Odyssea - Aqua Lung · geNerAL preCAutioNs & WArNiNgs WArNiNg: Before using the Odyssea, you must...

Odysseanon-magnetic

technical manual

Copyright NotiCe

This manual is copyrighted, all rights reserved. It may not, in whole or in part, be copied, photo copied, 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.

©2013 AquA LuNg AmeriCA. odysseA BC teChNiCAL mANuAL, p/N 18342

odysseA BC W/o CyLiNder p/N 394063

you can contact a technical Advisor via e-mail at: [email protected]

trademark noticeAqua Lung®, is a registered trademark of Aqua Lung America, Inc.

Warnings, cautions and notes:Pay special attention to information provided in warnings, cautions, and notes,

that is accompanied by these symbols:

A WArNiNg indicates a procedure or situation that, if not avoided, could result in serious injury or death to the user.

A CAutioN indicates any situation or technique that could cause damage to the product, and could subsequently result in injury to the user.

A note is used to emphasize important points, tips, and reminders.

2 odyssea technical manual

CoNteNts

ChANge reCord .................................................................................... 5iNtroduCtioN ......................................................................................... 6geNerAL preCAutioNs & WArNiNgs ............................................... 8produCt oVerVieW .............................................................................. 9speCiAL FeAtures ................................................................................. 9BC Air Breathing .................................................................................................................. 9

Pocket................................................................................................................................ 10

Drain Plug .......................................................................................................................... 10

AuXiLiAry Air CyLiNder ..................................................................... 10Filling the Auxiliary Cylinder............................................................................................... 10

Attaching the Auxiliary Cylinder ......................................................................................... 12

iNFLAtioN methods ............................................................................. 13Using the Oral Inflator........................................................................................................ 13

Using the Auxiliary Air Cylinder.......................................................................................... 13

deFLAtioN methods ........................................................................... 13Deflation via Oral Inflator ................................................................................................... 13

Deflation via Dual Exhaust Valve ....................................................................................... 14

Deflation via OPRV / Dump Valve ..................................................................................... 14

doNNiNg & AdJustmeNt proCedures .......................................... 15Donning ............................................................................................................................. 15

Adjusting strap length ........................................................................................................ 15

pre-diVe iNspeCtioN ........................................................................... 16post diVe CAre & mAiNteNANCe ..................................................... 20BC BLAdder remoVAL ....................................................................... 22BC BLAdder iNstALLAtioN ................................................................ 23AirWAy NoN-mAg mAiNteNANCe proCedures ............................ 24Airway Non-Mag Disassembly................................................................... 24Oral Inflator Disassembly .......................................................................... 24Dual Valve Disassembly ............................................................................ 25Oral Inflator Assembly ............................................................................... 26Dual Valve Assembly ................................................................................. 28Airway Non-Mag Assembly........................................................................ 29

3

CyLiNder VALVe NoN-mAg mAiNteNANCe proCedures ........... 30Disassembly .............................................................................................. 30Assembly ................................................................................................... 32Cylinder Valve Testing Procedures ............................................................ 33

CyLiNder VALVe CoNNeCtor NoN-mAg mAiNteNANCe proCedures ......................................................................................... 34Disassembly .............................................................................................. 34Assembly ................................................................................................... 34

FiNAL AssemBLy ANd testiNg .......................................................... 34BC pAtCh Kit iNstruCtioNs ............................................................. 36tABLe 1: List oF tooLs ...................................................................... 37tABLe 2: torque speCiFiCAtioNs ................................................... 39tABLe 3: reCommeNded CLeANers ANd LuBriCANts ............... 39proCedure A: CLeANiNg ANd LuBriCAtiNg ................................. 40eXpLoded pArts diAgrAm ................................................................ 41odysseA CompoNeNts ...................................................................... 43oVerhAuL pArts Kits ........................................................................ 44ANNuAL mAiNteNANCe ........................................................................ 45teChNiCAL dAtA ................................................................................... 45ANNuAL serViCe ANd iNspeCtioN reCord .................................. 46mAiNteNANCe Notes ........................................................................... 47WArrANty iNFormAtioN .................................................................... 49


ChANge reCordChange No. date title or description Change made by

5

introduction

This manual provides factory prescribed procedures for the correct service and repair of the Aqua Lung product described in this manual. It is not intended to be used as an instructional manual for untrained personnel. The procedures outlined within this manual are to be performed only by personnel who have received Factory Authorized training through an Aqua Lung Service & Repair Seminar. If you do not completely understand all of the procedures outlined in this manual, contact Aqua Lung to speak directly with a Technical Advisor before proceeding any further.

It is recommended that the Odyssea should be rinsed in fresh water after use, and it should be stripped down and serviced annually.However, if at all unsure about the correct functioning of the Odyssea, then it must be officially inspected immediately.

An Official Inspection consists of:

1. Testing instructions see Pre-Dive Inspection.2. Orally inflate the Odyssea. Check that the over pressure relief valve (OPRV)/rapid exhaust valve (REV) are operating correctly, tightened down properly and no leaks are detected.3. A visual inspection of the Odyssea checking that there is no excess wear to the hook/loop material, stitching points are not excessively coming undone, quick release buckles are in good working order and outer bag zipper is moving freely.4. Auxiliary cylinder is full and no leaks are detected. If the Odyssea fails any of the 4 steps it should be serviced by an Aqua Lung trained service technician.

general guidelines

1. In order to correctly perform the procedures outlined in this manual, it is important to follow each step exactly in the order given. Read over the entire manual to become familiar with all procedures before attempting to disassemble the product in this manual, and to learn which specialty tools and replacement parts will be required. Keep the manual open beside you for reference while performing each procedure. Do not rely on memory.

2. All service and repair should be carried out in a work area specifically set up and equipped for the task. Adequate lighting, cleanliness, and easy access to all required tools are essential for an efficient repair facility.3. As the valve/inflator is disassembled, reusable components should be segregated and not allowed to intermix with nonreusable parts or parts from other units. Delicate parts, including inlet fittings and crowns which contain critical sealing surfaces, must be protected and isolated from other parts to prevent damage during the cleaning procedure.4. Use only genuine Aqua Lung® parts provided in the overhaul parts kit for this product. DO NOT attempt to substitute an Aqua Lung® part with another manufacturer’s, regardless of any similarity in shape or size. 5. 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.6. 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 excessive stress.

general ConventionsUnless otherwise instructed, the following terminology and techniques are assumed:1. When instructed to remove, unscrew, or loosen a threaded part, turn the part counter-clockwise.2. When instructed to install, screw in, or tighten a threaded part, turn the part clockwise.3. When instructed to remove an o-ring, use the pinch method (see illustration below) if possible, or use brass or plastic o-ring removal tool. Avoid using hardened steel picks, as they may damage the o-ring sealing surface. All o-rings that are removed are discarded and replaced with brand new o-rings.

Pinch methodPress upwards on sides of o-ring to create a protrusion. Grab o-ring or insert o-ring tool at protrusion.


CAutioN: use only a plastic (pn 103102) or brass o-ring removal tool (pn 944022) when removing o-rings to prevent damage to the sealing surface. even a small scratch across an o-ring sealing surface could result in leakage. once an o-ring sealing surface has been damaged, the part must be replaced with new. do Not use a dental pick or any other steel instrument.

note: Before performing any disassembly, refer to the exploded parts drawing, which references all mandatory replacement parts. these parts should be replaced with new, and must not be reused under any circumstances, regardless of the age of the regulator or how much use it has received since it was last serviced.

7

4. The following acronyms are used throughout the manual: mp is Medium Pressure; hp is High Pressure; Lp is Low Pressure.5. Numbers in parentheses reference the key numbers on the exploded parts schematics. For example, in the statement, “...remove the o-ring (45) from the valve body ...”, the number 45 is the key number to the o-ring.

geNerAL preCAutioNs & WArNiNgsWArNiNg: Before using the Odyssea, you must have successfully received training and certification in the technique of sCuBA diving from a military or government operated diving school (or any recognized certification agency). Use of this equipment by a person who is not certified by a recognized agency shall render all warranties, express or implied, null and void.

WARNING: Use of SCUBA equipment by uncertified or untrained persons is dangerous and can result in serious injury or death.

WArNiNg: in an emergency such as an out of air situation or uncontrolled rapid descent, it is important to immediately remove and jettison weight immediately.

WArNiNg: in the event of an uncontrolled, rapid ascent, it is important to immediately begin venting air from the odyssea. Continue venting air to slow your ascent rate if neutral buoyancy cannot be reestablished.

WArNiNg: your jacket is not a lift bag. do Not rely on it to bring heavy objects to the surface. doing so may permanently damage the jacket, and could result in serious injury or death.

WArNiNg: NeVer lubricate any part of the jacket with any lubricant. Lubrication of certain parts and assemblies must only be performed by Aqua Lung trained service technician.

WArNiNg: do not apply any type of aerosol spray to the jacket. doing so may damage certain plastic components, including important valve connections.

WArNiNg: repair, service, or disassembly must not be attempted by persons who are not factory trained and authorized by Aqua Lung. unauthorized service will render the warranty null and void.

If you have any questions regarding your Buoyancy Compensator or these instructions, contact

Aqua Lung at (760) 597-5000

Your jacket primarily designed to help you maintain neutral buoyancy while in a comfortably balanced, face-down swimming position underwater. It is also designed to provide you with flotation so that you can rest on the surface, but it is not designed to function as a life preserver or personal flotation device (PFD). In order to meet U.S. Coast Guard regulations, a PFD must be designed so that it automatically rights you to a face-up position and holds your head out of the water on the surface.

The design characteristics of a personal flotation device are different from those of a buoyancy compensator. The ability of any flotation device to float you in a face-up position can also be affected by other diving equipment you wear, including a cylinder, weight or exposure suit, and whether it can be inflated before you lose consciousness.

For this reason, it is important always to dive with a buddy, and maintain close proximity with them at all times. Do not depend on any flotation device to hold your face above the surface in the event that you are rendered unconscious in the water while diving.

WARNING: The Odyssea is NOT a life jacket! It is not designed to provide face-up flotation in all situations; therefore it does not meet U.S. Coast Guard regulations for a life preserver or personal flotation device (PFD). if you become unconscious in the water without a buddy present to immediately give assistance, you may suffer serious injury or death from drowning.


WArNiNg: Although this manual provides some basic guidelines for certain buoyancy control techniques, it is not a substitute for training from a professional diving instructor. Failure to weight yourself properly may create a hazardous condition that could lead to serious injury or death. if you are unsure how to weight yourself in order to achieve optimum buoyancy underwater and on the surface, do not dive until you have obtained the necessary instruction from your diving instructor.

speCiAL FeAturesBC Air BreathingThe oral inflator is equipped with a breathing valve that allows the diver to breathe air from the buoyancy compensator. This device is only to be used in case of emergency. To breathe air from your BC, first slightly exhale through the oral inflator mouthpiece in order to remove the excess of water trapped in the mouthpiece’s body (Fig 1). Then, inhale through the mouthpiece. This will activate the breathing valve and deliver air from the BC bladder. When done inhaling, exhale through the mouthpiece. The breathing valve permits both inhaling and exhaling with out any manipulation.

produCt oVerVieW

This buoyancy jacket is specifically designed for military use with all types of back or chest-worn breathing apparatus, including semi-closed circuit or closed circuit rebreathers.The Odyssea features an air cylinder attachment that allows you to inflate the jacket with compressed breathing air. The air cylinder comes equipped with a standard connection for use on the jacket. The breathable inflator allows you to breathe from the bladder in an emergency situation. The distribution of the buoyancy chambers provides excellent safety performance, either during buoyant ascent (vertical stability) or at the surface (natural support position with head and shoulders out of water). The bladder is constructed of heavy duty urethane and is encosed in a 840 Denier nylon bag that resists cuts, tears and abrasion. Two drains with tethered caps on the bottom side makes draining fast and easy.The jacket has specially designed retainers for an emergency strobe light and a snorkel. In addition, it has a utility pocket located on the left front lobe.The Odyssea is suitable for all types of use. It must be fitted with an inconel cylinder to be completely non-magnetic.

pN 101239

Oral Inflator mouthpiece

Fig. 1

Depending on the depth, the auxiliary cylinder will only provide a few minutes of air, so you must immediately start a controlled ascent to the surface.

CAutioN: the inside of the bladder must be kept dry and clean of all contaminants. if not maintained properly, breathing from the BC in the case of an emergency could cause suffocation or asphyxiation due to contamination.

WARNING: Always keep in mind that breathing air from the BC also deflates the BC and changes your buoyancy. Always be prepared to add air in the BC from the emergency cylinder in order to get extra air to breathe and also extra buoyancy.

9

Filling the Auxiliary CylinderTo fill the cylinder, you will need the optional fill adapter w/ standard connection (Aqua Lung part number 101215).

1. Before attempting to fill the auxiliary cylinder, ensure that the fill adapter and valve are completely dry - especially in the area surrounding the valve outlet. Examine the cylinder markings to verify that it is rated for a fill pressure of 3,000 PSI (206 BAR).

2. Using a calibrated pressure gauge, check the supply cylinder is filled to 3,000 PSI (206 BAR). It is very important to ensure that the auxiliary cylinder is filled to its total capacity, but not overfilled.

pocketThe Odyssea features one large utility pocket located on the left front lobe of the BC, and two retainers on the right side designed to carry an emergency strobe light and a snorkel.

drain plugThe Odyssea is equipped with 2 drain plugs located on the back of each lobe of the BC. The plugs are used to rinse the inside of the bladder (see post dive care and maintenance section).

AuXiLiAry Air CyLiNderThe auxiliary cylinder is attached to the Odyssea by means of a threaded hand fitting (Fig. 2). Air is added to the Odyssea by opening the cylinder valve. Required for closed circuit and semi-closed circuit diving.

p/N 101314

p/N 101275

Fig. 2

WARNING: DO NOT attempt to fill the cylinder if the markings indicate that it is rated for a different fill pressure other than 3,000 PSI (206 BAR). Doing so may result in rupture or explosion in the event of fire or overfilling. Instead, immediately return the unit to a qualified technician and do not use under any circumstances.


4. Loosen the yoke knob. While supporting the auxiliary cylinder in one hand, attach the adapter to a fully pressurized 3,000 PSI (206 BAR) scuba cylinder (Fig. 4).

5. Close the relief plug on the adapter by turning clockwise until finger tight.

6. Open the handwheel on the auxiliary cylinder counter-clockwise until the valve is completely open.

7. VERY SLOWLY open the valve on the scuba cylinder.

Fig. 4

Relief Plug Yoke Knob

NOTE: Always fill the auxiliary cylinder as slowly as possible by turning the handwheel of the supply valve slowly to control the rate of fill. Rapid filling will generate heat and will result in an incomplete fill after the cylinder cools. Make sure not to over-inflate or inflate too rapidly. If the cylinder is warm to the touch afterward, the fill rate was too rapid.

WARNING: DO NOT attempt to fill the auxiliary cylinder from a supply cylinder which contains more than 3,000 psi (206 BAr). doing so may weaken and damage the safety burst plug assembly and/or cylinder.

3. Inspect the o-ring at the end of the fill adapter to make sure it is in good condition. Thread the adapter onto the threaded outlet boss on the cylinder valve until finger tight (Fig. 3).

Fig. 3standard connection

CheckO-ring

11

8. Close the valve of the supply cylinder and then the valve of the auxiliary cylinder. Slowly loosen the relief valve by turning it counter-clockwise to relieve the high pressure air trapped in the adapter.

9. Loosen the yoke knob and remove the adapter from the supply cylinder. Unscrew the adapter from the auxiliary cylinder valve. Place the dust cap back in place and tighten the yoke knob.

Fig. 5

Checko-ring

Fig. 6

Attaching the Auxiliary Cylinder

1. Before attaching the cylinder, inspect the O-ring located at the tip of the connector (Fig. 5).

2. Insert the cylinder into the retaining sleeve and align the threaded valve outlet with the connector. Turn the connector nut clockwise and thread onto the valve outlet until finger tight (Fig. 6).


iNFLAtioN methodsUsing the Oral Inflator

To orally inflate your BC (Fig. 7), place your lips on the oral inflator mouthpiece (A) and exhale a small amount of air into the mouthpiece to purge any water that may still be in the housing. While continuing to exhale into the mouthpiece, depress the oral inflator button (B) to inflate the BC. Immediately after exhaling, release the oral inflator button to prevent air from escaping.

using the Auxiliary Air CylinderTo inflate the BC using the auxiliary air cylinder, open the cylinder valve by turning the handwheel counter-clockwise. Close the cylinder valve when the bladder is adequately filled, otherwise, air will escape from the over pressure relief valves (OPRV).

Fig. 7

AB

NOTE: Depressing the oral inflator while the jacket is empty may cause water to enter the air bladder.

deFLAtioN methodsThroughout the course of a dive, it will be necessary to release air from the Odyssea using one of the three methods described in the following instructions. Each method uses a valve that is in a different location. The method you choose at any time may depend on whether you are making your initial descent feet-first, head-first, or maintaining neutral buoyancy underwater. Always remember to utilize the valve that is at the highest point on the bladder (closest to the surface), depending on your position in the water.

Deflation via Oral InflatorTo deflate the Odyssea using the oral inflator, lift the inflator body to its highest possible position (above the head). Press the oral inflator button (Fig. 7b) to start venting air. This method is most effective on the surface when starting the initial descent.

13

Deflation via Dual Exhaust ValveInside the inflator’s corrugated hose is a nylon cord that attaches the inflator to the dual valve at the top of the airway assembly. You can vent air from the Odyssea by firmly pulling straight down on the inflator. Once resistance is felt, only a pull of .25 in (7mm) is required. This rapid exhaust valve (REV) provides an effective and convenient way to vent air from the BC while in either an upright or facedown swimming position (Fig. 8). It also functions as an over pressure relief valve (OPRV) that will open automatically to relieve air pressure. This feature is very critical for preventing stress or damage to the BC’s bladder (Fig. 9).

Deflation via OPRV / Dump ValveIn addition to the over pressure relief valve (OPRV) that is integrated into the dual valve, the Odyssea has another OPRV/dump valve (Fig. 10) located on the lower right lobe (A), opposite the auxiliary air cylinder attachment. The OPRV’s primary function is to relieve excess air pressure inside the bladder, but it can also be opened manually by pulling on the ball and cord assembly (B) to quickly dump air.

A

B

Fig. 10

WARNING: Most training agencies recommend that you descend in an upright, feet-first position, in order to maintain a slower and more controlled descent. this is especially true if you experience difficulty equilizing your ears or if you are descending in low visibility conditions.

CAutioN: the proper function of the over pressure relief valve is vital to prevent damage to the BC bladder. unauthorized service or tampering may render these valves inoperable, and could cause the bladder to leak or burst. this type of damage is not repairable and is not covered under warranty.

Fig. 9Fig. 8


donning

One end of the crotch strap (1. Fig.11) has a single male quick-release buckle. The other end has two male quick-release buckles. Connect the single male connection to the female buckle located at the top of the Odyssea (A). Secure the excess webbing through the 3-bar slide (e).

Connect the rear lobe retaining strap to 2. one of the connection points on the lower lobe (B). Insert the free end of the lobe retaining strap through the sewn-in loop on the crotch strap (C).

Insert your arm through the straps as if you 3. were putting on a jacket. Reach back and hold the unconnected female buckle with one hand and insert the male buckle with the other hand (D).

Bring the free end of the crotch strap 4. (Fig.12) between your legs and connect it to the two lower female buckles at the front of the Odyssea (Fig. 12A).

Connect the chest strap to the two 5. upper female buckles at the front of the Odyssea just above where the crotch strap is attached (Fig. 12B). Adjust chest strap as needed.

Fig. 11

Fig. 12

Adjusting strap length

1. The length of the straps may be adjusted by holding the strap and moving the 3-bar slide (Fig. 11e) up or down the strap. After adjusting the position of the 3-bar slide, readjust the strap through the quick release buckle.

2. Once the straps are readjusted, don the Odyssea to make sure the adjustments are correct.

doNNiNg & AdJustmeNt proCedures

A

B

C

d

e

A

B

15

pull downon oral Inflator

WARNING: If you can hear any leaks, or if the bladder begins to deflate within 10 minutes, do Not attempt to use the odyssea until it has received service.

pre-diVe iNspeCtioN

1. Orally inflate the Odyssea until the bladder is completely full. Manually operate the OPRV/dump valve by pulling on the attached ball and cord to release air from the Odyssea (Fig. 13). Release the ball and cord, verify the OPRV/dump valve re-seats. Re-inflate the jacket and pull down on the oral inflator assembly to check the function of the REV, only a pull of 7mm (.25 in) is required once resistance is felt (Fig. 14) Use cylinder air if required to activate OPRV.

2. Fully inflate the Odyssea once again and let it sit for 10 minutes to check for leaks and firmness (Fig. 15).

Fig. 13 Fig. 14

Fig. 15

WArNiNg: Before each use, the odyssea must be given a thorough visual inspection and functional test. NeVer dive with an odyssea that shows signs of damage to its bladder or valves until it has received a complete inspection and service from an authorized repair technician.


3. Inspect all quick release buckles (both male and female ends) that are attached at the top, sides and on the crotch strap of the Odyssea for cracks, breakage or general damage. Please refer to the diagram in the donning and adjustment procedures section for specific quick release buckle locations (Figs. 16-18).

4. Check stitching points on the cylinder retaining sleeve, quick release buckles, webbing, crotch & lobe retaining straps. Verify there is no excess wear to any of the sections of webbing on the Odyssey (Figs. 19-21).

Check stitching points

Fig. 16 Fig. 17

Fig. 18

Fig. 19 Fig. 20

Fig. 21

17

6. Verify all hook and loop material is not excessively worn and it is in good working condition (Figs. 24-26).

5. Ensure the outer bag zipper is not damaged, none of the zipper teeth are missing, the zipper moves freely and is closed (Figs. 22 & 23).

Fig. 22 Fig. 23

Fig. 24 Fig. 25

Fig. 26


Fig. 30

8. Ensure that the auxiliary air cylinder has been completely filled to 3,000 PSI (206 BAR) (Fig 31).

7. Check the dual valve connector, caps, dump valve connector and cylinder connector making sure they are sealed and no air is escaping (Figs. 27-30).

Fig. 27 Fig. 28

Fig. 29

Fig. 31

19

post diVe CAre & mAiNteNANCe

With proper care, the Odyssea will provide many years of reliable service. The following preventive maintenance must be performed to extend the life of the Odyssea:

Avoid prolonged exposure to direct sunlight and extreme heat. Nylon fabric can 1. quickly fade when exposed to the sun’s ultraviolet rays, and extreme heat may damage the welded bladder seams.

Avoid repeated or prolonged use in heavily chlorinated water, which can cause 2. the Odyssea fabric to discolor and decay prematurely.

Do not allow the Odyssea to chafe against any sharp objects or rough surfaces3. that could abrade or puncture the bladder. Do not set or drop heavy objects such as block weights on the Odyssea.

Avoid any contact with oil, gasoline, aerosols, or chemical solvents.4.

After diving, give the Odyssea a thorough fresh water rinse. Unzip the outer 5. shell and check for water inside the urethane air bladder. If there is any water inside the bladder, it must be rinsed out with fresh water using the following procedure:

Fig. 32

Fig. 33 Fig. 34

a) Unscrew one of the drain caps (Fig. 32).

b) Using a garden hose, fill the bladder until about a 1/4 full and reinstall the drain cap. Thoroughly shake the bladder so the water rinses the entire inside of the bladder. Unscrew both drain caps and let all the water drain from the bladder. Leave the drain caps off until the inside of the bladder is dry (Fig. 33 & 34).


d) When components are completely dry, reinstall the drain caps, OPRV, cylinder connector and oral airway assembly. Orally inflate the Odyssea until it is partially inflated. Store the Odyssea partially inflated, away from direct sunlight, in a clean, dry area. Do not store in an enclosed space, such as a car trunk, where temperatures may fall below -18ºC (0ºF) or rise above 49ºC (120ºF).

c) Remove the airway assembly from the Odyssea by unscrewing the collar at the base of the connector. Rinse the airway thoroughly with fresh water inside and out. Hang the airway by the oral inflator end to allow for complete drainage and drying.

21

B.C. Bladder removal

1. Unscrew the connector nut on the cylinder valve connector (48) and remove the cylinder (52) from the BC. After the cylinder has been removed, loosen the cylinder valve connector and remove from the bladder connection.

2. Use a brass (944022) or plastic (101302) o-ring tool to remove the gasket (1) from the connector. The gasket can be reused if in good condition. Remove all straps with quick release buckles (53 & 54), both caps (55), dump valve (56) and airway (51).

3. Unzip external zipper, push bladder connectors into the outer bag (50). Carefully remove the bladder (49), making sure the connectors do not get caught on the outer bag.


BC Bladder installation

1. Insert the bladder (49) back into the outer bag (50) so that the connectors line up with the connector holes.

2. Inspect gasket(s) (1) for damage, this component may be reused if no damage is noticed. Use a shop towel to clean the gasket and any residue out of the connector groove as necessary. Place gasket(s) back into the connectors. Install caps (55), dump valve (56), and airway (51) back onto the corresponding connectors. Put strap assemblies (53 & 54) back into place.

3. Ensure the gasket (1) has been placed back into the connector in which the cylinder valve connector will be attached. Attach the cylinder valve connector (48) and turn clockwise until hand tight. Insert the auxiliary cylinder into the retaining sleeve and tighten the connector nut onto the cylinder valve adapter (44).

4. Turn the cylinder valve clockwise to the on position and inflate the bladder until the over pressure relief valve (OPRV) releases the excess air from the bladder. Turn off cylinder and remove the cylinder from the BC. Check both caps (55), dump valve (56), airway (51) and cylinder valve connector (48) for any signs of leakage. If no leakage is detected, let bladder stand inflated for one hour. Check the firmness of the bladder after one hour has passed. If the bladder has remained firm, no air loss has occurred. If the bladder has lost air, recheck all connections, inflate BC, submerge and check for leaks.

23

Airway (Non mag) disassembly

1. Turn the retaining collar and remove the dual valve assembly from the connector. Use a brass (944022) or plastic (101302) o-ring tool to remove the gasket (1) from the connector. The gasket can be reused if in good condition.

2. Using diagonal pliers (pn 9-45171), carefully remove the three clamps (11) from the spiral hose (13) securing the inflator and dual valve assemblies.

Airway Non-mag maintenance procedures

Oral Inflator

disassembly

2. Using a straight blade screwdriver, carefully lift out the fingers of the cage (27) and remove it from lower inflator housing (20).

note: Before performing any disassembly, refer to the exploded parts drawing which references all mandatory replacement parts. these parts should be replaced with new and must not be reused under any circumstances regardless of age or how much use it has received since it was last serviced.


CAutioN: do not cut the spiral hose while removing the clamp.

CAutioN: do not apply excessive force or pry against the housing/cage with the tip of the screwdriver.

3. Pull back the hose (13) from the mouthpiece body (18). Press the pin (17) out from one side using a pin punch or similar tool to release the braided nylon cord (12). Remove the hose (13) from the dual valve assembly, set the dual valve assembly to the side.

1. Using the spanner wrench (pn 129198) to hold the push button (26), remove the locknut (14) from the stem (22) with a 5.5mm nut driver. Use needle nose pliers to remove the washer (15) and the rubber valve (16). Discard nut (14) and rubber valve (15).


This Concludes Disassembly of the Oral InflatorBefore starting assembly, perform parts cleaning and lubrication in accordance with Procedure a: cleaning and Lubricating in the back of the manual.

dual Valve

disassembly

note: the outer cap is bonded to the body of the dual valve assembly with a non-permanent adhesive. It will be necessary to separate this bond prior to performing further disassembly by carefully following the procedure outlined below.

CAutioN: do not apply excessive force or use a hammer, mallet or other heavy instrument.

note: If the cap cannot be turned, repeat step 1 to break the adhesive bond.

seam

3. Remove the stem assembly and spring (21) through the front of the lower inflator housing (20). Remove the mouthpiece (19) from the mouthpiece body (18).

4. Using the spanner wrench (pn 129198), turn the push button (26) counter-clockwise to loosen. It may be necessary to secure the stem (22) in a vise or a pair of soft jawed pliers to loosen the push button (26) as a small amount of Loctite 425 or 480 is used to secure the button. Ensure the stem is protected from damage.

5. Remove the push button (26), washer (25) and the inflator diaphragm (24) from the stem (22). Next, remove the plastic valve (23) from the stem. It may be necessary to secure the stem in a vise or a pair of soft jawed pliers to remove the plastic valve as a small amount of Loctite 425 or 480 is used on the threads of the stem (22). Once removed, discard the push button (26), washer (25), inflator diaphragm (24) and plastic valve (23).

6. Clean any residual Loctite from the large threads of the stem (22).

1. Locate the seam that runs along the circumference between the dual valve body (2) and the outer cap (6), where the cap is fastened to the body. Using the plastic handle of a medium size screwdriver, or similar lightweight blunt instrument, rap sharply against all points of the seam on the cap to break the adhesive bond.

2. While holding the dual valve assembly secure, firmly grasp the outer cap (6) and turn it counter-clockwise to loosen. While main-taining slight inward pressure to counteract the spring pressure inside, continue turning the cap (6) until it has disengaged from the dual valve body (2). Remove the cap and the spring (5) beneath it. Closely examine the cap to check for any signs of thread damage, distortion, cracking, or chemical attack that may indicate the use of excessive force or incorrect adhesive during previous service.

25

this Concludes disassembly of the dual ValveBefore starting assembly, perform parts cleaning and lubrication in accordance with Procedure a: cleaning and Lubricating in the back of the manual.

Loctite 425 or 480

Oral Inflator

Assembly

note: Before performing any assembly, it is important to inspect all parts, both new and those that are being reused, to ensure that every part and component is per-fectly clean and free of any dust, corrosion or blemishes. Before dressing each o-ring with Christo-Lube®, check to ensure it is clean, supple and free of any blemish.

WArNiNg: use only genuine Aqua Lung® parts, sub-assemblies and components whenever assembling any Aqua Lung® product. do Not attempt to substitute an Aqua Lung® part with another manufacturer’s, regardless of any similarity in shape, size or appearance. doing so may render the product unsafe and could result in serious injury or death.

3. Remove the valve plate (4) with gasket (3) from the body (2) and remove the gasket from the valve plate. Discard the gasket and set the valve plate aside.

4. Locate the two holes on opposite sides of the barrel of the dual valve body (2) which hold the arms of the poppet guide (10). To remove the poppet guide and exhaust valve assembly from the dual valve body, press the arms of the poppet guide inward by simultaneously inserting two small probes through the opposing holes in the barrel.

5. When the arms of the poppet guide have disengaged from the body, firmly grasp the braided nylon cord (12) and pull the exhaust valve assembly straight out while holding the body secure. This will pull the poppet stem (8) out of the dump valve poppet (7). Remove the dump valve poppet and discard.

6. Remove the braided nylon cord (12) from the poppet stem (8). Pull the poppet stem and spring (9) straight out of the poppet guide (10).

1. Place the large end of the spring (21) into the lower inflator housing (20). Ensure the spring is oriented properly.

2. Place one drop of Loctite 425 or 480 onto the base of the large diameter threads of the stem (22). Screw the plastic valve (23) onto the large diameter threads of the stem until seated hand tight. The taper of the plastic valve must face towards the center of the stem.

note: only replace nylon cord if damage is found.


Loctite 425 or 480

CAutioN: do not use excessive force while installing the cage. doing so could cause damage to the case or lower housing.

This Concludes Assembly of the Oral Inflator. please refer to Final assembly and testing in the back of the manual.

3. Install the diaphragm (24) over the large threaded end of the stem (22) until it rests against the face of the plastic valve (23). Place the washer (25) on top of the diaphragm (24) followed by one drop of Loctite 425 or 480 onto the tip of the stem (large threads) and screw the button (26) onto the stem until it bottoms out against the washer.

4. Pass the stem assembly into the body, through the center of the spring (21). Ensure the stem assembly is centred properly.

5. Set the cage (27) with the fingers facing out over the push button (26) of the assembly. Place the entire lower inflator assembly face down on a clean surface against the cage. Secure the cage to the lower inflator assembly by using an arbor press or gently striking with a rubber mallet. Check the assembly to ensure all of the fingers of the cage are engaged in the internal groove of the lower inflator housing assembly.

6. Using needle nose pliers, place the rubber valve (16) flat end up over the small diameter threads of the stem (22). Install the washer (15) onto the small diameter thread end of the stem so that the washer is seated on top of the rubber valve. Place the locknut (14) into a 5.5mm nut driver and engage the locknut onto the stem assembly by turning clockwise.

7. Insert the pin spanner (pn 129198) into the holes on the button (26). Using the 5.5mm nut driver, turn the locknut (14) clockwise until approximately 1/4 inch of the threads of the stem (22) are exposed opposite the locknut.

8. Install mouthpiece (19) onto the mouthpiece body (18) with the curved end facing out until the lower inflator housing seats into the mouthpiece groove.

27

Distance between posts 30.5 cm (12 inches)

dual ValveAssembly

2. Insert the poppet stem (8) through the flat end of the poppet guide (10).

(3) Half HitchesOverhand Bow Knot

Large rib

CAUTION: Do not damage the knots with the flame.

1. Dip the dump valve poppet (7) into soapy water and press securely onto the barbed tip of the poppet stem (8). Slide the spring (9) onto the stem.

b. Compress the poppet assembly with the forked end out onto the poppet holding fixture. Using the inflator cord fixture, install the braided nylon cord (12) through the hole in the poppet stem (8) and round the inflator cord post 2 times (Two loops around post and two passes through the stem).

(Fixtures can be locally manufactured).

5. Position the poppet guide assembly so that the larger rib faces toward the open side of the dual valve body (2), away from the manifold. Lubricate the dump valve poppet with a small amount of soapy water, and align the arms of the poppet guide with the grooves inside the barrel of the body. Insert the assembly into the barrel only until the ears of the poppet guide rest above the rim.

a. Place the poppet assembly on a flat (clean) surface with the forked end up. Press down on the poppet guide (10) enough to pass the braided nylon cord (12) through the hole in the poppet stem (8) two times.

3. The nylon cord (12) may be assembled to the poppet stem (8) in one of two ways depending on the equipment available at the time of service.

note: Braided nylon cord needs to be 56 inches in length and 3/64 inches in diameter.

4. Tie a 1 inch (2.5 cm) loop on one end of the cord using a “Over-hand Bow Knot”. Secure the cord by going through the open loop with the opposite cord end and tying three (3) “Half Hitches”. Trim the excess cord to 1/4 inch (0.63 cm) at both knots and seal the cord ends using a propane lighter

note: If the nylon cord (12) was not replaced during service, skip to step 5 in this section.


Align here

gasgacinch here

this Concludes Assembly of the dual Valve. please refer to Final assembly and testing in the back of the manual.

Airway (Non mag) Assembly

6. Squeeze the arms of the poppet guide (10) so that the ears fit inside the barrel, and press the poppet guide completely inward until the ears snap into place inside their respective holes. Check to ensure that the dump valve poppet (7) has passed through the top of the barrel and remains properly seated over the end of the poppet guide (10) inside the dual valve body (2).

7. Install the gasket (3) onto the valve plate (4), and set the valve plate inside the dual valve body (2) with the gasket facing down.

8. Place the over pressure spring (5) directly in the center of the valve plate (4), standing up.

9. Carefully apply only one very small drop of Loctite brand 425 or 480 grade thread adhesive to the center thread of the outer cap (6). Position the cap directly over the spring and valve plate, and press down while turning clockwise to engage with the threads of the body. Continue turning clockwise by hand until snug.

1. Place the spiral hose (13) over the cord hook and com-press it to expose the hook. Use the cord hook to pull the braided nylon cord (12) through the spiral hose (small end of the hose).

2. Apply a small amount of Gasgacinch to the diameter of the dual valve body (2), allow 15 seconds to get tacky. Slide the spiral hose (13) onto the dual valve body.

3. Lightly fasten a clamp (11) over the spiral hose (13) so that it is evenly seated near the end. Position the end of the clamp to either side and pull the end of the clamp sufficiently snug. Trim the excess length with a pair of diagonal pliers (pn 9-45717).

10. Ensure the inside line of the bottom vent slot lines up with the center line of the dual valve body hose barb.

29

Clamp 1

Clamp 2

this Concludes Assembly of the Airway.please refer to Final assembly and testing in the back of the manual.

4. Insert retaining pin (17) half way into one hole of the body mouthpiece (18). Capture both loop ends of the braided nylon cord (12) using your thumb and index finger facing up, slide the hose (13) back for clearance. Rotate your wrist pointing your thumb and index finger down to form a “Larks Head Knot” on both loop ends. Capture the knot onto the pin (17) of the body mouthpiece.

5. Press the pin (17) by hand until it engages equally into both holes of the body mouthpiece (18). Apply a small amount of Gasgacinch to the diameter of the body mouthpiece hose barb. Allow 15 seconds for the adhesive to get tacky and slide the hose onto the body mouthpiece, with the mouthpiece facing to the right hand side of the user as worn.

6. Secure each of the two clamps (11) to the spiral hose (13). The outside clamp head faces in line with the mouthpiece. Clamp edge distance to the end of the hose is 1/8 inch (3.18mm). The other clamp faces the opposite direction over the pin (17).

Cylinder Valve (Non-mag) maintenance procedures

Cylinder Valve

note: Before performing any disassembly, refer to the exploded parts drawing, which references all mandatory replacement parts. these parts should be replaced with new, and must not be reused under any circumstances regardless of the age or how much use it has received since it was last serviced.


1. Open cylinder valve counter-clockwise and ensure cylinder (46) is fully depressurized. Place cylinder in cylinder vice jaws (pn 100398), secure in cylinder vise (pn 100397) and remove the cylinder valve from the cylinder by turning valve body (41) counter-clockwise with a 1-1/16 inch (27mm) crowfoot and flex wrench (pn 9-44363). When done, remove cylinder from cylinder vise.

2. Remove the o-ring (45) from the valve body (41). Use the appropriate o-ring tool (pn 944022). Discard o-ring.

disassembly


3. Use a large flat blade screwdriver to remove the handwheel nut (30), handwheel (31) and the handwheel washer (32) from the spindle (39).

5. Using the brass o-ring tool, remove o-ring (43) from the valve seat adapter (44). Discard o-ring. Remove the old blue Loctite from the valve seat adapter and valve body (41).

CAutioN: do not damage the internal surface of the valve seat adapter.

CAutioN: Loctite 242 is used to hold this part in place in addition to the torque applied during assembly.

4. Holding the valve body assembly in a vise, unscrew the valve seat adapter (44) from the valve body (41) using a flex wrench (pn 9-44363) with 5-mm hex key adapter (pn 8367A23).

8. Unscrew the valve seat (40) from the valve body (41) using the spindle (39). Discard valve seat.

7. Remove the spindle (39) from valve body (41). Remove back-up ring (35), o-ring (36), metal washer (37) and plastic washer (38) from the spindle (39).

6. Holding the valve body assembly in a vise, use a 22mm socket and flex wrench (pn 9-44363) to remove the valve plug (33) from the valve body (41). Remove the o-ring (34) from the valve plug using the appropriate o-ring tool (pn 944022). Discard o-ring.

note: If the valve seat adapter does not loosen, use a heat gun to heat up the body and adapter to loosen the adhesive.

31

9. Remove the safety plug (42a) from the port of the valve body (41) using a flex wrench (pn 9-44363) and 1/2” socket (pn 944333). Discard safety plug. Remove the safety disc, red (42b) and gasket (42c) from the port in the valve body. Discard safety disk and gasket.

this CoNCLudes disAssemBLy oF the CyLiNder VALVeBefore beginning reassembly, perform parts cleaning and lubrication in accordance with Procedure a: cleaning and Lubricating in the back of the manual.

Cylinder Valve (Non-mag) maintenance procedures

note: Before performing any reassembly, it is important to inspect all parts, both new and those that are being reused, to ensure that every part and component is perfectly clean and free of any dust, corrosion, or blemishes. Before dressing each o-ring with Christo-Lube®, check to ensure it is clean, supple, and free of any blemish.

WArNiNg: use only genuine Aqua Lung® parts, sub-assemblies, and components whenever assembling any Aqua Lung® product. do Not attempt to substitute an Aqua Lung® part with another manufacturer’s, regardless of any similarity in shape, size or appearance. doing so may render the product unsafe, and could result in serious injury or death.

1. Holding the valve body (41) in a vise, install the burst disk assembly in the following order: gasket (42c), safety disc (42b) and safety plug (42a). Torque the safety plug to 90 in/lbs (10.2 Nm) using a 1/2 inch socket (pn 944333) and inch pound torque wrench.

note: the Burst Plug Assembly Pn 487590 (42) comes as a complete kit, it is to be installed together and cannot be ordered as separate parts.

note: Install safety disc (42b) with the red side of the disc facing out of the port on the valve body.

note: Do not Lubricate the threads of the safety plug (42a).

2. Lubricate threads of valve seat (40) and screw into the valve body (41) using the spindle (39) until it bottoms against the crown.

Cylinder ValveAssembly


Loctite 242

6. Install washer (32) and handwheel (31) onto spindle (50).

7. Secure the handwheel (31) to the spindle (39) by placing the handwheel nut (30) onto the spindle and tighten it down with a large flat blade screwdriver until it stops.

CAutioN: Avoid cross threading the handwheel nut. if resistance is felt while screwing the handwheel nut onto the spindle, stop and start over.

8. Lubricate the o-ring (43) and install on the valve seat adapter (44). Apply one drop of Loctite 242 to the small threads of the valve seat adapter. Secure the valve body assembly in a vise, using a 5mm hex key adapter (pn 8367A23) and inch pound torque wrench tighten the valve seat adapter to 90 in/lbs (10.2 Nm).

3. Place parts in the following order onto the spindle (39). Lubricated plastic washer (38), metal washer (37), o-ring (36) and backup ring (35).

4. Insert the spindle assembly into the valve body (41) ensuring the spindle (39) aligns with the slot in the valve seat (40).

Alignspindle w/ slot

5. Lubricate the o-ring (34) and install it onto the valve plug (33). Ensure it is in the groove on the plug below the shoulder. Screw the valve plug (33) back into the valve body (41) until hand tight. Using a inch pound torque wrench and a 22mm socket, tighten the valve plug to 90 in/lbs (10.2 Nm). Ensure the o-ring is seated back inside the valve body.

9. Install a new lubricated o-ring (45) onto valve body (41). Lightly lubricate the threads of the valve body. Place cylinder in cylinder vice jaws (pn 100398), secure in cylinder vise (pn 100397) and screw the cylinder valve into the cylinder by turning valve body clockwise until hand tight. Using a 1-1/16 inch (27mm) crowfoot and foot pound torque wrench, tighten the valve assembly into the cylinder to 25 ft/lbs (34 Nm).

this Concludes Assembly of the Cylinder Valve

1. Fill cylinder to 500 PSI (34 BAR) and listen for audible leaks. Submerge in a fresh water supply and visually inspect valve for any leaks that may be present. If no leaks are detected, fill cylinder to 3,000 PSI (206 BAR), again listen for audible leaks and submerge in fresh water. If any leaks are detected, disassemble valve, replace worn parts, rebuild and retest.

Cylinder Valve testing procedures

33

2. Lay the gasket (1) flat inside the connector and mate the retaining collar of the cylinder valve connector (48) directly over it onto the manifold. Gently turn the collar clockwise to engage the threads, being careful to avoid cross threading and hold the cylinder valve connector in the desired position while tightening the retaining collar by hand until snug.

note: ensure the dual valve body (2) sealing surface is properly aligned with the connector on the BC. this is essential to achieve a proper seal.

Final Assembly and testing

1. Inspect gasket (1) for damage, this component may be reused if no damage is noticed. Use a shop towel to clean the gasket and any residue out of the connector groove as necessary. Lay the gasket flat inside the connector and mate the retaining collar of the dual valve body (2) directly over it, onto the manifold. Gently turn the collar clockwise to engage the threads, being careful to avoid cross threading, and hold the airway in the desired position while tightening the retaining collar by hand until snug.

WArNiNg: protective eyewear must be worn at all times during testing.

CAutioN: do not use tool to tighten the retaining collar onto the BC connector. doing so may result in over tightening and /or cross threading and could cause permanent damage that will require replacement of the BC bladder.

Cylinder Valve Connector (Non-mag)maintenance procedures

disassembly 1. Use a brass (944022) or plastic (101302) o-ring tool to remove the o-ring (47) from the end of the cylinder valve connector (48). Discard o-ring.

2. Use a shop towel to clean any residue out of the o-ring groove on the end of the cylinder valve connector as necessary.

Assembly 1. Place a new o-ring (47) into the groove on the end of the cylinder valve connector.

Cylinder Valve Connector

Cylinder Valve Connector


3. While holding the dual valve assembly secure, firmly grasp the inflator assembly and pull it in a straight line directly away from the dual valve assembly. Check the attachment points of the spiral hose (13) at both the dual valve assembly and the inflator assembly. If any signs of damage or decay can be detected to the spiral hose, it is important to replace the spiral hose before proceeding any further.

5. Finally, bend the spiral hose at a right angle. If the spiral hose shows any sign of separating from the inflator assembly it is im-portant to replace the clamp.

4. Immerse the inflator and surrounding area of the spiral tube in fresh water to wet the lower portion of the airway assembly. Grasp the spiral tube approximately six inches above the inflator assembly and pull the tube in a straight line away from the inflator with moderate force while holding the inflator secure. Check to ensure that no separation occurs at the attachment point, and the tube remains seated flush against the base of the inflator housing.

note: ensure the cylinder valve connector, oral airway assembly, caps and OPRV/dump valve are secured to the BC prior to submerging. Failure to do so will cause water to enter the internal bladder.

6. Manually inflate the BC until it is taut and fully inflated. Press the deflation button (26) and then pull down on the oral inflator to ensure a rapid and unobstructed exhaust using both methods of deflation. Fully inflate the BC once again, and listen closely for any signs of leakage.

Push to Deflate

Pull Down On Oral Inflator To Deflate

this Concludes Final Assembly and testing procedures

7. Connect the cylinder to the cylinder valve connector. Turn the cylinder valve clockwise to the on position and inflate the bladder until the over pressure relief valve (OPRV) releases the excess air from the bladder. Turn off cylinder and remove the cylinder from the BC. Check caps (55), airway (51), OPRV/Dump valve (56) and cylinder valve connector (48) for any signs of leakage. If no leak-age is detected, let bladder stand inflated for one hour. Check the firmness of the bladder after one hour has passed. If the bladder has remained firm, no air loss has occurred. If the bladder has lost air, recheck all connections, inflate BC, submerge and check for leaks. If a continuous leak is detected, the component must be disassembled and examined for damage or contamination of the seals and seating surfaces.

CAutioN: if the odyssea is being used for Non-mag applications, it must be tested on with a magnetometer iAW with stANAg requirements 2897 eod.

note: If leakage is not immediately detected, allow the BC to stand for at least one hour to ensure that none exists.

pull hose down

35

B.C. patch Kit instructions

1. Inspect the material of the BC surrounding the hole or tear to ensure that it is perfectly clean and dry. Rinse and dry the BC to clean if necessary.

B.C. patch Kit

WArNiNg: Adhesive should only be applied in a room with plenty of cross ventilation. Carefully read all cautions on the label of the adhesive, and avoid inhaling vapors.

WArNiNg: do not attempt to patch a tear or puncture which is located directly over an internal baffle, within 2 inches (50mm) of a seam or is larger than 1/2 inch (13mm) in diameter or length.

4. After twenty four (24) hours have elapsed, apply a generous second coat of adhesive to the material of the BC surrounding the hole or tear, and to the glossy surface only of the patch. Wait exactly twenty (20) minutes.

Glossy Side Non-Glossy Side

2. Check to ensure that the patch extends at least twice the diameter or length of the hole or tear on all sides.

3. Apply a generous coat of Weld-On 4784® adhesive to the material of the BC surrounding the hole or tear. Allow this preliminary coat to set for at least 24 hours.

CAutioN: it is important to prevent any adhesion between the internal surfaces of the bladder caused by the entrance of adhesive through the hole or tear. position the bladder as needed to maintain a separation of the bladder at the point of the hole or tear.

5. After twenty (20) minutes have elapsed, apply a third coat of adhesive to the BC material, a second coat to the parch. Wait ten (10) minutes for this coat to grow tacky, and immediately apply the patch over the hole or tear, using a small roller to press out any pockets of air that may be present between the patch and BC material. Position a 5 pound (2.27 kg) weight directly over the patch to apply pressure, and allow exactly one (1) hour for the patch to set.

6. Partially inflate the BC no more than 1/2 full, causing the inner surface of the bladder to separate if adhesion has occurred. Apply a final coat of adhesive over the entire patch area. Allow twenty four (24) hours to completely cure, an then fully inflate the BC to ensure that leakage is no longer present. If the BC does not remain completely full for at least one (1) hour, immerse it in fresh water to determine the source of leakage and repair as needed.

note: Do not allow the patch to set more than 1 hour before performing the next step.

this Concludes B.C. patch Kit instructions

WArNiNg: do not attempt to perform these procedures using patches or adhesive other than those provided in the BC patch Kit pn 42611.

note: ensure Weld-on 4784© adhesive is not more than 3 years old.

expiration date


PART # DESCRIPTION APPLICATION

129198 Adjustable Face Spanner

Removal/Installation of Oral Inflator Push Button (26)

101215 Tank Fill Adapter

Charging Cylinder

944022

103102

O-ring Tool Kit(Brass)O-Ring Tool (Plastic, 5 pk)

Removal/Installation of O-rings

820466 (2 oz.)

820467(16 oz.)

Christo-Lube MCG 111

Lubrication of O-rings/Parts

9-44363 Flex Handle Drive 3/8”

Removal/Installation of Valve Parts

100398 Vise Jaw Inserts for Cylinder( For Existing Shop Vise)

Removal/Installation of Cylinder Valve

9-45171 Diagonal Pliers(small)

Removal/Installation of Clamp (11 & 29)

941586 Modified Screwdriver(short)

Removal/Installation of Handwheel Nut (30)

8367A23 5mm Hex Key Adapter Removal/Installation of Adapter Valve Seat (44)

769354

9-44333

7/8 in Socket(22mm)

1/2 in Socket (13 mm)

Removal/Installation of Plug Valve (33)

Removal/Installation of Burst Plug (42)

FC34A 1-1/16 inch (27mm) Crowfoot Removal/Installation of Valve Body (41)

tABLe 1: List oF tooLs

37

tABLe 1: List oF tooLs (CoNtiNued)PART # DESCRIPTION APPLICATION

N/A Cord Hook(Locally Manufactured)

Installing Braided Nylon Cord (12) through Spiral Hose (13)

N/A Poppet Fixture(Locally Manufactured)

Removal/Installation of Braided Nylon Cord (12)

N/A Cord Fixture(Locally Manufactured)

Knot Tying Fixture for Braided Nylon Cord (12)

N/A 5.5mm Nut Driver Removal/Installation of Oral Inflator Locknut (14)

N/A Small Punch Removal/Installation of Poppet Guide (10) and Oral Inflator Pin (17)

N/A Pliers Removal/Installation of Oral Inflator Stem (22)

N/A 3/8 Drive Torque Wrench; 0-132 in.lbs (0-15 Nm)Range

Torquing of Parts

N/A 3/8 Drive Torque Wrench; 0-81 ft.lbs (0-110 Nm)Range

Torquing of Parts

N/A Screw Driver Removal/ Installation of Dual Valve Cap (6)

N/A Needle Nose Pliers

Removal/Installation of Inflator parts


tABLe 2: torque speCiFiCAtioNs

pArt # desCriptioN / Key item # torque101167 Plug, valve (33) 90 in.lbs (10.2 Nm)

101305 Body, valve (41) 25 ft.lbs (34 Nm)

101306 Adapter, valve seat (44) 90 in.lbs (10.2 Nm)

487950 Burst Plug assembly, non-mag (42) 90 in.lbs (10.2 Nm)

tABLe 3: reCommeNded CLeANers ANd LuBriCANts

LuBriCANt/CLeANer AppLiCAtioN sourCe

Christo-Lube mCg 111All o-rings

Aqua Lung, PN 820466, orLubrication Technologies 310 Morton Street Jackson, OH 45640 (800) 477-8704

oakite #31 Acid bath for reusable stainless steel and brass parts.

Oakite Products, Inc. 50 Valley Road Berkeley Heights, NJ 07922

White distilled vinegar Acid bath for reusable stainless steel and brass parts. “Household” grade

Non-ionic Liquid dishwashing detergent (diluted with warm water)

Degreaser for brass and stainless steel parts; general cleaning solution for plastic and rubber.

“Household” grade

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.

CAutioN: do not use muriatic acid for the cleaning of any parts. even if strongly diluted, muriatic acid can harm chrome plating and may leave a residue that is harmful to o-ring seals and other parts.

39

Cleaning Brass and stainless steel parts1. 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, household white distilled vinegar (acetic acid) in an ultrasonic cleaner will work well. DO NOT place plastic, rubber or silicone parts in vinegar.3. Remove parts from the ultrasonic cleaner and rinse with fresh water. If tap water is extremely “hard,” place the parts in a bath of distilled water to prevent any mineral residue. Agitate lightly, and allow to soak for 5-10 minutes. Remove and blow dry with low pressure 25 PSI (1.7 BAR) filtered air. Inspect closely to ensure proper cleaning and like-new condition.

Cleaning plastic & rubber partsParts made of plastic or rubber may be soaked and cleaned in a solution of warm water mixed with mild dish soap. Use only a soft nylon toothbrush to scrub away any deposits. Rinse in fresh water and thoroughly blow dry, using low pressure filtered air.

Cleaning hoses1. Hose fittings: Ultrasonically clean with soapy water*, vinegar is OK on tough corrosion (only hose ends).2. Run soapy water through hose if needed.3. Thoroughly rinse with fresh water (hang with hose ends down).4. Blow out hose before installing.

Lubrication and dressingAll o-rings should be lubricated with Christo-Lube® MCG 111. Dress the o-rings with a very light film of grease, and remove any visible excess by running the o-ring between thumb and forefinger. Avoid applying excessive amounts of Christo-Lube grease, as this will attract particulate matter that may cause damage to the o-ring.

*Soapy water is defined as “household” grade liquid dishwashing detergent diluted in warm water.

proCedure A: CLeANiNg ANd LuBriCAtiNg

CAutioN: do not place plastic and rubber parts in acid solutions. doing so may alter the physical properties of the component, causing it to prematurely degrade and/or break.


Loctite 425 or 480

11

11

2928

13

12

10

9

8

7

65

2

34

eXpLoded pArts diAgrAms1

101239 Airway Complete Non mag

Key # pN *Pn description qty1 15309 n/A Gasket, Connector Seal 42 42742 n/A Dual Valve Body Assembly ACME 13 15714 n/A Gasket, REOP 14 15698 n/A Plate, Valve 15 15643 n/A Spring, Over Pressure, Non-Mag 16 15707 n/A Cap REOP 17 778559 n/A Poppet, Dump Valve 18 778556 n/A Stem, Poppet, Non Mag 19 15644 n/A Spring, Pull Dump, Non-Mag 110 15649 n/A Guide, Poppet 111 15719 n/A Clamp, Black, Plastic Tie 312 17523 n/A Cord Braided Nylon 56 in13 15149 n/A Hose, Spiral, 11.5 in 114 101267 116622 Locknut, Non Mag 115 101247 n/A Washer, Non Mag 116 101226 840493 Valve, Rubber 117 15645 n/A Pin, Retaining, Non-Mag 118 101227 840211 Body, Mouthpiece 119 101237 840477 Mouthpiece 120 101231 840482 Housing, Lower Inflator 121 101246 840490 Spring, Non-Mag 122 101248 n/A Stem, Non-Mag 123 101232 840486 Valve, Plastic 124 101233 840487 Diaphragm, Inflator MP 125 101234 840488 Washer 126 101222 840489 Push Button 127 101236 840496 Cage 1

28 762979 841106 Whistle, Ball Type 129 104913 n/A Clamp Strap Black 1

Not included in the assembly 17141516

1819

20

21

22

23

24

25

26

27

Loctite 414 Superbonder

Loctite 425 or 480

*aqua Lung France Part numbers

41

30

31

32

33

34353637

38

39

40

45

41

46

43 44

Key # pN *Pn description qty30 101173 n/A Nut handwheel, Non-Mag 131 101172 444242 Handwheel 132 101171 213421 Washer Handwheel 133 101169 n/A Plug Valve, Non-Mag 134 820088P n/A O-ring (10 pk) 135 828009 444244 Ring Back-up 136 820010P n/A O-ring (25 pk) 137 101168 444238 Washer 138 101167 444237 Washer 139 101166 n/A Spindle, Non-Mag 140 101165 n/A Seat Valve, Non-Mag 141 101305 n/A Body, Valve 142 487590 n/A Burst Plug Assembly, Non Mag 142a N/A n/A Safety Plug 142b N/A n/A Disc, Safety Red 3,000 PSI (206 BAR) 142c N/A n/A Gasket Zytel #101 .206 x .032 143 820013 n/A O-ring (10 pk) 144 101306 n/A Adapter, Valve Seat, Non-Mag 145 820316P n/A O-ring (10 pk) 146 079125 n/A Cylinder 2.5 cu. ft. 3K PSI Black Alu 1

101275 Valve Assembly w/2.5CF Cylinder

42

42b42c

42a

Key # pN *Pn description qty47 820310P n/A O-ring (10 pk) 148 101314 n/A Connector, Cylinder Valve Fixed, Non-Mag 1

47

48

101314 Connector, Cylinder Valve, Fixed, Non-mag

90 in/lbs (10 Nm)

25 ft/lbs (34 Nm)

90 in/lbs (10 Nm)

90 in/lbs (10 Nm)

eXpLoded pArts diAgrAms




52

parts diagram - Front

1

4950

parts diagram - Back55

51

Key # pN description qty1 15309 Gasket, Connector Seal 449 394040 Bladder, Odyssea Export 150 394041 Outer Bag, Odyssea Export 151 101239 Airway Complete, Non-Mag 152 101275 Valve Assembly w/ 2.5 cf Cylinder, Non-Mag 148 101314 Connector, Cylinder Valve Fixed, Non-Mag 153 394093 Crotch Strap Kit 154 394089 Back or Chest Strap Kit 255 15665 Cap, Universal Connector 2

56 490620 Dump Valve, Conv. Kit ACME 32in (813 mm) Universal (Non-Mag) 1

53

48

5556

54

odysseA CompoNeNts

43

Key # pN *Pn description qty N/A 42611 n/A BCD Repair Kit 1

oVerhAuL pArts Kits

Key # pN *Pn description qty 47 820310 n/A O-ring 1

101314 Connector, Cylinder Valve, Fixed, Non-mag

Key # pN *Pn description qty 1 15714 n/A Gasket, REOP 1 7 778559 n/A Poppet, Dump Valve 1 11 15719 n/A Clamp, Black, Plastic Tie 3 14 101267 116622 Locknut, Non-Mag 1 16 101226 840493 Valve, Rubber 1 23 101232 840486 Valve, Plastic 1 24 101233 840487 Diaphragm, Inflator MP 1 25 101234 840488 Washer 1 26 101222 840489 Push Button 1

101240 Kit, Oral Inflator, Atlantis

Key # pN *Pn description qty 34 820088 n/A O-ring 1 35 828009 444244 Ring, Back-up 1 36 820010 n/A O-ring 1 38 101167 444237 Washer 1 40 101165 n/A Seat Valve, Non-Mag 1 42 487590 n/A Burst Plug Assembly, Non Mag 1 43 820013 n/A O-ring 1 45 820316 n/A O-ring 1

394099 Kit, maintenance Cylinder Valve



ANNuAL mAiNteNANCeThe Odyssea is subject to annual maintenance. All parts listed in the overhaul parts kits, must be replaced annually, even if they appear to be in good condition.

teChNiCAL dAtAComposition:

1 Bladder (Key #49) is constructed of heavy duty urethane with RF • welded seams and connectors.

1 Outer bag (Key #50) is constructed of 840 Denier nylon.• 1 Rapid exhaust valve (REV) is operated by an easily accessible cord, •

also acts as an over pressure relief valve (OPRV). (located on inside right lobe Key #56 and top of airway complete Key #51).

2 Drain caps (located rear inside lobes Key #55).•

1 Oral inflation system (Key #51).•

1 Cylinder fixed connector (Key #48).•

1 Auxiliary Air Cylinder, with Valve (standard connection) (Key #52).•

Features:

LIFT CAPACITY (Fresh Water) . . . . . . . . . 46 lbs (20L) CYLINDER CAPACITY . . . . . . . . . . . . . . . 1 X 2.5 cu.ft. (70.8L) CYLINDER WORKING PRESSURE . . . . 3,000 PSI (206 BAR) DUAL VALVE OPENING PRESSURE (non-mag) 1.3 - 2.3 PSI (.09 - .16 BAR)

OVER PRESSURE RELIEF VALVE OPENING PRESSURE (OPRV) (non-mag) 1 - 2 PSI (.07 - .14 BAR) DUAL VALVE & OVER PRESSURE RELIEF VALVE (OPRV) CLOSING PRESSURE IS 1 PSI (.07 BAR) UNDER OPENING PRESSURE

WEIGHT With cylinder . . . . . . . . . . . . . . 5.9 lbs (2.7 kg) Without cylinder. . . . . . . . . . . . 3.8 lbs (1.7 kg) PACKING (Individual box) . . . . . . . . . . . . . 24.5" X 16" X 4.5"

62.2cm X 41cm X 11.5cm TOTAL PACKED WEIGHT. . . . . . . . . . . . . 8.1 lbs (3.7 kg)

references:394063: Odyssea U.S.

Accessories: 101275.......2.5 cu.ft. (70.8 L) Cylinder with Valve.15665..........Cap, Universal Connector (for use without cylinder)15309..........Connector Seal Gasket 101215........Adapter, Tank Fill, Atlantis BC

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ANNuAL serViCe & iNspeCtioN reCord

Serial Number _________________________

Purchase Date _________________________

Date Service Technician Name & Number Technician Signature Stamp


mAiNteNANCe Notes

47

mAiNteNANCe Notes


WARNING: It is dangerous for untrained and uncertified persons to use the equipment covered by this warranty. therefore, use of these products by an untrained person renders any and all warranties null and void. use of sCuBA equipment by anyone who is not a certified diver, or receiving training through a recognized certification agency, shall render void all warranties, expressed or implied.

Restrictions The following restrictions apply to this warranty:

This warranty extends to inflator parts, and to the seams of the BC bladder. Factory• prescribed annual service by a trained technician is required.This warranty does not extend to abrasion, punctures, or tears of the bladder, or seam • separation caused by chemical attack; including prolonged exposure to chlorine.This warranty does not extend to damages caused by improper use, improper • maintenance, neglect, unauthorized repairs, modifications, accidents, fire, or casualty.Cosmetic damage, such as scratches, fraying, and nicks are not covered by this warranty.• This warranty covers products purchased in the United States. For warranties that • may apply elsewhere, please contact your local representative.Failure to meet any of the above requirements will render the warranty null and void.•

WArrANty iNFormAtioNAll warranty transactions must be accompanied by proof of original purchase from an Aqua Lung® authorized dealer/agent. Be sure to save your sales receipt, and present it whenever returning your Odyssea for warranty service.

the Aqua Lung® one year Limited Warranty™

Aqua Lung America warrants to the original purchaser for a period of one year from the date of purchase that the product will be free from defects in material and workmanship; provided that it receives normal use, proper care, and prescribed dealer service subject to those restrictions stated below. This limited warranty is extended only to the original purchaser for purchases made from an authorized Aqua Lung® dealer/agent, and is not transferable. This warranty is limited to repair or replacement only at the discretion of Aqua Lung America, Inc.

ALL WArrANties, iNCLudiNg, But Not Limited to, impLied WArrANties, or merChANtABiLity ANd FitNess For A pArtiCuLAr purpose Are Limited iN

durAtioN to A period eNdiNg oNe yeAr From the dAte oF purChAse.

AquA LuNg AmeriCA disCLAims ANd eXCLudes ANy LiABiLity For iNCideNtAL, or CoNsequeNtiAL dAmAges. some stAtes do Not ALLoW eXCLusioNs oF

LiABiLity, so this mAy Not AppLy to you.

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©2013 Aqua Lung International

2340 Cousteau Court • Vista, CA 92081Phone (760) 597-5000 • Fax (760) 597-4900www.aqualung.com/militaryandprofessional

Literature p/N 18342 rev. 2/13

oDYSSea

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