Combat Swimmer Assault Vest Technical Manual

CSAV
Combat Swimmer Assault Vest

technical manual
Rev.04/09
2 CSAV Technical Maintenance Manual
COPYRIGHT NOTICE
This owner’s manual is copyrighted, all rights reserved. It may not, in whole or in part, be copied,
photocopied, reproduced, translated or reduced to any electronic medium or machine readable form
without prior consent in writing from Aqua Lung International, Inc.
©2009 AQUA LUNG AMERICA

Combat Swimmers Assault Vest (CSAV)
Owner’s Manual P/N 769087
CSAV
PN 769100 (M/L) w/o cylinders
PN 769104 (L/XL) w/o cylinders
PN 769116 (M/L) w/ cylinders
PN 769117 (L/XL) w/cylinders
You can contact a Technical Advisor via e-mail at:

rbedard@aqualung.com
grubin@aqualung.com
dsumian@aqualung.com
dstancil@aqualung.com
Military Sales: ksilver@aqualung.com
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 which are accompanied
by these symbols:
A WARNING indicates a procedure or situation that may

result in serious injury or death to the user.
A CAUTION indicates any situation or technique that will

result in potential damage to the product.
A NOTE is used to emphasize important points, tips and

reminders.
3
CONTENTS
Change Record................................................................................................................................ 5
Introduction...................................................................................................................................... 6
General Precautions and Warnings............................................................................................... 8
Adjustable Harness..................................................................................................................... 9
Outer Container and Air Bladder................................................................................................. 9
Surelock™ Weight Pouches and Sheaths................................................................................ 10
Apparatus Attachment Straps................................................................................................... 10
System Layout............................................................................................................................... 11
Surelock™ Weight Integrated System...................................................................................... 11
Integrated Non-Ditchable Weight Pockets................................................................................ 12
LP Inflator Hose........................................................................................................................ 12
Inflation and Buoyancy.............................................................................................................. 13
Vest........................................................................................................................................... 13
Integrated Power Inflator with Rapid Exhaust Valve (REV)...................................................... 13
Over Presure Relief Valve (OPRV) and Rapid Exhaust Valve (REV)....................................... 13
Air Bladder................................................................................................................................ 13
Air Bladder Removal and Installation Procedure....................................................................... 14
Deflation Methods......................................................................................................................... 16
Deflation Via the Oral Inflator..................................................................................................... 16
Deflation Via the Rapid Exhaust Valve (REV)............................................................................ 16
Over Presure Relief Valve (OPRV)............................................................................................ 16
Areas of Adjustment..................................................................................................................... 17
Torso Length............................................................................................................................. 17
Torso Girth................................................................................................................................ 17
Additional Adjustment............................................................................................................... 18
Rear Sholder Adjustment.......................................................................................................... 18
Dive Apparatus Configuration...................................................................................................... 19
Weight Pouch Setup................................................................................................................. 19
Inflation System Setup.............................................................................................................. 19
Dive Apparatus Configuration...................................................................................................... 20
SCUBA Setup........................................................................................................................... 20
Single Cylinder Setup .............................................................................................................. 21
Twin Cylinder Setup.................................................................................................................. 23
MK 16 Setup............................................................................................................................. 27
MK 25 Setup............................................................................................................................. 28
Pre-Dive Inspection....................................................................................................................... 30
Inspection Checklist.................................................................................................................. 30
Post -Dive Inspection.................................................................................................................... 31
Inspection Checklist.................................................................................................................. 31
Post -Dive Care and Maintenance................................................................................................ 32
Cylinder Valve Maintenance Procedures.................................................................................... 34
Cylinder Valve Disassembly...................................................................................................... 36
Cylinder Valve Assembly........................................................................................................... 37
Cylinder Valve Final Assembly and Testing............................................................................... 33
Powerline w/ Dual Valve Maintenance Procedures.................................................................... 38
Powerline w/ Dual Valve Disassembly...................................................................................... 38
Powerline w/ Dual Valve Assembly........................................................................................... 38
Powerline Final Assembly and Testing...................................................................................... 39
Proposed Maintenance Checks................................................................................................... 41
B.C. Patch Kit Instructions........................................................................................................... 42
CSAV Major Components............................................................................................................. 43
Accessories and Strap Kit Matrix................................................................................................ 44
Table 1: List of Tools..................................................................................................................... 45
Table 2: Torque Specifications..................................................................................................... 47
Table 3: Recommended Cleaners and Lubricants..................................................................... 47
Procedure A: Cleaning and Lubricating...................................................................................... 48
Powerline w/ Dual Valve Exploded View..................................................................................... 49
Cylinder Valve Exploded View...................................................................................................... 50
Spare Parts Kits............................................................................................................................. 51
Technical Data............................................................................................................................... 52
Maintenance Notes........................................................................................................................ 53
Warranty Information.................................................................................................................... 55
5
CHANGE RECORD
Change No. Date Title or Description Change made by
Introduction
2. All service and repair should be carried out in
This manual provides factory prescribed procedures a work area specifically set up and equipped for
for the correct service and repair of the Aqua Lung the task. Adequate lighting, cleanliness and easy
product described in this manual. It is not intended access to all required tools are essential for an
to be used as an instructional manual for untrained efficient repair facility.
personnel. The procedures outlined within this 3. As the valve/inflator is disassembled, reusable
manual are to be performed only by personnel components should be segregated and not allowed
who have received Factory Authorized training to intermix with nonreusable parts or parts from
through an Aqua Lung Service & Repair Semi- other units. Delicate parts, including inlet fittings
nar. If you do not completely understand all of the and crowns which contain critical sealing surfaces,
procedures outlined in this manual, contact Aqua must be protected and isolated from other parts to
Lung to speak directly with a Technical Advisor prevent damage during the cleaning procedure.
before proceeding any further.
4. Use only genuine Aqua Lung® parts provided
in the overhaul parts kit for this product. DO
It is recommended that the CSAV should be NOT attempt to substitute an Aqua Lung® part
rinsed in fresh water after use and it should be with another manufacturer’s, regardless of any
stripped down and serviced annually. similarity in shape or size.
However, if at all unsure about the correct
functioning of the CSAV, then it must be officially 5. Do not attempt to reuse mandatory replacement
inspected immediately. parts under any circumstances, regardless of the
amount of use the product has received since it was
manufactured or last serviced.
An Official Inspection consists of: 6. When reassembling, it is important to follow
every torque specification prescribed in this manual,
1. Pre-dive checklist see page 30. using a calibrated torque wrench. Most parts are
2. Orally inflate the CSAV. Check that the over made of either marine brass or plastic and can be
pressure relief valve (OPRV)/rapid exhaust valve permanently damaged by excessive stress.
(REV) are operating correctly, tightened down
properly and no leaks are detected. General Conventions
3. A visual inspection of the CSAV checking that
there is no excess wear to the hook/loop material, Unless otherwise instructed, the following terminology
stitching points are not excessively coming undone, and techniques are assumed:
quick release buckles are in good working order 1. When instructed to remove, unscrew or loosen
and outer bag zipper is moving freely. a threaded part, turn the part counterclockwise.
4. Auxiliary cylinder(s) are full and no leaks are detected. 2. When instructed to install, screw in or tighten
If a CSAV fails any of the 4 steps, it should be inspected a threaded part, turn the part clockwise.
by an Aqua Lung trained service technician. 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
General Guidelines using hardened steel picks, as they may damage
the o-ring sealing surface. All o-rings that are
1. In order to correctly perform the procedures removed are discarded and replaced with brand
outlined in this manual, it is important to follow new o-rings.
each step exactly in the order given. Read over
the entire manual to become familiar with all
procedures before attempting to disassemble the Pinch Method
Press upwards on sides of o-ring to
product in this manual and to learn which special- create a protrusion. Grab o-ring or
ty tools and replacement parts will be required. insert o-ring tool at protrusion.
Keep the manual open beside you for reference
while performing each procedure. Do not rely on
memory.
7
CAUTION: Use only a plastic 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
(27) from the valve body...”, the number 27 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.
GENERAL PRECAUTIONS & WARNINGS
WARNING: Before using this vest, you must have successfully received training
and certification in the technique of SCUBA diving from a recognized certification
agency (or any Military or government operated diving school). 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.
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 CSAV while continuously exhaling. Continue venting air
to slow your ascent rate if neutral buoyancy cannot be re-established.
WARNING: Your CSAV is not a lift bag. DO NOT rely on it to bring heavy objects
to the surface. Doing so may permanently damage the vest and could result in
serious injury or death.
WARNING: Lubricating of parts is to be performed by a trained technician using

approved lubricants only.
WARNING: Do not apply any type of aerosol spray to the vest. Doing so may
damage certain plastic components, including important valve connections.
WARNING: Repair, service or disassembly is to be performed by a trained technician

only. 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.
9
SYSTEM OVERVIEW
The CSAV is designed for professional use with all types of back or chest worn breathing apparatus.
The CSAV's modular configuration allows for easy multi-mission adaptability. Simple torso and girth
adjustments allows the military diver to custom fit the CSAV. Your CSAV is comprised of the following
four (4) components:
1. Adjustable Harness (See Fig. 1)
- allows for size adjustments to be made for each individual diver.
- evenly distributes the weight of the chosen diving apparatus on the body.
Fig. 1
2. Outer Container and Air Bladder (See Fig. 2)
- 1000D black Cordura® outer bag with MOLLE style webbing for attaching mission related gear/pockets.
- 35 lb. lift capacity bladder made of 200 Denier urethane coated nylon.
Fig. 2
3. SureLock™ weight pouches and sheaths (See Figs. 3-4)

- can be mounted horizontally / vertically on the side of the vest or vertically on the back of the harness.
- positioning depends on type of diving apparatus used.
Fig. 3 Fig. 4
4. Apparatus Attachment Straps (See Fig. 5)

- female buckles are attached to the CSAV.
- male buckle strap kits are provided for each of the three (3) diving apparatuses: MK16, MK 25 &
SCUBA Single and Twin Tanks.
Fig. 5
11
SYSTEM LAYOUT
SureLock™ Weight Integrated System
The CSAV vest is supplied with four (4) removable SureLock™ weight pouches, two (2) 10-lb. pouches and
two (2) 20-lb. pouches. This is a positive locking mechanical release weight system. Each pocket is capable
of holding up to 10 lb. (4.5 kg) or 20 lb. (9 kg) respectively, of lead weights. Hard cast weights or soft weights
can be used. The sheath portion can be attached to the CSAV using the built in “MOLLE” style straps. The
weight pouches can then be inserted or removed in the same manner as other weight integrated diving
BCs. When the weight pouch is inserted in the sheath, the diver should hear and feel the pouch “click” in.
This assures the diver that the weight pouch is firmly and securely attached (See Figs. 6-9).
10lb pocket assembly front 20lb pocket assembly front
Fig. 6 Fig. 7
10lb pocket assembly back 20lb pocket assembly back
Fig. 8 Fig. 9
Integrated Non-Ditchable Weight Pockets
The CSAV is designed with two internal pockets designed for specific placement of two lead weight
pouches. These pockets, pictured below, are located on the rear/inside of the CSAV. Each has a secure
hook and loop closure. These are to be used with 4 lb. soft weights for MK25 and may be used for other
configurations as well (See Fig. 10).
Fig. 10
LP Inflator Hose
A LP inflator hose can be attached to the powerline inflator for open circuit diving. Test operation and
check for leaks (See Fig. 11).
Fig. 11
13
Inflation and Buoyancy

The distribution of the buoyancy chamber 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 unique "split horse collar" design of the CSAV provides a life vest that is easy to don, ditch and
comfortable to wear.
The CSAV can be inflated by:
• Pressurized HP or LP air cylinders.
• Power inflator.
• Oral inflator.
Vest
The vest is made of a rugged 1000 denier black Cordura®. It is designed to provide the following functions:
• Protect the diving air bladder from rips and tears.
• Provide a method of attachment for the rebreather, weight pouches, compressed air inflation
cylinders and other required equipment using the MOLLE attachment system.
Integrated Powerline Inflator with Rapid Exhaust Valve (REV)
The power inflator is equipped with a valve that also permits inflating the CSAV orally. The inflator assembly
is connected to the exhaust valve at the top of the airway with a heavy duty cable. By pulling down on the
inflator assembly, the diver opens the rapid exhaust valve (REV) and is able to easily vent the CSAV for
buoyancy adjustment.
Over Pressure Relief (OPRV) and Rapid Exhaust Valve (REV)

This dual purpose valve protects the bladder from overpressurization by opening the over pressure relief
valve (OPRV) automatically when the internal pressure exceeds ambient. The rapid exhaust valve (REV)
can also be opened manually to facilitate rapid dumping of air.
Air Bladder
The air bladder is heavy-duty 200-denier urethane coated nylon. The tested lift capacity of the CSAV is 35
lb. Its unique low-profile design is achieved through a system of RF welded ligaments that control the bladder
shape during inflation. It is designed to support the diver in a vertical manner while on the surface of the water
and offer balance and stability while diving.
AIR BLADDER REMOVAL AND INSTALLATION PROCEDURE
1. Hardware must be removed prior to removing the bladder. Unscrew the cylinders from the cylinder connectors.
Next, unscrew the cylinder connectors from the bladder (See Fig. 12).
Fig. 12
2. Unscrew the inflator airway from the connector, located on the left shoulder (See Fig. 13).
Fig. 13
15
3. Unzip the outer jacket and remove the bladder (See Fig. 14).
Fig. 14
4. To reinstall the bladder, properly align the threaded connectors on the bladder with the holes on the
jacket. Stuff the bladder back into the vest and insert the connectors through the holes. Reconnect the
inflator, cylinder connectors or caps. Inflate fully and let sit for 15 minutes to ensure proper air integrity
(See Fig. 15).
Fig. 15
DEFLATION METHODS
Throughout the course of a dive, it will be necessary to release air from the CSAV using one of the methods
described below. 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, depending on your position.
WARNING: Whenever you ascend, whether intentionally or accidentally, you must simultaneously
vent air from the vest as needed to maintain buoyancy control. If air is allowed to expand inside the
vest unchecked, you may experience a rapid, uncontrolled ascent, which could lead to serious injury
or death if not immediately corrected. To regain buoyancy control during an uncontrolled ascent, you
must continuously exhaust air from the vest until you have stopped ascending.
Deflation via the Oral Inflator
Air can be vented through the inflator by holding the inflator above your head and depressing the oral
inflator button. This method can be used for making an initial feet-first descent, but is not very useful
while you are in a facedown swimming position.
NOTE: Depressing the oral inflator while the vest is empty may cause water to enter the air bladder.
Deflation via the Rapid Exhaust Valve
Inside the inflator’s corrugated hose is a cable that attaches the inflator to the rapid exhaust valve (REV)
at the top of the airway assembly. You can vent air from the vest by gently tugging straight down on the
inflator. The rapid exhaust valve provides an effective and convenient way to vent air from the vest while
in either an upright or facedown swimming position.
Overpressure Relief Valve

The over pressure relief valve (OPRV) is located inside of the dual valve. This valve relieves air automatically
when the internal pressure of the bladder exceeds ambient, in order to prevent over pressurization.
CAUTION: The proper function of the over pressure relief valve is vital in order to prevent damage to the CSAV
bladder. Unauthorized service or tampering may render this valve inoperable and could cause the bladder to
leak or rupture. This type of damage is not repairable and is not covered under the terms and conditions of Aqua
Lung’s one year warranty.
17
AREAS OF ADJUSTMENT
Although the CSAV is available in two (2) sizes, the outer container and air bladder are the same size
for both models. The harness has three (3) areas of adjustment in order to achieve the best possible
fit for a wide range of divers.
1. Torso length - Find the metal knurled adjuster located at the top corner of the cummerbund.
Adjust the webbing length and secure the excess by using the hook & loop tabs sewn into the strap
ends (See Fig. 16).
Fig. 16
2. Torso Girth - The CSAV has three (3) side release buckles attached to the front of the container.
Don the CSAV, connect and adjust the front buckles. Secure the excess by using the hook & loop
tabs sewn into the strap ends. Lastly, to provide a snug fit, locate and adjust the webbing straps that
connect the container to the harness, located on the back of the harness (See Fig. 17).
Fig. 17
3. Additional adjustment - The CSAV cummerbund can offer an additional 3 - 9 inches of waist
band by removing the metal bolts and aligning the grommets as needed for a snug fit around the
body (See Fig. 18).
Fig. 18
4. Rear Shoulder adjustments - The shoulder straps featured on the CSAV are designed to allow the
diver several additional inches of room if needed. Line up the hook and loop material to the desired length
and then slide the straps in to secure. Release the rear hook & loop straps and slide the container down
on the shoulder straps for additional length (See Fig. 19).
Fig. 19
19
DIVE APPARATUS CONFIGURATION

Weight Pouch Setup
When setting up the CSAV to dive MK 16 or SCUBA, the placement and orientation of the weight
pouches is left to the discretion of the diver, either mounted vertically or horizontally (See Figs. 20-21).
NOTE: When setting up the CSAV to dive MK 25, follow the mandatory weight
configurations on page 28.
Fig. 20 Fig. 21
Inflation System Setup

The 1.5 cu. ft. air cylinders used for inflation are mandatory for the MK 16 and the MK 25.
For SCUBA, the primary source for inflating the vest is LP air from the 1st stage regulator through the
powerline inflator. It is suggested that the HP cylinder connectors used for MK16 and MK25 be removed
from the vest and blanked off using the caps PN 15665 (See Figs. 22-23).
Fig. 22 Fig. 23
DIVE APPARATUS CONFIGURATION
Scuba Setup:
There is one (1) CSAV strap kit that is designed to fit two (2) existing Aqua Lung made SCUBA cylinder
configurations, shown in the two (2) photos below (See Figs. 24-25).
Fig. 24 Fig. 25
Single cylinder, shown with CSAV Twin cylinder, shown with CSAV
Strap Kit (PN 769141). Strap Kit (PN 769141).
NOTE: The four MK 25 female buckles may be removed or left in place for
SCUBA diving operations. Simply undo the MOLLE connectors, remove and
store for future use (See Fig. 26).
Fig. 26
21
SINGLE CYLINDER SETUP

Strap Kit PN 769141
For scuba (single) configuration, use CSAV strap kit PN 769141.
NOTE: Pre-soak the nylon webbing in strap kit PN 769141 used for tank
bands prior to installation. This allows for more flexibility in the straps. The
stabilizer straps will not be used in this configuration.
1. Install traction sleeves onto tank bands. Skip the last loop in the traction sleeve, ensure hook and
loop is face up. Slide the traction sleeves all the way up to the cam-buckle. This allows the proper length
to attach the buckle to the loose end of the strap. (See Figs. 27-28).
DO NOT THREAD TANK BAND

THROUGH LAST SLOT
U U O
N N V
D D E
E E R
R R
Fig. 27 Fig. 28
2. Thread both tank bands through the upper and lower tank band loops on rear of the harness until
the traction sleeves are tight against the cam buckle (See Figs. 29-30).
Upper Tank
Band Loops
Lower Tank
Band Loops
Fig. 29 Fig. 30
3. Lay the vest face down on a clean surface. Carefully place the cylinder down on to the center of the
vest (See Fig. 31).
Fig. 31
4. Securing the tank bands (See Figs. 32-33).
• Align the cylinder so that there is 12 inches between the lower tank band and the bottom of the cylinder.
• Follow number sequence and directional arrows molded into cam buckle.
• Close cam buckle, fastening hook and loop material to secure.
12"
4
2 (ON BACK SIDE)
1 3
Fig. 32 Fig. 33
5. When both tank bands are installed properly, the ends of the tank bands should almost touch the
back of the vest as shown. Adjust as needed (See Fig. 34).
Fig. 34
23
TWIN CYLINDER SETUP

Strap Kit PN 769141
For scuba (twin) configuration, use CSAV strap kit PN 769141.
NOTE: Pre-soak the nylon webbing in strap kit PN 769141 used for tank
bands and stabilizer straps prior to installation. This allows for more flexibility in
the straps.
1. Using a 1/2 inch socket or wrench, remove the upper metal band on the mariner twin pack. Lay
the cylinder set down for safety after removal of the upper band (See Figs. 35-36).
CAUTION: Do not remove the lower metal band. Doing so could cause major
damage to the manifold while handling cylinders.
Fig. 35 Fig. 36
2. Install traction sleeves on to tank bands. Skip the last loop in the traction sleeve, ensure hook and
loop is face up. Slide the traction sleeves all the way up to the cam-buckle. This allows the proper length
to attach the buckle to the loose end of the strap (See Figs. 37-38).
DO NOT THREAD TANK BAND

THROUGH LAST SLOT
U U O
N N V
D D E
E E R
R R
Fig. 37 Fig. 38
3. Thread the tank bands through both lower tank band loops on the rear of the harness from the outside
to the middle. Hook and loop material should be facing inwards on both tank bands. Pull the tank bands
through until the traction sleeves on both bands are tight against the lower tank band loops and butting up
against the cam-buckle (See Figs. 39-41).
Stabilizer Strap Loops
Upper Tank Band Loops
Lower Tank Band Loops
Fig. 39 Fig. 40
Fig. 41
4. Weave both stabilizer straps through the stabilizer strap loops located near shoulders from the
outside to the inside. Allow 6 inches of strap to extend beyond loop as shown (See Fig. 42).
6"
Fig. 42
25
5. Lay the CSAV face down on a clean surface. Carefully lay the twin cylinders down onto the vest while
feeding the ends of the tank bands between the cylinders above the lower tank bands (See Fig. 43).
Fig. 43
6. Securing the tank bands: (See Figs. 44-45).

• Align cylinders so that there is12 inches between the tank straps and the bottom of the cylinders.
• Follow the number sequence and directional arrows molded into the cam-buckle.
• Close the cam buckle and fasten hook and loop to secure.
12"
2 (ON BACK SIDE)
1 3
Fig. 44 Fig. 45
7. Securing the stabilizer straps: (See Figs. 46-47).

• Weave the ends of the stabilizer straps between the cylinders.
• Feed the ends through the bale rings and tighten.
• Fasten hook and loop to secure.
8. When both tank bands and both stabilizer straps are installed properly, the ends should lay between
the cylinders as shown (See Figs. 46-47).
Fig. 46 Fig. 47
27
MK16 SETUP Strap Kit PN 769089
1. Attach all five (5) straps to the MK16 using standard Navy “dog bones.” Straps consist of two (2)
shoulder straps, two (2) waist straps and one (1) Y-crotch strap (See Figs. 48-49).
Fig. 48 Fig. 49
2. Shorten the straps to keep the MK16 high on the back.
NOTE: There are two sets of metal double rings sewn into the shoulder
straps on the adjustable harness. Use the forward position for MK16.
3. When attaching the bottom strap, make sure to connect the buckles to the female buckles on the
D-ring inside of the CSAV. Do NOT connect to the buckles outside of the CSAV (See Figs. 50-51).
Fig. 50 Fig. 51
MK25 SETUP Strap Kit PN 769092
WARNING: The following weight configurations are mandatory to dive

the MK25 with the CSAV.
MK25 with T-bit: a minimum of 16 lbs. must be worn.
- Install a 4 lb. weight in each of the 2 internal/non-ditchable weight
pouches. (refer to page 12).
- Install a 4 lb. weight in each of the 2 back mounted, SureLock™/
ditchable weight pouches.
MK25 with FFM: Diver preference per mission requirements.
WARNING: Gear placement on CSAV may also affect head up flotation.

Test dive all new gear configurations prior to use.
NOTE: Please note that additional weights, chosen to meet each diver’s
individual needs, will be placed in the SureLock™ weight pouches.
Fig. 52
1. Attach the four (4) straps to the MK25. Straps consist of two (2) shoulder and (2) waist straps.
Fig. 53 Fig. 54
29
2. Ensure the MOLLE straps on the CSAV are secure prior to mounting the MK 25 (See Fig. 55).
Fig. 55
3. Attach the MK 25 to the CSAV by connecting the male buckles on the MK 25 to the female buckles at the
shoulders and the waist of the CSAV. Adjust the straps as needed (See Fig. 56).
Fig. 56
CSAV Pre-dive Checklist

Diver Name_____________________________ Date_____________
CSAV Number_________
WARNING: Before each use, the CSAV must be given a thorough visual
inspection and functional test. NEVER dive with a CSAV that shows signs of
damage to its bladder or valves until it has received a complete inspection
and service.
Initials
______ 1. Inspect all buckles and hardware on the harness and container.
______ 2. Manually exercise the Rapid Exhaust Valve (REV) by pulling on the corrugated hose. The
Rapid Exhaust Valve only requires ¼” of travel to exhaust air. Excessive force is not required.
______ 3. Install fully charged air cylinders 3,000 PSI (206 BAR) and/or install LP inflator hose.
______ 4. Now either orally inflate or power inflate the CSAV until the Over Pressure Relief Valve
(OPRV) opens to relieve excess pressure, reseats and keeps the bladder fully inflated.
______ 5. Deflate the CSAV, check the function of both the rapid exhaust valve and the oral inflation
valve (see deflation methods). Ensure rapid and unobstructed exhaust from each valve.

______ 6. Fully inflate CSAV once again listen closely for any signs of leakage.
______ 7. Diving Supervisor check previous steps and record deficiencies below.
WARNING: If any leakage can be heard or if the bladder begins to deflate

within 5-10 minutes, DO NOT attempt to use the CSAV until it has been
repaired by a trained technician.
Remarks
Divers Signature Diving Supervisor Signature

31
CSAV Post-dive Checklist

Diver Name_____________________________ Date_____________
CSAV Number_________
NOTE: Following the post -dive maintenance procedures is essential to ensure the CSAV remains in proper
working condition.
Initials
______ 1. D
epress the oral inflate button and direct fresh water into the airway to rinse the interior of
the CSAV.
______ 2. D
isconnect the powerline inflator from the bladder. Rinse with fresh water. Hang
to dry with the OPRV down to allow complete drainage, utilizing the hook and loop retainer
on the vest.
______ 3. R
emove the two cylinder connectors to allow water to drain out of the bladder. Rinse out
cylinder connectors. Allow CSAV to dry overnight before reinstalling cylinder connectors.
______ 4. Reinstall cylinder connectors and powerline inflator. Inflate CSAV and ensure no water
remains inside bladder. Drain if required.
______ 5. Store CSAV partially inflated in a clean, dry area away from extreme temperatures:
no greater than 120˚F/49˚C and no less than 0˚F/-18˚C.
Remarks
Divers Signature Diving Supervisor Signature

POST DIVE CARE & MAINTENANCE

With proper care, the CSAV will provide many years of reliable service. The following preventive maintenance
must be performed to extend the life of the CSAV:
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 CSAV fabric
to discolor and decay prematurely.
3. Do not allow the CSAV 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 CSAV.
4. Avoid any contact with oil, gasoline, aerosols or chemical solvents.
5. After diving, give the CSAV a thorough fresh water rinse and check for water inside the 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 cylinder connectors or caps (if used).
b) Using a fresh water supply, fill the bladder until about a 1/4 full and reinstall the cylinder
connector or cap (if used). Thoroughly shake the bladder so the water rinses the entire inside
of the bladder. Unscrew both cylinder connectors, caps (if used) and dual valve/oral airway
assembly. Let all the water drain from the bladder. Leave the cylinder connectors, caps (if
used) and oral airway assembly off until the inside of the bladder is dry (Figs.57 & 58).
Fig. 57 Fig. 58
33
c) Reinstall the cylinder connectors, caps (if used) and dual valve/oral airway. Store the CSAV
deflated, away from direct sunlight and in a clean, dry area. Do not store in an enclosed space,
such as a car trunk, where temperatures may fall below 0ºF (-18ºC) or rise above 120ºF (49ºC)
(See Fig. 59).
Fig. 59
CYLINDER VALVE DISASSEMBLY PROCEDURE 3. Use a flat blade screwdriver, remove the handwheel nut
(12), handwheel (13) and the handwheel washer (14) from the
spindle (21).
Note: Before performing any disassembly, refer to the
new and must not be reused under any circumstances
regardless of the age of the valve or how much use it

removal tool (p/n 944022) when removing o-rings
to prevent damage to the sealing surface. Even
replaced with new. DO NOT use a dental pick or any
other steel instrument.
Valve Disassembly
1. Open cylinder valve counterclockwise and ensure cylinder (28) is

fully depressurized. Secure cylinder in cylinder vise (pn 100397) and Note: If the valve seat adapter (26) is not leaking, DO NOT
remove the cylinder valve from the cylinder by turning valve body Remove. Go directly to step 6.
(23) counterclockwise with a 1-1/16 inch (27mm) crowfoot and flex
wrench. When done, remove cylinder from cylinder vise. 4. Holding the valve body assembly in a vise, unscrew the valve
seat adapter (26) from the valve body (23) using a flex wrench
with 5-mm hex socket.
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.
2. Remove the o-ring (27) from the valve body (23). Use the appropriate
o-ring tool (pn 944022). Discard o-ring.
35
5. Using the brass o-ring tool, remove o-ring (25) from the valve 8. Unscrew the valve seat (22) from the valve body (23) using the
seat adapter (26). Discard o-ring. Remove the old blue Loctite spindle (21). Discard valve seat.
from the valve seat adapter and body.
9. Remove the safety plug (24a) from the port of the valve body
6. Holding the valve body assembly in a vise, use a 7/8" (22mm)
(23) using a flex wrench and 1/2” (13mm) socket. Discard safety
socket and flex wrench to remove the valve plug (15) from the
plug. Remove the safety disc, red (24b) and gasket (24c) from the
valve body (23). Remove the o-ring (16) from the valve plug (15)
port in the valve body. Discard safety disk and gasket.
using the appropriate o-ring tool (pn 944022). Discard o-ring.
THIS CONCLUDES DISASSEMBLY OF THE

CYLINDER VALVE
Before beginning reassembly, perform parts
cleaning and lubrication in accordance with
Procedure A: Cleaning and Lubricating p. 48
7. Remove the spindle (21) from valve body (23). Remove back-up
ring (17), o-ring (18), metal washer (19) and plastic washer (20) from
the spindle (21). Discard back-up ring, o-ring and plastic washer.
CYLINDER VALVE ASSEMBLY PROCEDURE 2. Lubricate threads of valve seat (22) and screw into the valve
body (23) using the spindle (21) until it bottoms against the crown.
NOTE: Before performing any reassembly, it is important to
inspect all parts, both new and those that are being reused, to
ensure that every part and component is perfectly clean and
free of any dust, corrosion or blemishes. Before dressing each
o-ring with Christo-Lube®, check to ensure it is clean, supple
and free of any blemish.
WARNING: Use only genuine Aqua Lung® parts,

sub-assemblies and components whenever assembling
any Aqua Lung® product. DO NOT attempt to substitute an
Aqua Lung® part with another manufacturer’s, regardless of
any similarity in shape, size or appearance. Doing so may
render the product unsafe and could result in serious injury
or death.
Valve Assembly
1. Holding the valve body (23) in a vise, install the burst disk
assembly in the following order: gasket (24c), safety disc (24b) 3. Place parts in the following order onto the spindle (21). Lubricated
and safety plug (24a). Torque the safety plug to 90 in/lb (10.2 Nm) washer (20), metal washer (19), o-ring (18) and backup ring (17).
using a 1/2 inch (13mm) socket and Inch Pound torque wrench.
NOTE: The Burst Disk Assembly PN 487590 (24)

comes as a complete kit, it is to be installed together
and cannot be ordered as separate parts.
Note: Install safety disc (24b) with the red side of the
disc facing out of the port on the valve body.
Note: DO NOT Lubricate the threads of the safety plug.

4. Insert the spindle assembly into the valve body (23) ensuring
the spindle (21) aligns with the slot in the valve seat (22).
Align
Spindle
w/ slot
5. Lubricate the o-ring (16) and install it on to the valve plug (15).
Ensure it is in the groove on the plug below the shoulder. Screw the
valve plug (15) back into the body (23) until hand tight. Using a Inch
Pound torque wrench and a 7/8 inch (22mm) socket, tighten the
valve plug to 90 in/lbs (10.2 Nm). Ensure the o-ring (16) is seated
back inside the valve body (23).
37
6. Install washer (14) and handwheel (13) onto spindle (21). 9. Install a new lubricated o-ring (27) onto valve body (23). Lightly
lubricate the threads of the valve body (23). Secure cylinder in
cylinder vise (pn 100397) and screw the cylinder valve into the
cylinder by turning valve body (23) 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).
7. Secure the handwheel (13) to the spindle (21) by placing the

handwheel nut (12) on to the spindle (21) and tighten it down with
a flat blade screwdriver until it stops.
CAUTION: Avoid cross threading the handwheel nut. If

resistance is felt while screwing the handwheel nut on to THIS CONCLUDES ASSEMBLY OF THE
the spindle, stop and start over.
CYLINDER VALVE
Final Assembly and Testing
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.
Note: If the valve seat adapter (26) was removed, continue

with step 8. If it was not removed, proceed to step 9.
8. Lubricate the o-ring (25) and install on the valve seat adapter
(26). Apply one drop of Loctite 242 to the threads of the valve
seat adapter. Secure the valve body assembly in a vise, using a
5mm hex bit and inch pound torque wrench tighten the valve seat
adapter to 90 in/lbs (10.2 Nm).
POWERLINE DISASSEMBLY PROCEDURE 4. Using side-cutters, carefully cut and remove the upper clamp
(3). Slide the hose (4) off the dual-valve assembly (2).
Note: Before performing any disassembly, refer to the
new and must not be reused under any circumstances
regardless of the age of the valve or how much use it

removal tool (p/n 944022) when removing o-rings This Concludes the Disassembly of the
to prevent damage to the sealing surface. Even Powerline Inflator
replaced with new. DO NOT use a dental pick or any POWERLINE ASSEMBLY PROCEDURE
other steel instrument.
Powerline Disassembly 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
1. Turn the retaining collar and remove the dual-valve assembly (2) from free of any dust, corrosion or blemishes. Before dressing each
the manifold. Remove the gasket (1) from the BC manifold. Inspect the o-ring with Christo-Lube®, check to ensure it is clean, supple
gasket for damage. If no damage is found, it may be reused.
and free of any blemish.
WARNING: Use only genuine Aqua Lung® parts,

sub-assemblies and components whenever assembling
any Aqua Lung® product. DO NOT attempt to substitute an
Aqua Lung® part with another manufacturer’s, regardless of
any similarity in shape, size or appearance. Doing so may
render the product unsafe and could result in serious injury
or death.
Powerline Assembly
2. Remove QD cover (6). Using side-cutters, carefully cut and
remove the lower clamp (3).
1. Fit the ribbed hose (4) over the cable assembly and onto the
barrel of the dual valve assembly (2), until it is mated flush at the
base of the barrel. Be sure to align the notch on the dual valve
body assembly (2) with the notch molded into the ribbed hose (4).
3. Pull the ribbed hose (4) off the powerline lower unit (7). Press
the pin out from one side with a pin punch or similar tool to release
the cable. Remove QD cover (6) from ribbed hose.
39
2. Lightly fasten a clamp (3) over the ribbed hose (4) so that it is This Concludes the Assembly of the
evenly seated inside the groove near the end. Position the end of the
clamp to either side, where it will not interfere with the connection with
Powerline Inflator
the QD hose and pull the end of the clamp sufficiently snug. Trim the
excess length with a pair of diagonal side cutters. Final Assembly and Testing of the Powerline
WARNING: Protective eyeware must be worn at all times

during testing.
1. Lay the gasket (1) flat inside the connection manifold and mate
the retaining collar of the body dual valve assembly (2) directly over
it, onto the manifold. Gently turn the collar clockwise to engage the
threads, being careful to avoid cross-threading and hold the airway
in the desired position while tightening the retaining collar by hand
3. Slide the QD cover (6) up the ribbed hose (4). Insert the cable until snug.
retaining pin partly through one of the holes of the powerline lower
unit. Pull back the ribbed hose (4) to expose the crimped retainer CAUTION: Do not use tool to tighten the retaining
of the cable and pass the retainer over the pin. Insert the pin collar onto the B.C. manifold. Doing so may result in
through the opposite side of the powerline lower unit (7), so that it
overtightening or crossthreading and could cause
is flush on both sides of the barrel.
permanent damage that will require replacement of
the bladder.
2. 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.
4. Fit the ribbed hose (4) over the powerline lower unit (7) until it
is mated flush at the base of the barrel. Lightly fasten a clamp (3)
over the ribbed hose so that it is seated evenly inside the groove
near the end. Tighten the clamp and trim the excess length with
diagonal side cutters.
3. Immerse the inflator and surrounding area of the ribbed hose in fresh 6. Depress the inflator button of the powerline inflator several
water to wet the lower portion of the airway assembly. Grasp the ribbed times to ensure that airflow is unobstructed. After releasing the
hose approximately six inches above the inflator assembly and pull the button, listen carefully to ensure that the airflow has completely
ribbed hose in a straight line away from the inflator with moderate force stopped. If internal leakage can be heard, replace the lower unit.
while holding the inflator secure. Check to ensure that no separation
occurs at the attachment point and the ribbed hose remains seated flush
against the base of the inflator housing.
7. Hold the inflator button depressed to fully inflate the B.C. until the
over pressure relief valve (OPRV) of the dual valve assembly opens
to release excess pressure inside the bladder of the B.C. Check the
4. Finally, bend the ribbed hose at a right angle to the inflator operation of the over presure relief valve (OPRV) by inflating the B.C.
assembly, in the direction opposite of the quick disconnect stem. repeatedly to ensure that the valve opens to relieve excess pressure,
If the ribbed hose shows any sign of separating from the inflator yet closes immediately to allow the bladder of the B.C. to remain taut
assembly it is important to replace the clamp. and fully inflated.
8. Press the deflation button and then pull down on the ribbed
hose to test the rapid exhaust valve (REV) to ensure a rapid and
unobstructed exhaust using both methods of deflation. Fully inflate
5. Verify that the first stage regulator which the powerline will be the B.C. once again and disconnect the powerline from the quick
used with has been recently serviced and is adjusted to a stable disconnect hose to listen closely for any signs of leakage.
MP of 130-145 PSI (9-10 bar). Attach the first stage to a cylinder
filled to 3,000 PSI(206 bar). Connect the powerline to the first
stage via the quick disconnect LP hose . Slowly open the valve of
the supply cylinder to pressurize the regulator.
9. If any leakage is heard or if the B.C. has begun to deflate within one
hour, fully inflate the B.C. once again with the powerline inflator and
hold the entire B.C. submerge in fresh water for at least one minute to
determine the source of leakage. During this time carefully observe the
powerline for any signs of bubble formation indicating a leak, especially
around the inflator buttons and B.C. connections. If a continuous leak is
CAUTION: Before pressurizing the first stage, it is impor- detected, the powerline must be examined for damage, contamination
tant to have a properly adjusted second stage attached to of the seals and seating surfaces. If contamination or damage is found,
the first stage. This will provide a safety relief valve if the replace the component.
MP exceeds 145 PSI (10 BAR). Failure to relieve increas-
ing MP may result in damage to the LP hose .
Note: If leakage is not immediately detected, allow
the B.C. to stand for at least one (1) hour to ensure that
none exists.
This Concludes final assembly and

testing of the powerline inflator
41
PROPOSED MAINTENANCE CHECKS FOR THE CSAV
1. Yearly – Perform interior cylinder inspection and clean cylinder.

a. Inspect operation of the cylinder valve.
2. Yearly – Perform a complete leak check on the CSAV.
a. Attach one full cylinder 3,000 PSI (206 BAR) to the vest.
b. Slowly open the cylinder and fully inflate the CSAV until the Over Pressure Relief
valve (OPRV) releases pressure. Close the cylinder.
c. Verify the Over Pressure Relief Valve (OPRV) re-seats and does not leak.
d. Test the Rapid Exhaust Valve (REV) by pulling on the oral inflator until air
releases. NOTE: ¼” is all the pull required. Excess force will damage the airway.
Release the oral inflator and verify no leakage from the REV.
e. Refill the CSAV and remove the cylinder from the vest.
f. Verify no leakage from the cylinder connectors.
g. Allow the vest to sit fully inflated for one hour.
h. After one hour, inspect the CSAV for fullness. If the pressure has gone down
significantly, refill the vest and check the CSAV for leakage by submerging the
vest fully in water and re-test. Repeat steps a-g until no leakage is present or
have the CSAV repaired by a trained technician prior to use.
3. Yearly – Replace the external o-ring on the cylinder connector.
a. Carefully remove the o-ring on the cylinder connector.
b. Replace the o-ring with the new lubricated o-ring.
4. Yearly – Inspect the strap assembly.
a. Inspect all straps for damage or chafing.
b. Inspect all hardware connectors for cracks or breakage.
c. Inspect de-rigging loops for damage (if equipped).
5. Every 5 Years – Rebuild air cylinder supply valve.
6. As Required – Paint HP air cylinder (if painted).
7. As Required – Prepare the BC for extended storage in excess of 30 days
a. Perform Step 2 yearly.
b. Remove both cylinder connectors, the airway and caps.
c. Store the CSAV deflated in a clean, dry area from extreme temperatures: no
greater than 120°F/49°C and no less than 0°F/-18°C.
d. Store cylinders with no less than 50 PSI (3 BAR) or more than 100 PSI (7 BAR).
INSTRUCTIONS FOR PATCH KIT (PN 42611)
Precautions and Warnings:

WARNING: Do not attempt to perform these procedures using patches or adhesives other than
those provided in the patch kit, PN 42611.
WARNING: Do not attempt to patch a hole or tear which is larger than 3/4” in diameter or length.
WARNING: Do not attempt to patch a tear or puncture which is located directly over or
within 2 inches of a seam or internal baffle.
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.
1. Inspect the material of the CSAV surrounding the hole or tear to ensure that it is perfectly
clean and dry. Rinse and dry the jacket to clean if necessary.
2. C heck to ensure that the patch extends at least twice the diameter or length of the holes or
tear on all sides.
3. A pply a generous coat of Weld-On 4784® Vinyl adhesive to the material of the jacket surrounding
the hole or tear. Allow this preliminary coat to set for at least twenty four hours.
CAUTION: It is important to prevent any adhesion between the internal surfaces of

the bladder caused by the entrance of adhesive through the hole or tear. Position
the bladder as needed to maintain a separation of the bladder at the point of the
hole or tear.
4. A fter twenty four hours have elapsed, apply a generous second coat of adhesive to the material
of the jacket surrounding the hole or tear and to the glossy surface only of the patch. Wait exactly
twenty minutes.
5. After twenty minutes have elapsed, apply a third coat of adhesive to the jacket material and a
second coat to the patch. Wait between 5-10 minutes for this coat to grow tacky and immediately
apply the patch over the hole or tear, using a small roller to press out any pockets of air that may be
present between the patch and jacket material. Position a 5 pound soft weight pouch directly over
the patch to apply pressure and allow exactly one hour for the patch to set.
NOTE: DO NOT allow the patch to set for more than one hour before performing the
next step.
6. P
artially inflate the CSAV no more than 3/4 full, causing the inner surfaces of the bladder to
separate if any adhesion has occurred. Apply a final coat of adhesive over the entire patch
area. Allow twenty four hours to completely cure and then fully inflate the jacket to ensure that
leakage is no longer present. If the jacket 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.
43
CSAV Major Components
2
1
3
11
6 7
9
10
8
4
5
Diagram # Item Description Part number

N/A CSAV w/o cylinders, M/L 769100
N/A CSAV w/o cylinders, XL 769104
1 Container, CSAV, Universal 769101
2 Powerline Inflator 42746
3 Harness, CSAV M/L 769102
Harness, CSAV XL 769103
4 Weight pouch, 10 lb. 769084
Weight pouch, 20 lb. 769144
5 Weight sheath, 10 lb. 769083
Weight sheath, 20 lb. 769143
6 Bladder 769105
7 Pocket 1.5 cu. ft. cylinder 769082
8 Gasket, connector seal 15309
9 Cylinder connector 101314
10 Cap 15665
11 Cylinder 1.5 cu. ft. w/ valve 101271
ACCESSORIES
PART NO. DESCRIPTION

101215 SCUBA Charging connector for 1.5 cu. ft. cylinder
101271 1.5 cu. ft. aluminum cylinder and valve
15309 Gasket
15665 Cap (for use without cylinder)
24827 LP inflator hose, 27”
42726 Powerline Inflator
710108USN Weight, 4 lb, MK25, CSAV
769082 Cylinder pocket
769083 Weight sheath, 10 lb.
769084 Weight pouch, 10 lb.
102100 3.0 cu. ft. Cylinder w/Valve HP inflation, 300 ft.
769123 Cylinder pocket HP Inflation
769146 Pocket 3.0 cu. ft. cylinder LPIS
108615 3.0 cu. ft. cylinder, LP Inflation System (LPIS)
108325 SCUBA Charging connector for LPIS
STRAP KIT MATRIX
PART NO. DESCRIPTION

769092 Strap kit, CSAV, MK25
769089 Strap kit, CSAV, MK16
769141 Strap kit, CSAV, SCUBA Single & Twin
45
Table 1: LIST OF TOOLS
PART # DESCRIPTION APPLICATION
9-45171 Side Cutters Removal/Installation of Clamp (3)
101215 Tank Fill Charging cylinder

Adapter
944022 O-ring Tool Removing and installation of o-rings
820466 Christo-Lube Lubrication of O-rings/Parts

(2 oz.) MCG 111
820467
(16 oz.)
9-44363 Flex Wrench Removal of Valve/Connector Parts
100398 Vise Insert Adapter Removal/Installation of Cylinder Valve

( For Existing Shop Vise)
100397 SEA / HABD Secures Cylinder for Removal/Installation of Cylinder Valve

Cylinder Vise
N/A 5mm Hex Removal/Installation of Valve Seat Adapter (26) 5mm key
Socket or Key
N/A 1-1/16 In (27mm) Removal/Installation of Valve Body (23)

Crowfoot
N/A Small Punch Removal/Installation Pin in (Lower Powerline Unit) (7)

Table 1: LIST OF TOOLS (continued)
PART # DESCRIPTION APPLICATION
N/A 3/8 Drive Torque Torquing of Parts

Wrench; 0-15 Nm
(0-132 In/lbs)
Range
N/A 3/8 Drive Torque Torquing of Parts

Wrench; 0-110 Nm
(0-81 Ft/lbs)
Range
N/A 7/8 in (22 mm) & Removal/Installation of Valve Plug (15) 7/8 in (22 mm) socket
1/2 in (13 mm) and Burst Disk Assembly (24) 8 1/2 in (13 mm) socket
socket
47
Table 2: Torque Specifications
PART # DESCRIPTION / KEY ITEM # TORQUE

101169 Plug, valve (15) 90 in/lbs (10 Nm)
101305 Body, valve (23) 25 ft/lbs (34 Nm)
487590 Plug, safety (24) 90 in/lbs (10 Nm)
101306 Adapter, valve body (26) 90 in/lbs (10 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 treat-

ment. 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.
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 or 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) filtered air
and inspect closely to ensure proper cleaning and like-new condition.
Cleaning Plastic & Rubber Parts

Parts made of plastic or rubber, such as powerline lower unit, dual vlave assembly, ribbed hose, etc.,
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 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.
49
powerline w/ dual valve exploded view
42746 Airway Complete, Powerline

Key # P/N Description Qty
42746 Airway complete, Powerline 1
1 15309 Gasket 1
1
2 42743 Dual Valve Assembly 1
3 15719 Clamp, Black 2
4 15740 Ribbed Hose 1 2
5 15735 Hose Clip 2
6 15029 QD Fitting Cover 1
7 42747 Lower Unit, Powerline 1
8 820011 O-ring 1
9 44827 LP Inflator Hose 27” 1
10 820043 O-ring 1
11 778564 Valve Core 1
3
4
5 9
10
7 3 11
Cylinder valve exploded view

12
101271 Valve Assembly w/1.5CF Cylinder

13 Key # P/N Description Qty
394099 Valve Rebuild Kit 1
12 101173 Nut, Handwheel 1
14
13 101172 Handwheel 1
15 90 In/lbs (10 Nm) 14 101171 Washer, Handwheel 1
15 101169 Plug, Valve 1
16 820088 O-ring 6-118 E0540-80 1
16
17 828009 Ring, Backup 8-009 N300-90 1
17
18 18 820010 O-ring 2-010 E0540-80 1
19 19 101168 Washer, Metal 1
20
20 101167 Washer 1
21 101166 Spindle 1
21 22 101165 Seat, Valve 1
23 101305 Body Valve 1
24 487590 Burst Disk Assy. 3,000 PSI (206 BAR), Valve 1
90 In/lbs(10 Nm)
22 24a N/A Safety Plug 1
24b N/A Disc, Safety Red 3,000 PSI 1
23 24c N/A Gasket Zytel #101 .206 x .032 1
24a 25 820013 O-ring 1
24b 25 26 101306 Adapter, Valve Seat 1
24c
24 27 820316 O-ring 2-016 E0667-70 1
28 079105 Cylinder, 1.5 cu. ft.. Black 3,000 PSI, (206 BAR) 1
25 Ft/lbs(34 Nm)
26
27 Loctite 242 (Blue)

90 In/lbs(10 Nm)
28 *PART NUMBERS IN BOLD ITALICS ARE INCLUDED
IN VALVE REBUILD KIT P/N 394099
101314 Cylinder Valve Connector

29 820310 O-ring 2-010 E0667-70 1
30 101314 Connector Fixed 1
29
30
51
SPARE PARTS KITS

769106 Spare Parts Field Kit
PN Description Qty
769106 Spare Parts Field Kit 1
101314 Connector, cylinder valve to vest 2
15050 Screw, threaded, stainless 3/8” male 8
15051 Barrel, threaded. stainless 1/4” female 8
15309 Gasket, connector seal 4
15665 Cap, universal connector 4
44827 Low pressure hose, 27” 2
42746 Airway, complete, powerline 1
769092 Strap kit, CSAV, MK-25 1
769089 Strap kit, CSAV, MK-16 1
769141 Strap kit, CSAV, SCUBA, Single & Twin 1
769105 Bladder, CSAV NSW, packaged 3
769098 Case, Pelican 1500, black, foam padded 1
769099 Kit, buckle set, 1”/1.5”/2”, spare, CSAV 1
769078 Hex key, L-shape, 1/8”, nickel plated 1
947448 Screwdriver, flat tip, 6” 1
101271 Valve Assembly w/ 1.5 cu.ft. cylinder 1
394099 Cylinder Valve Kit

N/S 394099 Cylinder Valve Kit 1
Cylinder Valve Connector

29 820310 O-ring 2-010 E0667-70 1
TECHNICAL DATA
CONTAINER / HARNESS:
• Outer container is constructed of strong 1000D Denier black Cordura®

• Inside mesh; #8855 Raschel Knit Mesh
• Horizontal webbing: 1" nylon AA-55301 with 1000 lb. breaking strength
• Harness: C1-1A, Mil-W-4088, black nylon webbing with 7000 lb. breaking strength
AIR BLADDER
• Material: Single bag welded construction in strong 200 Denier

urethane-coated nylon
• Inflation System: Powerline oral / power inflator with over pressure relief
• 2 drain ports
• Cylinder Connections: 2 HP air cylinders system, with valves
and connectors (sold separately.)
HP CYLINDER (can be purchased separately)
• Capacity: 1.5 cu.ft.

• Working Pressure: 3,000 PSI (206 BAR)
FEATURES
LIFT CAPACITY 35.0 lbs

11.0 lbs w/ cylinders (2)
WEIGHT
8.0 lbs w/o cylinders (2)
PACKING 213/8” X 10” X 31/2”
(indiv. box) (55 cm X 25.5cm X 11.5 cm)
53
Maintenance Notes
Maintenance Notes
55
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 vest 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.
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 has not received training through a recognized certification
agency, shall render void all warranties, expressed or implied.
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.
Restrictions
The following restrictions apply to this warranty:
• This warranty extends to inflator parts and to the seams of the CSAV bladder. Factory
prescribed annual service by a trained technician is required.
• This warranty does not extend to abrasion, punctures, 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.
CSAV
COMBAT SWIMMERS ASSAULT VEST
2340 Cousteau Court • Vista, CA 92081

Phone (760) 597-5000 • Fax (760) 597-4900
www.aqualung.com/military
©2009 Aqua Lung International Literature P/N 769087 Rev. 04/09

Combat Swimmer Assault Vest Technical Manual

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Combat Swimmer Assault Vest Technical Manual

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CSAV

Combat Swimmer Assault Vest

©2009 AQUA LUNG AMERICA

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

Warnings, Cautions and Notes

A WARNING indicates a procedure or situation that may

A CAUTION indicates any situation or technique that will

A NOTE is used to emphasize important points, tips and

CAUTION: Use only a plastic or brass o-ring

4. The following acronyms are used throughout

NOTE: Before performing any disassembly, refer to the

GENERAL PRECAUTIONS & WARNINGS

WARNING: In an emergency such as an out of air situation or uncontrolled rapid

WARNING: In the event of an uncontrolled, rapid ascent, it is important to immediately

WARNING: Lubricating of parts is to be performed by a trained technician using

WARNING: Repair, service or disassembly is to be performed by a trained technician

WARNING: A buoyancy compensator (BC) is NOT a life jacket! It is not designed

3. SureLock™ weight pouches and sheaths (See Figs. 3-4)

4. Apparatus Attachment Straps (See Fig. 5)

SureLock™ Weight Integrated System

10lb pocket assembly front 20lb pocket assembly front

10lb pocket assembly back 20lb pocket assembly back

Integrated Non-Ditchable Weight Pockets

Inflation and Buoyancy

Integrated Powerline Inflator with Rapid Exhaust Valve (REV)

Over Pressure Relief (OPRV) and Rapid Exhaust Valve (REV)

AIR BLADDER REMOVAL AND INSTALLATION PROCEDURE

Deflation via the Oral Inflator

Deflation via the Rapid Exhaust Valve

Overpressure Relief Valve

DIVE APPARATUS CONFIGURATION

Inflation System Setup

DIVE APPARATUS CONFIGURATION

SINGLE CYLINDER SETUP

For scuba (single) configuration, use CSAV strap kit PN 769141.

DO NOT THREAD TANK BAND

2 (ON BACK SIDE)

TWIN CYLINDER SETUP

For scuba (twin) configuration, use CSAV strap kit PN 769141.

DO NOT THREAD TANK BAND

Stabilizer Strap Loops

Upper Tank Band Loops

Lower Tank Band Loops

6. Securing the tank bands: (See Figs. 44-45).

2 (ON BACK SIDE)

7. Securing the stabilizer straps: (See Figs. 46-47).

MK16 SETUP Strap Kit PN 769089

MK25 SETUP Strap Kit PN 769092

WARNING: The following weight configurations are mandatory to dive

WARNING: Gear placement on CSAV may also affect head up flotation.

CSAV Pre-dive Checklist

WARNING: If any leakage can be heard or if the bladder begins to deflate

Divers Signature Diving Supervisor Signature

CSAV Post-dive Checklist

Divers Signature Diving Supervisor Signature

POST DIVE CARE & MAINTENANCE

a) Unscrew one of the cylinder connectors or caps (if used).

CAUTION: Use only a plastic or brass o-ring

1. Open cylinder valve counterclockwise and ensure cylinder (28) is

CAUTION: Loctite 242 is used to hold this part in place

CAUTION: Do not damage the internal surface of the

THIS CONCLUDES DISASSEMBLY OF THE

WARNING: Use only genuine Aqua Lung® parts,