Kirby Morgan SuperLite 17B Operation And Maintenance Manual Download Page 149

Page: 149 / 182

SuperLite

17B

135

8.9.4 Earphone Removal and Replacement

NOTE: If only the earphone speaker is damaged, it can be

replaced by removing the tie-wrap inside of the covers,

unscrewing the wire connection and replacing the neces-

sary components. There is no need to completely remove

the assembly from the communications module.

Tools Required:

1/8 ” flat Blade Screwdriver

NOTE: The earphones may be replaced individually if

needed.

1) Remove the nuts and washers from the communications

posts. If you are using the optional terminal block this may

be where the wires from the earphone and microphone

are connected.

2) Lift the terminal lugs off of the communications posts.

NOTE the position of the terminal wires.

3) Install the terminals for the new earphones. Note that

the wires must go on separate terminals as before.

4) Tighten the terminal nuts carefully, using a small drill

bit, pin punch or opened large paper clip in the post hole

to keep the post from turning. If the posts turn, it means

that the seal made by the silicone sealant on the helmet

shell has been broken. If this happens the posts will allow

water to leak into the helmet requiring resealing.

5) Test the communications to see if they are working.

8.9.5 Waterproof Connector

SuperLite

-17 helmets are supplied either with a set of

terminal posts or an optional waterproof connector. The

waterproof connector is durable but can fail if the wire and

fitting receives rough handling. To replace the connector

use the following procedure.

8.9.5.1 Connector Removal

Tools Required:

3/8” Open-end Wrench

5/8” Open-end Wrench

11/16 ” Open-end Wrench

Torque Wrench with 11/16 Open End Attachment

1) Remove the earphone wire lugs from the interior of the

communications posts or terminal block.
2) Remove the nut from the packing gland on the interior

of the helmet shell.

If you are using the terminal block, this is where you

will disconnect the earphones from the helmet.

Wiring diagram for a SuperLite

17B

Take care not to break the seal made by

the silicone sealant where the communi-

cations posts penetrate the helmet shell.

If these posts turn, the helmet will leak.

CAUTION

Microphone

Earphones

White

Red

White

Black

Red

Green

Red Black Red Black

Summary of Contents for SuperLite 17B

Page 1: ...ing Systems International EXO REX SuperFlow and DECA are all registered trademarks of Kirby Morgan Dive Systems Inc Use of these terms to describe products that are not manufactured by KMDSI is illegal The two dimensional images such as photographs and illustrations of our products are copyrighted and trademarks of Kirby Morgan Dive Systems Inc The three dimensional forms of our products are trade...

Page 2: ...928 7772 x 229 You must have a return autho rization 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 be repaired or replaced at no charge as deemed necessary by KMDSI This warranty becomes null and void if 1 The product is not registered with KMDSI within ten 10 days of purchase 2 The product has not be...

Page 3: ...77 description Pg 63 and 64 Chapter 5 made to two columns format and font changed to lower case instead of all caps Page 65 Added Whisker Clamp Replacement Kit Part 525 032 Page 66 Corrected text to read SL 17 instead of KM 37 and 57 in 6 2 last sentence and photo caption Page 102 step 17 corrected sssembly to read assembly Page 173 Torque Specification corrections Page 174 Added note about thread...

Page 4: ...dated images and diagrams with new whiskers 8 07 20 2010 Added wiring diagram to chapter 8 9 04 06 2011 Updated earphones throughout manual 10 06 17 2011 Changed 61 meters to 67 meters in Appendix 3 Table 3 SuperFlow 350 Regulator High Pressure Regulated Source 11 10 17 2011 Updated CE notifying body number from 0496 to 2049 12 05 09 2012 Updated CE notifying body address 13 05 13 2012 Updated cop...

Page 5: ...eneral Description 13 2 8 1 Helmet Shell 13 2 8 2 Gas Flow Systems 13 2 8 3 Emergency Gas Supply System EGS 18 2 8 4 Helmet Attachment to the Diver 18 2 8 5 Sealing Arrangement 18 2 8 6 Reducing Carbon Dioxide 19 2 8 7 Communications 20 2 8 8 Equalizing the Middle Ear 20 2 8 9 Face Port or Viewing Lens 21 2 8 10 Latch Catch Assembly Pull Pin 21 2 9 Accessories 21 2 9 1 Eye Protection for Welding 2...

Page 6: ...Diver Dons Helmet 43 3 9 4 Diver Check Gas Flow Systems 43 3 9 5 Communications Check 43 3 9 6 Diver Ready 43 3 9 7 Water Entry and Descent 44 3 10 Emergency Procedures 44 3 10 1 Flooding 44 3 10 2 Inhalation Resistance 44 3 10 3 Gas Flow Stops 44 3 10 4 Demand Regulator Free Flow 45 3 11 Post Dive Procedures 45 3 11 1 Removing the Equipment 45 3 11 2 Removing the Helmet 45 3 11 3 Storage of the H...

Page 7: ...2 Emergency Valve Assembly 62 6 5 3 Steady Flow Defogger Valve 62 6 5 4 Bias Device Adjustable Section of Demand Regulator 62 6 5 5 Neck Clamp and Yoke Assembly 62 6 5 6 Latch Catch Mechanism 62 Chapter 7 Breathing System Maintenance and Repairs 63 7 1 Introduction 63 7 2 One Way Valve 63 7 2 1 Disassembly Of The One Way Valve 63 7 2 2 Reassembly of the One Way Valve 64 7 3 Side Block Assembly 65 ...

Page 8: ...1 SuperFlow Regulator Steady Flows When Pressured Up Special Tools Used 93 7 8 12 Regulator Steady Flows When Pressured Up 95 7 8 13 Regulator has Low or No Flow When Pressurized 95 7 8 14 Unexplained Demand Regulator Free Flow 95 7 9 Oral Nasal 96 7 9 1 Oral Nasal General Information 96 7 9 2 Oral Nasal Removal 96 7 9 3 Inspection of Oral Nasal 96 7 9 4 Oral Nasal Replacement 97 7 10 Quad Valve E...

Page 9: ... 4 4 Weight Replacement 123 8 5 Chin Strap and Yoke Strap 125 8 5 1 Chin Strap Removal 125 8 5 2 Chin Strap Replacement 125 8 5 3 Removal of the Yoke Strap 126 8 5 4 Replacement of the Yoke Strap 126 8 6 Alignment Sleeve 128 8 6 1 Sleeve Removal and Inspection 128 8 6 2 Sleeve Replacement 128 8 7 Port Retainer 129 8 8 Face Port 129 8 8 1 General 129 8 8 2 Face Port and Nose Block Device Removal 12...

Page 10: ...ies 149 9 1 Introduction 149 9 2 Hot Water Shroud General 149 9 2 1 Installation of the Hot Water Shroud 149 9 3 Low Pressure Inflator Hose Installation on the B Sideblock 151 9 4 Weld Lens Weld Shield Assemblies 152 9 5 Use of Quick Disconnect 154 9 6 Double Exhaust System 155 9 6 1 Double Exhaust Kit Installation 155 Table of Equivalents 159 Appendix 1 Torque Specifications 160 Note on Torque Sp...

Page 11: ...cir Quest è un avviso importante Tradurlo Ceci est important Veuillez traduire Diese Mitteilung ist wichtig Bitte übersetzen lassen If you have any questions concerning this manual or the operation of your helmet contact KMDSI 805 928 7772 or by Email at info KMDSI com or Dive Lab Inc 850 235 2715 or at Divelab aol com IMPORTANT A word about this manual We have tried to make this manual as compreh...

Page 12: ...om a dealer be sure to send in the warranty registration card so we may keep you informed of any safety notices that affect this product If you resell or loan this helmet to another diver be sure this manual accompanies the helmet and that the person reads and understands the manual In addition to the manual a log book should be used to log all repairs maintenance and use WARNING Diving is a life ...

Page 13: ...ill depend on the diving situation and the use of associated equipment Many countries have specific laws and rules regarding commercial diving It is important for the user to understand the rules regulations and philosophy imposed by the governing regulating bodies whenever using commercial diving equipment KMDSI helmets and masks should never be used for motor sport racing aviation space craft us...

Page 14: ... due to problems with the incorrect set up of the equipment This could lead to serious person al injury or death Whenever KMDSI helmets or masks are used in European Countries which have adopted the C E certification programs they must only be used with C E certified components Diving operations should only be conducted within the limits of the operational specifications and in accordance with the...

Page 15: ...e 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 the path in diving equipment design We welcome all input from our customers The thinking of many good divers diving equipment engineers diving medical specialists diving organi zation administrators and their supporting person...

Page 16: ... 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 with welded stainless steel bands provides warmth for the divers head as well as pockets for the earphones The communications connections can be either a male waterproof plug in type or bare wire posts Both this mask and th...

Page 17: ...rols the diver s air supply communications and monitors the diver s depth It allows two divers clear push to talk two wire or round robin four wire communications The KMACS 5 is also available without communications The air supply can be either from a low pressure compressor or high pressure cylinders The adjust able first stage regulator reduces the high pressure air and supplies low pressure thr...

Page 18: ...f two major components the neck dam yoke assem bly and the helmet To don the helmet the diver first slips the angled neck dam with the attached yoke over their head The helmet is lowered onto the diver s head with the help of a tender then the yoke hinge tab is hooked onto the alignment screw on the rear weight The neck clamp is then slipped onto the helmet and locked The locking system not only s...

Page 19: ...e sealed pull pins and provides protection for the bottom end of the helmet Like the SL 17K 37 and 17C the diver is provided with an internally adjustable chin support This support along with the adjustable neck pad on the locking collar gives the diver a comfortable secure custom fit The quick change communications module available with either bare wire posts or a waterproof connector allows for ...

Page 20: ...NG Before attempting any diving in any type of contaminated water a com plete diving and topside course in hazardous materials emergencies should be completed The divers and the topside team must be properly trained and have the proper safety equipment All helmets and suits can leak water under certain conditions Divers should use extreme caution when diving in contaminated waters The Kirby Morgan...

Page 21: ...s 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 efficient maintenance of the helmet s com munications The advantages of this stainless steel helmet include the following Rugged helmet shell and other components No refinishing required if the surface is scratched or goug...

Page 22: ......

Page 23: ...echnical data and the pressure of use are relative to com pressed air 2 2 1 CE Marking On the frame of the helmet the CE mark is affixed 2049 KIRBY MORGAN DIVE SYSTEMS INC 1430 Jason Way Santa Maria CA 93455 EN250 2000 EN250 A1 2006 EN15333 1 2008 CLASS B HELMET MODEL YEAR OF PRODUCTION CE Mark In the mark the data reported are the following 1 the name and the address of the manufacturer 2 harmoni...

Page 24: ...lorida as well as by other the United States Navy s Experimental Diving Unit and other independent testing laboratories 2 5 Cage Code The cage code for identifying KMDSI products for U S government purchase purposes is 58366 2 6 Operational Specifications Limitations Umbilical minimum I D 3 8 9 5 mm of not more than two sections total length not to exceed 600 feet 183m Every model of KMDSI helmets...

Page 25: ...ior to water entry if the hot water system is not used Only equipment certified and tested according to EN 250 E DIN 58 642 may be used with the SL 17 helmet when conducting diving operations in European EC compliant countries The umbilical assembly should be composed of good quality diving hose that meets industry standards Generally gas hose will be married to the commu nications wire pneumofath...

Page 26: ...e design of the Quad Valve helps keep exhalation resistance low while maintaining excellent watertight integrity WARNING Before attempting any diving in any type of contaminated water a complete diving and topside course in hazardous materi als emergencies should be completed The divers and the topside team must be properly trained and have the proper safety equipment All helmets and suits can lea...

Page 27: ...refully controlled to assure the customer of a high quality durable helmet that will function properly The fol lowing is a general description of the features of the SL 17 1 The fiberglass shell face port or view port area remains unchanged The side block and bent tube assembly that transports air gas to the demand regu lator from the side block are also the same Most of the components in these ar...

Page 28: ... L D I V I N G G E A R D I V E L A B T E S T E D Defog Free Flow Valve Knob Regulator Adjustment Knob Equalization Device Oral Nasal Mask Port Retainer Handle Purge Button Helmet Shell Neck Clamp Assembly Latch Catch Mechanism Quad Valve Exhaust standard on all Kirby Morgan 37 helmets from 2005 on Sideblock Rear Weight EGS Valve Neck Dam Weight Non Return Valve ...

Page 29: ...he valve then into the regulator and out through the regulator exhaust to the Quad Valve whiskers The diver can breathe from this flow of gas if the demand regulator malfunctions Returning to the side block assembly the other pas sage for gas is to the demand regulator It goes to a bent tube assembly that connects to the inlet nipple of the demand regulator The flow of gas in the demand regulator ...

Page 30: ...he exact number of turns required is dependent on the supply pressure Diving a KMDSI helmet or BandMask with a bias setting greater than that just necessary to keep the demand valve from free flowing increases the work of breathing and reduces the diver s ability to perform heavy work The regulator adjustment knob should be adjusted to the easiest breathing setting at all times Adjusting the regul...

Page 31: ...ed for dry suits only When using the side block low pressure inflator port only good quality hoses and fittings should be used and must incorporate an in line flow restrictor to reduce gas flow in the event of hose failure Any hose or fitting failure in this arrangement will subject the diver to a decreased air supply Do not use the side block inflator port for any purpose other than attaching a d...

Page 32: ...pressure the hose resulting in hose rupture This would cause a loss of the entire emergency gas supply with pos sible serious injury or death The over pressure relief valve should be installed on every first stage used for bailout KMDSI Part 200 017 NOTE This valve can be adjusted for vari ous relief pressures 2 8 4 Helmet Attachment to the Diver On the SuperLite 17 A B the helmet shell has an O r...

Page 33: ...expanding the seal and placing it part way over the head can help reduce the force needed to install the seal Proper training is necessary to in stall the neck seal over the diver s head and onto their neck Although the possibility is very remote injury may result if this proce dure is not done properly If a diver does not know how to don the neck dam they must seek proper instruction before proce...

Page 34: ...is mounted improperly or is absent this can lead to a higher CO2 level inside the helmet A higher CO2 level can cause dizziness nausea headaches shortness of breath or blackout 2 8 7 Communications In the SL 17 both earphones and microphone are wired in parallel to the communications system The communications can be equipped with either a waterproof connector or binding posts for bare wire connect...

Page 35: ... 0 Mod I Helmets sold by KMDSI now have the Pull Pin Latch Catch Assembly Part Number 505 010 brass or 505 011 chrome on the helmet to lock the Yoke in position The mounting system for the Pull Pin Latch CatchAssembly is identical to the old style Push Pin Latch CatchAssembly 505 015 which is now obsolete Each Pull Pin Latch CatchAssembly is shipped with a Safety Pin Part Number 535 900 which we r...

Page 36: ...mbly and demand regulator to provide efficient gas heating for especially deep or cold dives Heating the diver s breathing gas is especially im portant in cold water or when breathing mixtures of helium and oxygen The hot water shroud is recommended for deep mixed gas diving 2 9 3 Special Regulator Tools Four special tools are available for internal adjust ment of the demand regulator assembly 105...

Page 37: ... filled pillows with styrofoam inserts to stabilize the helmet the weight of the box is usually 40 pounds 18 Kg the package dimension is 18 18 15 inches 460 460 380 mm one helmet is packed per box the helmets are sent to dealers by plane and truck Depending on how the dealer wants it sent Packaging Step 1 Packaging Step 2 Packaging Step 3 Packaging Step 4 Packaging Step 5 ...

Page 38: ...otection 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 for shipping your helmet as air cargo The part number for the bag is Part 500 901 2 11 Use of Kirby Morgan Original Replacement Parts Users of Kirby Morgan life support equipment are cautioned to always use Kirby Morgan original re placement parts Par...

Page 39: ...a gas or air supply hose and communication wire assem bled with waterproof tape and in some umbilicals wound similar to strands in a rope to form a single unit Some umbilicals also have included a hose for hot water a pneumofathometer hose and a strength member such as a cable or strong line It is strongly recommended that the air gas umbilical be married to a strength member in a manner that allo...

Page 40: ...re requirements When using a low pressure compressor 200 225 p s i follow the recommendations in Table 2 in Sec tion 2 5 for optimum performance In countries that have adopted C E standards only C E certified supply systems and components may be used in conjunction with the helmet Decompression diving always involves the risk of decompression sickness Omitted decompression due to loss of gas suppl...

Page 41: ...afety no tices and other important information concerning the helmet Please notify KMDSI of any change of address WARNING 3 4 Initial Adjustments to Your Helmet Before using the helmet for the first time it must be checked and adjusted for proper fit There are several adjustments that must be made to provide a more comfortable fit when wearing the helmet 3 4 1 Head Cushion The fit of the helmet is...

Page 42: ...e largest sharpest scissors available in order to make as few cuts as possible There must be no jagged edges on the neck dam or it may eventually tear Sew and or glue the edge of the original seam to keep the stitching from unraveling As the neoprene neck dam ages it will become looser due to a natural breakdown of the cells This is par ticularly true if the helmet is locked in and out of a bell o...

Page 43: ...d condition 6 Be sure the communications wires are hooked up and tested 7 Inspect the oral nasal mask Make sure it is on the regulator mount nut properly and the valve is installed properly 8 Make sure the head cushion is properly fastened inside the helmet 9 Check the screws on the port retainer They must be adjusted to the proper torque setting specifications noted in Appendix 1 of this manual T...

Page 44: ... tap on each earphone and the microphone listening to the taps on the amplifier speaker Talk into the amplifier speaker feeling the vibration on each earphone and the microphone with your fingertips Check the fit and tightness of the comm module mount nut 3 6 4 One Way Valve Check The one way valve must be tested daily prior to commencement of diving operations There are two ways to test the valve...

Page 45: ... where a nor mal gas supply can be reestablished For this reason an emergency gas supply bailout cylinder must be used on all dives The bailout cylinder is normally worn on the back using a combination backpack and lifting harness Do not dive without a diver worn Emer gency Gas System If the main gas supply is lost you will have nothing to breathe and may drown WARNING The diving harness must have...

Page 46: ...an emergency due to a loss of the main gas supply the emergency valve knob located on the side block is turned on supplying gas to the side block assembly and the regulator In European countries that have adopted C E certi fication only C E certified cylinders are allowed to be used and must have a minimum charged capacity available to the diver of 1400 N l 50 scf The emer gency gas supply must on...

Page 47: ...rized One valve to open First stage won t normally 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 regulator No loss of gas from cylinder if hose leaks or regulator leaks Disadvantages First stage will flood and must be serviced after each day of diving Configuration 3 On momentarily Off Advantages...

Page 48: ... you have a leak you will probably figure it out and will be able to take appropriate action Some divers keep the EGS gas cylinder valve shut during the dive Their rationale being in the event of an emergency they will simply open the EGS cylinder valve thus eliminating any EGS air gas unknow ingly being lost due to either a 1st stage failure or EGS hose failure KMDSI strongly recommends never div...

Page 49: ...xcessive force will deform and ruin the adapter A second wrench must be used when the helmet is disconnected as well otherwise the adapter and or the one way valve assembly may become loose and fail to make a seal If you are using waterproof connectors for your com Connecting the umbilical to the helmet If the one way valve or the adapter is loosened this will allow breathing gas to leak out of th...

Page 50: ...on the air supply for the helmet check to see that the free flow valve is closed and the regulator adjustment knob is all the way in Slowly bring up the gas pressure to the helmet to 150 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 properly check the breathing system you must...

Page 51: ...e neck clamp you must first remove the safety pin that engages the latch catch assembly Pull the pull pin knob out away from the helmet While holding the knob out lift the neck clamp handle up and out to release the tension on the clamp Swing the handle forward toward the front of the helmet Slide the yoke neck clamp assembly back wards away from the helmet until the rear hinge tab disengages from...

Page 52: ...just snug The chin strap tight ens on the outside of the chin cushion It does not sit against the diver s chin directly Push your head into the rear of the helmet Then pull the helmet down and from side to side until it is comfortable on your head Position the chin strap under your chin Pull the strap down and back towards the divers right until it is snug but comfortable Reach up inside the helme...

Page 53: ...rds on your neck This is to engage the hinge tab on the alignment sleeve The front edge of the neck clamp should be under and past the front edge of the helmet Keep your head tilted back and lift the front of the helmet up with one hand The tender must locate the rear hinge tab on the back of the yoke Lift the rear hinge tab out away from the helmet and up until it can slide over the alignment sle...

Page 54: ...seated against the bottom of the helmet DO NOT USE THE HANDLE AS A LEVER TO LIFT THE CLAMP This will damage the clamp mechanism The diver must hold the helmet down while the clamp is swung to their right to fully engage it against the bottom of the helmet Note how the tender is support ing the clamp mechanism with their left hand The clamp is swung to the diver s left Once it passes over center it...

Page 55: ...he loop on the adjustable end of the strap slides over the yoke on the diver s right side Tighten the yoke strap by pulling down on the free end to help ensure the helmet stays on properly KMDSI strongly recommends the utiliza tion of the safety pin Part 535 900 This pin is inserted just below the cam lock bail If a safety pin is not used there is a possi bility the clamp on the yoke latching sys ...

Page 56: ...r must be standing by to assist the diver in re moving the helmet if needed Suffocation could result WARNING 3 8 7 Sealing Integrity Check If there is any doubt that the helmet is sealing prop erly perform the following test prior to diving Turn the supply gas off at the dive control system and bleed the umbilical To perform this test the diver must have an assistant standing by The assistant shou...

Page 57: ...d others prefer a clip that is screwed together so the diver cannot easily remove it from their harness The securing of the umbilical keeps the pull of the hose at the diver s harness and not on the helmet 3 9 3 Diver Dons Helmet The diver dons the helmet as per this chapter 3 9 4 Diver Check Gas Flow Systems The diver must check out the breathing system them self as the tender finishes dressing t...

Page 58: ...e at the work site to compensate for the variation in umbilical supply pressure 3 10 Emergency Procedures 3 10 1 Flooding In the event of partial or complete flooding the diver may clear the helmet quickly by tilting the helmet down and activating the defogger control knob Pressing in on the manual purge button in the center of the regulator cover will evacuate water from the regulator if any rema...

Page 59: ...iver the dive should be aborted and the problem with the regulator corrected 3 11 Post Dive Procedures 3 11 1 Removing the Equipment After the diver is well clear of the water they may remove the helmet If the diver is working out of a stage they must not remove the helmet until the stage is on deck 3 11 2 Removing the Helmet On the SuperLite 17 A B the tender must first remove the safety pin befo...

Page 60: ...er Use of a higher setting could cause the foam to melt or start a fire WARNING 3 11 3 Storage of the Helmet Between Dives The helmet should be maintained per the daily main tenance section in Chapter 6 Also check the Dive Lab post dive checklist A2 4 at www divelab com 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 dried an...

Page 61: ...ls in communications mod ule corroded Clean terminals with wire brush Terminals should be bright shiny metal Battery weak Recharge use alternate D C source Loose wire Clean and repair Communications only work when wire is wiggled back and forth Break in diver s communication wire Splice wire if damage is minor Replace wire if damage is major Communications only work when connector is wiggled back ...

Page 62: ...ter Leakage Into Helmet Symptoms Probable Cause Remedy Water leakage into helmet Exhaust valve damaged or stuck open Seat or replace valve Binding posts or connector seal damaged Remove posts clean and reseal with RTV sealant Diaphragm damaged or not seated properly Seat or replace diaphragm O ring in neck dam ring damaged or missing Replace o ring Port retainer screws loose Tighten screws Neck da...

Page 63: ...t Supply pressure too 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 adjustment Adjust regulator No gas in umbilical Turn diver s gas supply on topside Blockage in breathing system Disassemble regulator clean and adjust 4 7 Emergency Gas Supply Valve Sympt...

Page 64: ......

Page 65: ...an be laminated placed on a clipboard and checked off with a grease pencil Completion should be logged in both the supervisors log and the helmet or mask log book The daily pre dive is minimum daily checks KMDSI recommends The daily pre dive may be modified to suit the needs of the user providing the basic intent of the checklist is being completed in a manner with the original intent 5 1 2 Daily ...

Page 66: ...orming routine overhauls of KMDSI SuperLite Helmets and Band Masks The checklist should be used in conjunction with the applicable Operations and Maintenance Manual for the model helmet being serviced and is primarily intended to guide and document the maintenance as it is com pleted Specific detailed procedures for each section of this checklist can be found in the Operations and Maintenance Manu...

Page 67: ... size rather than adjustable wrenches when possible Adjustable wrenches tend to slip and can round the edgesofsoftbrassparts Thefollowingwrenchesand tools are required to maintain the SL 17 Torque wrench with the following attachments 1 3 8 inch crows foot 7 16 inch open end wrench 9 16 inch open end wrench 5 8 inch open end wrench 11 16 inch open end wrench 3 4 inch open end wrench 13 16 inch ope...

Page 68: ...cant contact with plastic parts NOTE All parts on the helmet that require lubrication must be lubricated sparingly with the appropriate lubricant Silicone lubricant is not recommended for helmets used with oxygen Avoid mixing lubricants to preclude incompatibility All parts on Kirby Morgan helmets and masks must be adjusted to their proper torque specifications See Appendix 1 for a complete listin...

Page 69: ...commends a thorough external decontamination washing of the helmet neck dam yoke as soon as feasibly possible followed by a vigilant in spection of the interior of the helmet to ensure that no contaminant has entered Pay particular attention to the following parts prior to re use the Quad Valve assembly demand regulator diaphragm demand regulator exhaust valve communi cations post s or communicati...

Page 70: ...ngs that pass a visual inspection Inspect for deformities or compression set hardening or brittleness nicks or cuts pits or blis ters or any other signs of damage Cut and discard damaged O rings and replace them with new ones O Ring Reuse All O rings and soft goods should be replaced whenever scheduled overhauls are being completed During routine repairs or maintenance in between the overhauls O r...

Page 71: ...oce dures Metal parts that have visible corrosion should first be cleaned using the soap solution scrubbed with a nylon bristle brush then soaked in a solution of 50 white vinegar and water for less than 60 minutes They may also be placed in a ultrasonic sink followed by a light brushing and thorough rinsing with fresh water and air dried If corrosion is such that 50 50 vinegar will not clean comp...

Page 72: ...itation and or long term degradation of rubber and silicone components of this equip ment CAUTION 2 If the solution appears to be drying apply more solution to keep it wet for the full 10 minutes 3 After 10 minutes thoroughly rinse components under running potable water NOTE The purpose of this procedure is to sani tize the components exposed to each of the divers KMDSI recommends sanitizing be ac...

Page 73: ... nasal microphone and earphones Remove the earphone covers from the earphones so they can dry completely Cover the air inlet and emergency gas valve openings with dust caps when not in use Never disconnect any hose from the hel met unless all gas has been vented from the hose first If the hose is disconnected with pressure in the line the fittings may be damaged In addition the hose can whip about...

Page 74: ...t This will prolong the life of the inlet valve seat and keep the internal adjustment correct Close the emergency valve and steady flow valves 10 Lubricate the shaft of the nose block device with silicone lubricant 11 Rinse the neck dam assembly and allow to dry Remove the O ring from the bottom of the helmet clean and lubricate Avoid patching a torn or punctured neck dam If the patch comes off un...

Page 75: ...cant to collect sand or other debris Use only KMDSI original replacement spares when repairing your helmet The use of other manufacturer s parts will in terfere with the performance character istics of your life support equipment and may jeopardize your safety Additionally any substitutions will void all warranties offered by KMDSI WARNING 5 Reinstall the Quad exhaust cover so that it con nects to...

Page 76: ...pect the interior of the regulator body for corrosion and contamination Carefully inspect the diaphragm for cuts tears and deterioration If any damage is present replace the diaphragm per Chapter 7 of this manual Attach an air source to the umbilical adapter and set the supply pressure to between 135 150 p s i g 9 3 11 4 bar Adjust the regulator knob out until a slight free flow develops then adju...

Page 77: ...in doubt as to the proper torque setting contact your local authorized repair facility or KMDSI 7 2 One Way Valve NOTE The one way valve assembly should be disas sembled cleaned and the three O rings should be replaced at least annually Damaged and or corroded parts should be replaced A repair kit is available for replacement parts 525 330 7 2 1 Disassembly Of The One Way Valve Tools Required Soft...

Page 78: ...ng thoroughly removing nearly all excess lubricant to prevent foreign materials from sticking to these components 6 Replace the spring 7 2 2 Reassembly of the One Way Valve 1 Slide the new O ring over the poppet 2 Insert the new spring into the valve body followed by the poppet 3 Next install the new O ring and new wiper on the seat Thread the seat into the valve body 4 Tighten the seat to 150 inc...

Page 79: ... of the helmet shell far enough to secure the air train by means of the washer and nut The air train cup that fits over the stud is made of soft brass and cannot be used for a bearing surface to mount the side block RTV silicone rubber compound is used to form a gas tight seal between the side block and the exterior of the helmet shell 7 3 2 Side Block Assembly Removal Tools Required 7 16 11 16 an...

Page 80: ...ace by the rubber sealing compound silicone sealant that acts as a glue It may be necessary to rock just slightly or pry the side block from the helmet shell A thin putty knife can be pushed between the side block and the helmet shell to help free it You must remove the nut that secures the air train before you can proceed in removing the side block Do not use a screwdriver or chisel to remove the...

Page 81: ...ne seal ant tube and Material Safety Data Sheet WARNING Use silicone sealant in a well ventilated area Do not breathe the fumes from un cured silicone seal ant These fumes are dangerous and can cause unconscious If silicone sealant is blocking the air flow into the helmet it must be cleaned out If it is not the diver may not be able to prop erly defog the helmet or clear a flooded helmet quickly I...

Page 82: ...an be used to dissolve uncured sealant after tightening 2 Fit the side block to the helmet shell 3 Thread the screw through the helmet shell and lightly tighten into the side block body 4 Slide the flat washer and the lock washer onto the stud Run the stud nut down the stud and tighten to 35 inch pounds 4 Newton meters Do not overtighten 5 Tighten the screw to the correct torque 20 inch pounds Cle...

Page 83: ...ed from the side block body with the stem or a screwdriver 7 4 2 Cleaning and Lubricating 1 Clean all the metal first in the soapy water solution and then in a 50 50 dilute solution of white vinegar water Rinse in fresh water 2 Check the Nylon seat for wear and or contamina tion and replace if necessary Damage such as a rough face or cuts to the seat indicate it must be replaced 3 The Teflon washe...

Page 84: ...he stem and thread the bon net into the side block 6 Tighten the bonnet with a torque wrench to 100 inch lbs 7 Place the new Teflon washer and the control knob on the stem and rotate the stem counterclockwise until the seat assembly tops out fully open The control knob must turn smoothly without any binding The Side Block assembly and it s associated parts Binding or hard spots in the rotation cou...

Page 85: ...cking nut in a vise and carefully work the packing out with a small screw driver taking care not to damage the threads of the packing nut Replace the washer if needed 3 Inspect the stem seat for unevenness or wear and replace if necessary It must also be replaced if the stem is bent Damage will include damaged threads rounded flats that engage the control knob Also inspect the shaft to ensure the ...

Page 86: ...ge is present Re tape threads with Teflon tape 1 wraps start ing two threads back tighten using good engineering practice To reinstall the emergency valve body onto the side block the one way valve assembly should not be installed 7 5 3 Reassembly of Emergency Valve 1 Lightly lubricate the stem threads in the body as well as the bonnet threads 2 Replace the washer and packing on the stem then ligh...

Page 87: ...submersible pressure gauge should always be used with the EGS system to help minimize this risk WARNING 11 Before wrapping the threads with pipe tape check the fit of the valve assembly pipe threads to the mating threads of the side block There should be 2 turns of hand make up before needing to use a wrench If there is less make up call your nearest KMDSI dealer or Dive Lab for advice 12 Before i...

Page 88: ...time these components are deemed unserviceable These components do not require replacement during field repairs providing a careful visual inspection does not reveal wear or damage All soft goods should be carefully cleaned in accordance with Chapter 6 prior to inspection for reuse 7 6 2 Removal of the Bent Tube Assembly Tools Required 11 16 inch Open end Attachment on Torque Wrench 7 8 inch Open ...

Page 89: ...t the side block end 2 Push the regulator end of the bent tube assembly into the inlet nipple Slide it in until the side block end of the tube is aligned with the threads for the mount nut 3 Be sure the Teflon O ring is in place on the side block end of the bent tube then engage the threads on the tube to the side block and hand tighten 4 Start the regulator to bent tube mount nut onto the inlet n...

Page 90: ... o ring 7 7 2 Hose Assembly Inspection A style Side Block Inspect the hose fittings for slippage and thread damage Inspect the hose for gouges cuts blisters abrasions or any obvious signs of damage or deterioration If the hose is worn or damaged it must be replaced Inspect the o rings If they are worn or cracked they must be replaced Replace the hose O ring during overhauls and or annually NOTE KM...

Page 91: ...ier and the adjustment is better if these tools are used The above 4 tools are available together along with a tool case The Tool Kit with Pouch is Part 525 620 This kit is included with each new Kirby Morgan helmet that is equipped with the SuperFlow regulator Tool Kit with pouch Part 525 620 7 8 2 SuperFlow Demand Regulator Test for Correct Adjustment Fully Assembled To maintain optimum performa...

Page 92: ...greater than 1 8 before free flow is heard the demand regu lator requires internal adjustment per this chapter 7 8 3 Inspection of SuperFlow Regulator Body Interior Tools Required 1 4 inch Flat Blade Attachment on Torque Screwdriver 1 Remove the demand regulator clamp by removing the clamp screw 2 Lift off the regulator cover and diaphragm 3 Clean the diaphragm with the soapy solution per Chapter ...

Page 93: ... Open end Wrench Attachment on Torque Wrench 3 32 inch Punch Small Block of Wood Ball Peen Hammer Regulator Adjustment Tool Kit Part 525 620 Torque Wrench 1 Unscrew the regulator adjustment knob until it stops If the knob wobbles as you turn it or is ex tremely hard to turn the shaft is bent and needs to be replaced Also check the alignment of the tubes in the regulator to make certain they are st...

Page 94: ...inside of the adjustment tube is cor roded this indicates saltwater intrusion into the adjustment tube and assembly The demand regula tor requires removal from the helmet and cleaning per this Chapter 7 8 5 Reassembly of the SuperFlow Regulator Adjustment System Tools Required 3 4 inch Open end Wrench Attachment on Torque Wrench Silicone lubricant or oxygen compatible lubricant if used for oxygen ...

Page 95: ... of the way or completely removed 2 Remove the whiskers from the port retainer by re moving the screws Take care not to lose the spacers or kidney plates 3 Remove the nose block device per Chapter 8 Remove the whiskers from the helmet 4 Remove the oral nasal mask 5 The regulator mount nut is removed along with the sealing O ring 6 Cut the tie wrap that connects the regulator body to the Quad Valve...

Page 96: ...ment knob until it stops 4 The packing nut is now exposed enough to use a wrench on it for removal As the nut is backed off unscrew the knob also 5 The O ring and washer will remain on the adjust ment shaft 6 Tilt the regulator so that the spacer spring set and piston fall out of the adjustment tube of the regulator NOTE If the spacer and the spring set are stuck this indicates possible corrosion ...

Page 97: ...005 83 Blowapart drawing of the SuperFlow Regulator Adjustment knob Regulator body Diaphragm Cover Clamp Inlet valve Adjustment shaft Packing nut Piston Spacer Roller lever Spacer Nut Inlet nipple B Retaining pin Spring Washer Inlet nipple A Retaining clip Jam Nut Exhaust Valve Washer ...

Page 98: ...ket wrench from the KMDSI Tool Kit Part 525 620 through the adjustment tube and engage the adjustment nut on the inlet valve Loosen and remove the adjustment nut by rotating the socket wrench coun terclockwise 10 Tilt the regulator and drop out the inlet valve and washer 11 The spacer and lever will now fall out of the regulator body NOTE Ensure that the washer comes out with the rest of the compo...

Page 99: ...ea should be free of dirt and corrosion to ensure the valve can lay flat and seal properly NEVER lubricate the valve Lubricating the valve can allow dirt to stick to the seat causing poor performance and wet breathing 2 Inlet valve Check the condition of the rubber seat for wear and or deep grooves If the red silicone seat surface is stained to a dark color this is an indication that the air suppl...

Page 100: ...ed annual overhauls 6 Inspect the whisker wings Replace the whisker wings if they show signs of wear aging or any dam age The new whiskers used in the Quad Valve are much more rugged than the older latex double exhaust system and will give a much longer service life and provide better breathing performance at depth Older latex double exhaust systems should be replaced with the new Quad Valve exhau...

Page 101: ...rior of the regulator body Place the washer and the spacer over the end of the inlet valve stem As an alternate procedure the washer and spacer may be placed in the recess in the inside of the regulator body before inserting the inlet valve stem Trim any excess exhaust valve tail from the interior of the regulator 5 Using the socket wrench nut driver from the tool kit run the nut 126 onto the inle...

Page 102: ...ple to 40 inch pounds 9 Lightly lubricate the piston and spacer Install the piston spring set and spacer into the adjustment tube of the regulator body as shown in the blow apart drawing 10 Reassemble the adjustment knob assembly lightly lubricate the new O ring then install the new washer O ring on the adjustment shaft 11 Slide the packing nut onto the adjustment shaft then slip the knob onto the...

Page 103: ...ve inserts Then place the assemblies into the main body Install the port and starboard whiskers onto the main body and make sure the alignment is correct Then install the whisker clamps 15b For the old double exhaust or single exhaust stretch the exhaust whisker wing onto the exhaust flange of the regulator 16 Mount the regulator to the mask or helmet Lightly lubricate and install the sealing O ri...

Page 104: ...tighten the jam nut to 40 inch pounds 18 Ensuring the O ring is in place use a torque wrench a 1 1 4 socket and an extension torque the regulator mount nut to 100 inch pounds Next using a torque wrench with an 11 16 adapter torque the bent tube nut to the side block to 100 inch pounds 19 Attach the whisker wings to each side of the face port retainer using the screws plates and spacers Using a tor...

Page 105: ...r 6 Remove the inlet valve holder tool 7 Put the diaphragm and cover in place depressing the cover tightly to simulate a properly tightened clamp 8 Depress the purge button in the center of the cover 9 There must be 1 16 inch 1 5 mm to 1 8 inch 3 0 mm of free travel before the purge button actuates resulting in a slight flow of gas If a slight flow of gas develops with the purge button depressed l...

Page 106: ... the soft seat in the inlet valve stem to take a set against the inlet nipple If the regulator is to be used immediately be aware that the rubber seat will take a set changing the adjustment and the regulator s performance This will require the readjustment of the regulator after the first day of use 2 Normally if the regulator free flows the nut is too tight and must be loosened until the lever h...

Page 107: ...e inlet valve The plastic material that locks the nut is not designed for multiple reuse If the nut comes loose during a dive the regulator would free flow heavily In the situation where the diver is using bottled breathing gas this would result in a rapid consumption of breathing gas WARNING 4 If the regulator is not free flowing slowly back out on the adjustment knob until a slight free flow is ...

Page 108: ...lockwise to increase lever play Only turn the adjustment nut 1 8 turn at a time De press the lever momentarily after each adjustment and observe the lever play It may be necessary to complete this procedure several times as the proce dure requires estimating the proper position of the nut If the regulator free flow did not stop after this procedure refer to regulator disassembly and cleaning secti...

Page 109: ... mm of free travel before the purge button 123d comes in contact with the diaphragm actuating a slight flow of gas If a slight flow of gas develops with the purge button depressed less than 1 16 inch 1 5 mm the lever will require slightly more play If the purge button travels greater than 1 8 inch 3 0 mm the lever will require a reduction of play by adjusting 5 Recheck that gas source pressure is ...

Page 110: ...ed it must be replaced 2 Inspect the oral nasal valve If it is torn or damaged it must be replaced 3 Remove the valve body by pushing it out of the oral nasal 4 Remove the old valve by pulling it out 5 Install the new valve by feeding the thin tail through the valve body and pulling on it until the valve is seated Cut off the excess tail 6 Install the valve body in the oral nasal The valve MUST be...

Page 111: ...y The oral nasal valve must be replaced correctly to provide gas flow in the proper direction The flow through the valve must be from the interior of the helmet into the oral nasal mask This will allow the diver to breathe the gas from the defogger valve freely yet help to reduce carbon dioxide inside the helmet If the valve is not replaced properly this could make it difficult to breathe the gas ...

Page 112: ...alve uses the quad exhaust cover to connect the exhaust body to the exhaust main body All other parts are identical If you have an older SL 17 helmet you are strongly en couraged to upgrade your helmet to the Quad Valve design with the Quad Valve cover 7 10 1 Quad Valve Assembly Removal Tools Required Screwdriver Small cutting pliers NOTE It is necessary to first remove the regulator and Quad Valv...

Page 113: ...ated NOTE The exhaust valve and whisker wing exhaust valve inserts must be placed into the Quad Valve exhaust main body correctly to provide gas flow in the proper direction The flow must be from the inside of the Quad Valve exhaust main body out to starboard whisker wing and port whisker wing 5 Install an exhaust valve whisker wing exhaust valve insert assembly into both seating areas on each sid...

Page 114: ... also a good possibility that the clamp will come off of the whisker wing reducing the effectiveness of the exhaust system in keeping the breathing system dry If the whisker clamps are not installed properly the exhaust valves will leak This leads to a chance of backflow into the regulator through the exhaust valve In contaminated water diving this is a serious situation WARNING Whisker Assembly D...

Page 115: ...ch of the two whiskers Before doing the final tightening The whiskers must be aligned properly on the exhaust main body Note the correct alignment of the mold line that spans the whiskers and the exhaust main body Note the step on the inside of the whisker clamps These must be oriented in the correct position to retain the whisker wings properly of the clamps make sure that parting line on bottom ...

Page 116: ...de the regulator NOTE Before installing the new valve ensure that the spokes that hold the exhaust valve are smooth even and not bent The exhaust valve seating area should be free of dirt and corrosion to insure the valve can lay flat and seal properly NEVER lubricate the valve 1 Remove the regulator clamp screw and clamp 2 Remove the regulator cover and the diaphragm 3 Install the new regulator e...

Page 117: ...ust valve 7 11 3 Water Dump Valve Body Removal 1 The water dump body should never need servicing If it is to be removed you must first remove the three screws inside the helmet shell After this is done gently twist the valve body off of the helmet shell A putty knife may be used to slide between the valve body and the shell to break the RTV sealant 7 11 4 Water Dump Valve Body Remounting 1 To repl...

Page 118: ... a well ventilated area Do not breathe the fumes from un cured silicone seal ant These fumes are dangerous and can cause unconscious Components of the SuperLite 17 exhaust system Silicone sealant is used to seal the exhaust body to the helmet shell Quad exhaust cover Exhaust body Water dump valve Port retainer Exhaust valve Regulator body Starboard wing Exhaust main body Whisker exhaust valve inse...

Page 119: ...t blade screwdriver or a nut driver fully engage the screws Tighten until snug TIP the hex tool found in the Kirby Morgan regulator tool kit works very well for this purpose Part 525 620 Note Refer to 7 8 9 Reassembly of the SuperFlow 350 Demand Regulator on page 87 3 Reinstall the bent tube assembly and tighten the jam nut to 40 inch pounds 4 Retighten the regulator mount nut to 100 inch pounds 5...

Page 120: ...sker free Use caution not to lose the whisker spacers The rubber whisker is removed by stretch ing and pulling the rubber away from the back of the regulator whisker flange The whisker flange forms the exhaust valve seat and surrounds the regu lator silicone exhaust valve The whisker is held in place at the regulator body by being stretched over the whisker flange To remove it pull the whisker fre...

Page 121: ...mal overhauls or if damage is detected 6 Lightly lubricate the bent tube O ring and install the bent tube into the inlet nipple and thread the nut on several revolutions 7 Swing the bent tube into place on the side block engage the bent tube side block nut and hand tighten 8 Install the regulator retaining nut and O ring Torque the regulator retaining nut to 100 inch pounds 9 Lightly tighten both ...

Page 122: ...aust valve seat and surrounds the regulator The double exhaust system PN 525 102 in creases exhalation resistance and should not be used for dives deeper than 150 FSW Use of this system at deeper depths could lead to exhaustion and unconsciousness WARNING Location Part Number Description 1 530 032 Screws 3 2 550 087 Double Exhaust Main Body 3 520 042 Tie Wrap 2 4 510 561 Exhaust Valve 5 520 020 Va...

Page 123: ... Place the regulator back into the mount hole of the hel met mask frame Stretch the double exhaust kit whisker over the special main exhaust body ensuring the whisker is seated properly on the main exhaust body flange 10 Place the regulator into the helmet opening then attach the screws spacers and plate on each side of the port retainer and using a torque screwdriver torque to 12 inch pounds SPEC...

Page 124: ... removal 2 Loosen and remove the regulator mount nut and O ring 3 Remove the whisker wing for the Tri Valve Exhaust System from the port retainer held on each side of the helmet by two screws stand off spacers and one plate on each side Take care not to lose the four spacers 4 Removal of a Tri Valve Exhaust system will require the tie wrap that holds the Tri Valve Exhaust main body to the regulato...

Page 125: ...into and which way they face when mounted in the body They MUST be reinstalled facing the same way 4 Install a new exhaust valve into each whisker wing exhaust valve insert on the correct side by feeding valve tail through hole in center of valve insert and pulling on it until valve is seated NOTE The exhaust valve whisker wing exhaust valve inserts assembly must be placed into Tri Valve Exhaust m...

Page 126: ... also a good possibility that the clamp will come off of the whisker wing reducing the effectiveness of the exhaust system in keeping the breathing system dry If the whisker clamps are not installed properly the exhaust valves will leak This leads to a chance of backflow into the regulator through the exhaust valve In contaminated water diving this is a serious emergency WARNING Whisker Assembly D...

Page 127: ...ce the clamps around the clamp seating surface and tighten making sure that the clamp screws are properly positioned as shown in the drawing on the next page The correct orientation of the whiskers relative to the exhaust main body are as shown in the photo here Tighten the screws that hold the clamps until the screws are snug The threaded ends of the screws should be at least flush with the outer...

Page 128: ...etc when clean ing the relief bleed valve The use of cleaning solvents may lead to failure of the relief bleed valve WARNING Nylon toothbrush Vinegar Fresh water Mild dish soap Ultrasonic sink if available Magnifying glass New valve body o ring 7 16 2 Overpressure Relief Valve Disassembly and Cleaning 1 Turn off the gas supply to the first stage regulator then bleed off any remaining pressure Remo...

Page 129: ... until the emergency supply hose ruptures possibly causing injury and a complete loss of the Emergency Gas System EGS This procedure explains the steps necessary for readjust ing the relief bleed valve after it is cleaned overhauled or any time the valve is tested NOTE The relief bleed valve is lift checked and or adjusted using an adjustable first stage regulator equipped with a low pressure test...

Page 130: ...stage regulator one last time to recheck the lift pressure The valve should start forming bubbles or venting at between 180 200 p s i g 12 40 13 78 bar 7 After final lift check reset the regulator to the ap propriate over bottom setting Remove the intermedi ate pressure gauge TROUBLESHOOTING Problem Valve pops open and will not stop flowing Check If while setting the relief bleed valve the valve p...

Page 131: ...rts of the clamp as sembly for damage Check the hinge pins for a loose fit signs of cracking distortion or any damage 3 Visually inspect the adjustment stud for signs of cracking distortion bending stripped or damage threads or corrosion 4 Check the rear hinge tab and hinge for signs of cracking bending distortion and loose fasteners 5 Check the latch catch assembly for proper opera tion Check for...

Page 132: ...l Al though this material is far more durable than paint it can be scratched and chipped Light scratches can be removed by using an automotive rubbing compound and waxing Authorized KMDSI factory trained technicians can repair chips and scratches Do not attempt to install new thread inserts in the helmet shell for the port retainer screws by yourself If the installa tion is done improperly the por...

Page 133: ...oosen and remove the packing nut Loosen the nose block knob with a pair of pliers The nose block knob must be removed prior to remov ing the packing nut 3 Slip the two O rings off the end of the shaft of the nose block device and slide the nose block device out through the oral nasal mask 4 The padded end of the shaft may be bent with pliers to better fit an individual A larger pad of rubber can a...

Page 134: ...ssembly lubricate the two O rings 2 Slide the shaft through the oral nasal mask in the hel met shell 3 Place both O rings on the shaft followed by the pack ing nut and the knob 4 Tighten the packing nut until snug Do not over tighten as this will make it difficult to slide the nose block device in and out 5 Tighten the knob with the pliers padded by a cloth while holding the pad end with your hand...

Page 135: ... to prevent accidental damage to the helmet shell NOTE Weights only need to be removed if fiberglass damage of the helmet shell is suspected or mounting holes are to be drilled and tapped into the weights for camera or light mounting 1 The handle is removed by first unscrewing the top three port retainer screws 2 Remove the rear handle mount screw and washer Handle Rear weight Port weight Starboar...

Page 136: ...the front screws only until snug 4 Hold the handle in place and thread the rear mount screw 90 with its washer Torque to 20 inch pounds 5 Tighten the front mount screws to 12 inch pounds 6 Wipe off any excess RTV from the helmet shell Use a torque screwdriver to tighten the front handle screws to 12 inch pounds ness They can also cause long term damage to body tissue Read and follow all precaution...

Page 137: ... CAUTION helmet shell 3 On the side weights this is best done starting along the bottom edge 4 On the rear weight start removal at the corners 5 Be patient and take your time because the RTV is an excellent adhesive and makes removal of the weights difficult If you are hasty you may damage the helmet shell 8 4 4 Weight Replacement 1 Clean off old RTV as necessary using a block of wood or the woode...

Page 138: ...llow 24 hours for the sealant to cure before using the helmet ness They can also cause long term damage to body tissue Read and follow all precautions listed on the silicone seal ant tube and Material Safety Data Sheet WARNING Use silicone sealant in a well ventilated area Do not breathe the fumes from un cured silicone seal ant These fumes are dangerous and can cause unconscious RTV silicone seal...

Page 139: ...ays on the diver s head it may flood which can lead to drowning unconsciousness serious personal injury or death WARNING 8 5 1 Chin Strap Removal Tools Required Flat blade screwdriver 1 The chin strap is removed by removing the screws that secure the two snap tabs that penetrate the helmet shell and attach to the two front weights 2 Remove the snap tabs and the chin strap There is no need to remov...

Page 140: ...parated from each other 2 Look at the guide strap You will note that there is a short loop that is fastened at a right angle to the longer part of the strap The longer part of the strap has a large loop in the front and a smaller loop at the rear With the yoke sitting right side up slide the short loop that sits at the 90 degree angle over the right side of the yoke Slide the guide strap onto the ...

Page 141: ...nstalls 5 Install the non adjustable loop on the yoke strap on the side of the yoke where the latch catch as sembly is mounted In some cases it may be necessary to remove the latch catch to install the loop Follow the proce dures for removal and reinstallation per this chap ter 6 For proper use of the yoke strap see Chapter 3 of this manual Installation of the non adjustable loop on the yoke strap...

Page 142: ...ome dry suits without modification to the dry suit 8 6 1 Sleeve Removal and Inspection Tools required Torque Screwdriver Flat blade screwdriver adapter for torque wrench Wire Brush stainless steel or brass bristles only Loctite 222 or equivalent 1 To remove the sleeve simply unscrew it from its attachment to the rear weight The sleeve slips over the screw that holds it in place 2 Visually inspect ...

Page 143: ...he face port or viewing lens is made of a polycar bonate plastic Small scratches on the exterior are not important as they tend to disappear underwater However the face port is easily replaced by remov ing the port retainer and reinstalling a new O ring and face port The face port should be replaced anytime cracks are present or anytime nicks and scratches deeper than 1 16 are present or anytime t...

Page 144: ...will usually be found lodged in the whisker wings 7 Remove the old port and sealing O ring 8 8 3 Face Port and Nose Block Replacement 1 Clean the face port O ring groove carefully inspect ing it for any damage 2 Lightly lubricate the O ring with Dow Corning 111 The whiskers must be removed prior to removing the port retainer and port Be sure not to lose the whisker spacers Replace the face port if...

Page 145: ...rews Any over torque of a screw greater than 14 inch pounds can result in serious damage to the surrounding fiberglass in the port area This can lead to loosening of the port retainer and in extreme instances to flooding of the helmet The test procedure is designed to identify any inserts that have been damaged or become loose requir ing replacing Replacement of inserts should only be completed by...

Page 146: ...ver certain chemicals will attack the port and weaken it Some solvents used for lubri cant removal will also attack the port Use only mild detergents or organic soaps to clean the face port WARNING The face port for the SuperLite 17 and KMB 28 are not interchangeable Do not attempt to use a face port from a KMB 28 in a SuperLite 17 Although the port will fit into the helmet shell it will not seal ...

Page 147: ...can be carefully pulled out of the retainers in the helmet shell for inspection and disassembly 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 2 Check the wire connections They should be solid 3 Check the mylar diaphragm If the mylar is torn or loose replace the entire unit see 8 9 4 Earphone...

Page 148: ... The wires that connect it to the communica tions posts will follow 4 Install the terminals for the new microphone NOTE that the wires must go on separate terminals as before 5 On helmets with terminal nuts tighten the terminal nuts carefully using a small drill bit pin punch or opened large paper clip in the post hole to keep the post from turning If the posts turn it means that the seal made by ...

Page 149: ...If the posts turn it means that the seal made by the silicone sealant on the helmet shell has been broken If this happens the posts will allow water to leak into the helmet requiring resealing 5 Test the communications to see if they are working 8 9 5 Waterproof Connector SuperLite 17 helmets are supplied either with a set of terminal posts or an optional waterproof connector The waterproof connec...

Page 150: ... cause long term damage to body tissue Read and follow all precautions listed on the silicone seal ant tube and Material Safety Data Sheet WARNING Use silicone sealant in a well ventilated area Do not breathe the fumes from un cured silicone seal ant These fumes are dangerous and can cause unconscious Removal of the waterproof connector 3 Separate the connector packing gland assembly from the helm...

Page 151: ...ns Post Replacement 1 Clean off all the old RTV silicone sealant from the helmet shell and communications posts 2 Apply fresh RTV to the communications post s Check posts for cracks and smooth turning for proper wire cap ture Replace post if necessary 3 Insert the communications posts into the helmet shell Before bottoming it against the shell rotate it slightly to Begin the disassembly of the yok...

Page 152: ...ded surfaces for corrosion or degradation replace if questionable required 2 Remove the three screws and washers that secure the hinge to the yoke Using the stainless or brass wire brush clean all residual Loctite from all screws Thoroughly inspect all threaded surfaces for corrosion or degradation replace if questionable required 3 Perform all functional test inspection on the latch catch assembl...

Page 153: ...e latch catch mechanism in the top photo on this side of the page Also note that the centerline of the yoke bisects the entire helmet Note that the latch catch mechanism on this side of the page does not properly engage the bail on the neck clamp Also note the yoke is skewed and is not centered across the rest of the helmet ...

Page 154: ...tite thread locker or equivalent and install the three screws and washers at the rear of the yoke and into the hinge Tighten so they are just snug but you can still shift the yoke on the hinge You are now going to fine tune the yoke alignment to the helmet 3 With the helmet resting face down on the face port mount the yoke clamp assembly on the helmet completely and close the clamp without catchin...

Page 155: ...lose with excessive force The clamp must work properly with the dry suit If the adjustment stud adjustment nut is backed out all the way and the clamp closes with excessive force do not use Adjustments must be made with the yoke neck clamp assembly open 1 Visual inspection of the adjustment stud portion of the neck clamp is accomplished by loosening the lock nut with the washer all the way to the ...

Page 156: ...SI via your local dealer for possible repair Users must keep in mind that there are limits to restoring used or abused parts KMDSI uses a fixture that resembles the bottom of a SL 17A B to adjust all new neck clamps and this same fixture can often be used to reshape bent or deformed neck clamps If there is any question regarding the condition of the neck clamp don t use it Suspected worn or damage...

Page 157: ...ed Proper adjustment of the neck clamp places the bail of the neck clamp squarely in the groove of the latch catch body when the clamp is closed 4 If the neck clamp binds and does not close correctly after adjustment the neck clamp must be straight ened or an authorized KMDSI Service Center must accomplish this procedure 8 10 4 Neck Dam 8 10 4 1 Neck Dam Replacement Available Neck Dams Pre 84 Part...

Page 158: ...inge from the neck clamp and the neck dam 4 Remove the neck clamp lock nut and slip the threaded portion of the adjustment arm out of the retaining block Remove the lock washer and the nut and retain for future use 5 With the clamp lock nut removed from the threaded neck clamp adjustment bolt pull the front of the neck clamp open by pressing down on the block end of the neck clamp and up on the le...

Page 159: ... sure the rear sewn seam of the neck dam is next to but not on the hinge tab of the neck clamp where the rear hinge tab is mounted Install the clamp on the helmet shell and close The purpose for this is to ensure the neck dam material is properly aligned Note The clamp will require adjusting so that the neoprene gets compressed tightly against the helmet At this point feel for the hinge tab mounti...

Page 160: ... the square cut out of the neck dam in step 12 to avoid any inadvertent tearing or shredding of neck dam material 12 Visually inspect the previously removed hinge bolt and nut prior to reuse If any abnormalities are present or the nylon insert is worn replacement is recommended Tighten the nut onto the bolt until the end of the bolt protrudes past the nylon insert 13 Adjust the neck clamp per the ...

Page 161: ... to maintain initial torque however repeated use would The o ring on the base of the helmet should be re placed whenever it shows signs of wear disable the nut s designed locking capability 9 Feed the tab at the rear of the neck dam through the space between the sleeve and the rear hinge tab Pull the tab up as far as it will go NOTE You may find it easier to pull the tab through this space by tyin...

Page 162: ...p in the helmet 1 The head cushion is fastened into the helmet with snap tabs and pulls out easily 2 The separate layers of open cell foam sections that fill the head cushion bag primarily determine the fit of the helmet The diver s head can be moved forward into the oral nasal mask by increasing the thickness of the foam at the rear of the head cushion The diver s head can be moved up or down in ...

Page 163: ...icing will be encountered on deck when the surrounding air temperature is less than 32 F 0 C Regulator freezing is primarily due to the refrigera tion effect of breathing air pressure reduction and the addition of moisture from the divers exhalation coming in contact with the topside air temperature This happens as the gas expands in the regulator When the topside environment air temperature is co...

Page 164: ... still show 11 Attach the side block end of the bent tube to the side block assembly and using a torque wrench torque to 100 inch pounds 12 Re torque jam nut using a torque wrench torque to 40 inch pounds 13 Stretch the corrugated tube over PVC flanges on the regulator and the side block 14 Install the tie wraps on the corrugated tube over the PVC stiffeners and tighten then trim excess tail off 1...

Page 165: ...re whip to be sure it is present and in good condition 3 Carefully screw the low pressure whip into the side block 4 Tighten fitting to the specifications provided by the dry suit manufacturer Do not overtighten 5 Pressurize helmet and test connection for leaks When using the low pressure port on the side block for attachment of a low pressure hose a hose with built in flow restriction or the KMDS...

Page 166: ...ers facing the inside of the helmet The Weld Shield mounts with the lens and spring side facing inside the helmet 4 Install and tighten the two mount bolts into the port retainer Remove the two plug screws from the face port Insert the screws in the mount ears of the weld lens assembly 5 On the Weld Lens Assembly tighten the two lock nuts on the ends of the hinge studs so that the assembly can be ...

Page 167: ...ised by all divers regardless of helmet or band mask used to avoid the possibility of underwater explosions when cutting or welding Any underwater explosion can result in serious personal injury or death of the diver WARNING Use only the bolts provided with the kits for installation of these assemblies Lon ger bolts will damage the helmet shell and or the threaded inserts This could cause flooding...

Page 168: ...tor The connec tor splits the hose into two halves with a male connector on one end and a female connector on the other The female connector should be equipped with a sleeve lock that must be properly aligned before the hose can be disengaged Double shut off quick connects are recommended over open quick connects One end of the connector is designed to be attached to the EGS valve assembly while t...

Page 169: ... the water and you are certain they are compatible with all parts of your diving system Failure of any component of your life support system may lead to serious personal injury or death WARNING Mount the double exhaust system on the regulator 9 6 1 Double Exhaust Kit Installation Tools Required 1 4 Flat Blade Attachment on Torque Screwdriver Small pair of snips to trim tie wraps 1 Remove the two w...

Page 170: ...t body Make sure the internal rubber ridge is in the groove in the main exhaust body 10 Secure the exhaust whisker to the main exhaust with a tie wrap and trim off excess tail The double exhaust body must be sealed to the helmet shell with RTV Be sure to install the screws which help to secure the double exhaust body to the helmet shell Install the regulator on the helmet Attach the whisker to the...

Page 171: ...nd before every contaminated water dive Use a tie wrap to secure the double exhaust whisker to the double exhaust main body Completed installation of the double exhaust system The exhaust valves used in the double exhaust system and regulator must be regularly inspected and replaced when ever they show the slightest signs of wear If this is not done leakage into the helmet and breathing systems ma...

Page 172: ......

Page 173: ... BTU 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 Hg Atmospheres 0 03342 Inches of Mercury Hg Feet of Water 1 133 Inches of Mercury Hg PSI Lbs per Sq Inch 0 4912 Inches of Water PSI Lbs per Sq Inch 0 03613 Liters Cubic Centimeters 1000 Liters Ga...

Page 174: ...ote 1 68 555 195 One way valve 150 17 76 530 070 Screw for mounting weights 20 2 25 79 530 078 Screw for mounting weights 20 2 25 82 550 038 Regulator mount nut 100 11 3 87 530 090 Screw alignment 35 50 TL 4 5 6 90 530 070 Screw handle 20 2 25 94 530 040 Screw handle 12 1 3 98 530 317 Nut air train 35 4 101 530 317 Nut air train 15 1 6 102 530 050 Screw sideblock 20 2 25 103 530 052 Screw port plu...

Page 175: ...avoid getting Teflon tape in the valve Tighten pipe thread using good engineering practices For a neoprene neck dam turn the screw three turns Screws may need adjustment after several dives Use thread locking compound Loctite 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 ...

Page 176: ... governing bodies pertaining to enriched gas use However it is the opinion of Kirby Morgan that breathing gas mixtures up to 50 oxygen by volume The following section describes the maintenance and inspection procedures that are used to complete the Annual Monthly and Daily Checklists to ensure optimum reliability and performance These pro cedures are additionally utilized in conjunction with the d...

Page 177: ...uiring lubrica tion should be lubricated sparingly with lubricants approved for oxygen use such as Christo Lube Krytox or Flourolube KMDSI highly recommends using Christo Lube and uses Christo Lube during the assembly of all KMDSI gas train components Regardless of the approved lubricant used never mix different kinds of lubricants Persons mixing han dling and working with breathing gases should b...

Page 178: ... surface When underwater inhalation and exhalation resis tive effort increases due to the density of the breath ing gas and resistive effort of the equipment The increase in resistive effort can cause an increase in blood level CO2 because the diver cannot ventilate as freely as when breathing at the surface When breathing air at the deeper depths nitrogen narcosis can mask CO2 symptoms which can ...

Page 179: ...0 132 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 09 190 91 6 74 62 5 55 17 2 67 166 67 200 00 7 06 75 42 13 2 27 170 45 204 55 7 23 110 PSIG 7 59 BAR 40 100 31 4 03 161 21 193 45 6 83 50 83 25 3 52 175 76 210 91 7 45 62 5 67 20 3 03 189 39 227 27 8 03 75 50 1...

Page 180: ... 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 30 324 36 11 46 50 154 47 5 67 283 33 340 00 12 01 62 5 122 37 4 70 293 56 352 27 12 44 75 100 31 4 03 302 27 362 73 12 81 200 PSIG 13 8 BAR 40 192 59 6 82 272 73 327 27 11 56 50 166 51 6 03 301 52 361 82 12 78 62 5 132 40 5 00 312 50 375 00 13 25 75 102 31 4 09 306 82 368 18 13 01 210 PSIG 14 ...

Page 181: ...3 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 The old method of determining supply pressure was to multiply the dive depth by 445 PSI and then add the over bottom pressure called out in the depth ranges for the depth from the KMDSI operations manual The old method was based on a min...

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Kirby Morgan SuperLite 17B, Operation And Maintenance Manual

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