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Kirby Morgan 37SS, Operation And Maintenance Manual

The Kirby Morgan 37SS is a high-quality diving helmet designed for professional underwater use. To ensure safe operation, it is important to refer to the Operation and Maintenance Manual. You can download the manual for free from manualshive.com, providing essential guidance on using and maintaining this top-of-the-line diving equipment.

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© ⅯⅯⅩⅢ Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 130318002 

IX

Kirby Morgan

®

 37SS 

Table Of Contents

8.2 Helmet Shell Inspection

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

121

8.3 Nose Block Assembly

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

121

8�3�1 Nose Block Assembly Removal

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

121

8�3�2 Nose Block Device Replacement

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

122

8.4 Handle

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

123

8�4�1 Handle Removal 

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

123

8�4�2 Handle Grip Rubber

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

124

8.4.2.1 Handle Grip Rubber Removal

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

125

8.4.2.2 Handle Grip Rubber Replacement

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

125

8�4�3 Handle Replacement

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

125

8.5 Face Port

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

125

8�5�1 General

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

125

8�5�2 Face Port, Port Retainer, and Nose Block Device Removal

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

126

8�5�3 Face Port, Port Retainer and Nose Block Replacement

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

127

8�5�4 Special Note Regarding Face Ports

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

129

8�5�5 Port Retainer

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

130

8.6 Neck Dam 

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

130

8�6�1 Removal of the Neck Dam

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

130

8�6�2 Neoprene Neck Dam Replacement 

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

130

8�6�3 Latex Neck Dam Replacement

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

133

8�6�4 Trimming a Latex Neck Seal

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

134

8.7 Neck Dam Pull Strap

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

135

8�7�1 Neck Dam Pull Strap Removal

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

135

8�7�2 Neck Dam Pull Strap Replacement

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

135

8.8 Snap Tabs, Chin Strap, and Earphone Retainers

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

135

8�8�1 Snap Tab Removal

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

136

8�8�2 Snap Tab Replacement

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

136

8�8�3 Chin Strap Removal

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

136

8�8�4 Chin Strap Replacement

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

136

8.9 O-ring Seal Replacement 

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

138

8.10 Helmet Ring

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

138

8�10�1 Helmet Ring Repairs

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

138

8.11 Sealed Pull Pins

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

138

8�11�1 Removal of Sealed Pull Pins

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

138

8�11�2 Replacement of Sealed Pull Pins

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

139

8.12 Swing Tongue Catch 

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

139

8�12�1 Disassembly of the Swing Tongue Catch

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

140

8�12�2 Reassembly of the Swing Tongue Catch

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

141

8.13 Locking Collar

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

142

8�13�1 Locking Collar Removal

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

142

8�13�2 Locking Collar Disassembly

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

143

8�13�3 Locking Collar Reassembly

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

144

8.14 Head Cushion (pre October 2012)

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

145

8�14�1 Head Cushion Foam

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

145

8�14�2 Chin Cushion

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

146

8�14�3 Chin Cushion Foam

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

146

8.15 Communications System

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

147

8�15�1 General

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

147

8�15�2 Earphone Inspection

  � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �

147

Summary of Contents for 37SS

Page 1: ...ting requirements of all government and non government testing agencies throughout the world Only Kirby Morgan masks and helmets have achieved the Dive Lab CR Commercial Rated mark Kirby Morgan SuperL...

Page 2: ...y at 805 928 7772 You must have a return authoriza tion from KMDSI prior to the return of any item Upon approval from KMDSI return the defec tive part freight prepaid to the KMDSI plant The part will...

Page 3: ...ed regulator tool kit image on first page of chapter 6 pg 51 Removed Loctite 262 from same page Removed Loctite 262 from section 6 2 5 Thread Locker Removed Loctite 262 from the following caption on p...

Page 4: ...dous activity Even if you do every thing right there is always the potential for serious injury or death No one piece of diving equipment can prevent the possibility that you may be injured or killed...

Page 5: ...tions Limitations 10 2 6 1 Using a High Pressure Breathing Gas Supply 11 2 7 Helmet Features 12 2 8 General Description 16 2 8 1 Helmet Shell 16 2 8 2 Gas Flow Systems 16 2 8 3 Emergency Gas Supply Sy...

Page 6: ...e Way Valve Check 35 3 7 Emergency Gas System EGS 38 3 8 Setting Up to Dive 42 3 8 1 Flushing Out the Umbilical 42 3 8 2 Connecting the Umbilical to the Helmet 42 3 8 3 Opening the Breathing Gas Suppl...

Page 7: ...2 4 RTV Sealant 60 6 2 5 Thread Locker 60 6 3 General Cleaning Inspection Procedures 61 6 3 1 O Ring Removal Inspection Cleaning and Lubrication 62 6 3 2 General Cleaning Guidelines 62 6 3 2 1 Mild So...

Page 8: ...gulator on the Helmet 92 7 8 5 Reassembly of the SuperFlow 350 Regulator Adjustment System 94 7 9 Regulator Exhaust System Overhaul 95 7 9 1 Pod System and Regulator Removal 95 7 9 2 Removal of Water...

Page 9: ...ent 133 8 6 4 Trimming a Latex Neck Seal 134 8 7 Neck Dam Pull Strap 135 8 7 1 Neck Dam Pull Strap Removal 135 8 7 2 Neck Dam Pull Strap Replacement 135 8 8 Snap Tabs Chin Strap and Earphone Retainers...

Page 10: ...or Hose 155 9 2 1 Installation of the Low Pressure Inflator Hose 155 9 3 Weld Lens Assembly 155 9 3 1 Weld Lens Assembly Installation 155 9 4 Weld Shield Assembly 156 9 4 1 Weld Shield Assembly Instal...

Page 11: ...ces NOTICE This word is used to address practices not related to personal injury If English is not your native language and you have any difficulty understanding the language of any warnings as they a...

Page 12: ...res are necessary Do not dive in a contaminated environment unless you have been thor oughly trained and equipped for this type of diving Read this manual before using or maintaining the helmet even i...

Page 13: ...y causing regulator flooding This could lead to drowning B WARNING Surface supplied diving can be a strenuous activity The Kirby Morgan 37SS weighs approximately 30 lbs KMDSI recommends that persons w...

Page 14: ...he governing regulating bodies whenever using commercial diving equipment Whenever KMDSI helmets or masks are used in European Countries which have adopted the C E certification programs they must onl...

Page 15: ...t without the team of people that make up Kirby Morgan Dive Systems Inc KMDSI We feel it is important for the reader to understand that we at KMDSI consider ourselves as only part of the process along...

Page 16: ...cameras etc KMB 18 A B The KMB 18B Band Mask frame is constructed of hand laid fiberglass The head harness is a molded strong tear resistant neoprene rubber The hood which attaches to the mask frame w...

Page 17: ...or use in sur face supplied air diving operations The KMACS 5 controls the diver s air supply communications and monitors the diver s depth It allows two divers clear push to talk two wire or round ro...

Page 18: ...marily of two major components the neck dam yoke assembly and the helmet To don the helmet the diver first slips the angled neck dam with the attached yoke over his head The helmet is lowered onto the...

Page 19: ...emblies the helmet shell helmet ring assembly and the neck dam neck ring assembly The helmet comes with the large tube SuperFlow 350 adjustable demand regulator which provides an easier breathing gas...

Page 20: ...gulator It s machined from a stainless steel casting for the ultimate in performance and reliability Like all KMDSI regulators on our helmets and Band Masks we use only regulators that are specificall...

Page 21: ...he SuperFlow 350 is standard on this helmet The Kirby Morgan 37SS features a quick change communications module available with either bare wire posts or a waterproof connector and allows for easy effi...

Page 22: ......

Page 23: ...ablished by Dive Lab of Panama City Florida and is CR Commercially Rated rated with the SuperFlow 350 non balanced regulator C O M M E RCIALLY RATED P R O F E S S I O N A L D I V I N G G E A R D I V E...

Page 24: ...helmet on the Dive Lab web site at www divelab com 2 4 Regulator Performance 2 4 1 SuperFlow 350 Demand Regulators The SuperFlow 350 non balanced regulator is the standard demand regulator found on t...

Page 25: ...Inc 850 235 2715 or at Divelab aol com B DANGER Decompression diving always involves the risk of decompression sickness Omitted decompression due to a loss of the breathing gas supply or other accide...

Page 26: ...other outstanding helmet from Kirby Morgan The KM 37SS incorporates the innovative locking system and communications system of the SuperLite 27 onto a larger KM 37 size stainless steel shell The 37SS...

Page 27: ...ked into place on the helmet it is located up inside the protective helmet ring that the neck ring O ring seals to which protects the neck ring and neck dam from side impact damage during the dive 5 T...

Page 28: ...re released the neck dam maintains a positive seal and will not allow the seal to be broken until the locking collar actually clears the diver s shoulders Air Train diffuses the incoming breathingair...

Page 29: ...ifies getting out of the helmet Sealed Pull Pin Part of the latching system Wings Exhaust System Ultra low resistance exhalation system Very dry Adjustable Neck Pad Helps provide for a cus tomized fit...

Page 30: ...grity 2 8 General Description 2 8 1 Helmet Shell The helmet shell and neck ring is fabricated of 316L stainless steel as a one piece assembly This shell is the central structure for mounting all the c...

Page 31: ...ystem with the control knob The gas enters the helmet and flows through the air train which directs the gas onto the face port to help eliminate or clear fogging that forms on the port from the diver...

Page 32: ...the demand regulator inlet valve The adjustment knob has a range of approximately 13 turns from full in to full out The intent of this bias adjustment device is strictly to allow the diver to make ad...

Page 33: ...of the upper split rings and the lower stepped ring The neck dam is captured sandwiched between these parts The locking collar and neck pad assembly has a smaller opening than a diver s head so the h...

Page 34: ...her Screw The Locking Collar assembly The locking sealed pull pins can only be serviced by KMDSI or an authorized dealer Split Ring Neck Dam O ring Stepped Ring Strap Plate Pull Strap Screw The Neck D...

Page 35: ...rtant to reduce the volume of air gas space that the diver is breathing through Carbon dioxide CO2 can build up if proper flushing does not occur Arubber oral nasal mask is located inside the helmet t...

Page 36: ...These holes are plugged with blanking screws when a new helmet is shipped from the factory The KMDSI Welding Lens for Kirby Morgan helmets KMDSI Part 525 403 B CAUTION Be sure to use only the mount s...

Page 37: ...ity Improperly manufactured parts can cause accidents 2 10 Helmet Transport And Storage the kind of package is a cardboard box with air filled pillows with styrofoam inserts to stabilize the helmet th...

Page 38: ...The bottom of the bag is pad ded for additional protection Grommeted drain holes allow the bag to breathe The bag is also equipped with large carrying straps and side pockets The bag is not intended f...

Page 39: ...ill find that all Kirby Morgan diving hel mets and masks have the breathing system controls located in the same position The operation of this helmet will also be similar The diver must be tended at t...

Page 40: ...gas supply console configurations in use it is important to ensure that the gas supply system used is capable of supplying the helmet with the necessary pressure and flow of gas to allow the diver to...

Page 41: ...ace if needed order head cushion bag 3 4 1 3 Stuffing 1 Read 3 4 1 4 Head CushionAdjustment on page 27 of these instructions first 2 Compare to old foam and trim for adjustment 3 Stuff head cushion 3...

Page 42: ...the head cushion The spacer helps properly position the top and back of the head in the helmet by using a larger foam piece in the lower neck area which helps push the head forward and the nose and m...

Page 43: ...t out template 2 Match template to lower portion of head cushion side foams 3 Mark hole using pen 4 Trim holes in foa m NOTE The hole location and size are provided only as a general reference The siz...

Page 44: ...This page intentionally left blank...

Page 45: ...the front edge of the head cushion wrap the elastic Velcro Strap around to the top of the head cushion and secure The tag on the HCFS and sewing seam should be facing the back against the head cushion...

Page 46: ...ll probably be too tight if not properly trimmed The neck dam must be trimmed to fit your neck To trim the neck dam have your tender hold the neck dam opening so that the two edges of the neck dam are...

Page 47: ...must be properly lubricated for smooth operation Without a proper functioning O ring the helmet will leak and possibly flood Drowning could result Split Ring Neck Dam O ring Stepped Ring Strap Plate...

Page 48: ...ead forward so the locking collar neck pad assembly may be swung forward and locked up into its closed position The sealed pull pins must snap into place on the locking collar Lift your head back up a...

Page 49: ...ach part Failure to ad just parts to the recommended speci fications could lead to helmet failure and accidents This could be fatal 3 6 Preparing the Helmet for Diving 3 6 1 Clean Face Port Thoroughly...

Page 50: ...pressurized One valve to open First stage won t flood Disadvantages If hose or first stage leaks some or all EGS gas will be lost Configuration 2 Off On Advantages No pressure in One valve to open re...

Page 51: ...he regulator all the way 2 With the emergency hose pressurized turn on the emergency valve knob If any gas escapes out the end of the adapter the one way valve is faulty and must be rebuilt or replace...

Page 52: ...ete bail out system Most commercial divers wear a harness separate from the weight belt that is used for several purposes The harness is fitted with large metal rings usually brass or stainless steel...

Page 53: ...e emergency valve assembly located on the side block Use a good quality first stage for your emergency gas supply The first stage regulator must have at least two low pressure ports One port is used f...

Page 54: ...hat this method poses the least amount of risk for the diver Probably the most serious problem with any of the other possible configurations is that the first stage will almost certainly flood if it i...

Page 55: ...r can monitor his emergency supply B WARNING Some divers keep the EGS gas cylin der valve shut during the dive Their rationale being in the event of an emergency they will simply open the EGS cylinder...

Page 56: ...ench to hold the adapter or inlet fitting and a second wrench to turn the swivel fitting on the hose If this is not done the adapter will turn inside the one way valve If this happens repeatedly the t...

Page 57: ...o the helmet to 150 p s i g 10 2 bar Slowly back out on the regulator adjustment knob until a slight free flow develops then turn the adjustment knob in clockwise until the free flow just stops To pro...

Page 58: ...assembly Begin to pull the neck dam down over your head The neck dam should slide over the divers head without excessive strain The neck dam should be as low as possible on your neck The neck dam is...

Page 59: ...eck pad assembly fully The locking collar must be completely open for the diver to don the helmet It is essential for the diver to ensure that the breathing system is working properly before he enters...

Page 60: ...helmet Grasp the base of the helmet with your fingers and push the neck dam ring up into the neck ring on the base of the helmet Again check for head cushion neck foam interference The neck dam ring f...

Page 61: ...er are stationed im mediately adjacent to the diver s air manifold and you are certain the air is on to the manifold If the diver is unable to flow air to the helmet either through the umbilical or th...

Page 62: ...est underwater should screw the regulator adjustment knob out i e away from the regulator until a slight steady flow occurs and the regulator can be heard to hiss This will help to eliminate any exces...

Page 63: ...The diver must report to the surface immediately after the entry It is a good policy to descend 10 or 20 FSW 3 6 MSW pause and check the regulator adjustment knob to ensure adjustment for the least br...

Page 64: ...itch the helmet underwater unless conditions absolutely require that B DANGER Ditching the helmet underwater must be avoided If the diver ditches the helmet underwater he will not be able to see In ma...

Page 65: ...4 Daily Maintenance on page 65 If the helmet is not going to be used for a period of time the head cushion should be removed The head cushion should be rinsed dried and replaced in the hat before stor...

Page 66: ......

Page 67: ...mm module corroded Clean terminals with wire brush Terminals should be bright shiny metal Battery weak Recharge Loose wire Clean and repair Communications only work when wire is wiggled back and forth...

Page 68: ...pen Seat or replace valve Communications module O ring extruded or damaged Replace o ring Communications module not prop erly tightened Comm module Damaged Binding posts or connector seal damaged Diap...

Page 69: ...oo low Increase supply pressure Regulator improperly set up Regulator does not supply gas Gas supply pressure too low Increase supply pressure to mini mum required for depth Regulator is out of adjust...

Page 70: ......

Page 71: ...d Function Checklist A2 3 The checklist can be laminated placed on a clip board and checked off with a grease pencil Comple tion should be logged in both the supervisors log and the helmet or mask log...

Page 72: ...edure A2 1 is intended to aid persons performing routine overhauls of KMDSI SuperLite Helmets and Band Masks The checklist should be used in conjunction with the applicable Operations and Maintenance...

Page 73: ...ct size when possible The following wrenches and tools are required to maintain the KM 37SS Torque wrench with the following attachments 7 16 inch open end wrench 9 16 inch open end wrench 5 8 inch op...

Page 74: ...ant Silicone grease is not recommended for helmets used with oxygen Avoid mixing lubricants to pre clude incompatibility 6 2 3 Teflon Tape All pipe thread fittings used on our helmets masks and compon...

Page 75: ...on newer helmets a satin brushed finish B WARNING DO NOT use car wax on rubber com ponents as the ingredients may cause premature degradation to the rubber resulting in failure of equipment and possib...

Page 76: ...If during routine corrective maintenance O rings are to be reused only reuse O rings that pass a visual inspection Inspect for deformities or compression set hardening or brittleness nicks or cuts pi...

Page 77: ...cover and diaphragm 3 Sanitize the regulator interior and flush sanitizing fluid through the whiskers Rinse with fresh water 4 Reinstall the diaphragm cover clamp and screw 5 Tighten the clamp screw...

Page 78: ...s is accomplished using one of four approved germicidal cleansing solutions There are four examples of solutions shown below along with the necessary ordering information and mixing instructions NOTE...

Page 79: ...r Make sure the air is off and the breath ing system of the helmet is unpressurized To vent the system open the defogger valve knob and emergency gas valve knob until all gas flow stops B WARNING Neve...

Page 80: ...om accumulating under these areas Operate the sealed pull pins as you run water over them Wipe the inside of the helmet out with a clean damp rag Do not depress the purge button while rinsing the regu...

Page 81: ...locking collar assembly will not lock prop erly and the helmet may come off the diver s head If this happens underwa ter drowning could result 6 5 2 Neck Dam Ring Assembly Inspect the neck dam carefu...

Page 82: ...ice packing nut and lubricate the two O rings and nose block shaft Re tighten the nut just to the point where the nose block device will still slide but requires a firm push or pull The nose block O r...

Page 83: ...mask from the helmet Remove the microphone so you can remove the oral nasal mask 4 Using small Phillips screwdriver carefully remove the two clamps screws nuts then pull the whiskers away from the mai...

Page 84: ...he regulator gets cleaned 6 After cleaning with soap Carefully inspect every thing that has been cleaned for any obvious signs of deterioration or damage replace any components in question Inspect the...

Page 85: ...ly tight enough so that it cannot be loosened by hand 3 Install the microphone in the oral nasal mask then check to make sure the oral nasal valve is installed so the valve opens into the mask 4 Reins...

Page 86: ......

Page 87: ...po nents that require the use of lubricants sealing and thread locking compounds should also be serviced Most fasteners have a torque value It is impera tive that all fasteners which have a torque val...

Page 88: ...foreign matter of any type and clean if necessary Clean in accordance with the KMDSI cleaning instructions If corrosion is present clean using the acidic solution as outlined in the KMDSI cleaning pr...

Page 89: ...excessive corrosion How ever the side block should be completely removed at least every three years of active use to ensure fasten ers are not corroded or frozen The side block assembly is held in pl...

Page 90: ...nch socket with driver 5 32 hex key ball end hex key screwdriver is helpful 1 Removal of the side block assembly requires re moving the air train Nut that secures stud Air train body Air train Alignme...

Page 91: ...in body The air train snaps into the body and is held in place by a small barb on the tube that fits into a matching groove in the rubber air train body The outer curve of the air train tube must be p...

Page 92: ...nd helmet shell 7 4 4 Side Block Assembly Replacement If a new side block is being installed or if the sideblock has been removed and rebuilt make sure it aligns correctly in the holes of the helmet s...

Page 93: ...ain body and helmet shell and lightly tighten into the side block body 5 Install the large sleeve onto the stud Slide the flat washer and the lock washer onto the stud Run the stud nut down the stud a...

Page 94: ...the washer will stick to the inside of the knob Remove the nut from the defogger valve knob Components of the sideblock including the EGS valve and the defogger or free flow valve O ring O ring Washer...

Page 95: ...onnet is removed 5 The seat assembly can be unscrewed from the side block body with the stem or a screwdriver Valve seat As you unscrew the bonnet the valve stem and seat will usually come out of the...

Page 96: ...to the seat indicate it must be replaced It is also a good indicator of possible line containments 3 The Teflon washer and o ring must be replaced if worn 4 Be sure to place a light coating of lubrica...

Page 97: ...d thread the bon net into the side block Install the bonnet onto the stem Make sure the o ring and washer are in place 5 Tighten the bonnet with a torque wrench to 100 inch lbs 6 Place the new Teflon...

Page 98: ...rgency Gas System Valve Assembly Unlike previous models of Kirby Morgan helmets and band masks the emergency valve body is built into the side block The design of the valve is very similar to the defo...

Page 99: ...the stem remains in the side block body it can be lifted out after the bonnet is removed 5 The seat assembly can be unscrewed from the side block body with the stem or a screwdriver or using the stem...

Page 100: ...mage such as a rough face or cuts to the seat indicate it must be replaced 3 The Teflon washer and o ring must be replaced if worn 4 Be sure to place a light coating of lubricant on all internal movin...

Page 101: ...ead the bon net into the side block Install the bonnet onto the stem Make sure the o ring and washer are in place 5 Tighten the bonnet with a torque wrench to 100 inch lbs 6 Place the new Teflon washe...

Page 102: ...ds the handle in place 8 To test the valve attach the supply whip from the EGS first stage to EGS mask valve 9 Ensure the defogger valve knob is open and the EGS Valve is shut 10 Pressurize EGS Valve...

Page 103: ...ul visual inspection does not reveal wear or damage All soft goods should be carefully cleaned in accordance with KMDSI proce dures prior to inspection for reuse 7 7 2 Removal of the Bent Tube Assembl...

Page 104: ...removed refer to the section on sideblock replacement for installation instructions B CAUTION Use two wrenches or hold the hex part of the body in a vise while remov ing or turning the seat with a wre...

Page 105: ...rench Part 525 611 the socket wrench Part 525 612 and the castle wrench Part 525 618 should be used to work on the SuperFlow 350 regulator whenever possible Disassembly assembly and adjustment can be...

Page 106: ...e diaphragm for holes tears or any signs of deterioration by hold ing it up to a white light and stretching and pulling Check for a good bond between the metal disc and the silicone Replace diaphragm...

Page 107: ...pin using a 3 32 punch Use a block of wood with a hole drilled through it to support the knob Position the knob so the roll pin is over the hole The adjustment knob can be held against the wood block...

Page 108: ...corrosion and the adjustment assembly can travel freely Ensure the alignment tube is not bent or misaligned from impact and that the threads are clean NOTE If the inside of the adjustment tube is cor...

Page 109: ...crews Also some of the screw heads are positioned on the outside of the helmet shell while others are on the inside The exhaust and dewatering valves are made of high grade silicone The exhaust and de...

Page 110: ...ker spac ers or kidney plates Remove the screws that secure the kidney plates and whiskers 4 Remove the bent tube assembly as per this chapter 5 Remove the nose block device as per Chapter 8 Protect t...

Page 111: ...he locknuts may be reused once Be sure to replace them upon the next pod gasket inspection Failure to replace with the second maintenance could result in an improper seal of the pod or loosening of th...

Page 112: ...er 520 032 Adjustment Nut 530 303 Diaphragm 510 553 Inlet Nipple O ring 510 014 Exhaust valve 510 552 1 Remove the regulator cover clamp screw and clamp 2 Remove the regulator cover and the diaphragm...

Page 113: ...fter the regulator has been disassembled clean and inspect all parts Any parts showing signs of wear damage or deterioration should be replaced If this is an annual overhaul KMDSI recommends replace m...

Page 114: ...ess silicone from the valve assembly It will take approximately 12 hours for full cure of the silicone Note After the silicone has completely cured double check the soft seat surface for excess cured...

Page 115: ...50 solution of vinegar and water A tube brush should be used to clean the inside of the regulator body B CAUTION Use only mild soap such as hand dish washing soap Use only a tube brush that does not...

Page 116: ...ude into the exhaust valve opening and interfere with proper regulator performance 2 Trim off any excess material from the gasket that might interfere with the operation of the exhaust valve 3 Install...

Page 117: ...sert the valve into the bent tube end of the regulator body Place the washer sharpen side first then the spacer over the end of the inlet valve stem As the end of the insert valve stem comes through t...

Page 118: ...ring then install the new washer and O ring on the adjustment shaft 12 Slide the packing nut onto the adjustment shaft then slip the knob onto the end of the shaft Hold the shaft and rotate the knob u...

Page 119: ...ath 18 Install the left and right whiskers then inspect and install the clamps Place whisker clamps around the grooves on each of the two whiskers Before doing the final tightening of the clamps make...

Page 120: ...also make marks on the whiskers with a felt tip pen 21 Carefully inspect the bent tube for damage and contamination The bent tube must be free of dents and compressions deeper than 1 8 and should not...

Page 121: ...ve must be properly connected to the regulator and the quad exhaust extension on the pod 24 Adjust the regulator following instructions in this chapter Make sure diaphragm mating surfaces are clean an...

Page 122: ...me NOTE Be very careful to not place undue stress on the lower arms of the lever as this will disfigure the lower blades and cause spongy operation 11 To bend the lever down place the disk end of the...

Page 123: ...nd washer must be removed C The regulator body has never been properly ser viced and there is corrosion inside the body making proper inlet valve travel impossible 5 Check the free play at the lever T...

Page 124: ...k the adjust ments It is rare that the lever requires bending in a regulator that has been in service Usually levers only require bending in new installations or because of damage during disassembly 9...

Page 125: ...e Chapter 8 for this procedure 2 Remove the microphone 3 The oral nasal mask can then be pulled off the regulator mount nut It is held on by a snap fit 7 14 2 Inspection of Oral Nasal 1 Inspect the or...

Page 126: ...e way around the mount nut 3 Reinstall the microphone 4 Reinstall the nose block device See Chapter 8 for complete instructions on reinstalling the nose block device 7 15 Reinstalling the Pod on the H...

Page 127: ...ight The nuts are positioned on the outside of the pod on the two bolts on the bottom below the regulator 5 Using the hex key and socket or wrench tighten the nuts gradually in a staggered pattern suc...

Page 128: ...ulator per this chapter 7 16 Reinstalling the Regulator on the Helmet Tools Required Regulator removal tool Flat blade torque screwdriver 13 16 open end wrenches 1 Stretch the main exhaust body over t...

Page 129: ...e block Make sure the connection between the bent tube and the regulator is snug using a 7 8 torque wrench and a 7 8 standard wrench 7 The whisker should have a straight angled surface from the helmet...

Page 130: ...always be used on all Emergency Gas Supply EGS bail out first stage regulators to prevent the hose from rupturing in the event the first stage pressure creeps The Kirby Morgan relief valve body is mad...

Page 131: ...ar and water and allow to soak for 15 to 30 minutes If using an ultrasonic sink reduce time to 15 minutes B WARNING Do not use cleaning solvents i e min eral spirits bleach etc when clean ing the reli...

Page 132: ...screw on the relief bleed valve hex nut is rotated too far too fast the relief bleed valve will pop open This could possibly require the air to be secured at the cylinder or supply source to reset th...

Page 133: ...full test pressure but minimizing high flow potential Problem After resetting the first stage to 135 p s i g 9 3 bar the valve continues to leak Check This indicates the valve body seating surface or...

Page 134: ......

Page 135: ...pection The helmet shell is constructed using 316L stainless steel It is extremely durable but can be damaged Helmets that have suffered damage may be repair able but repairs to the helmet shell must...

Page 136: ...precautions listed on the neo prene cement can Allow neoprene cement to cure for a minimum of 24 hours before using helmet 8 3 2 Nose Block Device Replacement 1 Prior to reassembly lubricate the two...

Page 137: ...o slide the nose block device in and out Do not tighten the nose block packing too much or the nose block device will not slide easily 5 Tighten the knob with the pliers padded by a cloth while holdin...

Page 138: ...Handle Blowapart drawing of the handle and helmet shell Unscrew the front three handle retainer screws 2 Remove the rear handle mount screws and wash ers You can then remove the handle Remove the scre...

Page 139: ...ide of the handle 8 4 3 Handle Replacement 1 Position the handle on the helmet 2 Apply Loctite 248 to the screws Install all of the screws both front and rear finger tight Be sure to install the washe...

Page 140: ...Blade Attachment on Torque Screwdriver Slip Joint Pliers and a Rag or cloth NOTE Wrap a rag around the nose block knob while removing to prevent chrome damage when turning with pliers 1 First remove t...

Page 141: ...hapter 8 Face Port KM 37SS Port retainer system Remove the port retainer Remove the face port 8 5 3 Face Port Port Retainer and Nose Block Replacement 1 Clean the face port o ring groove carefully in...

Page 142: ...ly available There are no equivalent o rings manufactured by other ven dors This o ring must be replaced with a new KMDSI o ring Failure to do so could lead to seal failure resulting in leaks or flood...

Page 143: ...specs when tightening the port retainer screws 7 Install the nose block device from the interior of the oral nasal mask and out through the nose block guide on the port retainer 8 Slide the two lubric...

Page 144: ...stainless steel like most of the components of the helmet The nose block guide is threaded into the port retainer and is eas ily replaced if damaged Under normal use the port retainer should never ne...

Page 145: ...the split rings in alignment The base of the neck dam will be marked and notched for alignment with the joints on the split rings 1 Lay the split neck dam ring on a flat level work table with the two...

Page 146: ...the neoprene on instal lation 7 Insert theAllen head screws into the aligned holes on either side of the pull strap groove and start the screws You must apply enough pressure to penetrate the neoprene...

Page 147: ...ave a clean cut with no loose strips of neoprene hanging from the neck dam that could interfere with the seal of the o ring Trim the excess neoprene using a sharp razor 18 Check the torque adjustment...

Page 148: ...of the groove where the pull strap is mounted This will help hold and align everything while the other screws are being put in 6 Use a torque screwdriver with a 7 64 Allen wrench attachment Press dow...

Page 149: ...the neck dam at a time trying it on after each trim Trim latex neck dams with the largest sharpest scissors available 3 When you are done the neck dam should be just snug enough that it does not leak...

Page 150: ...e retainer 2 Remove any corrosion from the sealing surface with a soft brush and dilute white vinegar solution Rinse thoroughly and ensure the threads are com pletely dry before continuing installatio...

Page 151: ...he directions in the MSDS before using this material B CAUTION Wear safety goggles or safety glasses with side shields when using Loctite This material may irritate your eyes Read and follow the direc...

Page 152: ...0 1 Helmet Ring Repairs The metal ring on the base of the helmet is part of the helmet shell casting If the ring is damaged such as damage to the sealing surface or the ring is bent the helmet must be...

Page 153: ...rect for the pins to work The cam angle must be correct for the pins to work properly 2 The screws have a factory applied locking com pound on the threads no thread locker is required 3 Insert the scr...

Page 154: ...moved or you can also use a 90 degree screwdriver to remove the spring this may take time but pod removal can be avoided See Chapter 7 for the procedure for removing the pod and regulator assembly 2 R...

Page 155: ...ritate your eyes Read and follow the directions in the MSDS before using this material All of the screws in the swing tongue catch assembly should be lightly coated with Loctite 248 prior to assembly...

Page 156: ...catch Also test prior to diving with the system to ensure proper operation Properly assembled swing tongue catch 9 If needed reinstall the pod and regulator assembly per Chapter 7 8 13 Locking Collar...

Page 157: ...washers 3 Turn the sealed pull pins until they are disengaged and lift the locking collar away 4 Clean all parts that will be reused 8 13 2 Locking Collar Disassembly Tools Required 3 8 Slot blade att...

Page 158: ...in the neck pad 4 Slide the neck pad onto the locking collar The neck pad must be oriented so that the groove for the pull strap will be on the inside of the helmet The large flange on the neck pad m...

Page 159: ...e pro truding hinge pin 13 Tighten the nut until the bolt threads just protrude past the end of the Nylock insert Do not overtighten This will possibly cause the hinge on the collar to bind The end of...

Page 160: ...Foam Like the head cushion the foam in the chin cushion must be replaced when the foam begins to crumble The foam for the chin cushion is included when the kit for the head cushion is ordered Compone...

Page 161: ...sembly 1 Remove the clear cover first and slide it along the wire to get it out of the way Remove the earphone protector and then peel back the black rear cover Removing the rubber cover from the earp...

Page 162: ...for proper installation and tightness The best way to check is by simply loosening the mount nut by hand Counter clockwise 1 8 to turn then retightening by hand Three fingers is all that is required...

Page 163: ...the communications module Tighten by hand until snug against the helmet Do not use a wrench to tighten this part B WARNING The communication retainer nut should never be tightened using a spanner or o...

Page 164: ...ably need to be replaced soon 1 Remove the entire communications assembly as per this chapter 2 Remove the rubber cover of the communications module 3 Remove the screws and washers from the com munica...

Page 165: ...assembly 146 into the communications module 2 Screw the waterproof connector into the nut Tighten until snug 3 Slip the earphone and microphone wires back into the module 4 Place the screws with wash...

Page 166: ...erved Document 130318002 Chapter 8 Communications System Kirby Morgan 37SS Installing the green wire Installing the black wire Installing the white wire Installing the red wire Installing the red micr...

Page 167: ...the earphone and microphone wire lugs from the interior of the communications module 5 Remove the nuts the wiring harness and washers from the communications posts 6 Remove the communications posts f...

Page 168: ...o not overtighten Use a wrench to tighten the binding post nuts 5 Wipe off any excess silicone sealant from the module 6 Slip the earphone and microphone wires back into the module through the slot in...

Page 169: ...e block Save this plug Remove the plug from the side block and install the inflator hose here 2 Check the O ring on the low pressure whip to be sure it is present and in good condition Carefully screw...

Page 170: ...down from its own weight Tighten the weld lens assembly 9 4 Weld Shield Assembly 9 4 1 Weld Shield Assembly Installation Tools Required 3 8 inch Open End Wrench 1 4 inch Flat BladeAttachment on Torque...

Page 171: ...emainder of the location numbers 2 Insert the mount screws through the spacer washers and then through the weld shield mount ears 3 With the shield facing out from the helmet or mask install and tight...

Page 172: ...158 Kirby Morgan Dive Systems Inc All rights reserved Document 130318002 Chapter 9 Use of Quick Disconnect Kirby Morgan 37SS Quick Disconnect...

Page 173: ...per Minute 42 44 Horsepower Foot Pound per Minute 33 000 Horsepower Foot Pounds per Second 550 Horsepower Watts 745 7 Hours Days 0 04167 Hours Weeks 0 005952 Inches Centimeters 2 54 Inches of Mercury...

Page 174: ...100 11 3 Helmet Drawing 17 530 083 Screw sideblock 35 4 21 530 317 Nut air train assy 35 4 9 7 1 KM 37SS Torque Table 2 Helmet Shell Neck Ring Torque Specifications Helmet Drawing 6 530 058 Screw han...

Page 175: ...regulator knob 40 4 5 Helmet Drawing 33 550 081 Regulator mount nut 100 11 3 9 7 3 KM 37SS Torque Table 4 Communications Torque Specifications Helmet Drawing 115 530 308 Nut communications posts Snug...

Page 176: ...assembly of compo nents is explained in a step by step manner that may not necessarily call out that all O rings and normal consumable items will be replaced The manual is written in this way so that...

Page 177: ...ntaminants may require cleaning after each dive Helmet and mask components requiring lubrica tion should be lubricated sparingly with lubricants approved for oxygen use such as Christo Lube Krytox or...

Page 178: ...ing extreme rates on the surface When underwater inhalation and exhalation resistive effort increases due to the density of the breathing gas and resistive effort of the equipment The increase in resi...

Page 179: ...76 23 3 30 132 12 158 55 5 60 50 63 19 2 91 145 45 174 55 6 17 62 5 44 13 2 33 145 83 175 00 6 18 75 33 10 2 00 150 00 180 00 6 36 100 PSIG 6 9 BAR 40 86 26 3 61 144 24 173 09 6 11 50 72 22 3 18 159 0...

Page 180: ...46 180 PSIG 12 42 BAR 40 181 55 6 48 259 39 311 27 11 00 50 148 45 5 48 274 24 329 09 11 62 62 5 115 35 4 48 280 30 336 36 11 88 75 93 28 3 82 286 36 343 64 12 14 190 PSIG 13 11 BAR 40 190 58 6 76 270...

Page 181: ...ng a 3 8 9 5 mm umbilical 600 foot 183 meters long made up of two 300 foot 91 meter sections Appendix 4 Standard Kirby Morgan Surface Supply Pressure Formula Old Method Old Pressure Table Calculation...

Page 182: ......

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