1. Legend 1 st Stage

2. Please Turn Off The Cell Phones

3. 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

4. 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

5. Product Features Go directly to Disassembly

6. Features Models Over-Balanced Diaphragm Design Dry Chamber (Environmentally Sealed) Air Turbo System Available In 300 Bar DIN Polyurethane Sheath

7. Features Easy Access To HP Seat Hose Configuration High Pressure Seat Conical Filter Nitrox Compatible

8. Features (Models) Five Models –Legend LX –Legend LX Supreme –Legend –Legend Supreme –Legend Glacia

9. 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

10. 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

11. Features (Dry Chamber) Protects main spring from freeze-up Keeps spring chamber free of contamination & corrosion No messy oil

12. Features (Air Turbo System) Shortcut between MP reservoir and diaphragm chamber Diaphragm reacts faster to pressure drop Reg becomes more responsive to air demand

13. Features (Yoke Or DIN) 3365 psi yoke (232 Bar) 4351 psi DIN (300 Bar)

14. Features (Polyurethane Sheath) Provides shock resistance Covers entire brass body Enhances cosmetics of first stage Replacement sheaths can dress up used regs

15. Features (Easy Access) End plug also balancing chamber Eliminates spring block and spring

16. 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

17. Features (High Pressure Seat) Best in industry! Operates up to 4500 psi Resilient to deep coining Forgiving of contaminants

18. Features (Conical Filter) More porous than previous filters Greater surface area –Better filtration –Better flow Same filter used in yoke or DIN configuration

19. 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

20. 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

21. 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

22. 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

23. Disassembly

24. Remove One HP Port Plug 4mm hex key

25. Remove Cap 8mm hex key

26. Remove Ribbed Washer

27. Remove Secondary Diaphragm

28. Remove Piston

29. Remove Spacer

30. Remove Adjustment Screw 8mm hex key Remove washer

31. Remove Main Spring

32. Install Vise Mounting Tool Vise mounting tool (p/n 100395) CAUTION: If using a CO2 cartridge, use a HP adapter so threads dont break off in 1 st stage port ! Or discharged CO2 cartridge w/HP adapter

33. Remove Spring Retainer Install vise mount tool into bench vise –32mm wrench –17mm hex key for Glacia CAUTION: NEVER mount 1 st stage directly in vise !

34. Remove Spring Pad

35. Remove Thrust Washer NOTE: Pull thrust washer to one side and rotate

36. Remove Diaphragm Recommended method: –Keep finger over diaphragm –Use a quick blast of LP air –Alternate method to follow

37. Remove Pin Support & Pin

38. Remove HP Plug 8mm hex key

39. Remove HP Seat & Spring

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

41. Remove Diaphragm (Alternate) Push out with seat extraction tool (p/n 109437)

42. Remove HP Plug O-ring

43. 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

44. Remove Crown Orifice Work over padded surface –Use extraction tool –Insert tool at an angle

45. Remove Crown O-ring

46. Disassemble ACD Yoke (Auto-Closure Device) Click here Non-ACD Legend Click here Legend ACD (DIN)

47. Disassemble ACD (Yoke) Mount in vise –Remove yoke screw & dust cap –15 adj. wrench –Remove yoke retainer

48. Remove O-ring & Filter

49. Loosen Yoke Shutter Valve Install yoke retainer back into yoke –Install dust cap & yoke screw –Snug down yoke screw

50. Turn Clockwise Carefully clamp yoke retainer in vise by the wrench flats –Use 3mm hex key –Turn clockwise to loosen yoke shutter valve

51. Remove Yoke Screw Remove from vise –Remove yoke screw & dust cap

52. Remove ACD From Yoke Separate ACD components

53. Remove Shutter Valve O-ring Push shutter valve out of shutter crown Remove o-ring first

54. Remove Shutter Crown O-ring Remove o-ring from inside groove of shutter crown

55. Yoke ACD Components Click here move to next step

56. Disassemble ACD DIN Remove dust cap

57. Install DIN To Yoke Converter DIN to yoke converter (p/n 125237)

58. Remove Shutter Valve Remove DIN shutter valve Secure 1 st stage into vise –4mm hex key NOTE: Early versions require a 3mm hex key

59. Remove DIN To Yoke Converter Remove shutter crown

60. Remove Shutter Crown O-rings

61. Remove Spring

62. Remove DIN Screw 7/16 or 11mm deep socket

63. Remove DIN Screw O-ring

64. Remove Handwheel

65. Remove Filter Holder 17mm wrench

66. Remove Filter & O-ring Seat extraction tool

67. DIN ACD Components

68. Disassemble Legend (Yoke) Mount in vise –Remove yoke screw & dust cap –15 adjustable wrench Click here Legend (DIN)

69. Remove C-clip & Filter Shield Reversible circlip pliers (p/n 111100)

70. Remove Filter & O-ring Use blunt end of seat extraction tool Click here move to next step

71. Disassemble Legend (DIN) Mount in vise –Remove dust cap –6mm hex key –Remove DIN connector

72. Remove Handwheel

73. Remove DIN Connector Filter & O-ring seat extraction tool

74. Remove Face O-ring

75. Remove All Port Plugs Remove body from vise –Remove vise mounting tool –4mm hex key

76. Remove Sheath

77. This Concludes Disassembly

78. Cleaning & Lubrication Go directly to Reassembly

79. 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)

80. 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 !

81. 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

82. 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

83. Reassembly

84. Install Sheath

85. Install Port Plugs 4mm hex key –Leave out 1 MP and 1 HP plug Install port plug o-rings

86. Inspect Crown Orifice Critically inspect the crown orifice under magnification –Confirm it is acceptable for reuse Sealing area O-ring groove

87. Install Crown O-ring

88. Install Crown Orifice Use seat installation tool –Place crown against plastic handle –Push crown into the body –Make sure crown is seated evenly

89. Install Backup Ring In HP Plug Concave side facing out; fits up against o-ring

90. Install HP O-ring

91. Install HP Plug O-ring

92. Install HP Seat & Spring

93. Install HP Plug 8mm hex key –Compress & turn simultaneously

94. Torque HP Plug 8mm hex key adapter –In/lb torque wrench –45 in/lbs (4.9 Nm) Torque: 45 in/lbs 4.9 Nm

95. Install Pin & Pin Support Press down several times, should feel spring loaded

96. Install Diaphragm & Thrust Washer Press edges to ensure its evenly seated Either side faces up –Press edges to ensure its evenly seated

97. Install Spring Pad Click here for Legend Glacia

98. Install Main Spring & Washer

99. Install Adjustment Screw 8mm hex key –Capture first few threads –DO NOT thread all the way in

100. Install Spring Retainer Main spring fits into adjustment screw

101. 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

102. Install Spring Retainer

103. Torque Spring Retainer Install vise mount tool into body, mount in vise –Use 17mm hex key adapter & ft/lb torque wrench –Torque to 18 ft/lbs (24.5 Nm) Torque: 18 ft/lbs 24.5 Nm

104. Install Main Spring & Washer

105. Install Adjustment Screw 8mm hex key –Capture first few threads –DO NOT thread all the way in

106. Preset Adjustment Screw 2-3 threads showing above inside rim

107. Assemble ACD Yoke (Auto-Closure Device) Click here Non-ACD Legend Click here Legend ACD (DIN)

108. Assemble ACD (Yoke) Install o-ring into shutter crown –Use seat installation tool to help guide o-ring

109. Shutter Valve Into Shutter Crown

110. Install Shutter Valve O-ring

111. Set Spring In Spring Retainer

112. Set Shutter Crown On Spring

113. Place Sub-Assembly In Yoke

114. Install Dust Cap & Yoke Screw Compress the spring by tightening the yoke screw until snug

115. Tighten Counter-Clockwise 3mm hex key –Tighten shutter valve counter- clockwise 3-full turns

116. Tighten Yoke Screw Snug

117. 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

118. Remove Yoke Retainer

119. Measure Shoulder 1.5mm

120. Install Unlubricated O-ring & Filter

121. Assemble Legend (Yoke) Install filter shield –Flat side of C-clip faces upward Click here Legend (DIN)

122. Install Filter & O-ring Install unlubricated o-ring Insert conical end first

123. Install Inlet Fitting Pass inlet fitting thru yoke –Keep filter facing up; prevents o-ring from falling out

124. 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

125. Install Yoke Screw Dust cap over threads w/Aqua Lung logo facing out –Remove 1 st stage from vise –Remove vise mount tool Click here move to next step

126. Assemble ACD (DIN)

127. Install O-rings In Shutter Crown Install unlubricated face o-ring

128. Install DIN Screw O-ring

129. Insert Filter Holder Into Handwheel

130. Install DIN Screw Thread DIN screw into filter holder –7/16 or 11mm deep socket –Tighten DIN screw hand-tight

131. Assemble ACD (DIN) Install filter Install unlubricated o-ring into filter holder

132. Install DIN Adapter Hold 1 st stage inlet side down –7/16 or 11mm deep socket –Thread DIN adapter up into body until snug

133. Torque DIN Screw Mount 1 st 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

134. Install Spring & DIN Crown

135. Install DIN To Yoke Converter

136. Insert DIN Shutter Valve

137. 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

138. Remove DIN To Yoke Converter Remove 1 st stage from vise –Remove vise mounting tool

139. Assemble Legend (DIN) Install unlubricated o-ring

140. Install Filter & Unlubricated O-ring

141. Install DIN Adapter Hold 1 st stage inlet side down –Thread DIN adapter up into body until snug by hand

142. Torque DIN Adapter Mount 1 st stage in bench vise –Ft/lb torque wrench –6mm hex key adapter –Torque to 18 ft/lbs (24.5 Nm) Torque: 18 ft/lbs 24.5 Nm

143. Adjusting & Final Assembly

144. Adjusting Medium Pressure (MP) Install MP gauge (p/n 111610) into 1 st stage MP port –If gauge lacks over-pressure relief valve, attach properly adjusted 2 nd stage as relief valve in case of HP leak

145. Adjusting Medium Pressure (MP) Attach Legend to fully charged cylinder 3000 psi (206 bar)

146. 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

147. Adjusting Medium Pressure (MP) With relief valve open on gauge, slowly open cyl. valve & pressurize the 1 st stage

148. 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

149. 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

150. 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

151. 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

152. Install Spacer & Ribbed Washer Spacer flats face upward, align flats w/spring retainer flats

153. Install Piston (Load Transmitter) Dry chamber parts must be installed while under pressure

154. Install Diaphragm Cup side faces down –Diaphragm edge fits into outer groove –Work edges with finger

155. Torque Cap Mount 1 st 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

156. Testing

157. 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

158. Immersion Test With Legend still pressurized –Submerge in bath of water –Look for streaming bubbles; dont mistake trapped air for leaks –Note leak source; refer to troubleshooting table in Technical Maintenance Manual

159. This Concludes Service Of Legend 1 st Stage Rev 07/10/07