tecHnicaL manUaL

Transcription

tecHnicaL manUaL

Odyssea
non-magnetic
TECHNICAL MANUAL
Rev 10/11
2
Odyssea 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.
©2011 Aqua Lung America.
Odyssea BC (EXPORT) TECHNICAL Manual, PN 18369
PN# 394059 (Export)
You can contact a Technical Advisor via e-mail at:
Aqua Lung France
[email protected]
Aqua Lung America
[email protected]
[email protected]
Trademark Notice
Aqua 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.
3
CONTENTS
INTRODUCTION.......................................................................................... 5
GENERAL PRECAUTIONS AND WARNINGS........................................... 7
PRODUCT OVERVIEW............................................................................... 9
SPECIALTY FEATURES.............................................................................. 9
BC Air Breathing........................................................................................... 9
Pocket........................................................................................................ 10
Drain Cap................................................................................................... 10
AUXILIARY AIR CYLINDER...................................................................... 10
Filling the Auxiliary Cylinder....................................................................... 10
Attaching the Auxiliary Cylinder.................................................................. 12
INFLATION METHODS.............................................................................. 13
Using the Oral Inflator................................................................................ 13
Using the Auxiliary Air Cylinder.................................................................. 13
DEFLATION METHODS............................................................................ 13
Deflating Via the Oral Inflator..................................................................... 14
Deflating Via the Dual Exhaust Valve......................................................... 14
Over Pressure Relief Valve (OPRV) . ....................................................... 14
DONNING AND ADJUSTMENT PROCEDURES...................................... 15
Donning...................................................................................................... 15
Adjusting Strap Length............................................................................... 15
PRE-DIVE INSPECTION............................................................................ 16
POST DIVE CARE & MAINTENANCE...................................................... 20
BC BLADDER REMOVAL ........................................................................ 22
BC BLADDER INSTALLATION................................................................. 23
AIRWAY NON-MAG MAINTENANCE PROCEDURES............................. 24
Airway Non-Mag Disassembly................................................................... 24
Oral Inflator Disassembly........................................................................... 24
Dual Valve Disassembly............................................................................. 25
Oral Inflator Assembly................................................................................ 26
Dual Valve Assembly.................................................................................. 28
Airway Assembly........................................................................................ 29
CYLINDER CONNECTOR (GERS) MAINTENANCE PROCEDURES..... 30
Disassembly............................................................................................... 30
Assembly.................................................................................................... 31
4
CYLINDER VALVE MAINTENANCE PROCEDURE................................. 32
Disassembly............................................................................................... 32
Assembly.................................................................................................... 34
Cylinder Valve Testing Procedures............................................................. 35
FINAL ASSEMBLY AND TESTING........................................................... 36
BC PATCH KIT INSTRUCTIONS . ............................................................ 38
TABLE 1: LIST OF TOOLS....................................................................... 39
TABLE 2: TORQUE SPECIFICATIONS.................................................... 41
TABLE 3: RECOMMENDED CLEANERS AND LUBRICANTS................ 41
PROCEDURE A: CLEANING AND LUBRICATING.................................. 42
EXPLODED PARTS DIAGRAM................................................................. 43
ODYSSEA COMPONENTS....................................................................... 45
OVERHAUL PARTS KITS......................................................................... 46
TECHNICAL DATA.................................................................................... 47
MAINTENANCE NOTES............................................................................ 48
WARRANTY INFORMATION..................................................................... 49
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 Conventions
Unless otherwise instructed, the following terminology and techniques are assumed:
1. When instructed to remove, unscrew, or loosen
a threaded part, turn the part counterclockwise.
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 oring sealing surface. All o-rings that are removed are
discarded and replaced with brand new o-rings.
Pinch Method
Press upwards on sides of o-ring to
create a protrusion. Grab o-ring or
insert o-ring tool at protrusion.
6
CAUTION: Use only a plastic (pn 103102) or brass
(pn 944022) o-ring removal tool 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.
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 (55)
from the valve body ...”, the number 55 is the key
number to the o-ring.
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
GENERAL PRECAUTIONS & WARNINGS
WARNING: 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 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 an 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.
WARNING: A buoyancy compensator (BC) 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.
8
Your buoyancy compensator is 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: 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.
If you have any questions regarding your
Buoyancy Compensator or these instructions, contact
an Aqua Lung Technical Representative
9
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 closedcircuit rebreathers.
The Odyssea features an air cylinder attachment that allows you to inflate the vest with
compressed breathing air. The air cylinder comes equipped with Groupe d’ Etudes
et de Recherches Sous-Marines (GERS M20) 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 the water).
The bladder is constructed of heavy duty urethane and is enclosed 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 on the left lobe.
The Odyssea is suitable for all types of uses. It must be fitted with an inconel
cylinder to be completely non-magnetic.
SPECIAL FEATURES
BC Air Breathing
The oral inflator is equipped with a breathing valve that allows the diver to
breathe air from the buoyancy compensator when inflated. This device is only
to be used in case of an 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 mouth piece’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 without any manipulation.
Oral Inflator
Mouthpiece
PN 101239
Fig. 1
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.
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.
10
Pocket
The Odyssea features one large utility pocket located on the left lobe of the BC
and two retainers on the right side designed to carry an emergency strobe light
and a snorkel.
Drain Plug
The Odyssea is equipped with two drain caps located on the back of each lobe
of the BC. The caps are used to rinse the inside of the bladder.
AUXILIARY AIR CYLINDER
The 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 840970
P/N 101338
Fig. 2
Filling the Auxiliary Cylinder
To fill the cylinder, you will need an optional fill adapter w/ GERS connection Aqua
Lung part number 840817.
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 200
BAR (2,900 PSI).
2. Using a calibrated pressure gauge, check the supply cylinder is filled
to 200 BAR (2,900 PSI). It is very important to ensure that the auxiliary
cylinder is filled to its total capacity, but not overfilled.
WARNING: DO NOT attempt to fill the cylinder if the markings indicate that it is rated
for a different fill pressure other than 200 BAR (2,900 PSI) 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.
11
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).
Check
O-ring
Fig. 3
4. Loosen the yoke knob. While supporting the auxiliary cylinder in one hand, attach
the adapter to a fully pressurized 200 BAR (2,900 PSI) scuba cylinder (Fig. 4).
Relief Plug Yoke Knob
Fig. 4
5. Relief plug is fixed in the closed position on the GERS fill adapter when filling
the auxiliary cylinder from a scuba cylinder.
WARNING: DO NOT attempt to fill the auxiliary cylinder from a supply cylinder which contains more than 200 BAR (2,900 PSI). Doing so may weaken and damage the cylinder.
6. Open the handwheel on the auxiliary cylinder counterclockwise until the valve is completely open.
7. VERY SLOWLY open the valve on the scuba cylinder.
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. If the cylinder is warm to the touch afterward, the
fill rate was too rapid.
12
8. Close the valve of the supply cylinder and then the valve of the auxiliary
cylinder. Slowly purge the relief plug by depressing it down with your finger 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.
Attaching the Auxiliary Cylinder
1. Before attaching the cylinder, inspect the o-ring located at the tip of the
connector (Fig. 5).
Check
O-ring
Fig. 5
2. Insert the cylinder into the retaining sleeve and align the threaded valve outlet
with the cylinder connector. Turn the knurled knob counterclockwise and thread
the cylinder connector onto the valve outlet until finger tight (Fig. 6).
Fig. 6
13
INFLATION METHODS
Using 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.
a
b
Fig. 7
Using the Auxiliary Air Cylinder
To inflate the BC using the auxiliary air cylinder, open the cylinder valve by turning the
handwheel counterclockwise. Close the cylinder valve when the bladder is adequately
filled, otherwise, air will escape from the over pressure relief valves.
DEFLATION METHODS
Throughout 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 Inflator
To deflate the Odyssea using the oral inflator, lift the inflator body to its highest
possible position (above the head). Press the oral inflator button (See Fig.7B) to
start venting air. This method is most effective on the surface when starting the
initial descent.
NOTE: Depressing the oral inflator while the jacket is empty may cause water to enter the
air bladder.
14
Deflation via Dual Exhaust Valve
Inside the inflator’s corrugated hose is a nylon line 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 7mm (.25 in) is required. The Rapid Exhaust Valve (REV) provides an effective and convenient way to vent air from the BC while in either an upright or face
down swimming position (Fig. 8). It also functions as an over pressure relief valve
(OPRV) valve 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).
Fig. 8
Deflation via Over Pressure Relief Valve (OPRV)
In 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 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.
Fig. 9
A
B
Fig. 10
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.
WARNING: Most training agencies recommend that you descend in an upright, feetfirst position, in order to maintain a slower and more controlled descent. This is especially true if you experience difficulty equalizing your ears or if you are descending
in low visibility conditions.
15
DONNING & ADJUSTMENT PROCEDURES
Donning
1. One end of the crotch strap (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)
2. Connect the rear lobe retaining strap to
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).
3. Insert your arm through the straps as if you
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).
E
A
B
D
C
Fig. 11
4. Bring the free end of the crotch strap
(Fig.12) between your legs and connect it to
the two lower female buckles at the front of the
Odyssea (Fig. 12A).
B
A
5. Connect the chest strap to the two upper female
buckles at the front of the Odyssea just above
where the crotch strap is attached (Fig. 12B).
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.
Fig. 12
16
PRE-DIVE INSPECTION
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.
Inspection Checklist
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.
Pull Down
On Oral
Inflator
Fig. 13
Fig. 14
2. Fully inflate the Odyssea once again and let it sit for 10 minutes to check for
leans and firmness (Fig. 15).
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.
Fig. 15
17
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).
Fig.16
Fig. 17
Fig. 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).
Fig. 19
Check stitching points
Fig. 21
Fig. 20
18
5. Ensure the outer bag zipper is not damaged, none of the zipper teeth are missing and the zipper moves freely and is closed (Figs. 22 & 23).
Fig. 22
Fig. 23
6. Verify all hook and loop material is not excessively worn and it is in good working condition (Figs. 24-26).
Fig. 24
Fig. 25
Fig. 26
19
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. 30
8. Ensure that the auxiliary air cylinder has been completely filled to
200 BAR (2,900 PSI) (Fig. 31).
Fig. 31
20
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:
1. Avoid prolonged exposure to direct sunlight and extreme heat. Nylon
fabric can quickly fade when exposed to the sun’s ultraviolet rays and
extreme heat may damage the welded bladder seams.
2. Avoid repeated or prolonged use in heavily chlorinated water, which can cause the Odyssea fabric to discolor and decay prematurely.
3. Do not allow the Odyssea to chafe against any sharp objects or rough surfaces that could abrade or puncture the bladder. Do not set or drop heavy objects such as cylinders or block weights on the Odyssea.
4. Avoid any contact with oil, gasoline, aerosols, or chemical solvents.
5. After diving, give the Odyssea a thorough fresh water rinse. Unzip the outer 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:
a) Unscrew one of the drain caps (Fig. 32).
Fig. 32
b) Using a fresh water supply, fill the bladder until about a 1/4 full and re
install the drain cap. Thoroughly shake the bladder so the water rinses the
entire inside of the bladder. Unscrew both drain caps, cylinder connector,
OPRV and oral airway assembly and let all the water drain from the bladder.
Leave the drain caps, cylinder connector, OPRV and oral airway assembly off
until the inside of the bladder is dry (Figs. 33 & 34).
Fig. 33
Fig. 34
21
c) 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).
22
BC Bladder Removal
1. Unscrew the knurled nut on the GERS cylinder connector
and remove the cylinder from the BC. After the cylinder has been
removed, loosen the cylinder connector (60) and remove the cylinder connector from the bladder connection.
2. Remove all straps with quick release buckles (61 & 62), both
caps (63), gaskets (12), dump valve (64), and airway (59).
3. Unzip external zipper, push bladder connectors into the outer bag
(58). Carefully remove the bladder (57), making sure the connectors
do not get caught on the outer bag.
23
BC Bladder Installation
1. Insert the bladder (57) back into the outer bag (58) so that the
connectors line up with the connector holes.
2. Inspect gasket(s) (12) for damage, this component may be
reused if no damage is noticed. Place gasket(s) back into the connectors. Install caps (63), dump valve (64), and airway (59) back
onto the corresponding connectors. Put strap assemblies (61 &
62) back into place.
3. Ensure the gasket (12) has been placed back into the connector in which the cylinder connector will be attached. Attach the
GERS cylinder connector (60) and turn clockwise until hand tight.
Insert the auxiliary cylinder into the retaining sleeve and tighten the
knurled nut onto the cylinder valve adapter.
4. Turn the cylinder valve on to 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 (63), dump valve (64), airway (59) and cylinder
connector (60) 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.
24
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 valve or how much use it
has received since it was last serviced.
CAUTION: Use only a plastic (pn 103102) or brass
o-ring removal tool (pn 944022) when removing orings 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.
Airway Non-Mag Maintenance
Procedures
3. Pull back the hose (24) from the mouthpiece body (29). Press
the pin (28) out from one side using a pin punch or similar tool to
release the braided nylon cord (23). Remove the hose (24) from the
dual valve assembly, set the dual valve assembly to the side.
ORAL INFLATOR
Disassembly
1. Using the spanner wrench (pn 129198) to hold the push button
(37), remove the locknut (25) from the stem (33) with a 5.5mm nut
driver. Use needle nose pliers to remove the washer (26) and the
rubber valve (27). Discard nut (25) and rubber valve (27).
Airway (Non Mag) Disassembly
1. Turn the retaining collar and remove the dual valve assembly
from the connector. Remove the gasket (12) from the connector.
2. Using a straight blade screwdriver, carefully lift out the fingers of
the cage (38) and remove it from lower inflator housing (29).
2. Using diagonal pliers (pn 9-45171), carefully remove the three
clamps (22) from the spiral hose (24) securing the inflator and dual
valve assemblies.
CAUTION: Do not apply excessive force or pry against
the housing/cage with the tip of the screwdriver.
CAUTION: Do not cut the spiral hose while removing
the clamp.
25
3. Remove the stem assembly and spring (32) through the front of
the lower inflator housing (31). Remove the mouthpiece (30) from
the mouthpiece body (29).
Airway (Non Mag) Disassembly
DUAL-VALVE
Disassembly
4. Using the spanner wrench (pn 129198), turn the push button (37)
counterclockwise to loosen. It may be necessary to secure the stem
(33) in a vise or a pair of soft jawed pliers to loosen the push button
(37) as a small amount of Loctite 425 or 480 is used to secure the
button. Ensure the stem is protected from damage.
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.
1. Locate the seam that runs along the circumference between the
dual valve body (13) and the outer cap (17), 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.
Seam
5. Remove the push button (37), washer (36) and the inflator
diaphragm (35) from the stem (33). Next, remove the plastic valve
(34) from the stem (33). 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 (33). Once removed, discard the push button (37), washer
(36), inflator diaphragm (35) and plastic valve (34).
CAUTION: Do not apply excessive force or use a hammer, mallet or other heavy instrument.
2. While holding the dual valve assembly secure, firmly grasp
the outer cap (17) and turn it counter-clockwise to loosen. While
maintaining slight inward pressure to counteract the spring pressure inside, continue turning the cap (17) until it has disengaged
from the dual valve body (13). Remove the cap and the spring
(16) 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.
6. Clean any residual Loctite from the large threads of the stem (33).
NOTE: If the cap cannot be turned, repeat step 1 to
break the adhesive bond.
This Concludes Disassembly of the Oral Inflator
Before starting assembly, perform parts cleaning and lubrication in accordance with Procedure A: Cleaning and Lubricating in the back
of the manual.
26
3. Remove the valve plate (15) with gasket (12) from the body (13)
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 (13) which hold the arms of the poppet guide (21). 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.
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 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, subassemblies 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.
Airway (Non Mag) Assembly
ORAL INFLATOR
Assembly
5. When the arms of the poppet guide have disengaged from the
body, firmly grasp the braided nylon cord (23) and pull the exhaust
valve assembly straight out while holding the body secure. This will
pull the poppet stem (19) out of the dump valve poppet (18). Remove
the dump valve poppet and discard.
6. Remove the braided nylon cord (23) from the poppet stem (19).
Pull the poppet stem (19) and spring (20) straight out of the poppet guide (21).
1. Place the large end of the spring (32) into the lower inflator
housing (31). 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 (33). Screw the plastic valve (34)
onto the large diameter threads of the stem (33) until seated hand
tight. The taper of the plastic valve must face towards the center
of the stem.
Loctite
425 or 480
This Concludes Disassembly of the Dual Valve
of the manual.
27
3. Install the diaphragm (35) over the large threaded end of the
stem (33) until it rests against the face of the plastic valve (34).
Place the washer (36) on top of the diaphragm (35) followed by one
drop of Loctite 425 or 480 onto the tip of the stem (large threads)
and screw the button (37) onto the stem (33) until it bottoms out
against the washer (36).
6. Using needle nose pliers, place the rubber valve (27) flat end up
over the small diameter threads of the stem (33). Install the washer
(26) onto the small diameter thread end of the stem (33) so that
the washer (26) is seated on top of the rubber valve (27). Place the
locknut (25) into a 5.5mm nut driver and engage the locknut onto
the stem assembly by turning clockwise.
Loctite
425 or 480
4. Pass the stem assembly into the body, through the center of the
spring (32). Ensure the stem assembly is centred properly.
5. Set the cage (38) with the fingers facing out over the push button
(37) of the assembly. Place the entire lower inflator assembly face
down on a clean surface against the cage (38). 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.
7. Insert the pin spanner (pn 129198) into the holes on the button.
(37). Using the 5.5mm nut driver, turn the locknut (25) clockwise
until approximately 1/4 inch of the threads of the stem (33) are
exposed opposite the locknut.
8. Install mouthpiece (30) onto the mouthpiece body (29) with the
curved end facing out until the lower inflator housing seats into the
mouthpiece groove.
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.
28
DUAL-VALVE
Assembly
1. Dip the dump valve poppet (18) into soapy water and press securely onto the barbed tip of the poppet stem (19). Slide the spring
(20) onto the stem.
3. Compress the poppet assembly with the forked end out onto
the poppet holding fixture. Using the inflator cord fixture, install the
braided nylon cord (23) through the hole in the poppet stem (19)
and round the inflator cord post 2 times (Two loops around post
and two passes through the stem). Tie a 2.5 cm (1 inch) loop on
one end of the cord using a “Overhand 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 at
both knots and seal the cord ends using a propane lighter (fixtures
can be locally manufactured).
CAUTION: Do not damage the knots with the flame.
2. Insert the poppet stem (19) through the flat end of the poppet
guide (21).
Distance between posts
30.5 cm (12 inches)
Overhand Bow Knot
(3) Half Hitches
4. Position the poppet guide assembly so that the larger rib faces
toward the open side of the dual valve body (13), 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.
Large Rib
29
5. Squeeze the arms of the poppet guide (21) 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 (18) has passed through the
top of the barrel and remains properly seated over the end of the
poppet guide (19) inside the dual valve body (13).
1. Ensure the inside line of the bottom vent slot lines up with the
center line of the dual valve body hose barb. Place the spiral hose
over the cord hook and compress it to expose the hook. Use the
cord hook to pull the braided nylon cord through the spiral hose
(small end of the hose).
Align Here
6. Install the gasket (14) onto the valve plate (15), and set the valve
plate inside the dual valve body (13) with the gasket facing down.
2. Apply a small amount of Gasgacinch to the diameter of the dual
valve body (13), allow 15 seconds to get tacky. Slide the spiral
hose (24) onto the dual valve body (13).
Gasgacinch
` Here
7. Place the over pressure spring (16) directly in the center of the
valve plate (15), standing up.
3. Lightly fasten a clamp (22) over the spiral hose (24) 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 diagonal pliers (pn 9-45717).
8. Carefully apply only one very small drop of Loctite brand, 425
or 480 grade thread adhesive to the center thread of the outer cap
(17). 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.
This Concludes Assembly of the Dual Valve.
30
4. Insert retaining pin (28) half way into one hole of the body
mouthpiece (29). Capture both loop ends of the braided nylon cord
(23) using your thumb and index finger facing up, slide the hose
(24) 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 (28) of the body mouthpiece.
exploded parts drawing, which references all mandatory
new, and must not be reused under any circumstances
regardless of the age of the valve or how much use it has
received since it was last serviced.
CAUTION: Use only a plastic (pn 103102) or brass oring 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.
Cylinder Connector (GERS)
Maintenance Procedures
Disassembly
5. Press the pin (28) by hand until it engages equally into both
holes of the body mouthpiece (29). 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.
1. Remove the GERS connector (60) from the BC connector by
unscrewing counterclockwise.
2. Remove the gasket (12) and closely inspect it for damage, if damaged replace the gasket. Examine the BC connector for any damage.
If any debris is found in the groove, use a clean cloth to remove.
6. Secure each of the two clamps (22) to the spiral hose (24). The
outside clamp head faces in line with the mouthpiece. Clamp edge
distance to the end of the hose is 3.18mm (1/8 inch). The other
clamp faces the opposite direction over the pin (28).
Clamp 2
Clamp 1
This Concludes Assembly of the Airway.
3. Looking at the bottom side of the cylinder connector locate the
retaining ring (11). Using circlip pliers (pn 111100), remove the snap
ring (11) from the connector (6). Remove the connector assembly
from the handwheel (10).
31
4. Use the o-ring removal tool (pn 944022) to remove o-ring (1)
from valve reducing connector (2) and o-ring (7) from the groove on
the outside of connector (2) and discard the o-rings.
5. While holding the connector (6) with soft jaw pliers, use the
5mm hex key adapter (pn 8367A23) to remove the cylinder valve
connector (2) from the connector (6). Remove knurled nut (3) and
set aside for reuse.
NOTE: Before performing any assembly, it is important
reused, to ensure that every part and component is perfectly clean and free of any dust, corrosion, or blemishes.
ensure it is clean, supple, and free of any blemish.
WARNING: Use only genuine Aqua Lung® parts, subassemblies, 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,
Cylinder Connector (GERS)
Maintenance Procedures
Assembly
1. Insert o-ring (8) onto sealing pin (9) and o-ring (1) into cylinder
valve connector (2).
Note: The cylinder valve connector is installed with Loctite 414 Superbonder adhesive, remove excessive adhesive prior to reinstallation.
6. Using a flat blade screwdriver, hold the sealing pin (9) in place
and unscrew the locknut (4) with a 5mm nut driver, discard locknut.
Remove the spring (5) from the sealing pin (9).
2. Install the sealing pin (9) into the small end of the connector (6).
While holding the sealing pin (9) with a flat blade screwdriver, install
the spring (5) onto the sealing pin, inside the connector (6). Place the
locknut (4) into the 5mm nut driver and screw the locknut (4) onto the
sealing pin (9) until it is flush with the end of the pin threads.
7. Remove the sealing pin (9) from the small end of the connector
(6). Take the o-ring (8) off of the sealing pin (9), discard o-ring (8)
and connector (6).
This Concludes Disassembly of the GERS Cylinder Connector
Before starting assembly, perform parts cleaning and lubricating in accordance with Procedure A: Cleaning and Lubricating in the back
of the manual.
32
3. Place the threaded opening of the knurled nut (3) over the end
of the cylinder valve connector (2). Place (1) one drop of Loctite
#414 Superbonder on the bottom threads of cylinder valve connector (2). Screw the cylinder valve connector (2) into the connector
(6). Hold the collar of the connector (6) with soft jaw pliers, using
the 5mm hex key adapter (pn 8367A23), tighten the cylinder valve
connector (2) into the connector (6) hand tight, then an additional
1/4 turn.
(1) Drop of Loctite
#414 Superbonder
Note: Excessive Loctite 414 Superbonder may cause the
knurled nut to stick to the valve reducing connector. Rotate
the knurled nut to free.
CYLINDER VALVE MAINTENANCE
PROCEDURES
exploded parts drawing, which references all mandatory
new, and must not be reused under any circumstances
regardless of the age of the valve or how much use it has
received since it was last serviced.
CAUTION: Use only a plastic (pn 103102) or brass oring 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.
CAUTION: Do not cross thread or overtighten the
valve reducing connector into the connector, this
can cause irreversible damage to components.
Valve Disassembly
CAUTION: Protective eyeware must be worn during installation of cylinder valve connector into the connector.
1. Open cylinder valve counterclockwise and ensure cylinder (56)
is fully depressurized. Secure cylinder in cylinder vise (pn 100397)
and remove the cylinder valve from the cylinder by turning valve
body (54) counterclockwise with a 27mm (1-1/16 inch) crowfoot
(pn FC34A) and 3/8” flex handle drive (pn 9-44363). When done,
remove cylinder from cylinder vise.
4. Install o-ring (7) into the groove on the connector (6), then install
connector into handwheel (10) from the outside.
5. Turn the GERS connector assembly over so that the bottom of
the assembly is face up. Use circlip pliers (pn 111100) to install the
retaining ring (11). Verify that the flat side of the retaining ring is up
and the retaining ring is completely closed securing the connector
assembly into the handwheel (10).
This Concludes Assembly of the GERS Cylinder
Connector.
2. Remove the o-ring (55) from the valve body (54). Use the appropriate o-ring tool (pn 944022). Discard o-ring.
33
3. Use the modified screwdriver (pn 941586), remove the handwheel nut (41), spring (42), handwheel (43) and washer (44) from
the spindle (49).
6. Holding the valve body assembly in a vise, use a 22mm (7/8
inch) socket (pn 769354) and 3/8” flex handle drive (pn 9-44363) to
remove the valve plug (45) from the body (54).
7. Remove the o-ring (46) from the valve plug (45) using the appropriate o-ring tool (pn 944022). Discard o-ring.
4. Unscrew the valve seat adapter (52) from the body (54) using
a 3/8” flex handle drive (pn 9-44363) and 5mm hex key adapter
(pn 8367A23).
CAUTION: Loctite 242 is used to hold this part in place
in addition to the torque applied during assembly.
8. Unscrew the valve seat (51) from the body (54) using the spindle (49) and oldham (50). Remove the oldham (50) and valve seat
(51), discard the valve seat.
Note: If the valve seat adapter does not loosen, use a heat
gun to heat up the body and adapter to loosen the adhesive.
CAUTION: Do not damage the internal surface of
the valve seat adapter.
9. Using your fingers, remove the washer (47) from the spindle
(49). Take the brass o-ring tool (pn 944022) and remove the o-ring
(48) from the groove in the spindle (49). Discard the o-ring.
5. Remove the o-ring (53) from the valve seat adapter (52) and
discard it.
Note: If the washer (47) does not come out on the spindle (49), check for it inside the valve plug (45).
This Concludes Disassembly of the Cylinder Valve.
of the manual.
34
CYLINDER VALVE MAINTENANCE
PROCEDURES
NOTE: Before performing any reassembly, it is important
reused, to ensure that every part and component is perfectly clean and free of any dust, corrosion, or blemishes.
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,
3. Lubricate the o-ring (46) and install it on to the valve plug (45).
Screw the valve plug (45) back in to the body (54) until hand tight.
Using a Newton Meter torque wrench and a 22mm (7/8 inch) socket, (pn 769354) tighten the valve plug to 15 Nm (133 in.lbs). Ensure
the o-ring (46) is seated inside the body (54).
4. Install the washer (44) over the tip of the spindle (49) followed
by the handwheel (43).
Valve Assembly
1. Lubricate the o-ring (48) and install it into the groove of the
spindle (49). Next, install a lubricated washer (47) back on to the
spindle (49).
5. Place the spring (42) over the tip of the spindle (49) so that it is
resting on top of the handwheel (43). Install the handwheel nut (41)
onto the spindle (49), start threading it by hand, then tighten the
rest of the way with a modified screwdriver (pn 941586). It should
be tightened down until the spindle (49) is even with the top of the
handwheel nut (41).
2. Lubricate the threads and screw the valve seat (51) into the body
(54) using the oldham (50) and spindle (49). Insert the handwheel
(43) over the tip of the spindle, this will ensure that the valve seat
(51) is properly seated. After the valve seat has been tightened,
remove the handwheel, leaving the spindle and oldham in place.
CAUTION: If any resistance is felt while threading
handwheel nut onto spindle, stop and start over. Ensure that cross threading is not occurring.
35
6. Apply a small amount of lubrication to the o-ring (53) and fit onto
the valve seat adapter (52). Apply one drop of Loctite 242 to the
small threads and screw the valve seat adapter (52) into the body
(54) hand tight. Using a Newton Meter torque wrench along with
a 5mm hex key adapter (pn 8367A23), apply 10 Nm (89 in.lbs) of
torque to the valve seat adapter (52).
Loctite 242 here
CAUTION: Do not lubricate threads of the valve seat
adapter.
7. Lubricate o-ring (55) and place it onto the body over the threads
and up on the shoulder. Lightly lubricate the threads of the body
(54). Install cylinder (56) into cylinder vise (pn 100397) and screw
the body into the cylinder until hand tight. Using a 27mm (1-1/16
inch) crowfoot (pn FC34A) and Newton Meter torque wrench, tighten valve assembly into cylinder to 30 Nm (22 ft.lbs).
This Concludes Assembly of the Cylinder Valve
Cylinder Valve Testing Procedures
1. Fill cylinder to 34 BAR (500 PSI) and listen for audible leaks.
Submerge in a fresh water supply and visually inspect valve for any
leaks that may be preset. If no leaks are detected, fill cylinder to
200 BAR (2,900 PSI), again listen for audible leaks and submerge
in fresh water. If any leaks are detected, disassemble valve, replace worn parts, rebuild and retest.
36
FINAL ASSEMBLY AND TESTING
WARNING: Protective eyewear must be worn at all
times during testing.
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 airway
tube at both the dual valve assembly and the inflator assembly. If
any signs of damage or decay can be detected, it is important to
replace the airway tube before proceeding any further.
1. Lay the gasket (12) flat inside the connector and mate the retaining
collar of the dual valve body (13) 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.
NOTE: Ensure the dual valve body (13) sealing surface
is properly aligned with the connector on the BC This is
essential to achieve a proper seal.
NOTE: Ensure that cylinder connectors, oral airway assembly, caps and OPRV are secured to the BC prior to
submerging. Failure to do so will cause water to enter the
internal bladder.
2. Lay the gasket (12) flat inside the connector and mate the retaining collar of the cylinder connector (60) directly over it onto the
manifold. Gently turn the collar clockwise to engage the threads,
being careful to avoid cross threading and hold the GERS cylinder
connector in the desired position while tightening the retaining collar
by hand until snug.
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.
5. Finally, bend the airway tube at a right angle. If the airway tube
shows any sign of separating from the inflator assembly it is important to replace the clamp.
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.
37
6. Manually inflate the BC until it is taut and fully inflated. Press
the deflation button (37) 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
7. Connect the cylinder to the cylinder connector, turn the cylinder
valve on to 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 (63), airway (59),
OPRV (64) and cylinder connector (60) 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. If a continuous leak is detected, the component
must be disassembled and examined for damage or contamination
of the seals and seating surfaces.
NOTE: If leakage is not immediately detected, allow the BC
to stand for at least one hour to ensure that none exists.
This Concludes The Testing Procedures For
The Airway (Non-Mag)
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.
38
BC 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.
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 twenty four hours.
WARNING: Do not attempt to patch a tear or puncture
which is located directly over an internal baffle, within
50mm (2 inches) of a seam or is larger than 13mm (1/2
inch) in diameter or length.
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.
BC Patch Kit
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.
4. After twenty four 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 minutes.
Glossy Side
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.
Non-Glossy Side
5. After twenty minutes have elapsed, apply a third coat of adhesive to the BC material, a second coat to the patch. Wait between
five to ten 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 2.27 kg (5 Lb.) weight directly over the patch to
apply pressure, and allow exactly one hour for the patch to set.
2. Check to ensure that the patch extends at least twice the diameter or length of the hole or tear on all sides.
NOTE: DO NOT allow the patch to set more than one
hour before performing the next step.
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 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 hour, immerse it in fresh water to
determine the source of leakage and repair as needed.
This Concludes BC Patch Kit Instructions
39
Table 1: LIST OF TOOLS
PART #
DESCRIPTION
APPLICATION
129198
Adjustable Face
Spanner
Removal/Installation of Oral Inflator Push Button (39)
101215
Tank Fill
Adapter
Charging cylinder
944022
O-ring Tool Kit
(Brass)
Removal/Installation of o-rings
103102
O-Ring Tool
(Plastic, 5 pk)
820466
(2 oz.)
Christo-Lube
MCG 111
Lubrication of O-rings/Parts
9-44363
Flex Handle
Drive 3/8”
Removal/Installation of Valve/Connector Parts
111100
Circlip Pliers
Removal/Installation of Circlip (11) on GERS connector
100398
Vise Jaw Inserts for Cylinder
( For Existing Shop Vise)
Removal/Installation of Cylinder Valve
100397
Table Mount
Cylinder Vise
Secures Cylinder (56) for Removal/Installation of Cylinder
Valve
9-45171
Diagonal Pliers
(small)
Removal/Installation of Clamp (22 & 26)
941586
Modified
Screwdriver
(short)
Removal/Installation of Handwheel Nut (41)
820467
(16 oz.)
8367A23
769354
5mm Hex Key Adapter
22mm (7/8 inch)
Socket
Removal/Installation of Adapter Valve Seat (52) and Cylinder Valve Connector (2)
Removal/Installation of Plug Valve (45)
40
Table 1: LIST OF TOOLS (continued)
PART #
DESCRIPTION
APPLICATION
FC34A
27mm (1-1/16 inch) Crowfoot
Removal/Installation of Valve Body (54)
N/A
Cord Hook
(Locally Manufactured)
Installing Braided Nylon Cord (23) through Spiral Hose (24)
N/A
Poppet Fixture
Removal/Installation of Braided Nylon Cord (23)
N/A
Cord Fixture
Knot Tying Fixture for Braided Nylon Cord (23)
N/A
5.5mm Nut Driver
5mm Nut Driver
Removal/Installation of Oral Inflator Locknut (27)
Removal/Installation of GERS Cylinder Connector Sealing
Pin Nut (4)
N/A
Small Punch
Removal/Installation of Poppet Guide (21) and Oral Inflator
Pin (30)
N/A
Pliers
Removal/Installation of Oral Inflator Stem (35)
N/A
3/8 Drive Torque
Wrench; 0-15 Nm
(0-132 in.lbs)
Range
Torquing of Parts
N/A
3/8 Drive Torque
Wrench; 0-110 Nm
(0-81 ft.lbs)
Range
Torquing of Parts
N/A
Screw Driver
Removal/ Installation of Dual Valve Cap (17), Connector
Sealing Pin (9)
N/A
Soft Jawed Pliers
Removal/Installation to Secure GERS Connector (6)
N/A
Needle Nose
Pliers
Removal/Installation of Inflator parts
41
Table 2: Torque Specifications
PART #
DESCRIPTION / KEY ITEM #
TORQUE
840923
Plug, valve (45)
15 Nm (133 in.lbs)
840917
Body, valve (54)
30 Nm (22 ft.lbs)
840919
Adapter, valve seat (52)
10 Nm (89 in.lbs)
Table 3: Recommended Cleaners and Lubricants
LUBRICANT/CLEANER
Christo-Lube MCG 111
APPLICATION
SOURCE
All o-rings
Aqua Lung, PN 820466, or
Lubrication Technologies
310 Morton Street
Jackson, OH 45640
(800) 477-8704
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.
Acid bath for reusable stainless steel and
brass parts.
Oakite #31
Oakite Products, Inc.
50 Valley Road
Berkeley Heights, NJ 07922
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.
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
42
Procedure A: Cleaning and Lubricating
Cleaning Brass and Stainless Steel Parts
1. 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 1.7 BAR (25 PSI) filtered air.
Inspect closely to ensure proper cleaning and like-new condition.
Cleaning Plastic & Rubber Parts
Parts 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.
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.
Cleaning Hoses
1.
2.
3.
4.
Hose fittings: Ultrasonically clean with soapy water*; vinegar is OK on tough corrosion (only hose ends).
Run soapy water through hose if needed.
Thoroughly rinse with fresh water (hang with hose ends down).
Blow out hose before installing.
Lubrication and Dressing
All 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.
43
EXPLODED PARTS DIAGRAMS
13
12
101338 Connector Cylinder Valve Export Straight
Key #
1
2
3
4
5
6
7
8
9
10
PN
820038P
101090
101029
101335
101332
101334
820089
820005
101328
101341
PN*
124704
N/A
N/A
N/A
840443
850442
N/A
N/A
N/A
862476
11
101344
850443
Description
O-ring (20 pk)
Connector, valve reducing
Nut, Knurled
Locknut 5mm
Spring
Connector
O-ring
O-ring
Pin, sealing
Handwheel
Retaining ring non-mag
15.7mm
Qty
1
1
1
1
1
1
1
1
1
1
14
GERS
Loctite
425 or 480
15
1
2
Loctite 414 Superbonder
18
19
3
4
20
5
1
17
16
21
6
*Aqua Lung France Part Numbers
8
23
7
22
24
9
39
40
10
22
11
101239 Airway Complete Non Mag
Key #
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
PN
PN*
Description
15309
N/A
Gasket, connector seal
42742
N/A
Dual valve body assembly ACME
15714
N/A
Gasket, REOP
15698
N/A
Plate, valve
15643
N/A
Spring, over pressure, non-mag
15707
N/A
Cap REOP
778559
N/A
Poppet, dump valve
778556
N/A
Stem, poppet, non mag
15644
N/A
Spring, pull dump, non-mag
15649
N/A
Guide, poppet
15719
N/A
Clamp, black, plastic tie
17523
N/A
Cord braided nylon (1 in)
15149
N/A
Hose, spiral, 11.5 in
101267
116622
Locknut, non mag
101247
N/A
Washer, non mag
101226
840493
Valve, rubber
15645
N/A
Pin, retaining, non-mag
101227
840211
Body, mouthpiece
101237
840477
Mouthpiece
101231
840482
Housing, lower inflator
101246
840490
Spring, non-mag
101248
N/A
Stem, non-mag
101232
840486
Valve, plastic
101233
840487
Diaphragm, inflator MP
101234
840488
Washer
101222
840489
Push button
101236
840496
Cage
Not included in the assembly
Qty
4
1
1
1
1
1
1
1
1
1
3
56 in
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
39
40
762979
104913
1
1
841106
N/A
Whistle ball type
Clamp strap black
28
30
25
26
27
29
Loctite 414 Superbonder
31
32
33
Loctite 425 or 480
34
35
36
37
38
44
EXPLODED PARTS DIAGRAMS
840970 .43L Cylinder w/Valve (export)
41
42
43
44
15 Nm
45
46
47
48
49
50
10 Nm
PN*
840922
228121
228176
213421
840923
850218
840523
840163
840921
840199
228365
840919
850219
840917
850228
840955
Description
Nut, handwheel
Spring
Handwheel
Washer
Plug, valve
O-ring
Washer
O-ring
Spindle
Oldham
Seat, valve
Adapter, valve seat
O-ring
Body
O-ring
Cylinder .43L 220 BAR, black alu
51
Loctite 242
Key #
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
54
53
30 Nm
52
55
56
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
45
ODYSSEA COMPONENTS
12
60
57
59
58
65
Parts Diagram - Front
Key #
12
57
58
59
60
61
62
63
PN
15309
394040
394041
101239
101338
394093
394089
15665
64
490620
65
840970
Description
Gasket, Connector Seal
Bladder, Odyssea Export
Outer Bag, Odyssea export
Airway Complete, Non-Mag
Connector, Cylinder Valve Str. Export
Crotch Strap
Back or Chest Strap
Cap ,Universal Connector
Dump Valve, conv kit ACME 813mm
(32 in) universal (non-mag)
Cylinder, .43Lw/ Valve (Export)
Qty
4
1
1
1
1
1
2
2
1
1
61
62
63
Parts Diagram - Back
63
64
46
OVERHAUL PARTS KITS
840556 Kit, Cylinder Connector
Key # PN
1
820038
4
101335
6
101334
7
820089
8
820005
11
101344
PN*
124704
N/A
850442
N/A
N/A
850443
Description
O-ring
Locknut 5mm
Connector
O-ring
O-ring
Retaining Ring, non-mag
Qty
1
1
1
1
1
1
101240 Kit, Oral Inflator, Atlantis
Key #
14
18
22
27
31
31
37
38
40
PN
15714
778559
15719
101267
101226
101232
101233
101234
101222
PN*
N/A
N/A
N/A
116622
840493
840486
840487
840488
840489
Description
Gasket, REOP
Poppet, dump valve
Clamp, black
Locknut
Valve, rubber
Valve, plastic
Diaphragm, inflator
Washer
Push button
Qty
1
1
3
1
1
1
1
1
1
840971 Kit, Cylinder (Export)
Key #
46
47
48
51
54
55
PN*
850218
840523
840163
228365
850219
850228
Description
O-ring
Washer
O-ring
Seat, valve
O-ring
O-ring
Qty
1
1
1
1
1
1
Key # PN
N/A
42611
Description
Bladder Repair Kit
Qty
1
47
TECHNICAL DATA
ANNUAL MAINTENANCE
The 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.
Composition:
•
1 Bladder (Key #57) is constructed of heavy duty urethane with RF welded seams and connectors.
•
1 Outer bag (Key #58) 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 #64 and top of airway complete Key #59).
•
2 Drain caps (located rear inside lobes Key #63).
•
1 Oral inflation system (Key #59).
•
1 Auxiliary Air Cylinder, with Valve (GERS connection) (Key #65).
(** Refer to Odyssea Components for specific locations)
Features:
LIFT CAPACITY (Fresh Water) . . . . . . . . . 20L (46 lbs)
CYLINDER CAPACITY . . . . . . . . . . . . . . . . 1 X .43L
CYLINDER WORKING PRESSURE . . . . . 200 BAR (2,900 PSI)
DUAL VALVE OPENING PRESSURE (non-mag) .09 - .16 BAR (1.3 - 2.3 PSI)
OVER PRESSURE RELIEF VALVE OPENING PRESSURE (OPRV) (non-mag) .07 - .14 BAR (1 - 2 PSI)
DUAL VALVE & OVER PRESSURE RELIEF VALVE (OPRV) CLOSING PRESSURE IS .07
BAR (1 PSI) UNDER OPENING PRESSURE
WEIGHT (with cylinder) . . . . . . . . . . . . . . 2.7 kg (5.9 lbs)
(without cylinder) . . . . . . . . . . . 1.7 kg (3.8 lbs)
PACKING (Individual box) . . . . . . . . . . . . . 62.2cm X 41cm X 11.4cm
24.5” X 16” X 4.5”
TOTAL PACKED WEIGHT . . . . . . . . . . . . . 3.7 kg (8.1 lbs)
References:
394059: Odyssea Export
Accessories:
840970........0.43 L cylinder with valve (GERS connection)
15665..........Cap (for use without cylinder)
15309..........Connector seal gasket
840817........Adapter, tank fill, GERS
48
Maintenance Notes
49
WARRANTY INFORMATION
All 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, 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.
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.
ODYSSEA
NON-MAGNETIC
2340 Cousteau Court • Vista, CA 92081
Phone (760) 597-5000 • Fax (760) 597-4900
www.aqualung.com/militaryandprofessional
©2011 Aqua Lung International
Literature P/N 18369 Rev. 10/11

tecHnicaL manUaL

Transcription

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