Kirby Morgan 525-115 Manual

The following is Kirby Morgan's approved method for testing the threaded inserts on the Kirby Morgan BandMask
and fiberglass helmets. Testing of the threaded inserts that accept the screws for the port retainer should be done at
least ONCE A YEAR. More often if frequent cutting and welding is performed (reference checklists for helmets
and Band Mask appendices on Kirby Morgan or Dive Lab websites).
When testing the threaded inserts on a helmet or mask, or when removing and replacing the port retainer, it is
crucial that the KMDSI recommended torque specs be followed when tightening the port retainer screws. Any
over torquing of a screw can result in serious damage to either the threaded insert or the surrounding fiberglass
or plastic in the port area. This can lead to loosening of the port retainer and in extreme instances to flooding of
the helmet. This testing procedure is designed to locate any inserts that have been damaged and need replacing.
Any replacement/repair of inserts and the surrounding fiberglass must be carried out by a certified technician that
has been factory trained specifically in threaded insert repair/replacement. Any other repair/replacement is not
authorized by KMDSI and is a potential safety hazard. NOTE: Damaged KMB 28 frames or KMB 28 inserts are
not repairable/replaceable. This calls for a replacement frame.
One of the main causes of insert damage is the over torquing of the port retainer screws. This can be the final
result of poor maintenance of the mask/helmet. Poor maintenance of the O-ring and O-ring groove on the mask/
helmet shell can lead to leaks around the port retainer. Overtightening of the retainer will not solve the leak and
will damage the fiberglass surrounding the inserts. Be sure that only a KMDSI P/N 510-260 O-ring is used for the
seal under the face port. This O-ring is a specially molded soft compound and was designed specifically for this
application. Other O-rings, while being approximately the same size, will not perform correctly and can cause
leaks in the port area, mistakenly leading to overtightening, causing insert damage.
Definitions:
Port Retainer: The metal frame that holds the port in place against the sealing O-ring of the mask or helmet main
shell or frame.
Face Port: The transparent view port that the diver sees through.
Port Retainer Mount Screws: Screws that hold the port retainer to the frame or shell of the mask/helmet.
Kirby Morgan Dive Systems, Inc.
www.KirbyMorgan.com email: kmdsi@KirbyMorgan.com
Part #525-115
Threaded Insert Test Block Kit
Part # Description
430-075 Washer
530-045 Screw
550-115 Insert Test Block
-Threaded Insert Testing Procedure-
© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved.
1430 Jason Way Santa Maria, California 93455
Phone: 805/928-7772
Document # 130611006
Fax: 805/928-0342
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