SERVICE MANUAL

SECOND STAGE
LX and LEGEND

Copyright ©2005 Aqualung France

Rev. 02/2005
 Index

COPYRIGHT............................................................................................................................... 3
INTRODUCTION........................................................................................................................ 3
WARNINGS, ATTENTION, NOTE...……………........................................................................ 3
MAINTENANCE.......................................................................................................................... 3
GENERAL INSTRUCTIONS.....................……........................................................................... 3
GENERAL CONVENTIONS….................................................................................................... 4
DISASSEMBLY PROCEDURE…................................................................................................4
REASSEMBLY PROCEDURE......…...........................................................................................7
SECOND STAGE ADJUSTMENT................................…............................................................9
FINAL ASSEMBLY.....................................................….................................................….........10
Table 1. Troubleshooting guide................................................…............................…................11
Table 2. List of tools and service kits..........................................………........................…….......12
Table 3. Recommended cleaners and lubricants...............................................................…..... 13
Procedure A. Cleaning and lubricating........................................................................................14
Table 4. Torque settings..........................................................................................………........ 15
Table 5. Checking specifications..............................................................................……............16
Exploded view of Legend second stage......................................................................................17
F I R S T T O D I V E 3

COPYRIGHT GENERAL INSTRUCTIONS

This manual is the property of Aqualung France. Any 1. In order to carry out the procedures described in this
copying, photocopying, reproduction, translation, electronic manual correctly it is important that you follow the steps
distribution (email, Internet...), even partial, and in whatever in the exact order indicated. Read the manual through
format, is expressly forbidden without the written consent of completely so that you become familiar with all the
Aqualung France. procedures, the special tools and the replacement parts,
before starting to disassemble the product. Keep this
©2005 Aqua Lung France. manual open near to you so that you can refer to it step
by step. Do not rely on your memory..

INTRODUCTION 2. All servicing and repair procedures should be carried

out in a workshop that is clean, well lit, easy to access
This manual gives the instructions and the recommendations and specially fitted for the purpose.
for the disassembly, the cleaning, the checking, the
reassembly and the adjustment of an Aqualung regulator. 3. The regulator body should never be directly held in the
This manual is not an instruction manual for unqualified jaws of a vice. To hold the body, screw the tool 006230
personnel. The procedures described in this manual are into the HP port and then grip the tool with the vice.
intended only for qualified personnel who have been trained
in the servicing of Aqualung equipment during a specialised 4. Once the regulator has been disassembled, the re-
course. usable components should be separated from the
If you do not understand certain procedures in this manual components that need to be replaced. Fragile items with
you should contact an Aqualung service consultant before seats or crowns with critical sealing surfaces should be
undertaking any operation. separated and protected during servicing in order to
prevent any damage.

WARNINGS, ATTENTION, NOTES 5. Use only spare parts from Aqualung service kits. Never
replace an Aqualung part with one from another
Certain icons have been used to facilitate the reading and manufacturer, even if it appears similar.
understanding of this manual. They have the following
meanings : 6. Never re-use regulator parts which should be replaced
on the pretext that the regulator has seen little use since
its manufacture or since its last service.
WARNING: Indicates situations that could result in
serious or fatal accidents if the advice given is not 7. When reassembling, check that the torque used
conforms with that shown in Table 4, Torque. Some
followed correctly.
parts can be irretrievably damaged if the acceptable
. . torque is exceeded.

ATTENTION: Indicates a situation or action that

could cause serious damage to the product,
GENERAL CONVENTIONS
making it dangerous if the advice given is not The conventions described below define the actions to be
followed correctly. carried out when an instruction is given.

NOTE : Notes are used to emphasize 1. Unscrew: to unscrew a threaded part, turn it anti-
important points as well as information which clockwise.
needs to be remembered.
2. Screw: to screw a threaded part, turn it clockwise.
MAINTENANCE 3. Remove the O-ring: To remove an O-ring follow the
method below, using the special tool provided for this
Attention: Whatever the number of dives purpose. Any tool that could damage the O-ring should
carried out during a year, the regulator should be avoided. In every case, replace the O-ring removed
receive a complete service each year. If the with a new one.
regulator is used in a chlorinated or
Press simultaneously on the
aggressive environment the service period
two sides of the O-ring in
should be reduced to six months. order to form an ‘eye’. .
Insert the special tool into this
eye to remove the O-ring.
In order to conform with the Aqualung Regulator
Lifetime Guarantee, all servicing (inspection, servicing
and repairs) should be recorded in the Service Record
incorporated in the regulator User Manual.
 from the hose nipple. Take care not to damage the O-
4. The acronyms used: ring groove. Remove the O-ring from the hose threaded
LP: Low Pressure end.
MP: Medium Pressure
HP: High Pressure

5. Numbers in brackets indicate the part number of the

component shown on the exploded view attached.

DISASSEMBLY PROCEDURE
Note: Before commencing disassembly, consult
the exploded view to check the reference
numbers of all parts requiring replacement.
These parts should all be replaced by new parts
and should not be re-used on the pretext that
the regulator has seen little use since its
manufacture or since its last service.

Attention: Use only the special tool when

removing O-rings in order to avoid damaging the
seal recess. The slightest scratch on a sealing
surface could cause a leak. If a surface should be
damaged then this part should be replaced with a
new one. Do not use any pointed instrument or 2.
metal tool to remove O-rings. Slide back the hose
protectors and check that
there are no signs of
impact and that the
crimped ends are in good
condition and that they
firmly grip the hose. If
not, it should be
replaced.
3. Unscrew the outer ring (2). Remove the cover (16).

4. Use tool (129001) to unscrew the diaphragm retainer

(15). Remove the washer (14) and the diaphragm (13).

5. Use a 11/16’’ spanner to undo the nut (5). Remove the

heat exchanger.
1. Use two 11/16’’ spanners to block the nut (5) and to
unscrew the end nut on the hose. Remove the O-ring
F I R S T T O D I V E 5

6. Turn the adjustment handwheel anti-clockwise to the 11. Insert a rod or tool (116236) into the insert (threaded
end. Hold the lever (8) down against the insert (7) and side) and push out the valve seat assembly. Separate
pull on the handwheel to remove the insert assembly the components of the valve seat.
from the casing (1). Remove the O-ring (4).

7. Hold the lever (8) against the insert (7) and remove the
12. Use your fingernail to remove the seat (18) and the
venturi control(6). Remove the plug (25). Remove the
small O-ring (20) of the shuttle valve (12).
venturi control O-ring (24).

8. 13. Unscrew the seat (9) 6 or 7 turns using a screwdriver.

Push the plastic part of tool (116236) into the insert to
The spring pin (11)
push out the seat. Remove the seat O-ring (10).
should come out. If it
remains in the body push
it out using a small rod or
screw in the adjusting
screw one turn using a
4mm Allen key and try
again.

9. Using a 4mm Allen key, unscrew and remove completely

the insert adjusting screw.
Remove the O-ring (22).

14.
10. Remove the O-ring (4) from the insert.
 To remove the bubble
deflector (28), first 1. If the exhaust valve has been removed, pass the valve
immerse the casing in tail through the hole in the casing from the outside and
hot water (50°C).for 2- pull gently until the notch is inside the casing. If it is a
3 minutes. new valve cut off any excess tail leaving about 5mm.
Pull on one end of the
deflector to remove it.

15.
Lift the exhaust valve
(27) and check that its
surface is clean and
free of scratches. It
should be flexible and 2.
its edges should be
Immerse the deflector
clean. If it is in good
in hot water (~50°C) for
condition it is not
2-3 minutes. Fit the
necessary to remove it
deflector (28) over the
and it can be re-used.
moulding on the casing
If there are any signs
and press on the
of deterioration it
domed part to push the
should be replaced.
deflector home.

16. If the regulator is a Legend LX Supreme, remove the lip

shield (36). Remove the mouthpiece collar (29) then the
mouthpiece (17). 3. Fit a new lubricated O-ring (20) into the shuttle valve
throat (12). Insert a new valve seat (18) into the shuttle
valve.

END OF DISASSEMBLY 4. Insert the spring (19) into

the balancing chamber
(21). Carefully guide the
shuttle valve tail into the
spring and insert it into the
Before starting to re-assemble balancing chamber.
the regulator, make sure that all
replacement parts have been
cleaned and lubricated in
accordance with Procedure A : 5.
Cleaning and Lubricating on
If the lever has been
page 13. disassembled, replace it
taking care to put it on the
same side as the indent on
the insert. The insert hole
should be on the right when
the insert is seen thread
uppermost..

RE-ASSEMBLY PROCEDURE
F I R S T T O D I V E 7

6. Insert the assembled shuttle valve, notch downwards, 10. Fit a new lubricated O-ring (24) onto the venturi control
into the insert, holding the lever at right angles to the (6). Position the control handle upwards and push it fully
insert. Push the shuttle valve in until it passes the notch. home into the casing.
To check that it is correctly fitted, turn the insert over,
the shuttle valve should stay inside.

11. While holding the lever down, fit the insert inside the
casing from the venturi control side. Make sure that the
flats on the insert fit into the flats on the casing.
7. Fit a new lubricated O-ring (22) on the adjusting screw.

12. Fit a new lubricated O-ring (4) on the insert and fit it
8. Fit the adjusting screw into the insert. The lever should against the casing. Slide the heat exchanger (3), it’s
now be under tension (due to the spring). Screw the widest part first, onto the insert. Screw on the nut (5)
adjusting handwheel in until the hole that accepts the and tighten it at 0.5 m.kg.
spring pin is exposed. Fit the spring pin (11) into its
position. Gently unscrew the adjusting handwheel until it
applies sufficient tension on the spring pin tp prevent it
from falling out.

Hole exposed

9. Fit a new lubricated O-ring (4) on the insert (7).

13. Fit a new lubricated O-ring (10) onto the adjustable seat
(9). Fit the seat (threaded part first) into the insert and
push it fully home using a screwdriver.
14. With the flat side of the casing at eye level, screw in the Fit the diaphragm (13) in the casing. Press all around
adjusting knob until the lever is about 4mm below the the edges with a finger to ensure that it is in place. Fit
level of the casing edge. Now unscrew it until the lever the washer (14) directly in contact with the diaphragm..
just shows above the edge of the casing.

15. Using a 4mm Allen key tighten the adjusting screw one 19.
Manually screw the
turn for Supreme models and ¾ turn for other models.
diaphragm retainer
(15) fully home, flat
face toward the
diaphragm. Use tool
(129001) to tighten it
an additional ¼ turn.
The spring pins for the
Titan and Legend are
different in shape.

After tightening the diaphragm retainer (15), hold the top

of the diaphragm and gently pull it in all directions to
16. Fit a new lubricated O-ring on the threaded end of the
ensure that it is firmly in place in the housing. If not, refit
hose. Fit a new lubricated O-ring on the hose nipple.
it.

20. Fit the Legend or LX purge button making sure that the
name plate is the right way up. While holding the purge
button screw the ring fully home. Tight slightly the outer
ring with the wrench( P/N 129198)

17.
Lever adjustment: Connect
the tool (122046) to the
second stage and the MP
hose to the tool. Connect
this assembly to a Legend 21. Checking the venturi
first stage adjusted as
follows: 21.1 Place the venturi control in the “ + “ position.
Titan LX, Legend : MP = 9.5b 21.2 Press on the purge button. The regulator should free
Titan LX Suprême, Legend flow.
Supreme : MP = 8.5 b While the regulator is free flowing, move the control to
the “ – “ position. The free flow should stop immediately.
If it does not stop, screw the seta in 1/8 turn and try
Put the regulator under again.
pressure. Slide tool 20.1
(129001) along the top
edge of the casing. In the
highest position the tool
should press on the
lever, causing an airflow.
In the lowest position the
nd
2 stage should not leak
air. Adjust the seat using Put at + and purge Put at – to stop free flow
the tool until the
adjustment is correct.

18. 22. Turn off the air supply and purge the second stage.
Tighten nut (5) using a 11/16” torque wrench at 0.5
F I R S T T O D I V E 9

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 1. Put the regulator under pressure with a 200 bar (±10
paragraph Final Checks bar) supply.

Note: Tests 2,3 and 4 require the use

23. Refit the mouthpiece (17) onto the casing. If it is a of a Regulator Test bench.
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.
2. Opening effort check. Apply an increasing inhalation
flow. When the MP starts to fall, note the effort reading
and compare it with the limits shown on Table 5.
Checking specifications. If the opening effort is
outside the limits then check Table 1. Troubleshooting
Guide.

3. Flow/effort test . Apply an inhalation flow of 400 l/min

and check that the effort does not exceed 15 mbar. If
the effort exceeds this then check Table 1.
Troubleshooting Guide.

24. If the regulator is a Legend Supreme, fit the lip shield 4. Leak test. Connect the first stage to a cylinder charged
(36) over the mouthpiece and against the mouthpiece to 200 bar, open the cylinder valve and immerse the set
strap. in a fresh water bath for one minute. Check that there
are no leaks. If a leak is detected, disassemble the
nd
entire 2 stage; check all sealing surfaces and the
correct positioning of all parts.

END OF REASSEMBLY
 Table 1. Troubleshooting Guide

SYMPTOM POSSIBLE CAUSE TREATMENT

1. Refer to First stage Troubleshooting
1. MP too high
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

Leak or free flow at 2nd stage

4. The lever (8) is bent 4. Replace the lever

5. The sealing face of the seat (9) is

5. Replace the seat
damaged.

6. The spring (19) is damaged 6. Replace the spring

1. Refer to First stage Troubleshooting

1. MP too low
Guide
2. The valve (9) is not correctly adjusted,
2. Readjust the lever and the valve
the lever adjustment is too low
Insufficient purge flow or work of
breathing too high 3. MP hose obstructed 3. Clean or replace the hose

4. Le lever (8) is bent 4. Replace the lever

1. Hole in mouthpiece (17) 1. Replace the mouthpiece

2. Diaphragm (13) damaged 2. Replace the diaphragm

3. Exhalation valve (27) damaged 3. Replace the valve

Water leak 4. The venturi control O-ring (24) is dirty,

4. Replace the O-ring
worn or damaged
5. The diaphragm is not correctly fitted 5. Disassemble the purge button and
between the casing (1) and the washer (14) refit the assembly correctly
6. Check the sealing face of the
6. The casing is damaged.
exhalation valve. Replace the casing

7. The O-ring (4) is damaged. 7. Replace the O-ring

8. The insert O-ring (4) is damaged. 8. Replace the O-ring

F I R S T T O D I V E 11

Table 2. List of Tools and Service Kits

US
REF DESCRIPTION APPLICATION PART
NO.
116222 MP pressure gauge complete 0/16B Checking medium pressure 111610
N/C O-ring tool Fitting and removing O-rings 944022
129001 Spring clip tool Fitting and removing diaphragm clip (15) 129001
116236 Seat fitting tool Seat assembly/disassembly 109436
129198 Ring tool for Legend LX Tighten/loosen gold/silver ring on Legend LX N/a
N/C Seat adjustment tool Adjusting seat under pressure 100190
N/C Torque wrench 0.5 m.kg Plugs N/a
N/C 17mm flat wrench Nut (5) N/a
N/C Medium flat wrench seat N/a
N/C Flat wrench 11/16” (x2) Hose nut N/a
N/C 4mm Allen key MP et HP plugs N/a

129007 Service kit 2nd stage Legend / LX BP Legend, BP LX, BP Legend LX 900012

Tools from service kit 116245 :

 Table 3. Recommended cleaners and lubricants

LUBRICANT / CLEANER APPLICATION SOURCE

Cristo-Lube MCG 111 All O-rings 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 Oakite Products, Inc.
steel parts.

NETALU Acid bath for cleaning brass and stainless Aqualung, ref. 455001
steel parts.

Diluted white vinegar Acid bath for cleaning brass and stainless Household stores
steel parts.

Attention: Do not use hydrochloric acid for cleaning parts. Hydrochloric acid, even when well
diluted, attacks the coating of metal parts and leaves a corrosive deposit that damages plastic
parts and O-rings.

Washing-up liquid (diluted with hot water) Degreases brass and stainless steel parts; Household stores
general cleaning of plastic and rubber
parts.
F I R S T T O D I V E 13

Procedure A
Cleaning and Lubricating
(All Aqualung Regulators)

Cleaning brass and stainless steel parts.

1. Pre-clean by soaking in NETALU diluted to 25%.
2. 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.
3. Rinse in demineralised or fresh water to avoid calcium deposits. Soak for 10 minutes. Dry with filtered low pressure air and
then check that their condition is now suitable for re-use.

Cleaning plastic, rubber and anodised aluminium parts.

For anodised aluminium parts : soak in a « NETALU diluted to 25% ». Rinse in fresh water and dry with low-pressure filtered air.
For plastic parts. (casings, plugs..) : clean in an ultrasonic bath containing a mixture of washing-up liquid and hot water. Use only a
toothbrush with nylon bristles to remove any deposits. Rinse in fresh water and dry with low pressure filtered air

Attention: D not place plastic and rubber parts in contact with acid solutions. This could alter their physical
properties and cause degradation and premature breakdown.

Cleaning parts for Nitrox/O2 use.

1. Metal parts : Pre-clean by soaking in NETALU diluted to 25%.
2. Ultrasonic cleaning in Promoclean TP108 diluted at 5% .
3. Rinse in demineralised water. Soak for 10 min.
4. Dry in the open air in a clean and dust-free atmosphere. Place the parts on a white cloth, allow to dry and check after
drying that the cloth shows no grease deposits and that the condition of the parts is appropriate for re-use with Nitrox/O2.

Cleaning hoses.
If there is significant corrosion then it is permissible to soak only the ends in an ultrasonic bath, avoiding any possibility of the
solution entering the hose. Rinse in fresh water and allow to dry with the connections hanging down. Dry the inside with filtered
compressed air before reconnecting the hose to the regulator.

Wiping.
To wipe parts, use a white filter paper, a pure cotton cloth or any other material that does not produce fluff.

Inspection.
Visually check under a white light (day light or artificial light).
The parts are completely free of any traces of :

1. organic materials (oil, grease, paint, rust…)

2. cleaning agents
3. dust
4. humidity

Lubrication.
When handling O-rings wear unpowdered latex gloves. It is important not to allow contact between the internal components and the
skin or any other source of contamination when the regulator is being prepared for Nitrox use. All seals should be lubricated with
Cristolube MCG111. Cover the seals with a light film of grease and remove any excess by rolling the seal between finger and
thumb. Do not use an excess of grease, this can have the effect of accumulating particles which could damage the O-rings.
 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 3.5 mbar
Octopus LX / Octopus Legend /Legend Supreme and Titan LX
Supreme : between 3.3 et 4.3 mbar

Effort / Flow MP at 9.5 bar ± 0.5 bar: Legend, Titan LX

MP at 8.5 bar ± 0.5 bar: Versions Supreme 15 mbar maxi at 400 L/min
F I R S T T O D I V E 15

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 D I V E 19

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 21

Exploded view of Octopus Legend second stage.

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