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Kirby Morgan 47 Operation And Maintenance Manual

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Operations and Maintenance Manual
E-Mail: kmdsi@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 Kirby Morgan 47 Helmet. It is page dated June 2012. 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 Kirby Morgan 47 helmet meets or exceeds all performance and testing requirements of all gov-
ernment and non-government testing agencies throughout the world. They are CE approved. It is
approved for use on all commercial and military work underwater.
Kirby Morgan, SuperLite
®
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.
© ⅯⅯⅩⅡ 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.
Kirby Morgan 47 Helmet
KMDSI Part #100-070
Patented, Foreign Patents Pending, other patents apply.
Kirby Morgan Dive Systems, Inc.
Santa Maria, CA 93455, USA
Telephone (805) 928-7772, FAX (805) 928-0342
, BandMask, Band Mask, KMB, KMB-Band Mask, DSI, Diving Systems International, EXO, REX
Document Number 120614002
1430 Jason Way
WARNING
,
®

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  • Page 1 Morgan Dive Systems, Inc. The three dimensional forms of our products are trademark, trade design and trade dress protected. © ⅯⅯⅩⅡ 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.

  • Page 2: Warranty Information

    ® 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 three hundred sixty five (365) days from date of purchase. This warranty covers all metal, fiberglass, and plastic parts. This warranty does NOT cover rubber parts, communications components, or head cushions.

  • Page 3: Record Of Changes

    ® 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

    � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 6 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 7 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 8 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � VIII © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 9 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � Appendix 3 Table 3 Topside High-Pressure Regulator Settings for use with the Kirby © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 10: Definition Of Signal Words Used In This Manual

    Any updates/changes will be posted on the KMDSI website and may be downloaded for insertion/correction. Important Safety Information: This Kirby Morgan diving helmet is intended for use by trained divers who have successfully completed a recognized training course in surface supplied diving.
  • 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 operations using the Kirby Morgan 47. Use of the Kirby Morgan 47 with a pre-existing physical/medical 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 Oral Nasal Mask EGS Valve Equalization Device Regulator Adjustment Knob Non-Return Valve Pull Pin Exhaust ® System Communications Module Purge Button The Kirby Morgan 47 helmet ® ™ © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 15 They are not the part number. Next to the exploded drawing is a list of the “location” numbers that match the Kirby Morgan part num- bers along with the name of the part. Always check the part number when ordering to make sure it is correct.

  • Page 16: Full-Face Masks And Manifolds

    2) no comfort insert is required on the 28 3) the face ports for the 18 and the 28 differ slightly in size. Both the KMB 18 and KMB 28 are approved. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 17 (tender) and one or more surface-supported divers, recompres- sion chambers, or other submersible systems. ™ SuperMask M-48 ™ marked w/ Rebreather pod © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 18: Kirby Morgan Diving Helmets

    SuperLite 17A/B Kirby Morgan ® ® ™ approved and marked approved and marked ™ ™ Yoke and Latch Catch Neck Pad and Assembly Sealed Pull Pins. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 19 In all other respects, this tube adjustable demand regulator. The helmet is helmet is nearly identical to the Kirby Morgan 37. available in the umbilical over the shoulder, “B” configuration only. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 20 All helmets and suits can leak water under certain conditions. Divers should use extreme caution when diving in contaminated waters. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 21 • Rugged helmet shell and other components • No refinishing required if the surface is scratched or gouged • Elimination of threaded inserts for securing port retainer to helmet shell © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 23: Cr Marking

    All the tables reporting the technical data deteriorates or is not legible the user and the pressure of use are relative to should contact the manufacturer. compressed air. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 24: 2�2�2� Notified Body

    Dive Lab at Panama City, Florida. It meets or exceeds member to receive all the strain. There are also good all current U.S. Navy and European diving standards. quality umbilicals available that are assembled at © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 25: Helmet Features

    A quick change communications module, available in either bare wire posts or a waterproof connector, © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 26 Kirby Morgan ® allows for easy, efficient maintenance of the com- 3) The neck dam on the KM 47 is sandwiched be- munications in the helmet. tween the neck dam rings, securely holding it in place. Replacement neck dams install easily. Latex or foam neoprene neck dams are available.

  • Page 27: General Description

    Part #525-330). the gas onto the face port to help eliminate or clear fogging that forms on the port from the diver’s warm breath. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 28 “round robin” or assembly to be unsealed from the diver/tender both mics “on” communications helmet. This simplifies getting out system is used. of the helmet. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 29 Main tube Diaphragm Horseshoe Roller lever Cover Starboard Whisker Inlet valve Adjustment O-ring lock nut Washer Cover Nipple tube Retaining Ring Exploded view of the REX regulator. ® © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 30: 2�9�3 Emergency Gas Supply System (Egs)

    200-017) is fully adjustable and rebuildable and has the diver’s need. The regulator continues to match the been designed to relieve any over-pressurization of diver’s inhalation as the rate increases, peaks, then © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 31: 2�9�4 Helmet Attachment To The Diver

    2.9.4 Helmet Attachment to the Diver gas supply hose. A leaky first stage can On the KM 47, the ring on the base of the helmet overpressure the hose resulting in hose shell has a machined O-ring sealing surface. The rupture.

  • Page 32: 2�9�5 Sealing Arrangement

    NOTE: If you must trim the neck dam, be careful not to trim off too much material. The neck dam must fit snugly. While it may be a slight bit uncomfortable out of the wa- © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 33: 2�9�6 Reducing Carbon Dioxide

    The pad may also be turned upside down (to provide more clearance under the diver’s nose) by rotating the shaft. The KMDSI Welding Lens for Kirby Morgan helmets (KMDSI Part #525-403) © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 34: Helmet Transport And Storage

    A special took kit, Part #325-630 is available that will assist you in removing and adjusting the REX ® regulator on the Kirby Morgan 47 helmet. Packaging Step 2 © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 35: Use Of Kirby Morgan Original Replacement Parts

    Users of Kirby Morgan life support equipment are cautioned to always use Kirby Morgan original re- Packaging Step 5 placement parts. Parts manufactured by third party companies can cause accidents. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 36 Kirby Morgan ® Look for the Kirby Morgan logo on Kirby Morgan products. This is your assurance that you are getting genuine Kirby Morgan replacement parts. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 37: Chapter 3.0 Operating Instructions

    Operating Instructions WARNING This manual is our effort to explain the operation, maintenance and use of the Kirby Morgan hel- met. 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 model of commercial diving helmet that they have not previously used or trained in, prior to use on the job.
  • Page 38 4.5 acfm to the diver at depth. Only systems that can deliver the required gas flow should be used. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 39: First Use Of Your Kirby Morgan Diving Helmet

    A neck dam that is too tight could cause the diver to pass out due to pres- sure on the carotid artery in the neck. This could lead to severe personal injury or death. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 40: 3�4�3 Adjusting The Neck Pad

    Do not trim more Washer Adjustment nut Teflon ® Washer Washer Locking collar Hinge bolt Washer Screw Locking Collar components. T-washer Neck pad © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 41: Pre Dress-In Procedure

    8) Inspect the sealed pull pin on each side of the helmet. They must engage and disengage properly. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 42: Preparing The Helmet For Diving

    You can test the one way valve by connecting the bailout bottle to the emergency valve and pressurizing the sideblock. There must be no gas leakage through the one way valve. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 43: Emergency Gas System (Egs)

    This harness is the best method of securing the emergency breathing gas to the diver. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 44 If the first stage develops a leak, the full pressure of the tank could be placed on the low pressure hose. This could cause the hose to burst. The overpressure relief valve will bleed off any leak. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 45 In this way, if you have a leak, you will probably figure it out and will be able to take appropriate action. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 46 • No use of cylinder gas unless emergency occurs Disadvantages • Regulator will flood and need service daily • Two valves to open in * Requires ability to reach cylinder emergency valve without difficulty © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 47 EGS regulator if not frequently serviced and resulting in pos- sible injury or death. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 48: Setting Up To Dive

    To separate the connectors remove the tape, grasp them at the thickest part, place your thumbs against each other, and push apart until the connectors are disconnected. Connecting the waterproof connectors. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 49: Opening The Breathing Gas Supply To The Helmet

    If the face port fails underwater the helmet will flood and drowning may result. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 50: Donning The Kirby Morgan Helmet

    The neck dam is always turned up against the diver’s neck. This is very important! With the neck The tender must be available to assist the diver while he is dressing into his helmet. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 51 Lower the under the hat on the diver’s shoulders. The diver helmet onto the back of your head first, then pivot inserts the tongue on the neck dam/ring assembly © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 52 If the pins are not engaged correctly the neck dam/ring assembly may not seal and the helmet could flood. The diver could drown as a result. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 53: Testing The Breathing System

    This could lead to suffocation and allow breathing. death. With the neck dam ring on the diver’s head, the helmet is installed and the locking collar closed. When the © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 54 Grab the neck ring at the front and use your fingers to gather the neck dam away from your neck in the front. Lift the neck dam over your head. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 55: Diving Procedures

    It is essential for the diver to ensure that the breathing system is working properly before he enters the water. Note the correct attachment of the diver’s umbilical to his harness and the use of a submersible pressure gauge for the bailout system. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 56: Emergency Procedures

    Once at the surface, or inside the bell, the diver may remove the helmet if needed. Never ditch the helmet underwater unless conditions absolutely require that. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 57 If you fall out of the stage with the helmet off but still at- tached to your harness it may be very dif- ficult to swim. Drowning may result. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 58: Post Dive Procedures

    © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 59: Troubleshooting

    Troubleshooting 4.1 General Kirby Morgan diving helmets are highly reliable life support equipment which should not malfunction if proper preventative maintenance procedures are followed. Most problems encountered in using the helmet can be easily remedied. The following information covers most potential operating difficulties.

  • Page 60: Side Valve Malfunction

    Remove hair from this space. base of helmet. Head cushion or chin strap caught Clear cushion or dam under o-ring at neck dam. Regulator assembled improperly. Check for proper assembly. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 61: Demand Regulator Malfunction

    Service regulator. Knob difficult to turn. Stem bent. Replace stem. Valve will not flow gas. Foreign matter in valve. Disassemble, clean, and reassemble. Stripped control knob. Replace knob. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 63: Routine Maintenance

    The daily and monthly inspections will determine The checklist can be laminated placed on a clipboard the necessity for overhaul with greater accuracy than and checked off with a grease pencil. Completion © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 64 The checklist’s are intended to be used for all models of KMDSI SuperLite and KM Helmets and band ® masks. All KMDSI helmet and band mask manuals can be downloaded free at www.kirbymorgan.com. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 65 #2 Phillips blade screwdriver clean rags 7/64 inch Allen wrench driver 9/64 inch Allen wrench driver Other tools may be required for certain specialized 5/32 inch Allen wrench driver operations. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 66 If the face port fails underwater the helmet will flood and drowning may re- sult. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 67: Thread Locker

    Ensure that all excess thread lock- er has been removed. Allow thread locker to cure for at least 3 hours prior to using the component. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 68: General Cleaning Guidelines

    See the most up-to-date procedures for cleaning on age or premature failure of the seal. the Dive Lab website at www.divelab.com. 6.3.1.2 O-ring Inspection: If during routine corrective maintenance O-rings © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 69 The regulator cover and diaphragm need to be removed for cleaning and sanitizing. See Chapter 7 for regulator service procedures. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 70 (gallon), Infection Control Technology ): Ready to lung irritation and/or long-term degrada- use. tion of rubber and silicone components Infection Control Technology of this equipment. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 71: Daily Maintenance

    To wash the head cushion, place it in a solution of Uncover the earphones so they may dry. mild dish soap. Lightly brush the fabric with a soft © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 72: Locking Collar Assembly & Helmet Ring

    A damaged neck cum powder to the neck dam prior to storage and to dam should be replaced. prepare it for the next dive. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 73: Communications Inspection

    If the foam is worn or crumbling it must be replaced (order Part #510-672). Inspect the chin cushion. It, too, must be in good © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 74: Post Dive Disassembly

    Exhaust Thrust Valve Washer Tie Wrap Exhaust Main Body Regulator body Valve Seat Exhaust valve Diaphragm Cover Starboard Whisker Washer The REX Exhaust System ® Cover Retaining Ring © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 75: Post Dive Reassembly

    This would allow the dia- phragm to fall out and the helmet would flood. This could lead to serious person- al injury or death. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 76 Depending on the contaminants, this could lead to serious personal in- jury or death. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 77: One Way Valve

    Ei- seat being followed by the spring. ther situation may lead to personal in- jury or death. The only functional part remaining in the valve © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 78 150 inch lbs. (17 Newton Meters) with kit.) All o-rings should be replaced during normal/ a torque wrench. annual overhauls. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 79 ® tape can interfere with the performance of the one-way valve or the regulator and may block the diver’s air supply. This could lead to death through suffocation. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 80: Side Block Assembly

    With the other wrench, loosen the low- er bent tube nut by turning the wrench up. 3) Unscrew the bent tube nut until it comes free, Remove the nut that holds the air train. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 81 Stud Valve stem Side block O-ring Seat Washer O-ring O-ring Plug Bonnet Knob O-ring Spring Bent tube O-ring Locknut Washer Components of the Side Block © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 82 Seat Washer The air train is mounted on the stud O-ring that is threaded into the sideblock. O-ring Plug Bonnet Knob O-ring Spring Bent tube O-ring Locknut Washer © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 83 A small amount of silicone sealant must be evenly applied to the side block prior to installation on the helmet shell. Use only Dow Corning RTV 732 Multi Purpose sealant or equivalent. ® © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 84 The valve stem usually comes out with the bonnet. The seat should be removed for inspection. Clean all the metal parts to remove salts. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 85: Defogger Valve

    13/16” Open End Attachment on Torque Wrench Minimum mandatory replacement parts during overhaul: Washers, o-rings O-ring Washer Seat O-ring Bonnet Knob Valve Spring Side stem block Washer Locknut Proper assembly of the defogger valve. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 86: Emergency Valve Assembly

    Rinse with fresh wa- ter. Clean all parts. See the cleaning instructions in Remove the lock nut, spring and knob. Chapter 6. Undo the packing nut. Inspect the packing and washer. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 87: Reassembly Of Emergency Valve

    Tighten using good engineer- Valve Body The components of the emergency valve. Packing Knob Lock nut Valve Stem Washer Packing nut Spring © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 88 Any worn fire or explosions which may cause se- or damaged components must be re- vere personal injury or death. placed. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 89: Bent Tube Assembly

    Replace the o-ring on the bent tube if it is worn or free swiveling mount nut on this end of the bent damaged. tube can be unthreaded completely and can slide down the tube. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 90: Reinstallation Of The Bent Tube Assembly

    If the nipple tube threads in- ward this can damage the sealing surface of the inlet valve. NOTE: Run the mount nut up on the inlet nipple hand tight only. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 91: Demand Regulator & Exhaust System Overhaul

    Remove the screws that secure the kidney plates Remove the regulator mount nut. and whiskers. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 92 12) Loosen the adjustment shaft packing nut then body then remove the horseshoe by pulling it off the remove the adjustment knob and shaft assembly main tube. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 93 Main tube Diaphragm Roller lever Cover Horseshoe Starboard Whisker Adjustment O-ring lock nut Washer Cover Inlet valve Nipple tube Retaining Ring Blowapart drawing of the REX regulator. ® © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 94 16) Shake out the inlet valve, it will drop through the inlet nipple side of the tube. The adjustment assembly including the sprint and spacers. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 95 Always replace the valves during sched- uled overhauls. Note: If you need to replace just the seat, this part must be glued to the inlet valve © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 96: Precautions For Cleaning

    22) You will need to remove the sleeve if you are replacing the exhaust whisker body. Nipple tube Inlet valve Use extreme care when cleaning the nipple tube and main tube to avoid damage. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 97 Knob Roll pin O-ring Spacer Spring Adjustment shaft Spacer Sleeve The adjustment system must be clean and properly lubricated to turn freely. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 98 Back side of regulator o-ring o-ring Note the engraved letter “B” on the main tube. It must face outwards, away from the helmet to be installed properly. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 99 The lever is installed before the horseshoe is 10) Press the main tube all the way into the body installed. until the lever legs are up against the inside wall of the regulator body. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 100 21) Install the left and right whiskers then inspect and age and contamination. Install new valves ensuring install the tie wraps. they are installed onto the correct side of the plastic body. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 101 You can also make jury or death. marks on the whiskers with a felt tip pen. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 102 If needed, turn the regulator assembly on the helmet to allow alignment of the bent tube to the side block. This is how the whiskers should look when they are properly installed on the regulator. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 103 This would allow the dia- phragm to fall out and the helmet would flood. This could lead to serious person- al injury or death. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 104 With the air supply connected, turn the adjustment The regulator can also be adjusted when it is on knob all the way out and back in 3 turns the helmet. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 105: Oral/Nasal Mask

    Nose block Regulator device Mount Nut Exhaust valve Exhaust Oral/Nasal valve body Mask The oral nasal mask and the parts associated with it are easy to access. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 106: Reinstalling The Regulator On The Helmet

    Failure to adjust whiskers. parts to the recommended specifica- tions could lead to helmet failure and ac- cidents. This could be fatal. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 107 6) Install the diaphragm, thrust washer, flexible cover and cover ring to the regulator assembly using the special spanner wrench, as shown. 7) Tighten the regulator mount nut to 80 inch pounds. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 108 NOTE: A deep groove in the soft seat is normal. Nylon toothbrush Replacement is only necessary if the rubber seat is Vinegar, Fresh water deteriorated, cut, and/or chipped. Mild dish soap Ultrasonic sink, if available © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 109 4) Wet the relief valve with soapy water to help in- dicate gas flow 5) Slowly bring up air pressure while watching the intermediate pressure gauge until the pressure gauge © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 110 This procedure also explains the steps necessary for readjusting after cleaning or overhaul. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 111: Helmet Shell Inspection

    & Installation see Chapter 6. For General Clean- should be only be completed by technicians ing Guidelines, including KMDSI recommended specifically trained and certified in these cleaning, sanitizing solutions, and procedures, see procedures. Chapter 6. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 112: Nose Block Assembly

    Enlarged view of nose block device installed Oral/nasal mask Nose block device Nose Block Knob Blowapart drawing of the nose block device and supporting hardware. O-rings Packing nut © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 113: Handle And Weights

    5) Tighten the front mount screws to 12 inch pounds. 6) Wipe off any excess RTV from the helmet shell. Remove the screw at the rear of the handle. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 114 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. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 115 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). © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 116: Face Port

    6) The four whisker spacers must not be misplaced. 7) Remove the old port and sealing O-ring. They will usually be found lodged in the whisker. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 117 Part Be sure to install the O-ring on the back of the port #525-115 Thread Insert Testing Block Kit. retainer. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 118 KMDSI. Handle Port retainer O-ring Nose block Packing nut device Helmet shell Faceport O-ring Kidney plate Spacer Nose block knob Port arrangement Kirby Morgan 47 © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 119: Special Note Regarding Ports

    The nose block guide is threaded into the port re- tainer, and is easily replaced if damaged. Under nor- mal use, the port retainer should never need replace- ment. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 120: Neck Dam

    Blowapart drawing of neck dam assembly for the helmet. 3) Place the stepped ring over the neck dam. The © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 121 Use a small, sharp punch to locate the bottom The neck dam must also be properly aligned from hole. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 122 The cutting edge of the blade should follow the outside rim of the split rings. The point of the blade should © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 123: 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. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 124 This may feel a bit snug above water, but will be very comfortable under water. Trim latex neck dams with the largest, sharpest scissors available. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 125: Neck Dam Pull Strap

    2) Install the two screws that hold the chin strap in Fill the holes where the chin strap attaches with position, using the two screws supplied with the sealant before installing the strap. chin strap replacement kit. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 126: O-Ring Seal Replacement

    This could lead to drowning. 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. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 127: Helmet Ring

    3) Insert the screws into the helmet ring and tighten to 12 inch lbs (1.3 Newton Meters) of torque. Unscrew the hex head screws. The cam angle must be correct for the pins to work properly. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 128: Swing Tongue Catch

    (A quick dry rubber cement works well). Helmet shell Screw Washer Spring spacer Spacer Swing tongue Screw catch Spring Washer Screw Diagram of the swing tongue catch. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 129 Make sure you have not lost the Teflon washer ® when you are ready to reassemble the swing tongue catch. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 130: Locking Collar Removal

    3) Turn the sealed pull pins until they are disen- gaged and lift the locking collar away. Take care not to lose the Teflon washers Loosen the bolt to remove it from the hinge. ® © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 131 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. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 132: Locking Collar Reassembly

    12) Install the second washer onto the protruding hinge pin. 13) Tighten the nut until the bolt just protrudes past the end of the nylock insert. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 133: 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. Note: If the head moves, the helmet should follow. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 134: Communications System

    Comm Module Cover Microphone Screw Earphone Comm Module Washer Washer O-ring Comm Post Comm Nut Wiring Harness The components of the communications system are shown here in exploded view. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 135: Microphone Replacement

    2) Carefully push the communications module through the opening in the helmet shell. The com- munications posts, or waterproof connector assem- Install the microphone in the oral nasal mask. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 136 1. Green WPC Wire 505-047 2. Black (Right) White (Left) Earphone Assem- bly Wires 515-019 Microphone Right Earphone Short Left Earphone Long Diagram depicting correct earphone wire insertion for the Waterproof Connector © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 137: Ⅿⅿⅹⅱ Kirby Morgan Dive Systems, Inc. All Rights Reserved. Document #120614002

    5) Thread the screws into the communications module. 6) Tighten the screws until snug. Do not overtight- 7) Install the rubber cover. Installing the Mount Nut. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 138 Kirby Morgan ® Installing the white wire. Tightening the Mount Nut. Installing the green wire. Installing the red wire. Installing the black wire. Installing the red microphone wire. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 139 Installing the left earphone wires. 4) Screw the nuts on the communications posts and tighten until snug. Do not overtighten. 5) Wipe off any excess silicone sealant from the © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 140 Fumes from this material may irritate your lungs. Read and follow the directions in the MSDS before using this material. Use a wrench to tighten the binding post nuts. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 141: Low Pressure Inflator Hose

    3) Tighten fitting to the specifications provided by the dry suit manufacturer. Do not overtighten. 4) Pressurize helmet and test connection for leaks. Remove the plug from the side block and install the inflator hose here. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 142: Weld Lens Assembly

    Use only the screws provided with the 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. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 143: Weld Shield Assembly

    KMDSI SuperFlow first stage regulator (or any high perfor- ® mance regulator) used for the bail-out supply. The KMDSI Weld Shield Assembly (KMDSI Part #525-400) © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 145: Table Of Equivalents

    PSI (Pounds per Sq. Inch) 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 © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 146: Appendix 1: Torque Specifications

    Mount nut, communications penetrator 2.25 555-178 Packing nut, waterproof connector 2.25 530-024 Screw, split ring Latex Latex Neoprene* Neoprene* 1.58 530-031 Screw, chin strap 550-113 Adjustment nut, neck pad © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 147: Note On Torque Specifications

    222 or equivalent, medium strength only. ® 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. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 148 Kirby Morgan helmets and masks © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 149 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. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 150 CO because the diver cannot ventilate as freely as when breathing at the surface. When breathing air at the deeper depths, nitrogen narcosis can mask © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

  • Page 151: Appendix 3 Table 1 Work Rate Expressed As Respiratory Minute Volume (Rmv)

    50 (heavy work) 62.5 (severe work) 75 (severe work) 92.5 150 P.S.I.G. (10.35 BAR) 40 (heavy work) 10.5 50 (heavy work) 11.7 62.5 (severe work) 75 (severe work) 13.3 © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 152 KMDSI recommends using no less than 40 RMV. ® For more information, check the Dive Lab website, www.divelab.com Click on Technical Section and check for Surface-Supplied Breathing Requirements. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...
  • Page 153 Performance is based on a minimum of 75 RMV to depths of 220 FSW (67 MSW) using a 3/8 (9.5mm) um- bilical 600 foot (183 meters) long, made up of two 300 foot (91 meter) sections. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120614002...

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