torque specification 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. 1.
The washer may be inside the adjustment F Note: screw. If so, gently tap the adjustment screw 8. Using an 8mm hex wrench, unscrew the HP plug (1). Turn the reglator over so the spring (5) and HP seat (6) fall out into your hand. Separate the spring from the HP seat. 9. Remove the o-ring (2) from the HP plug (1). Using a brass o-ring tool, remove the o-ring (4) and backup ring (3) from inside the HP plug. against the work bench and the washer will fall out. 6. 7.
Legend First Stage Service Manual If the first-stage has a yoke, go to step 11A; if it has a DIN connector, go to step 11B. 12. Loosen the vise and remove the first stage. Remove the vise mounting tool from HP port. Using a 4mm hex wrench, remove all the port plugs (15 & 17) and their o-rings (14 & 16). 13. Pull on the narrow end of the protective sheath (11) and slide it off the body (10). 11A. Removing the Yoke a. Secure the vise mounting tool into a bench vise with the yoke facing upward.
REASSEMBLY PROCEDURES 1. Slide the protective sheath (11) on the first stage body (10). Make sure all the ports and inlet fitting opening align with the holes in the sheath. 2. Install new, lubricated o-rings (14 & 16) on all the port plugs (15 & 17). Install all the port plugs, except for one HP port, and tighten them using a 4mm hex wrench. 3. 4. Install the new backup ring into the HP plug (1) with the concave side facing outward.
8. 9. Legend First Stage Service Manual Turn the regulator over so the medium pressure side is facing upward. Drop the pin (7) through the center hole. Place the pin support (18) over the pin. Press on the pin support a few times. It should feel like a spring-loaded button. Press a new diaphragm (19a) into the first stage body. Run your finger around the edge of the diaphragm to make sure it is properly seated.
a socket extension to a foot-pound torque wrench. Pass the socket extension through the top of the yoke and insert it into the socket. Tighten the inlet fitting to 18-20 foot-pounds. Remove the torque wrench and socket. d. c. Remove the first-stage from the vise. Hold the firststage with the inlet opening facing downward. Insert the threaded end of the DIN connector through the threaded side of the handwheel (39) and screw it into the first stage body until finger tight.
4. Legend First Stage Service Manual Close the cylinder valve and depressurize the regulator by opening the gauge relief valve or by pressing the second stage purge button. Close the gauge relief valve and repressurize the system. The MP should still read 135 psi. If the pressure reading is different than the original setting, repeat steps 3 and 4 until the MP is stable. FINAL ASSEMBLY 1. Orient the spacer (25) so the side with straight edges is facing upward.
Table 1 - Troubleshooting Guide SYMPTOM High pressure creep (also causes second-stage leaks) External air leakage -0rSecondary diaphragm distended or burst Restricted air flow or high inhalation resistance through entire system POSSIBLE CAUSE TREATMENT 1. HP Seat (6) is worn or damaged 1. Replace HP seat 2. Crown (9) damaged. 2. Replace crow 3. O-ring (4) damaged or worn. 3. Replace O-ring 4. HP plug (1) internal wall damaged 4. Replace HP plug 5. O-ring (8) damaged or worn 5.
Legend First Stage Service Manual Table 2 - Recommended Tool List PART NO. DESCRIPTION APPLICATION 111610 I.P.
Table 3 - Recommended Lubricants & Cleaners LUBRICANT / CLEANER Christo-Lube® MCG-111 APPLICATION All O-rings seals SOURCE Aqua Lung, PN 820466, or Lubrication Technologies 310 Morton Street Jackson, OH 45640 (800) 477-8704 CAUTION: Silicone rubber requires no lubrication or preservative treatment. DO NOT apply grease or spray to silicone rubber parts. Doing so may cause a chemical breakdown and premature deterioration of the material.
Legend First Stage Service Manual 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.
Table 4 - Torque Specifications PART NUMBER DESCRIPTION (KEY NUMBER) TORQUE 716021 Spring retainer (21) 25±2 foot-lbs 716018 Inlet Fitting (30) 20±2 foot-lbs 124602 DIN Connector (38) 20±2 foot-lbs 129120 HP Plug (1) 43-45 inch-pounds HP Port Plug (15), LP Port Plug (17) 16-18 inch-pounds 129118, 129119 Table 5 - Test Bench Specifications TEST CONDITION ACCEPTABLE RANGE Leak Test Inlet 2,500-3,000 (±100) psig No leaks allowed Medium Pressure Inlet 2,500-3,000 (±100) psig 135±5
Legend First Stage Service Manual TECHNICIAN'S NOTES
Legend Exploded Parts Drawing Key # Part # ------ 129060 ------ 900014 1 ----- 129120 2 ----- 824407 3 ----- 119129 4 ----- 820080 5 ----- 122244 6 ----- 105940 7 ----- 102002 8 ----- 820038 9 ----- 106027 10 ---- 129111 11 ---- 129112 12 ---- 129151 13 ---- 820011 14 ---- 820072 15 ---- 129118 16 ---- 820011 17 ---- 129119 18 ---- 129121 19 ---- 103425 20 ---- 124560 21 ---- 129122 22 ---- 106356 Description First Stage Complete Overhaul Parts Kit (Yoke and DIN) HP Plug O-ring Backup ring O-ring Spri
2340 Cousteau Court, Vista, California 92083 www.aqualung.com Rev.
