Odyssea Non-Magnetic

Odyssea non-magnetic

technical manual 2 Odyssea Technical Manual

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.

Odyssea BC W/O CYLINDER P/N 394063

You can contact a Technical Advisor via e-mail at: [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

CHANGE RECORD...... 5 INTRODUCTION...... 6 GENERAL PRECAUTIONS & WARNINGS...... 8 PRODUCT OVERVIEW...... 9 SPECIAL FEATURES...... 9 BC Air Breathing...... 9 Pocket...... 10 Drain Plug...... 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 Deflation via Oral Inflator...... 13 Deflation via Dual Exhaust Valve...... 14 Deflation via OPRV / Dump Valve...... 14 DONNING & 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 Non-Mag Assembly...... 29 4 Odyssea Technical Manual

CYLINDER VALVE NON-MAG MAINTENANCE PROCEDURES...... 30 Disassembly...... 30 Assembly...... 32 Cylinder Valve Testing Procedures...... 33 CYLINDER VALVE CONNECTOR NON-MAG MAINTENANCE PROCEDURES...... 34 Disassembly...... 34 Assembly...... 34 FINAL ASSEMBLY AND TESTING...... 34 BC PATCH KIT INSTRUCTIONS ...... 36 TABLE 1: LIST OF TOOLS...... 37 TABLE 2: TORQUE SPECIFICATIONS...... 39 TABLE 3: RECOMMENDED CLEANERS AND LUBRICANTS...... 39 PROCEDURE A: CLEANING AND LUBRICATING...... 40 EXPLODED PARTS DIAGRAM...... 41 ODYSSEA COMPONENTS...... 43 OVERHAUL PARTS KITS...... 44 ANNUAL MAINTENANCE...... 45 TECHNICAL DATA...... 45 ANNUAL SERVICE AND INSPECTION RECORD...... 46 MAINTENANCE NOTES...... 47 WARRANTY INFORMATION...... 49 5

CHANGE RECORD

Change No. Date Title or Description Change made by 6 Odyssea Technical Manual

Introduction 2. All service and repair should be carried out in a work area specifically set up and equipped for the This manual provides factory prescribed procedures task. Adequate lighting, cleanliness, and easy access for the correct service and repair of the Aqua Lung to all required tools are essential for an efficient repair product described in this manual. It is not intended facility. to be used as an instructional manual for untrained 3. As the valve/inflator is disassembled, reusable personnel. The procedures outlined within this components should be segregated and not allowed manual are to be performed only by personnel who to intermix with nonreusable parts or parts from have received Factory Authorized training through other units. Delicate parts, including inlet fittings an Aqua Lung Service & Repair Seminar. If you do and crowns which contain critical sealing surfaces, not completely understand all of the procedures must be protected and isolated from other parts to outlined in this manual, contact Aqua Lung to speak prevent damage during the cleaning procedure. directly with a Technical Advisor before proceeding 4. Use only genuine Aqua Lung® parts provided any further. in the overhaul parts kit for this product. DO NOT attempt to substitute an Aqua Lung® part It is recommended that the Odyssea should be with another manufacturer’s, regardless of any rinsed in fresh water after use, and it should be similarity in shape or size. stripped down and serviced annually. 5. Do not attempt to reuse mandatory replacement However, if at all unsure about the correct functioning parts under any circumstances, regardless of the of the Odyssea, then it must be officially inspected amount of use the product has received since it was immediately. manufactured or last serviced. 6. When reassembling, it is important to follow every An Official Inspection consists of: 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 1. Testing instructions see Pre-Dive Inspection. damaged by excessive stress. 2. Orally inflate the Odyssea. Check that the over pressure relief valve (OPRV)/rapid exhaust valve General Conventions (REV) are operating correctly, tightened down properly and no leaks are detected. Unless otherwise instructed, the following terminology and techniques are assumed: 3. A visual inspection of the Odyssea checking that there is no excess wear to the hook/loop material, 1. When instructed to remove, unscrew, or loosen stitching points are not excessively coming undone, a threaded part, turn the part counter-clockwise. quick release buckles are in good working order 2. When instructed to install, screw in, or tighten and outer bag zipper is moving freely. a threaded part, turn the part clockwise. 4. Auxiliary cylinder is full and no leaks are 3. When instructed to remove an o-ring, use the detected. If the Odyssea fails any of the 4 steps pinch method (see illustration below) if possible, it should be serviced by an Aqua Lung trained or use brass or plastic o-ring removal tool. Avoid service technician. using hardened steel picks, as they may damage the o-ring sealing surface. All o-rings that are General Guidelines removed are discarded and replaced with brand new o-rings. 1. In order to correctly perform the procedures outlined in this manual, it is important to follow Pinch Method each step exactly in the order given. Read over Press upwards on sides of o-ring to the entire manual to become familiar with all create a protrusion. Grab o-ring or procedures before attempting to disassemble insert o-ring tool at protrusion. 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. 7

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.

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.

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. 8 Odyssea Technical Manual 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 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.

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.

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: 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 Aqua Lung at (760) 597-5000 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 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.

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. 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.

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 Odyssea Technical Manual

Pocket The 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 Plug The 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 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 101275

P/N 101314

Fig. 2 Filling the Auxiliary Cylinder To 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.

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. 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

Standard connection Fig. 3 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).

Relief Plug Yoke Knob

Fig. 4 5. Close the relief plug on the adapter by turning clockwise until finger tight.

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.

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.

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. 12 Odyssea Technical Manual

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.

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 connector. Turn the connector nut clockwise and thread 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 counter-clockwise. Close the cylinder valve when the bladder is adequately filled, otherwise, air will escape from the over pressure relief valves (OPRV). 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 itshighest 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.

NOTE: Depressing the oral inflator while the jacket is empty may cause water to enter the air bladder. 14 Odyssea Technical Manual

Deflation via Dual Exhaust Valve Inside 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).

Fig. 8 Fig. 9

Deflation via OPRV / Dump Valve 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’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 A dump air. 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, 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. 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 A E 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 B through the sewn-in loop on the crotch strap (C). D

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 C insert the male buckle with the other hand (D).

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

A 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 Odyssea Technical Manual

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.

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 leaks 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 Fig. 20 Check stitching points

Fig. 21 18 Odyssea Technical Manual

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

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 3,000 PSI (206 BAR) (Fig 31).

Fig. 31 20 Odyssea Technical Manual

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 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 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).

Fig. 33 Fig. 34 21 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.

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). 22 Odyssea Technical Manual

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

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). 23

4. Turn the cylinder valve clockwise to the on position and BC Bladder Installation 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 1. Insert the bladder (49) back into the outer bag (50) so that the valve (56), airway (51) and cylinder valve connector (48) for connectors line up with the connector holes. 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.

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). 24 Odyssea Technical Manual

3. Pull back the hose (13) from the mouthpiece body (18). Press Note: Before performing any disassembly, refer to the the pin (17) out from one side using a pin punch or similar tool to exploded parts drawing which references all mandatory release the braided nylon cord (12). Remove the hose (13) from the replacement parts. These parts should be replaced with dual valve assembly, set the dual valve assembly to the side. 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: 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. Oral Inflator

Disassembly

Airway Non-Mag Maintenance 1. Using the spanner wrench (pn 129198) to hold the push button Procedures (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). 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 a straight blade screwdriver, carefully lift out the fingers of the cage (27) and remove it from lower inflator housing (20).

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.

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 (21) through the front of the lower inflator housing (20). Remove the mouthpiece (19) from Dual Valve the mouthpiece body (18). 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.

1. Locate the seam that runs along the circumference between the 4. Using the spanner wrench (pn 129198), turn the push button (26) dual valve body (2) and the outer cap (6), where the cap is fastened counter-clockwise to loosen. It may be necessary to secure the stem to the body. Using the plastic handle of a medium size screwdriver, (22) in a vise or a pair of soft jawed pliers to loosen the push button or similar lightweight blunt instrument, rap sharply against all points (26) as a small amount of Loctite 425 or 480 is used to secure the of the seam on the cap to break the adhesive bond. button. Ensure the stem is protected from damage.

Seam

5. Remove the push button (26), washer (25) and the inflator diaphragm (24) from the stem (22). Next, remove the plastic valve CAUTION: Do not apply excessive force or use a hammer, (23) from the stem. It may be necessary to secure the stem in a mallet or other heavy instrument. 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 2. While holding the dual valve assembly secure, firmly grasp the (25), inflator diaphragm (24) and plastic valve (23). outer cap (6) and turn it counter-clockwise to loosen. While maintaining 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.

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

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 Odyssea Technical Manual

3. Remove the valve plate (4) with gasket (3) from the body (2) and NOTE: Before performing any assembly, it is important remove the gasket from the valve plate. Discard the gasket and set to inspect all parts, both new and those that are being the valve plate aside. 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 4. Locate the two holes on opposite sides of the barrel of the dual may render the product unsafe and could result in serious valve body (2) which hold the arms of the poppet guide (10). To injury or death. 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. Oral Inflator

Assembly

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

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.

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. 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). Loctite 425 or 480

This Concludes Disassembly of the Dual Valve Before starting assembly, perform parts cleaning and lubrication in accordance with Procedure A: Cleaning and Lubricating in the back of the manual. 27

3. Install the diaphragm (24) over the large threaded end of the 6. Using needle nose pliers, place the rubber valve (16) flat end stem (22) until it rests against the face of the plastic valve (23). up over the small diameter threads of the stem (22). Install the Place the washer (25) on top of the diaphragm (24) followed by one washer (15) onto the small diameter thread end of the stem so that drop of Loctite 425 or 480 onto the tip of the stem (large threads) the washer is seated on top of the rubber valve. Place the locknut and screw the button (26) onto the stem until it bottoms out against (14) into a 5.5mm nut driver and engage the locknut onto the stem the washer. assembly by turning clockwise.

Loctite 425 or 480

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

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. 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.

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.

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 Odyssea Technical Manual

b. Compress the poppet assembly with the forked end out onto Dual Valve the poppet holding fixture. Using the inflator cord fixture, install the braided nylon cord (12) through the hole in the poppet stem (8) and Assembly round the inflator cord post 2 times (Two loops around post and two passes through the stem). 1. Dip the dump valve poppet (7) into soapy water and press securely (Fixtures can be locally manufactured). onto the barbed tip of the poppet stem (8). Slide the spring (9) onto the stem.

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

Distance between posts 30.5 cm (12 inches)

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

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 Overhand Bow Knot (3) Half Hitches time of service. 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 Note: Braided nylon cord needs to be 56 inches in with the opposite cord end and tying three (3) “Half Hitches”. Trim length and 3/64 inches in diameter. the excess cord to 1/4 inch (0.63 cm) at both knots and seal the cord ends using a propane lighter a. Place the poppet assembly on a flat (clean) surface with the forked end up. Press down on the poppet guide (10) enough to CAUTION: Do not damage the knots with the flame. pass the braided nylon cord (12) through the hole in the poppet stem (8) two times. 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.

Large Rib 29

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

Align Here

This Concludes Assembly of the Dual Valve. Please Refer to Final Assembly and Testing in the back of the manual.

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.

Airway (Non Mag) Assembly

1. Place the spiral hose (13) over the cord hook and compress it to expose the hook. Use the cord hook to pull the braided nylon cord (12) through the spiral hose (small end of 8. Place the over pressure spring (5) directly in the center of the the hose). valve plate (4), standing up.

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.

Gasgacinch Here

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.

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). 30 Odyssea Technical 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 Cylinder Valve (Non-Mag) Maintenance (12) using your thumb and index finger facing up, slide the hose Procedures (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. 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.

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.

Cylinder Valve Disassembly 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 1. Open cylinder valve counter-clockwise and ensure cylinder (46) is diameter of the body mouthpiece hose barb. Allow 15 seconds for the fully depressurized. Place cylinder in cylinder vice jaws (pn 100398), adhesive to get tacky and slide the hose onto the body mouthpiece, with secure in cylinder vise (pn 100397) and remove the cylinder valve the mouthpiece facing to the right hand side of the user as worn. 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.

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

Clamp 2

Clamp 1

This Concludes Assembly of the Airway. Please Refer to Final Assembly and Testing in the back of the manual. 31

3. Use a large flat blade screwdriver to remove the handwheel 6. Holding the valve body assembly in a vise, use a 22mm socket nut (30), handwheel (31) and the handwheel washer (32) from the and flex wrench (pn 9-44363) to remove the valve plug (33) from spindle (39). the valve body (41). Remove the o-ring (34) from the valve plug using the appropriate o-ring tool (pn 944022). Discard o-ring.

4. Holding the valve body assembly in a vise, unscrew the valve 7. Remove the spindle (39) from valve body (41). Remove back-up seat adapter (44) from the valve body (41) using a flex wrench (pn ring (35), o-ring (36), metal washer (37) and plastic washer (38) from 9-44363) with 5-mm hex key adapter (pn 8367A23). the spindle (39).

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

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.

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

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). 32 Odyssea Technical Manual

9. Remove the safety plug (42a) from the port of the valve body (41) Cylinder Valve 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 Assembly the port in the valve body. Discard safety disk and gasket.

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. THIS CONCLUDES DISASSEMBLY OF THE CYLINDER VALVE Note: Install safety disc (42b) with the red side of the disc facing out of the port on the valve body. Before beginning reassembly, perform parts cleaning and lubrication in accordance with Note: DO NOT Lubricate the threads of the safety plug (42a). 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. 2. Lubricate threads of valve seat (40) and screw into the valve body (41) using the spindle (39) until it bottoms against the crown. 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. 33

3. Place parts in the following order onto the spindle (39). 7. Secure the handwheel (31) to the spindle (39) by placing the Lubricated plastic washer (38), metal washer (37), o-ring (36) handwheel nut (30) onto the spindle and tighten it down with a and backup ring (35). 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.

4. Insert the spindle assembly into the valve body (41) ensuring the spindle (39) aligns with the slot in the valve seat (40). 8. Lubricate the o-ring (43) and install on the valve seat adapter Align (44). Apply one drop of Loctite 242 to the small threads of the valve Spindle seat adapter. Secure the valve body assembly in a vise, using a w/ slot 5mm hex key adapter (pn 8367A23) and inch pound torque wrench tighten the valve seat adapter to 90 in/lbs (10.2 Nm).

Loctite 242

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 9. Install a new lubricated o-ring (45) onto valve body (41). Lightly plug to 90 in/lbs (10.2 Nm). Ensure the o-ring is seated back inside lubricate the threads of the valve body. Place cylinder in cylinder vice the valve body. 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).

6. Install washer (32) and handwheel (31) onto spindle (50). This Concludes Assembly of the Cylinder Valve

Cylinder Valve Testing Procedures

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. 34 Odyssea Technical Manual

Cylinder Valve Connector (Non-Mag) Final Assembly and Testing Maintenance Procedures WARNING: Protective eyewear must be worn at all times during testing. Cylinder Valve Connector 1. Inspect gasket (1) for damage, this component may be reused if Disassembly 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 1. Use a brass (944022) or plastic (101302) o-ring tool to remove flat inside the connector and mate the retaining collar of the dual the o-ring (47) from the end of the cylinder valve connector (48). valve body (2) directly over it, onto the manifold. Gently turn the Discard o-ring. 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 (2) sealing surface is properly aligned with the connector on the BC. This is essential to achieve a proper seal.

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.

Cylinder Valve Connector

Assembly 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. 1. Place a new o-ring (47) into the groove on the end of the cylinder Gently turn the collar clockwise to engage the threads, being careful to valve connector. avoid cross threading and hold the cylinder valve connector in the desired position while tightening the retaining collar by hand until snug.

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. 35

3. While holding the dual valve assembly secure, firmly grasp the 6. Manually inflate the BC until it is taut and fully inflated. Press inflator assembly and pull it in a straight line directly away from the the deflation button (26) and then pull down on the oral inflator to dual valve assembly. Check the attachment points of the spiral hose ensure a rapid and unobstructed exhaust using both methods of (13) at both the dual valve assembly and the inflator assembly. If any deflation. Fully inflate the BC once again, and listen closely for any signs of damage or decay can be detected to the spiral hose, it is signs of leakage. important to replace the spiral hose before proceeding any further. Push to Deflate

Pull hose down

Pull Down On Oral Inflator To Deflate

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.

7. Connect the cylinder to the cylinder valve connector. Turn the cylinder valve clockwise to the on position and inflate the bladder 4. Immerse the inflator and surrounding area of the spiral tube in fresh until the over pressure relief valve (OPRV) releases the excess air water to wet the lower portion of the airway assembly. Grasp the spiral from the bladder. Turn off cylinder and remove the cylinder from tube approximately six inches above the inflator assembly and pull the the BC. Check caps (55), airway (51), OPRV/Dump valve (56) and tube in a straight line away from the inflator with moderate force while cylinder valve connector (48) for any signs of leakage. If no leak- holding the inflator secure. Check to ensure that no separation occurs age is detected, let bladder stand inflated for one hour. Check the at the attachment point, and the tube remains seated flush against the firmness of the bladder after one hour has passed. If the bladder base of the inflator housing. 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.

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

This Concludes Final Assembly and Testing Procedures

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. 36 Odyssea Technical Manual

3. Apply a generous coat of Weld-On 4784® adhesive to the material B.C. Patch Kit Instructions of the BC surrounding the hole or tear. Allow this preliminary coat to set for at least 24 hours. WARNING: Do not attempt to perform these procedures using patches or adhesive other than those provided in the BC Patch Kit pn 42611.

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.

WARNING: Adhesive should only be applied in a room with plenty of cross ventilation. Carefully read CAUTION: It is important to prevent any adhesion between all cautions on the label of the adhesive, and avoid the internal surfaces of the bladder caused by the entrance inhaling vapors. 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. B.C. Patch Kit 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

Expiration Date

NOTE: Ensure Weld-On 4784© adhesive is not more than 3 years old.

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 1. Inspect the material of the BC surrounding the hole or tear to this coat to grow tacky, and immediately apply the patch over the hole ensure that it is perfectly clean and dry. Rinse and dry the BC to or tear, using a small roller to press out any pockets of air that may be clean if necessary. 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.

2. Check to ensure that the patch extends at least twice the diameter NOTE: DO NOT allow the patch to set more than 1 hour or length of the hole or tear on all sides. 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 (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.

This Concludes B.C. Patch Kit Instructions 37

Table 1: LIST OF TOOLS PART # DESCRIPTION APPLICATION 129198 Adjustable Face Removal/Installation of Oral Inflator Push Button (26) Spanner

101215 Tank Fill Charging Cylinder Adapter

944022 O-ring Tool Kit Removal/Installation of O-rings (Brass) 103102 O-Ring Tool (Plastic, 5 pk)

820466 Christo-Lube Lubrication of O-rings/Parts (2 oz.) MCG 111

820467 (16 oz.)

9-44363 Flex Handle Removal/Installation of Valve Parts Drive 3/8”

100398 Vise Jaw Inserts for Cylinder Removal/Installation of Cylinder Valve ( For Existing Shop Vise)

9-45171 Diagonal Pliers Removal/Installation of Clamp (11 & 29) (small)

941586 Modified Removal/Installation of Handwheel Nut (30) Screwdriver (short)

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

769354 7/8 in Socket(22mm) Removal/Installation of Plug Valve (33)

9-44333 1/2 in Socket (13 mm) Removal/Installation of Burst Plug (42)

FC34A 1-1/16 inch (27mm) Crowfoot Removal/Installation of Valve Body (41) 38 Odyssea Technical Manual

Table 1: LIST OF TOOLS (continued)

PART # DESCRIPTION APPLICATION N/A Cord Hook Installing Braided Nylon Cord (12) through Spiral Hose (13) (Locally Manufactured)

N/A Poppet Fixture Removal/Installation of Braided Nylon Cord (12) (Locally Manufactured)

N/A Cord Fixture Knot Tying Fixture for Braided Nylon Cord (12) (Locally Manufactured)

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 Torquing of Parts Wrench; 0-132 in.lbs (0-15 Nm) Range

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

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

N/A Needle Nose Removal/Installation of Inflator parts Pliers 39

Table 2: Torque Specifications

PART # DESCRIPTION / KEY ITEM # TORQUE 101167 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

Aqua Lung, PN 820466, or Christo-Lube MCG 111 Lubrication Technologies All o-rings 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.

Oakite Products, Inc. Acid bath for reusable stainless steel and Oakite #31 50 Valley Road brass parts. 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.

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

Degreaser for brass and stainless steel Non-ionic Liquid dishwashing parts; general cleaning solution for plastic “Household” grade detergent (diluted with warm water) and rubber. 40 Odyssea Technical Manual

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 25 PSI (1.7 BAR) 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. 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 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. 41

EXPLODED PARTS DIAGRAMS

1 2 Loctite 425 or 480 101239 Airway Complete Non Mag 3 4 6 Key # PN *PN Description Qty 5 1 15309 N/A Gasket, Connector Seal 4 2 42742 N/A Dual Valve Body Assembly ACME 1 3 15714 N/A Gasket, REOP 1 7 4 15698 N/A Plate, Valve 1 5 15643 N/A Spring, Over Pressure, Non-Mag 1 8 6 15707 N/A Cap REOP 1 7 778559 N/A Poppet, Dump Valve 1 8 778556 N/A Stem, Poppet, Non Mag 1 9 9 15644 N/A Spring, Pull Dump, Non-Mag 1 10 15649 N/A Guide, Poppet 1 10 11 15719 N/A Clamp, Black, Plastic Tie 3 12 17523 N/A Cord Braided Nylon 56 in 13 15149 N/A Hose, Spiral, 11.5 in 1 12 14 101267 116622 Locknut, Non Mag 1 11 15 101247 N/A Washer, Non Mag 1 16 101226 840493 Valve, Rubber 1 13 17 15645 N/A Pin, Retaining, Non-Mag 1 28 18 101227 840211 Body, Mouthpiece 1 29 19 101237 840477 Mouthpiece 1 20 101231 840482 Housing, Lower Inflator 1 21 101246 840490 Spring, Non-Mag 1 22 101248 N/A Stem, Non-Mag 1 11 23 101232 840486 Valve, Plastic 1 24 101233 840487 Diaphragm, Inflator MP 1 25 101234 840488 Washer 1 26 101222 840489 Push Button 1 27 101236 840496 Cage 1 14 17 15 Not included in the assembly 16 28 762979 841106 Whistle, Ball Type 1 29 104913 N/A Clamp Strap Black 1 19 18 *Aqua Lung France Part Numbers

Loctite 414 Superbonder

Loctite 425 or 480 23 24 25

27 42 Odyssea Technical Manual

EXPLODED PARTS DIAGRAMS

101275 Valve Assembly w/2.5CF Cylinder 30 Key # PN *PN Description Qty 30 101173 N/A Nut handwheel, Non-Mag 1 31 31 101172 444242 Handwheel 1 32 101171 213421 Washer Handwheel 1 N/A 32 33 101169 Plug Valve, Non-Mag 1 34 820088P N/A O-ring (10 pk) 1 90 in/lbs 35 828009 444244 Ring Back-up 1 (10 Nm) 33 36 820010P N/A O-ring (25 pk) 1

34 37 101168 444238 Washer 1 35 38 101167 444237 Washer 1 36 39 101166 N/A Spindle, Non-Mag 1 37 40 101165 N/A Seat Valve, Non-Mag 1 38 41 101305 N/A Body, Valve 1 42 487590 N/A Burst Plug Assembly, Non Mag 1 39 42a N/A N/A Safety Plug 1 42b N/A N/A Disc, Safety Red 3,000 PSI (206 BAR) 1 42c N/A N/A Gasket Zytel #101 .206 x .032 1 90 in/lbs (10 Nm) 40 43 820013 N/A O-ring (10 pk) 1 44 101306 N/A Adapter, Valve Seat, Non-Mag 1

41 45 820316P N/A O-ring (10 pk) 1 46 079125 N/A Cylinder 2.5 cu. ft. 3K PSI Black Alu 1 42a *Aqua Lung France Part Numbers 42b 42c 42 90 in/lbs 43 44 (10 Nm)

45 25 ft/lbs (34 Nm)

101314 Connector, Cylinder Valve, Fixed, Non-Mag

Key # PN *PN Description Qty 47 820310P N/A O-ring (10 pk) 1 48 101314 N/A Connector, Cylinder Valve Fixed, Non-Mag 1

*Aqua Lung France Part Numbers 43

ODYSSEA COMPONENTS

1 51 52

50 49

Parts Diagram - Front

Key # PN Description Qty 1 15309 Gasket, Connector Seal 4 49 394040 Bladder, Odyssea Export 1 50 394041 Outer Bag, Odyssea Export 1 51 101239 Airway Complete, Non-Mag 1 52 101275 Valve Assembly w/ 2.5 cf Cylinder, Non-Mag 1 48 101314 Connector, Cylinder Valve Fixed, Non-Mag 1 53 394093 Crotch Strap Kit 1 54 394089 Back or Chest Strap Kit 2 55 15665 Cap, Universal Connector 2 Dump Valve, Conv. Kit ACME 32in (813 mm) 56 490620 1 Universal (Non-Mag)

56 55 55 54 Parts Diagram - Back 44 Odyssea Technical Manual

OVERHAUL PARTS KITS

101314 Connector, Cylinder Valve, Fixed, Non-Mag

Key # PN *PN Description Qty 47 820310 N/A O-ring 1

101240 Kit, Oral Inflator, Atlantis

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

394099 Kit, Maintenance Cylinder Valve

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

Key # PN *PN Description Qty N/A 42611 N/A BCD Repair Kit 1

*Aqua Lung France Part Numbers 45

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.

TECHNICAL DATA Composition: • 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 46 Odyssea Technical Manual

ANNUAL SERVICE & INSPECTION RECORD

Serial Number ______Purchase Date ______

Date Service Technician Name & Number Technician Signature Stamp 47

Maintenance Notes 48 Odyssea Technical Manual

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/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.

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