SERVICE MANUAL SECOND STAGE LX and LEGEND Copyright ©2005 Aqualung France Rev.
Index COPYRIGHT............................................................................................................................... 3 INTRODUCTION........................................................................................................................ 3 WARNINGS, ATTENTION, NOTE...……………........................................................................ 3 MAINTENANCE................................................................................................................
F I R S T T O 3 D I V E COPYRIGHT GENERAL INSTRUCTIONS This manual is the property of Aqualung France. Any copying, photocopying, reproduction, translation, electronic distribution (email, Internet...), even partial, and in whatever format, is expressly forbidden without the written consent of Aqualung France. 1. In order to carry out the procedures described in this manual correctly it is important that you follow the steps in the exact order indicated.
. The acronyms used: LP: Low Pressure MP: Medium Pressure HP: High Pressure 5. Numbers in brackets indicate the part number of the component shown on the exploded view attached. from the hose nipple. Take care not to damage the Oring groove. Remove the O-ring from the hose threaded end. DISASSEMBLY PROCEDURE Note: Before commencing disassembly, consult the exploded view to check the reference numbers of all parts requiring replacement.
F I R S T T O 5 D I V E 6. Turn the adjustment handwheel anti-clockwise to the end. Hold the lever (8) down against the insert (7) and pull on the handwheel to remove the insert assembly from the casing (1). Remove the O-ring (4). 11. Insert a rod or tool (116236) into the insert (threaded side) and push out the valve seat assembly. Separate the components of the valve seat. 7. Hold the lever (8) against the insert (7) and remove the venturi control(6). Remove the plug (25).
To remove the bubble deflector (28), first immerse the casing in hot water (50°C).for 23 minutes. Pull on one end of the deflector to remove it. 1. If the exhaust valve has been removed, pass the valve tail through the hole in the casing from the outside and pull gently until the notch is inside the casing. If it is a new valve cut off any excess tail leaving about 5mm. 15. Lift the exhaust valve (27) and check that its surface is clean and free of scratches.
F I R S T 6. T O D I V E Insert the assembled shuttle valve, notch downwards, into the insert, holding the lever at right angles to the insert. Push the shuttle valve in until it passes the notch. To check that it is correctly fitted, turn the insert over, the shuttle valve should stay inside. 7 10. Fit a new lubricated O-ring (24) onto the venturi control (6). Position the control handle upwards and push it fully home into the casing. 11.
Fit the diaphragm (13) in the casing. Press all around the edges with a finger to ensure that it is in place. Fit the washer (14) directly in contact with the diaphragm.. 14. With the flat side of the casing at eye level, screw in the adjusting knob until the lever is about 4mm below the level of the casing edge. Now unscrew it until the lever just shows above the edge of the casing. 15. Using a 4mm Allen key tighten the adjusting screw one turn for Supreme models and ¾ turn for other models. 19.
F I R S T T O 9 D I V E m.kg FINAL CHECKS Note : If you have a regulator Test Bench, carry out these test before refitting the mouthpiece. Instructions for the check are given in the paragraph Final Checks 23. Refit the mouthpiece (17) onto the casing. If it is a Comfobite mouthpiece, check that the support section is on top. Fit the mouthpiece strap (29) into its groove. The collar lever should point down on the hose side. 1. Put the regulator under pressure with a 200 bar (±10 bar) supply.
Table 1. Troubleshooting Guide SYMPTOM Leak or free flow at 2nd stage Insufficient purge flow or work of breathing too high Water leak POSSIBLE CAUSE TREATMENT 1. MP too high 1. Refer to First stage Troubleshooting Guide 2. The valve (18) is worn or damaged. 2. Replace the valve 3. The seat (9) is not correctly adjusted 3. Readjust the seat 4. The lever (8) is bent 4. Replace the lever 5. The sealing face of the seat (9) is damaged. 5. Replace the seat 6. The spring (19) is damaged 6.
F I R S T T O 11 D I V E Table 2. List of Tools and Service Kits DESCRIPTION APPLICATION US PART NO.
Table 3. Recommended cleaners and lubricants LUBRICANT / CLEANER Cristo-Lube MCG 111 APPLICATION All O-rings SOURCE Aqualung, ref. 480025 Attention: Silicone parts do not require lubrication. Do not grease them. Greasing silicone parts can change their molecular construction and cause premature degradation of the material. Oakite #31 Acid bath for cleaning brass and stainless steel parts. Oakite Products, Inc. NETALU Acid bath for cleaning brass and stainless steel parts. Aqualung, ref.
F I R S T T O 13 D I V E Procedure A Cleaning and Lubricating (All Aqualung Regulators) Cleaning brass and stainless steel parts. 1. 2. 3. Pre-clean by soaking in NETALU diluted to 25%. Cleaning in an ultra-sonic bath filled with a mixture of washing-up liquid + hot water. If some resistant deposits remain then fill the ultrasonic bath with white vinegar and repeat. DO NOT put plastic, rubber, silicone or anodised aluminium parts in contact with vinegar.
Table 4. Torque values N° REFERENCE DESCRIPTION FORCE AP2031 Nut (5) 0.5 m.kg. Table 5. Checking specifications TEST INSTRUCTIONS SPECIFICATIONS Leak Test 160 bar < Working pressure < 200 bar No leak Medium Pressure 160 bar < Working pressure < 200 bar MP at 9.5 bar ± 0.5 bar: Legend and Titan LX MP at 8.5 bar ± 0.5 bar: Legend Supreme and Titan LX Supreme Opening effort 160 bar < Working pressure < 200 bar Titan LX / Legend: between 2.5 mbar and 3.
F I R S T T O 15 D I V E Maintenance Notes.
Exploded view of Legend second stage. Exploded view of Legend Supreme second stage.
F I R S T T O D I V E 17
Exploded view of LX second stage.
F I R S T T O 19 D I V E Exploded view of LX Supreme second stage.
Exploded view of Octopus LX second stage.
F I R S T T O D I V E Exploded view of Octopus Legend second stage.
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