legend 1 st stage. please turn off the cell phones
TRANSCRIPT
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Legend 1st Stage
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Please Turn Off The Cell Phones
4
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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
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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
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Product Features
Go directly to Disassembly
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Features
• Models
• Over-Balanced Diaphragm Design
• Dry Chamber (Environmentally Sealed)
• Air Turbo System
• Available In 300 Bar DIN
• Polyurethane Sheath
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Features
• Easy Access To HP Seat
• Hose Configuration
• High Pressure Seat
• Conical Filter
• Nitrox Compatible
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Features (Models)
• Five Models
– Legend LX
– Legend LX Supreme
– Legend
– Legend Supreme
– Legend Glacia
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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
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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
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Features (Dry Chamber)
• Protects main spring from freeze-up
• Keeps spring chamber free of contamination & corrosion
• No messy oil
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Features (Air Turbo System)
• Shortcut between MP reservoir and diaphragm chamber
• Diaphragm reacts faster to pressure drop
• Reg becomes more responsive to air demand
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Features (Yoke Or DIN)
3365 psi yoke (232 Bar)
4351 psi DIN (300 Bar)
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Features (Polyurethane Sheath)
• Provides shock resistance
• Covers entire brass body
• Enhances cosmetics of first stage
• Replacement sheaths can “dress up” used regs
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Features (Easy Access)
• End plug also balancing chamber
• Eliminates spring block and spring
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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
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Features (High Pressure Seat)
• Best in industry!
• Operates up to 4500 psi
• Resilient to deep coining
• Forgiving of contaminants
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Features (Conical Filter)
• More porous than previous filters
• Greater surface area
– Better filtration
– Better flow
• Same filter used in yoke or DIN configuration
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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
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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
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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
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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
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Disassembly
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Remove One HP Port Plug
• 4mm hex key
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Remove Cap
• 8mm hex key
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Remove Ribbed Washer
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Remove Secondary Diaphragm
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Remove Piston
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Remove Spacer
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Remove Adjustment Screw
• 8mm hex key
• Remove washer
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Remove Main Spring
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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
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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!
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Remove Spring Pad
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Remove Thrust Washer
NOTE: Pull thrust washer to one side and rotate
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Remove Diaphragm
• Recommended method:
– Keep finger over diaphragm
– Use a quick blast of LP air
– Alternate method to follow
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Remove Pin Support & Pin
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Remove HP Plug
• 8mm hex key
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Remove HP Seat & Spring
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Remove HP Seat & Spring
NOTE: Pin will come out during this class because diaphragm is still installed
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Remove Diaphragm (Alternate)
• Push out with seat extraction tool (p/n 109437)
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Remove HP Plug O-ring
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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
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Remove Crown Orifice
• Work over padded surface
– Use extraction tool
– Insert tool at an angle
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Remove Crown O-ring
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Disassemble ACD Yoke (Auto-Closure Device)
Click here Non-ACD Legend
Click here Legend
ACD (DIN)
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Disassemble ACD (Yoke)
• Mount in vise
– Remove yoke screw & dust cap
– 15” adj. wrench
– Remove yoke retainer
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Remove O-ring & Filter
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Loosen Yoke Shutter Valve• Install yoke retainer back into yoke
– Install dust cap & yoke screw
– Snug down yoke screw
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Turn Clockwise• Carefully clamp yoke retainer in vise by the
wrench flats
– Use 3mm hex key
– Turn clockwise to loosen yoke shutter valve
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Remove Yoke Screw
• Remove from vise
– Remove yoke screw & dust cap
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Remove ACD From Yoke
• Separate ACD components
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Remove Shutter Valve O-ring
• Push shutter valve out of shutter crown
• Remove o-ring first
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Remove Shutter Crown O-ring
• Remove o-ring from inside groove of shutter crown
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Yoke ACD Components
Click here move to next step
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Disassemble ACD DIN
• Remove dust cap
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Install DIN To Yoke Converter
• DIN to yoke converter (p/n 125237)
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Remove Shutter Valve
• Remove DIN shutter valve
• Secure 1st stage into vise
– 4mm hex key
NOTE: Early versions require a 3mm hex key
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Remove DIN To Yoke Converter
• Remove shutter crown
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Remove Shutter Crown O-rings
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Remove Spring
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Remove DIN Screw
• 7/16” or 11mm deep socket
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Remove DIN Screw O-ring
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Remove Handwheel
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Remove Filter Holder
• 17mm wrench
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Remove Filter & O-ring
• Seat extraction tool
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DIN ACD Components
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Remove All Port Plugs
• Remove body from vise
– Remove vise mounting tool
– 4mm hex key
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Remove Sheath
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This Concludes Disassembly
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Cleaning & Lubrication
Go directly to Reassembly
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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)
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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 !
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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
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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
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Reassembly
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Install Sheath
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Install Port Plugs
• 4mm hex key
– Leave out 1 MP and 1 HP plug
• Install port plug o-rings
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Inspect Crown Orifice
• Critically inspect the crown orifice under magnification
– Confirm it is acceptable for reuse
Sealing area
O-ring groove
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Install Crown O-ring
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Install Crown Orifice
• Use seat installation tool
– Place crown against plastic handle
– Push crown into the body
– Make sure crown is seated evenly
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Install Backup Ring In HP Plug
• Concave side facing out; fits up against o-ring
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Install HP O-ring
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Install HP Plug O-ring
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Install HP Seat & Spring
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Install HP Plug
• 8mm hex key
– Compress & turn simultaneously
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Torque HP Plug
• 8mm hex key adapter
– In/lb torque wrench
– 45 in/lbs (4.9 Nm)
Torque: 45 in/lbs 4.9 Nm
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Install Pin & Pin Support
• Press down several times, should feel spring loaded
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Install Diaphragm & Thrust Washer
• Press edges to ensure it’s evenly seated
• Either side faces up
– Press edges to ensure it’s evenly seated
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Install Spring Pad
Click here for Legend Glacia
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Install Main Spring & Washer
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Install Adjustment Screw
• 8mm hex key
– Capture first few threads
– DO NOT thread all the way in
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Install Spring Retainer• Main spring fits into adjustment
screw
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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
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Preset Adjustment Screw
• 2-3 threads showing above inside rim
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Assemble ACD Yoke (Auto-Closure Device)
Click here Non-ACD Legend
Click here Legend ACD
(DIN)
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Assemble ACD (Yoke) • Install o-ring into shutter
crown
– Use seat installation tool to help guide o-ring
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Shutter Valve Into Shutter Crown
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Install Shutter Valve O-ring
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Set Spring In Spring Retainer
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Set Shutter Crown On Spring
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Place Sub-Assembly In Yoke
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Install Dust Cap & Yoke Screw
• Compress the spring by tightening the yoke screw until snug
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Tighten Counter-Clockwise
• 3mm hex key
– Tighten shutter valve counter-clockwise 3-full turns
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Tighten Yoke Screw Snug
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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
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Remove Yoke Retainer
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Measure Shoulder
1.5mm
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Install Unlubricated O-ring & Filter
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Install Inlet Fitting• Pass inlet fitting thru yoke
– Keep filter facing up; prevents o-ring from falling out
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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
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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
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Assemble ACD (DIN)
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Install O-rings In Shutter Crown
• Install “unlubricated” face o-ring
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Install DIN Screw O-ring
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Insert Filter Holder Into Handwheel
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Install DIN Screw• Thread DIN screw into
filter holder
– 7/16” or 11mm deep socket
– Tighten DIN screw hand-tight
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Assemble ACD (DIN)
• Install filter
• Install “unlubricated” o-ring into filter holder
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Install DIN Adapter• Hold 1st stage inlet side down
– 7/16” or 11mm deep socket
– Thread DIN adapter “up” into body until snug
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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
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Install Spring & DIN Crown
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Install DIN To Yoke Converter
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Insert DIN Shutter Valve
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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
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Remove DIN To Yoke Converter
• Remove 1st stage from vise
– Remove vise mounting tool
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Adjusting & Final Assembly
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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
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Adjusting Medium Pressure (MP)• Attach Legend to fully charged cylinder
3000 psi (206 bar)
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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
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Adjusting Medium Pressure (MP)
• With relief valve open on gauge, slowly open cyl. valve & pressurize the 1st stage
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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
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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
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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
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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
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Install Spacer & Ribbed Washer
• Spacer flats face upward, align flats w/spring retainer flats
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Install Piston (Load Transmitter)
• Dry chamber parts must be installed while under pressure
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Install Diaphragm
• Cup side faces down
– Diaphragm edge fits into outer groove
– Work edges with finger
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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
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Testing
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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
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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
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This Concludes Service Of Legend 1st Stage
Rev 07/10/07Rev 07/10/07