Kirby Morgan SuperLite 27 Operation And Maintenance Manual

Kirby Morgan SuperLite 27 Operation And Maintenance Manual

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Operations and Maintenance Manual
E-Mail: Info@KirbyMorgan.com, Web Site:www.KirbyMorgan.com
Manual prepared by Marine Marketing and Consulting, Dive Lab, Inc., and KMDSI.
NOTE: This manual is the most current for the SuperLite 27 Helmet. It is page dated May 2008. Future changes will
be shown on page III and the changed pages will carry the date of change. Previous manuals may not reflect these
updates.
Diving with compressed breathing gas is a hazardous activity. Even if you do everything
right there is always the danger that you may be killed or injured. No piece of diving
equipment can prevent the possibility that you may be killed or injured any time you
enter the water.
The SuperLite 27 helmet is CE Approved and meets or exceeds all performance and testing require-
ments of all government and non-government testing agencies throughout the world. It is approved
for use on all commercial and military work underwater. Only Kirby Morgan masks and helmets
have achieved the CR (Commercial Rated) mark, the highest United States of America rating.
Kirby Morgan, SuperLite, BandMask, Band Mask, KMB, KMB-Band Mask, DSI, Diving Systems International, EXO, REX,
SuperFlow and DECA are all registered trademarks of Kirby Morgan Dive Systems, Inc. Use of these terms to describe products
that are not manufactured by KMDSI is illegal.
The two dimensional images (such as photographs and illustrations) of our products are © copyrighted and trademarks of Kirby
Morgan Dive Systems, Inc. The three dimensional forms of our products are trademark, trade design and trade dress protected.
© Copyright 1970-2007 Kirby Morgan Dive Systems, Inc. All rights reserved. This manual is made available for the express use of
the owner of this Kirby Morgan product. No part of this manual may be reproduced, stored in any retrieval system, or transmitted,
or used in any form or by any means, whether graphic, electronic, mechanical, photocopy, or otherwise by technology known or
unknown, without the prior written permission of Kirby Morgan Dive Systems, Inc.
®
SuperLite
KMDSI Part # 100-027
Kirby Morgan Dive Systems, Inc.
1430 Jason Way
Santa Maria, CA 93455, USA
Telephone (805) 928-7772, FAX (805) 928-0342
WARNING
Document Number
27 Helmet
080528001

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Summary of Contents for Kirby Morgan SuperLite 27

  • Page 1 Manual prepared by Marine Marketing and Consulting, Dive Lab, Inc., and KMDSI. NOTE: This manual is the most current for the SuperLite 27 Helmet. It is page dated May 2008. Future changes will be shown on page III and the changed pages will carry the date of change. Previous manuals may not reflect these updates.
  • Page 2 SuperLite 27 WARRANTY INFORMATION Kirby Morgan Dive Systems, Inc. warrants every new mask, helmet, or KMAC Air Control System to be free from defects in workmanship for a period of ninety (90) days from date of purchase. This warranty covers all metal, fiberglass, and plastic parts. This warranty does NOT cover rubber parts, communications components, or headliners.
  • Page 3 SuperLite 27 RECORD OF CHANGES It is the responsibility of the owner of this product to register their ownership with Kirby Morgan Dive Systems, Inc., by sending the warranty card provided. This card is to establish registration for any necessary warranty work and provides a means of communication that allows KMDSI to contact the user regarding this product.
  • Page 4 We do not herein make any effort to teach the principles of diving. The information in this manual is intended for users of Kirby Morgan helmets and persons that maintain or service Kirby Morgan helmets.
  • Page 5: Table Of Contents

    3.8.2 Connecting the Umbilical to the Helmet 3.8.3 Opening the Breathing Gas Supply to the Helmet 3.8.4 Fogging Prevention 3.8.5 Donning the Helmet 3.8.6 Testing the Breathing System 3.8.7 Sealing Integrity Check © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 6 6.3.2.1 Soap Solution for General Cleaning and Leak Detector Use 6.3.2.2 Acidic Cleaning Solution and Procedures 6.3.2.3 Germicidal Cleaning Solutions and Procedure 6.4 Daily Maintenance 6.5 Monthly Maintenance (or between jobs) © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 7 7.10.2 Tri-Valve™ Exhaust Valve & Regulator Exhaust Valve Replacement 7.10.2.1 Tri-Valve™ Exhaust Valve Replacement 7.10.2.2 Regulator Exhaust Valve Replacement 7.10.3 Tri-Valve™ Assembly Installation 7.11 Main Exhaust Assembly Water Dump © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 8 8.12.2 Reassembly of the Swing Tongue Catch 8.13 Locking Collar 8.13.1 Locking Collar Removal 8.13.2 Locking Collar Disassembly 8.13.3 Locking Collar Reassembly 8.14 Head Cushion and Chin Cushion VIII © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 9 Note on Torque Specifications Appendix A2 - Maintenance and Inspection Procedures Appendix 3 - Pressure Tables Appendix 4 - Standard KMDSI Surface Supply Pressure Formula - Old Method © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 10: Definition Of Signal Words Used In This Manual

    Important Safety Information: This SuperLite 27 diving helmet is intended for use by trained divers who have successfully completed a recognized training course in surface supplied diving. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 11 Diving is a life threatening occupation. Even if you do everything right you can still be killed or injured. None of the models of Kirby Morgan helmets or masks can prevent ac- cidents, injuries or death due to improper training, poor-health, improper supervision, improper job requirements, improper maintenance or acts of God.
  • Page 12 30 lbs. KMDSI recommends that persons with a previous neck or back injury seek professional medical approval prior to engaging in surface supplied diving opera- tions using the SuperLite 27. Use of the SuperLite 27 with a pre-existing physical/medi- cal condition may result in death or serious injury.
  • Page 13 Always read the Material Safety Data Sheet (MSDS) for any chemical - adhesive, clean- ing agent, or lubricant - used on your Kirby Morgan helmet. Some of these chemicals may cause serious bodily injury or death if used improperly or without the proper per- sonal protective equipment.
  • Page 14 EGS valve Equalization device Non-return valve Pull pin Regulator adjustment knob Tri-Valve Exhaust Communications port standard on all SuperLite 27 helmets The SuperLite 27 helmet ™ © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 15: Chapter 1.0 - General Information Kmdsi Products

    They are not the part number. Next to the exploded drawing is a list of the “location” numbers that match the Kirby Morgan part numbers along with the name of the part. Always check the part number when ordering to make sure it is correct.
  • Page 16: The Kirby Morgan Diving Helmets, Masks & Air Control System

    37, 47, and 57. All are commercially rated and marked. SuperLite 17A/B Kirby Morgan 37 ™ marked approved and marked Neck Pad and Yoke and Latch Catch Sealed Pull Pins. Assembly © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 17 The helmet also features the SuperFlow 350 large tube adjustable demand regulator. The helmet is available in the umbilical over the shoulder, “B” configuration only. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 18 Regulator. It's machined from a stainless steel cast- ing for the ultimate in performance and durability. This commercially rated regulator delivers all the breathing gas you need for the most demanding work underwater. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 19 • No refinishing required if the surface is scratched or gouged. • Faster production of helmets for customer deliv- ery. • Elimination of threaded inserts for securing the port retainer to the helmet shell. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 20 Both models have a modular communications design in size. that permits rapid and simple maintenance. The optional Hard Shell provides surfaces for mounting lights, cameras etc. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 21 The Communication Set is a multipurpose intercom- munication system that provides reliable and clear communications between a topside operator (tender) and one or more surface-supported divers, recompres- © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 22: Product Specifications

    SuperFlow regulator. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 23: Cage Code

    Unlike the old double exhaust, the Tri-Valve component failure resulting in does not limit the diving depth. serious injury. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 24 Only proven systems that allow for varying the gas supply pressure to the diver should be used for umbilical diving. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 25: Helmet Features

    The double exhaust was replaced by the Tri-Valve™ System. The unique design of the Tri-Valve™ helps © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 26 This low-pressure area lowers are made of a chemical resistant compound and are the work of breathing and adds another barrier to quite robust. water leaking in. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 27: Helmet Shell

    Most of the components in these areas are interchangeable between the 17A/B and the SL 27. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 28: Gas Flow Systems

    Never attempt to remove or service the chromed ring on the base of the helmet shell. Improper servicing of this ring can lead to helmet flooding and death. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 29 Adjusting the regulator fur- regulator malfunctions. ther in than necessary to keep from free- flowing increases breathing resistance. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 30: Emergency Gas Supply System (Egs)

    Low pressure hoses may be connected to the side block. first stage used for bailout. KMDSI Part #200-017 NOTE: This valve can be adjusted for various relief pressures. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 31: Helmet Attachment To The Diver

    This could lead to drowning. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 32: Sealing Arrangement

    See Appendix 1 for proper torque specifications. Do not over tighten. This could lead to helmet flooding and drowning could result. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 33: Accessories

    Longer screws can damage the port retainer mounting inserts and cause the face port O-ring to leak. The KMDSI Weld Shield Assembly (KMDSI Part #525-400) © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 34: Helmet Carrying Bag

    #525-620). This tool kit ships standard with every Kirby Morgan helmet and band mask equipped with the SuperFlow 350 regulator. The Regulator Tool Kit, Part #525-620. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 35: Chapter 3.0 Operating Instructions

    Operating Instructions WARNING This manual is our effort to explain the operation, maintenance and use of this Kirby Morgan Dive Systems life support equipment. We do not herein make any effort to teach the principles of diving. It is our assumption the reader is a qualified diver. We highly recommend that all divers should train under controlled conditions, in the use of any commercial diving helmet that they have not previously used, or trained in, prior to use on the job.
  • Page 36 In countries that have adopted C.E. standards only C.E. certified supply systems and components may be used in conjunction with the helmet. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 37: First Use Of Your Kirby Morgan Diving Helmet

    Neck dam and locking collar components. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 38: Adjusting The Neck Pad

    Trim the neck dam until it is T-washer snug, then stretch it before use. Neck pad Locking Collar components. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 39: Pre Dress-In Procedure

    8) Inspect the sealed pull pin on each side of the hel- met. They must engage and disengage properly. 9) Make sure the head cushion and chin cushion are properly fastened inside the helmet. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 40: Preparing The Helmet For Diving

    A one way valve repair kit is available for rebuilding these valves (Part # 525-330). © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 41 Scuba regulators may also be used. Connect the first stage hose with a set of quick disconnecting locking sleeves to the emergency valve assembly located on the side block. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 42 EGS hose and the Emergency Valve. This could cause the low-pressure hose to burst resulting in the complete loss of the EGS system. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 43 Disadvantages • Regulator will flood and need service daily • Two valves to open in * Requires ability to reach cylinder emergency valve without difficulty © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 44 In this way, if you have a leak, you will probably figure it out and will be able to take appropriate action. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 45: Setting Up To Dive

    This could also result in a loss of all pressure to the helmet, leaving the diver with nothing to breathe. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 46: Opening The Breathing Gas Supply To The Helmet

    © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 47 Lower Be sure the head cushion is attached to the bottom © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 48 If you have not positioned the sealed pull pins into the locking position you may do it now with the locking collar/neck pad assembly in place. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 49: Testing The Breathing System

    If the diver does not turn the air on he will not be able to breathe, unless the neck dam is pulled away from his neck. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 50: Diving Procedures

    The tender must make sure there is a sufficient length the diver enters the water from the bell and pauses of umbilical clear if the diver is using a jump entry. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 51: Adjust Regulator For Low Work Rates

    In extreme circumstances, carbon dioxide can cause unconsciousness. This could lead to suffocation and death. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 52: Emergency Procedures

    Immediately notify topside, check to ensure your umbilical is clear and return to the diving station us- ing the emergency breathing supply. Avoid making a rapid ascent if at all possible. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 53: Post Dive Procedures

    Once the pins are disengaged grasp the pull strap and pull down on it to remove the helmet. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 54: Chapter 4.0 Troubleshooting

    Troubleshooting 4.1 General Kirby Morgan diving helmets are highly reliable diving helmets which should not malfunction if proper pre- ventative maintenance procedures are followed. Most problems encountered in using the helmet can be easily remedied. The following information covers most potential operating difficulties.
  • Page 55: One Way Valve Malfunction

    Port retainer screws loose. Tighten screws. Neck dam torn. Replace neck dam. Hair caught between o-ring and Remove hair from this space. base of helmet. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 56: Demand Regulator Malfunction

    Stem (20) difficult to turn. Stem (20) bent. Replace stem. Valve (27) will not flow gas. Foreign matter in valve. Disassemble, clean, and reassemble. (See Section 7.5). © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 57: Chapter 5.0 Inspection

    A2.3. Daily Set-Up and Functional Checklist any doubt as to the serviceability of a part or com- A2.4. Supervisor’s Equipment Checks Prior to ponent it should be replaced. Entry © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 58: Yearly Maintenance

    KMDSI SuperLite and KM Helmets and band masks. All KMDSI helmet and band mask manuals can be downloaded free at www.kirbymorgan.com. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 59: Chapter 6.0 General Preventative Maintenance

    1/8, 1/4, and 3/8 inch flat blade screwdrivers rubbing compound #2 Phillips blade screwdriver automotive wax 7/64 inch Allen wrench driver clean rags 9/64 inch Allen wrench driver 5/32 inch Allen wrench driver © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 60: Component And Parts Cleaning

    If the face port fails underwater the helmet will flood and drowning may result. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 61: Teflon Tape

    Read and follow the d i r e c t i o n s i n t h e MSDS before using this material. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 62: Thread Locker

    CAUTION Wear eye protection when using Loctite. This material may irritate your eyes. Read and follow the directions in the MSDS before using this material. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 63: General Cleaning & Inspection Procedures

    Do not use solvents or bleach for cleaning. These agents are toxic and use of them may result in injury or death to personnel and damage to equipment. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 64: O-Ring Removal/Inspection/Cleaning And Lubrication

    6.3.2.3 Germicidal Cleaning Solutions and Procedure Sanitizing of the oral-nasal mask/regulator of Kirby Morgan commercial diving masks and helmets is accomplished using one of four approved germicidal © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 65 NOTE: The purpose of this procedure is to sani- tize the components exposed to each of the divers. KMDSI recommends sanitizing be performed daily © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 66: Daily Maintenance

    3) If the head cushion is wet, remove it from the hel- met and rinse it with fresh water. The head cushion © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 67: Monthly Maintenance (Or Between Jobs)

    Inspect the o-ring on the neck dam ring assembly. It must be in good condition with no nicks, tears, or cracking. Replace the o-ring if it shows signs of wear. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 68: Head Cushion And Chin Cushion

    Replace the cover and replace the tie wrap. 6.5.4 Communications Inspection Visually inspect the earphones, microphone, wires, © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 69 SuperLite 27 Manual Inspect the exhaust valve for cracks or tears and replace as needed. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 70: Chapter 7.0 Breathing System Maintenance And Repairs

    Either followed by the spring. situation may lead to personal injury or death. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 71: Reassembly Of The One Way Valve

    5) Be careful to wipe the poppet and poppet o-ring lead to death through suffocation. thoroughly, removing nearly all silicone to prevent foreign materials from sticking to these compo- nents. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 72 SuperLite 27 Tighten the non-return (one-way valve) in the sideblock to 150 inch lbs. (270 kg.cm) with a torque wrench. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 73: Side Block Assembly

    This recess may be filled tor inlet nipple. with RTV in older helmets. The RTV must be scraped free to reveal the screw. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 74 A thin putty knife can be pushed between the side block and the helmet shell to help free it. Components of the Side Block & Air Train Air Train Air Train Gasket © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 75: Side Block Assembly Replacement

    Safety Data Sheet. could lead to drowning. Air Train Air Train Screw Gasket The air train is mounted on the stud that is threaded into the sideblock. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 76 In addition, if the demand regulator is not delivering air properly, the diver cannot use the free flow system as a source of breathing air. This could lead to suffocation. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 77: Defogger Valve

    The valve stem usually comes out with the bonnet. Clean all the metal parts to remove salts. The seat should be removed for inspection. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 78: Reassembly Of The Defogger Valve

    O-ring Washer Seat O-ring Bonnet Knob Valve Spring Side stem block Washer Locknut Proper assembly of the defogger valve. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 79: Emergency Valve Assembly

    Replace the emergency valve body if any damage is found. Remove the lock nut, spring and knob. Inspect the packing (22) and washer. Undo the packing nut. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 80: Reassembly Of Emergency Valve

    -1/2 turn. Valve Body The components of the emergency valve. Packing Knob Lock nut Valve Stem Washer Packing nut Spring © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 81 © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 82: Bent Tube Assembly

    Always start removal at the side block end. Replace the o-ring on the bent tube if it is worn or damaged. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 83: Reinstallation Of The Bent Tube Assembly

    6) Hold the mount nut on the end of the bent tube with a wrench and tighten the jam nut against it with a torque wrench to 40 inch pounds. Tool Kit with pouch - Part #525-620. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 84: Demand Regulator Test For Correct Adjustment, Fully Assembled

    Kirby Morgan. Use of other diaphragms may degrade performance and may cause increased breathing re- sistance. This can lead to fatigue and the inability to work at full capacity. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 85 3) Punch out the roll pin using a 3/32 punch. Use a block of wood with a 1/4” hole drilled through it to support the knob. Position the knob so the roll pin © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 86: Reassembly Of Adjustment System

    Use the inlet valve holder from the The regulator mount nut is removed with the regulator tool kit to accurately align these holes. proper wrench. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 87 Adjustment The regulator assembly. Retaining shaft Spacer Regulator Packing Piston body Gasket Diaphragm Inlet valve Clamp Inlet nipple Spacer Exhaust Cover valve Exhaust Roller lever Flange © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 88 #525-620) through the adjustment tube and engage the adjustment nut on the inlet valve. Loosen and remove the adjustment nut by rotating the socket wrench coun- terclockwise. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 89: Inspection Of Demand Regulator Parts

    6) Inspect the whisker. Replace the whisker if it shows signs of wear, aging or any damage. See Section 7.9 for the Tri-Valve Exhaust System. The exhaust valve must be in good condition. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 90 5) Install the washer on the inlet valve. Align the flange and the gasket. Apply a drop of threadlocker to the screws. Install the exhaust valve in the regulator body. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 91 9) Check the roller lever. The lever legs MUST be drawing located in the Appendix. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 92 Exhaust Main Retaining shaft Body Spacer Packing Piston Kidney Regulator Plate body Diaphragm Inlet valve Clamp Inlet nipple Spacer Exhaust Cover valve Exhaust Roller lever Flange Gasket © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 93 12 inch pounds. 23) Adjust the regulator following instructions in in this chapter. 24) Install the diaphragm, cover, clamp and screw. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 94: Tuning The Superflow 350 Regulator

    Continue until proper tolerances are reached. 11) To bend the lever down, place the disk end of the © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 95: Regulator Steady Flows When Pressured Up: Special Tools Used

    (clockwise) to reduce lever play or “Out” (counter to be bent down slightly. If the regulator does not clockwise) to increase lever play. free flow, slowly depress the purge button until a © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 96 In the situation where the diver is using bottled breathing gas this would result in a rapid consumption of breathing gas. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 97: Regulator Has Low Or No Flow When Pressurized

    One-way valve b. Side block assembly 1. Defogger valve 2. Emergency Valve Assembly 3. Bent Tube Assembly © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 98: Oral/Nasal

    3) Remove the valve body by pushing it out of the oral nasal. 4) Remove the old valve by pulling it out. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 99: Tri-Valve Exhaust

    Water purge deflector Exhaust valve Exhaust main body Exhaust valve insert Exhaust valve Whisker Gasket Exhaust valve Flange Exploded view of the Tri-Valve™ exhaust system. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 100: Tri-Valve™ Exhaust Valve Replacement

    The exhaust valves must be installed properly in the inserts or they will not seal or perform properly. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 101: Regulator Exhaust Valve Replacement

    The regulator exhaust valve must be seated properly. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 102: Tri-Valve™ Assembly Installation

    7/8” adapter to 40 inch pounds. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 103: Main Exhaust Assembly Water Dump

    The components of the Valve purge water dump valve on the Valve body, SuperLite 27 are shown purge here. Exhaust valve Tie wrap Water Purge Deflector Water dump body © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 104: Water Dump Valve Removal

    Water dump body installs here Water purge deflector Water flows through dump valve and out water purge deflector Flow direction through valve Water dump body © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 105: Water Dump Valve Body Removal

    They can also cause long term damage to body tis- sue. Read and follow all precautions listed on the silicone sealant tube. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 106: Overpressure Relief / Bleed Valve Overhaul Procedures

    NOTE: A deep groove in the soft seat is normal. 1/8” Allen wrench Replacement is only necessary if the rubber seat is Nylon toothbrush deteriorated, cut, and/or chipped. Vinegar, Fresh water © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 107: Overpressure Relief Valve Reassembly

    5) Slowly bring up air pressure while watching the intermediate pressure gauge until the pressure gauge indicates 180- 200 p.s.i.g. (12.40-13.78 bar). If the © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 108 This procedure also explains the steps necessary for readjusting after cleaning or overhaul. pressure port. Installation in a high © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 109: Chapter 8 Corrective Maintenance

    Guidelines, including KMDSI recommended specifically trained and certified in these cleaning, sanitizing solutions, and procedures, see procedures. Section 6.3. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 110: Nose Block Assembly

    Nose block device Helmet shell Port retainer Oral/nasal mask Packing Blowapart drawing of the nose block device and O-ring Knob, supporting hardware. nose block © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 111: Handle And Weights

    Torque to 35 inch pounds. 5) Tighten the front mount screws to 12 inch pounds. Remove the screw at the rear of the handle. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 112: Side Weight Removal

    Do not use a screwdriver or similar sharp instrument to remove the weights, as it will damage the fiberglass finish. Use only wooden wedges under corner edg- es of the weights. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 113: Weight Replacement

    2) Use a wooden wedge and a mallet to break the seal between the weight and the helmet shell. 3) Remove the weight and clean off all the old RTV (silicone sealant). © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 114: Face Port

    5) Be sure not to lose the small O-ring that is locat- Remove the face port. ed on the back side of the port retainer at the nose block device packing. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 115: Face Port And Nose Block Replacement

    Re- place the handle as per Section 8.4. Be sure to install the O-ring on the back of the port retainer. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 116 Without the correct tension the port retainer may come loose and the helmet could flood. This could lead to drown- ing. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 117: Special Note Regarding Ports

    Although the port will fit into the helmet shell, it will not seal properly. This could lead to flooding of the helmet, resulting in serious personal injury or death. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 118: Neck Dam

    Blowapart drawing of neck dam assembly for the helmet. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 119 4) The alignment marks on the neck dam must be Use a small, sharp punch to locate the bottom positioned directly over the joints in the split rings. hole. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 120 Once the cut is started, pull on the neoprene and maintain tension on it as you continue cutting. The cutting edge of the blade should follow the outside © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 121: Latex Neck Dam Replacement

    4) Lubricate the tips of the neck dam mounting screws lightly with silicone grease. This will prevent Use the screw to punch through the neck dam. them from grabbing and twisting the rubber. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 122: Trimming A Latex Neck Seal

    There should be no jagged edges on the neck dam or it may tear. Trim only 1/4 inch (6.0 mm) off the neck dam at a time, trying it on after each trim. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 123: Neck Dam Pull Strap

    2) Install the two screws that hold the chin strap in sealant before installing the strap. position, using the two screws supplied with the chin strap replacement kit. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 124: O-Ring Seal Replacement

    Wear eye protection when using RTV sealant. This material may irritate your eyes. Read and follow the directions in the MSDS be- fore using this material. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 125: Helmet Ring

    3) Insert the screws into the helmet ring and tighten to 12 inch lbs (39kg.cm.) of torque. The cam angle must be correct for the pins to work Unscrew the hex head screws properly. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 126: Swing Tongue Catch

    3) Remove the screw from the left side of the swing tongue catch. Spring Spacer Spring spacer Swing Catch Diagram of the swing tongue catch. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 127: Reassembly Of The Swing Tongue Catch

    Make sure you have not lost the Teflon washer ® when you are ready to reassemble the swing tongue catch. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 128: Locking Collar

    4) Clean all parts that will be reused. Slide the bolt out from the hinge. Loosen the bolt to remove it from the hinge. Take care not to lose the two Teflon washers © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 129: Locking Collar Disassembly

    T-washers and adjustment nuts for reuse. Prior to disassembly of the locking collar, mark Slide the neck pad off the locking collar. the position of the washers. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 130: Locking Collar Reassembly

    13) Install the second washer onto the protruding hinge pin. 14) Tighten the nut until the bolt just protrudes past the end of the nylock insert. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 131: Head Cushion And Chin Cushion

    The foam for the chin cushion is included when the kit for the head cushion is ordered. The head cushion foam is easily replaceable. The chin cushion. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 132: Communications System

    Comm Post O-ring Back ferrule Comm nut Front ferrule Terminal Waterproof Connector O-ring Packing gland The components of the communications system are shown here in exploded view. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 133: Removal Of Communications Assembly

    The wire for the left speaker is tucked into the space between the bottom of the oral nasal mask and the helmet shell. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 134: Earphone Replacement

    Note the position of the terminal wires. 5) Install the terminals for the earphones. Note that the wires must go on separate terminals as before. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 135: Waterproof Connector

    4) Remove the earphone and microphone wire lugs 7) Install the rubber cover. from the interior of the communications module. 5) Remove the nuts, the wiring harness and washers from the communications posts. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 136: Communications Post Replacement

    Use good ventilation when using RTV seal- ant. Fumes from this material may irritate your lungs. Read and follow the directions in the MSDS before using this material. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 137: Chapter 9.0 Accessories For The Superlite

    Loosen the jam nut at the regulator. If the bent tube will not swivel freely, you must loosen the large nut at the regulator. Remove the free flow knob. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 138 14) Trim the excess ends from the tie wraps. Slide one of the PVC pieces over the bent tube and insert it into the regulator shroud. Install the corrugated tube. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 139 15) Reinstall the defogger knob, spring, and lock nut. Tighten with a flat blade screwdriver until the valve stem is flush with the lock nut face. 16) Reinstall the emergency valve knob, spring, and © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 140: Low Pressure Inflator Hose

    P/N 555-210 must be used. Without a restrictor, a hose failure could deplete the Emergency Gas Supply very rapidly leading to suffocation. This could result in serious personal injury or death. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 141: Weld Lens Assembly Installation

    Weld Lens Kit for installation of this as- sembly. Longer screws will damage the helmet shell and/or the threaded inserts. This could cause flooding through the port. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 142: Weld Shield Assembly

    KMDSI SuperFlow first stage regulator (or any high perfor- mance regulator) used for the bail-out supply. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 143: Table Of Equivalents

    Inches of Mercury (Hg) 2.036 Quarts Gallons 0.25 Square Feet Square Inches Temperature ( F - 32) Temperature ( 0.5555 Tons (U.S.) Pounds 2000 Watts Horsepower 0.001341 © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 144: Appendix 1: Torque Specifications

    Packing nut, waterproof connector 2.25 530-022 Screw, chin strap 530-024 Screw, split ring 14 - latex neck dam, * 1.5 - latex neck dam,* 550-113 Adjustment nut, neck pad © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 145: Note On Torque Specifications

    * For a neoprene neck dam, turn the screw three turns. Screws may need adjustment after several dives. Checklist, Maintenance, and Pre-Dive Inspections For the most current check lists, helmet maintenance procedures, and pre-dive inspections, please check on the Internet at www.divelab.com. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 146 Kirby Morgan helmets and masks © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 147 Regardless of the approved lubricant used, never mix different kinds of lubricants. Persons mixing han- dling and working with breathing gases should be properly trained in all aspects of safe gas handling. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 148 When breathing air at the deeper depths, nitrogen narcosis can mask CO © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 149 3.61 270.45 324.55 11.46 180 PSIG / 12.42 BAR 6.48 259.39 311.27 11.00 5.48 274.24 329.09 11.62 62.5 4.48 280.30 336.36 11.88 3.82 286.36 343.64 12.14 © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 150 222.73 267.27 9.44 120 PSIG / 8.28 BAR 4.79 191.52 229.82 8.12 4.36 218.18 261.82 9.25 62.5 3.73 232.95 279.55 9.87 72.5 3.20 239.77 287.73 10.16 © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 151 5.03 377.27 452.73 15.99 210 PSIG / 14.49 BAR 1.00 40.00 48.00 1.70 6.79 339.39 407.27 14.39 62.5 6.03 376.89 452.27 15.98 5.24 393.18 471.82 16.67 © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 152 Surface Gauge in BAR Minimum Maximum Minimum Maximum P.S.I.G. P.S.I.G. 0-60 0-18 13.8 61-100 19-30 11.4 101-132 31-40 12.4 133-165 41-50 20.7 *166-220 51-61 18.6 20.7 © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...
  • Page 153 (30-40) (9.3) 133-165 (40-50) (11.4) 166-220 (50-67) (15.5) For more information on determining supply pressure related information check the Dive Lab web site at www. divelab.com. © Copyright 1970-2008 Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 080528001...

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