Kirby Morgan SuperLite 27 Operation And Maintenance Manual Download Page 67

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SuperLite

6.1 Introduction

This section covers the preventative maintenance

necessary on the SuperLite

diver’s helmet. A

helmet that is kept clean and in good repair will offer

far better service to the user. This helmet is designed

for easy access to all areas for proper inspection and

servicing. Numbers appearing in parenthesis below

are “location” numbers that are used in the blow apart

illustration at the rear of this manual.

6.2 Required tools, Cleaning Agents,

Lubrication

All KMDSI helmets and masks are designed with the

professional diver in mind. Most maintenance can

be performed by the diver using common tools and

this manual. There are some repairs however, that

must be accomplished only by KMDSI authorized

repair facilities. This includes fiberglass and helmet

neck ring repairs, face port inserts and sealed pull pin

overhauls. For technical assistance please telephone

your nearest authorized dealer or call KMDSI at

(805) 928-7772.
Every diver should carry sufficient tools and spare

parts to maintain his/her helmet in top working condi-

tion. It is very impor tant to use wrenches of the correct

size rather than adjustable wrenches when possible.

Adjustable wrenches tend to slip and can round the

edges of soft brass parts. The following wrenches and

tools are required to maintain the SuperLite

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 open end wrench

7/8 inch open end wrench

1 inch open end wrench
Torque screwdriver and these attachments:

1/8, 1/4, and 3/8 inch flat blade screwdrivers

#2 Phillips blade screwdriver

7/64 inch Allen wrench driver

9/64 inch Allen wrench driver

5/32 inch Allen wrench driver

Chapter 6

General Preventative Maintenance

Tools required to do proper maintenance on the

SuperLite

Open end wrenches in the following sizes:

3/8 inch

7/16 inch

9/16 inch

3/4 inch

7/8 inch

1 inch
Two adjustable wrenches, 6 & 8 inches in length.

3/8 inch flat blade screwdriver with a notch in the

center of the tip.

1/4 inch flat blade stubby screwdriver

needle nose pliers

diagonal cutting pliers

slip joint pliers

3/32 inch punch

putty knife

O-ring removal tool

KMDSI regulator repair tools: Part #525-620

ball peen hammer

Whisker Clamp Replacement Kit: Part # 525-032

tie wrap: Part # 520-042

Silicone lubricant

Loctite

222 Thread locker

#320, 400, 600 wet/dry sandpaper

rubbing compound

automotive wax

clean rags

Summary of Contents for SuperLite 27

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

Page 2: ... 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 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 been pr...

Page 3: ... Page 94 95 103 104 pertaining to whisker clamps Picture on 102 to show whisker clamps Page 59 Added Whisker Clamp Replacement Kit Part 525 032 Page 68 6 5 6 Inspect the Exhaust Valve step 1 replaced tie wraps text with Whisker Clamp Replacement Kit text Step two appended with the text and valve bodies Page 92 updated diagram to show whisker clamps Page 101 updated diagram to show whisker clamps P...

Page 4: ...from 0496 to 2049 11 06 18 2012 Updated CE notifying body address 12 06 18 2012 Update copyright date to roman numerals 13 01 15 2013 Updated email and copyright information Diving with compressed breathing gas is a hazardous activity Even if you do everything right there is always the potential for serious injury or death No one piece of diving equipment can prevent the possibility that you may b...

Page 5: ...ons 10 2 7 Helmet Features 12 2 8 General Description 15 2 8 1 Helmet Shell 15 2 8 2 Gas Flow Systems 15 2 8 3 Emergency Gas Supply System EGS 17 2 8 4 Helmet Attachment to the Diver 18 2 8 5 Locking Sealed Pull Pins 19 2 8 6 Sealing Arrangement 19 2 8 8 Communications 19 2 8 9 Equalizing the Middle Ear 19 2 8 10 Face Port or Viewing Lens 20 2 9 Accessories 20 2 9 1 Eye Protection for Welding 20 2...

Page 6: ...ystems 40 3 9 5 Communications Check 40 3 9 6 Diver Ready 40 3 9 7 Water Entry and Descent 40 3 9 8 Adjust Regulator for Low Work Rates 41 3 10 Emergency Procedures 42 3 10 1 Flooding 42 3 10 2 Inhalation Resistance 42 3 10 3 Gas Flow Stops 42 3 10 4 Demand Regulator Free Flow 42 3 11 Post Dive Procedures 43 3 11 1 Removing the Equipment 43 3 11 2 Removing the Helmet 43 3 11 3 Storage of the Helme...

Page 7: ...ing 59 6 5 2 Neck Dam Ring Assembly 59 6 5 3 Head Cushion and Chin Cushion 60 6 5 4 Communications Inspection 60 6 5 5 Lubricate Nose Block O Rings Tools Required 60 6 5 6 Inspect the Exhaust Valve 60 Chapter 7 Breathing System Maintenance and Repairs 63 7 1 Introduction 63 7 2 Torque Values 63 7 3 One Way Valve 63 7 3 1 Disassembly Of The One Way Valve 63 7 3 2 Reassembly of the One Way Valve 64 ...

Page 8: ...Removal 96 7 10 2 Tri Valve Exhaust Valve Regulator Exhaust Valve Replacement 96 7 10 2 1 Tri Valve Exhaust Valve Replacement 96 7 10 2 2 Regulator Exhaust Valve Replacement 97 7 10 3 Tri Valve Assembly Installation 97 7 11 Main Exhaust Assembly Water Dump 98 7 11 1 Water Dump Valve Removal 99 7 11 2 Water Dump Valve Replacement 100 7 11 3 Purge Valve Body Removal and Replacement 100 7 11 4 Purge ...

Page 9: ... 122 8 12 1 Disassembly of the Swing Tongue Catch 122 8 12 2 Reassembly of the Swing Tongue Catch 123 8 13 Locking Collar 124 8 13 1 Locking Collar Removal 124 8 13 2 Locking Collar Disassembly 125 8 13 3 Locking Collar Reassembly 126 8 14 Head Cushion and Chin Cushion 127 8 14 1 Head Cushion Foam 127 8 14 2 Chin Cushion Foam 127 8 15 Communications System 128 8 15 1 General 128 8 15 2 Earphone In...

Page 10: ...endix A2 Maintenance and Inspection Procedures 144 Appendix 3 Supply Pressure Requirements Tables 146 Appendix 3 Table 1 Work Rate Expressed as Respiratory Minute Volume RMV 147 Appendix 3 Table 2 Compressor Supply Table SuperFlow and SuperFlow 350 147 Appendix 3 Table 3 SuperFlow 450 SS Balanced Regulator 148 Appendix 3 Table 4 SuperFlow SuperFlow 350 Regulator 150 High Pressure Regulated Source ...

Page 11: ...andario traducir 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 kmdsi KirbyMorgan com or Dive Lab Inc 850 235 2715 or at Divelab aol com IMPORTANT A word about this manual We have tried to make th...

Page 12: ...ce and use Diving is a life threatening occupation Even if you do everything right you can still be killed or injured None of the models of Kirby Morgan helmets or masks can prevent accidents injuries or death due to improper training poor health improper supervision improper job requirements improper maintenance or acts of God This helmet was completely checked and should be ready to dive as it w...

Page 13: ...acing aviation space craft use or for chemical warfare use The helmet must never be used by persons in poor physical condition by persons with previous head neck or back injuries which could be aggravated by its use The helmet should not be used by persons under the in fluence of drugs or alcohol Furthermore infants children or persons under the age of 18 should never wear KMDSI helmets and masks ...

Page 14: ...established by the governing authority in the specific country or geographical location where the diving operations are being conducted If you have any questions concerning this manual or the operation of your helmet contact KMDSI 805 928 7772 or at kmdsi KirbyMorgan com or Dive Lab Inc 850 235 2715 or at Divelab aol com WARNING Always read the Material Safety Data Sheet MSDS for any chemical adhe...

Page 15: ...stment Knob Equalization Device Oral Nasal Mask Port Retainer Handle Purge Button Helmet Shell Communications Port Tri Valve Exhaust standard on all SuperLite 27 helmets Sideblock EGS Valve Pull Pin Non Return Valve The SuperLite 27 helmet 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 L A B T E S T E D ...

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Page 17: ...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 organiza tion administrators and their supporting personne...

Page 18: ...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 the...

Page 19: ...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 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 adjustable first stage regulator reduces the h...

Page 20: ...f 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 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 se...

Page 21: ...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 22: ...ned 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 specifi cally designed for surface supplied diving that will perform over the wide range of pressures delivered by low pressure compressors An ordinary Scuba regulator mounted on a diving helmet is not capable of delivering the g...

Page 23: ...s standard on this helmet The Kirby Morgan 37SS features a quick change com munications module available with either bare wire posts or a waterproof connector and allows for easy efficient maintenance of the helmet s communications 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...

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Page 25: ...ory of PPE III WARNING The helmet has been tested with air and CE certificates for use with air up to 50 meters Compressed air must be compliant with the EN 12021 All the tables reporting the technical 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...

Page 26: ...or Performance 2 4 1 SuperFlow and SuperFlow 350 Demand Regulators The SuperFlow 350 non balanced regulator is the standard demand regulator found on the SL 27 KM 37 and KMB 18 28 Band Masks NOTE Pre Sep 2004 KMB 28 plastic frames will only except the smaller mount tube found on the SuperFlow non 350 regulator The SuperFlow 350 is fully CE marked and CR rated The SuperFlow 450 SS balanced regulato...

Page 27: ... the diver whenever diving operations are conducted using air or mixed gas in waters colder than 33 F 1 C to reduce the possibility of demand regulator icing NOTE Usually the greatest danger of demand regulator icing will be encountered on deck when the surrounding air temperature is less than 32 F 0 C This effect is primarily due to the refrigera tion effect of breathing air pressure reduction an...

Page 28: ...his custom fit and balance seats the helmet comfortably for long periods of time even when working in the face down position A quick change communications module available in either bare wire posts or a waterproof connector allows for easy efficient maintenance of the com munications in the helmet The SL 27 is configured to receive the umbilical over the shoulder In the past the optional Double Ex...

Page 29: ...ar and neckdamlockingsystem Even when the latches are released theneckdammaintainsaposi tive seal and will not allow the seal to be broken until the col lar actually clears the diver s shoulders thuspreventingany flooding of the helmet Air Train diffuses the incoming breathing air gas onto the face plate to defog the lens Silicone Oral Nasal Mask is made of a superior silicone material which is hy...

Page 30: ...to all KMDSI helmets include the face port and retainer ring communications components the oral nasal mask the nose block device the air train most demand regulator components Many of the breathing system components on these helmets are also compatible with the KMB 18B and 28B This helps reduce the inventory of spare parts that must be carried by commercial diving companies Each step of the manufa...

Page 31: ...by Morgan SL 27 head cushions should be used to assure proper operation and comfort 10 The handle that is fitted to the top of the SL 27 and the port weight are areas that can be used as mounting brackets for lights TV cameras etc 11 The communications system is a modular quick change design 2 8 General Description 2 8 1 Helmet Shell The helmet shell 61 is fabricated of noncorrosive rigid fibergla...

Page 32: ...k 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 assembly is controlled by the inlet valve that supplies gas to the diver on inhalation demand only and shuts off during the exhalation cycle The SuperFlow demand regulator senses the start of the divers in...

Page 33: ...tor 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 dry suit hose Low pressure hoses may be connected to the side block...

Page 34: ...t be accidentally dislodged on most divers The neck pad pushes against the neck dam and lower por tion of the head cushion firmly securing the helmet to the diver s head The neck pad also helps prevent neck dam ballooning Each diver must personally adjust the fit on his helmet by adjusting the neck pad as well as the head cushion All of these parts together help provide a good fit Both sides of th...

Page 35: ...placing it part way over the head can help reduce the force needed to install the seal Proper training is necessary to install the neck seal over the diver s head and onto his neck Although the possibility is very remote injury may result if this pro cedure is not done properly If a diver does not know how to don the neck dam he must seek proper instruction before proceeding 2 8 7 Reducing Carbon ...

Page 36: ...to helmet flooding and drowning could result 2 9 Accessories 2 9 1 Eye Protection for Welding The Welding Lens assembly Part 525 403 or the new Weld ShieldAssembly Part 525 400 may be installed on the port retainer 78 using the predrilled and tapped holes that are provided These holes are plugged with blanking screws 79 when a new hel met is shipped from the factory The weld lenses are standard 2 ...

Page 37: ...rench These three wrenches make regulator adjustment much easier The tools come in a convenient wallet sized pouch with instructions Part 525 620 This tool kit ships standard with every Kirby Morgan helmet and band mask equipped with the SuperFlow 350 regulator The Regulator Tool Kit Part 525 620 2 10 Helmet Transport And Storage the kind of package is a cardboard box with air filled pillows with ...

Page 39: ...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...

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Page 41: ...ication 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 allows the strength member to receive t...

Page 42: ...uirements Tables on page 146 With the many different gas supply console con figurations 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 work safely and efficiently In countries that have adopted C E standards only C E certified supply systems and components may be used in conjuncti...

Page 43: ...l foam at the rear of the head cushion The diver s head can be moved up or down in the helmet by decreasing or increasing the foam pads at the top of the head cushion Usually a diver with a small head will use all the foam that comes with a new hat A diver with a larger head will need to remove a layer of foam in the center top and back of the head cushion The foam may be cut with scissors to prov...

Page 44: ...d and plate can slide back and forth Be sure the head cushion snaps are attached to the bottom of the helmet Pick up the helmet and pull the nose block device knob out fully Position the helmet on your head so Locking Collar components Never dive with a neck dam that is too tight A neck dam that is too tight could cause the diver to pass out due to pres sure on the carotid artery in the neck This ...

Page 45: ...pection of the helmet system must be made to be sure it is in proper work ing order This must be done well in advance of the dive so any problems can be fixed without delaying the dive The following steps are part of the recom mended daily maintenance 3 5 1 Pre Dive Visual Inspection Visually inspect the exterior and interior of the hel met 1 The demand regulator cover should not be dented 2 The n...

Page 46: ...b and all locking collar parts to ensure smooth and proper operation 3 6 3 Check Communications Check the communications system for proper opera tion Put the helmet on and talk to an assistant on the amplifier If you are by yourself with the helmet off take the helmet near the amplifier and tap on each earphone and the microphone listening to the taps on the amplifier speaker Talk into the amplifi...

Page 47: ...other equipment Usually the harness is also designed to provide a means of lifting an unconscious diver from the water This harness is the best method of securing the emergency breathing gas to the diver A small tank can be mounted horizontally on the lower rear or front while larger tanks are usually mounted vertically in the center back similar to a Scuba diver s tank Some harness designs incor ...

Page 48: ...ressure gauge must be connected to the high pressure port on the first stage so that the diver can monitor his emergency supply WARNING Never dive without an over pressurization relief valve installed on the EGS regulator 1st stage Without the relief valve if the EGS regulator develops an internal leak or carries away the full pressure of the EGS cylinder would be placed on the low pressure EGS ho...

Page 49: ...zed 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 R...

Page 50: ...es this make it very easy to check your emer gency gas pressure prior to diving it also allows you in most cases to periodically check the pressure in your system while you dive In this way if 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...

Page 51: ... the hose and the helmet must only be made up snug Excessive 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 munications take extra care in handling these pieces To connect the male and femal...

Page 52: ...bonate face port prior to the dive to help prevent fogging during the dive A mild liquid dish washing soap or other commercially available anti fogging solutions may be applied with a soft rag or paper towel to the interior of the port The diver should use a solution which has been found satisfactory in the past However do not use an aero sol spray on the polycarbonate lens The propellants in some...

Page 53: ...properly With the diver holding the helmet the tender should now connect the quick disconnect fittings for the bailout supply Open the regulator adjustment knob and the defogger control knob for a steady flow from both just prior to the diver dressing into the helmet With the helmet face down pull the sealed pull pins and open the locking collar neck pad assembly fully Be sure the head cushion is ...

Page 54: ...s must be in the locking position If they are in the open position rotate until they snap into the locking position Grab the neck ring on the helmet with your fingers on the outside of the ring and using your thumbs push the locking collar neck pad assembly up into position until it locks with the sealed pull pins If you have not positioned the sealed pull pins into the locking position you may do...

Page 55: ...ach sealed pull pin and turning so each remains in the open position Tilt your head and the helmet forward and swing the locking collar assembly back behind your shoulders Do not perform this test unless the diver and his tender are stationed immediately adjacent to the diver s air manifold and you are certain the air is on to the mani fold If the diver is unable to flow air to the helmet either t...

Page 56: ... the diver to make adjustments for variations in umbilical supply pressure This adjustment device is not intended as a minimum maximum device Minimum and maximum applies to supply pressure only The adjustment knob should be adjusted by the diver to be at the easiest breathing setting at all times Diving a KMDSI helmet or band mask with a bias setting greater than that just necessary to keep the de...

Page 57: ...te may be quite slow 10 15 breaths per minute When this occurs the diver s exhalations may not be sufficient to move enough breathing gas through the helmet exhaust to adequately wash out carbon dioxide CO2 In order to ensure that carbon dioxide does not ac cumulate in the helmet divers who are at rest under water should screw the regulator adjustment knob out i e away from the regulator until a s...

Page 58: ...egulator usually in dicates the main gas supply has stopped The diver should first open the emergency valve by turning the knob If there is still no flow from the demand regulator the defogger valve knob should be opened Keep in mind that if the defogger valve is left open the bailout bottle will drain very quickly particularly if the diver is deep Immediately notify topside check to ensure your u...

Page 59: ...asten the umbilical from the harness and take the helmet from the diver and set it aside Closing the locking collar neck pad as sembly onto the helmet before setting the hat down on a rough deck will help protect the helmet neck ring from damage The harness and bailout bottle is then removed 3 11 3 Storage of the Helmet Between Dives If the helmet is not going to be used for a period of time the h...

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Page 61: ...als in communications module 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: ...st valve damaged or stuck open Seat or replace valve Communications module O ring extruded or damaged Replace o ring Communications module not prop erly tightened Tighten module mount nut Communications module damaged Replace 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 r...

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...

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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: ...forming 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 Man...

Page 67: ...ather than adjustable wrenches when possible Adjustable wrenches tend to slip and can round the edgesofsoftbrassparts Thefollowingwrenchesand tools are required to maintain the SuperLite 27 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: ...e port fails underwater the helmet will flood and drowning may result WARNING WARNING Do not use aerosol lubricants Many aerosol pro pellants will damage plastic Avoid lubricant contact with plastic parts NOTE All parts on the helmet that require lubrication must be lubricated sparingly with the appropriate lubricant DO NOT USE AEROSOL SPRAYLUBRICANTS Many aerosol propellants will damage plastic A...

Page 69: ...on WARNING more than 1 wraps could cause excess Teflon tape to travel into the breathing system 6 2 4 RTV Sealant Certain components used in KMDSI helmets and masks use RTV adhesive sealant to provide bond ing and sealing KMDSI recommends Dow Corning RTV 732 multi purpose sealant When sealant is Use good ventilation w h e n u s i n g RT V sealant Fumes from this material may irritate your lungs Re...

Page 70: ...t use care to insure excess seal ant is wiped clean so as not to interfere with other components Sealant should be allowed to cure fo 24 hours before use 6 2 5 Thread Locker KMDSI recommends Loctite 222 as the thread locking compound that should be used on components that call for a thread locker Threads should be clean and dry prior to applying thread locker Ensure that all excess thread locker h...

Page 71: ...bly possible followed by a vigilant inspection of the interior of the helmet to ensure that no contaminant has entered Pay particular attention to the following parts prior to re use whisker demand regulator diaphragm demand regulator exhaust valve exhaust valve Tri Valve Ex haust Valve s communications post s or communica tions connector assembly and neck dam If in doubt about the serviceability ...

Page 72: ...formities Replace o rings if any damage is found or suspected 6 3 2 General Cleaning Guidelines Cleaning and sanitizing of the SuperLite 27 should be accomplished upon completion of use and or prior to storage Clean is defined as free of dirt rust particles lubricant and oil and other contaminants as viewed by the unaided eye Sanitizing is defined as eliminating germs and mi croorganisms Sanitizin...

Page 73: ...edure Unless otherwise directed use the following pro cedure to disinfect the SL 27 oral nasal mask and regulator 1 Wet or immerse all components to be sanitized Allow components to stay in contact with the solu tion for at least 10 minutes 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 ...

Page 74: ... helmet with snap tabs Remove it from the helmet rinse it with fresh water and allow it to dry 5 Remove the communications assembly from the Cover the air inlet and emergency gas valve openings with dust caps when not in use Neverdisconnectanyhosefromthehelmet 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 add...

Page 75: ...met used less than 10 diving days a month Appendix A2 2 should also be performed any time the serviceability of the helmet is in question Check the two sealed pull pins to make sure they operate smoothly and engage the pins on the locking collar properly If the sealed pull pins stick or do not provide adequate tension it is essential to return your helmet to your dealer or KMDSI for service Do not...

Page 76: ...ration Connect to the deck amplifier and talk back and forth Replace any weak earphone or microphone Open the earphone rubber covers and remove the protectors Allow to dry thoroughly Replace defective earphones 6 5 5 Lubricate Nose Block O Rings Tools Required 7 16 inch Open End wrench 1 Unscrew the nose block device packing nut and lubricate the two o rings and nose block device shaft Retighten t...

Page 77: ...l rights reserved Document 130115001 61 SuperLite 27 Inspect the exhaust valve for cracks or tears and replace as needed For further exhaust valve removal replacement and inspection refer to 7 11 Main Exhaust Assembly Water Dump on page 98 ...

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Page 79: ... repair facility or KMDSI 7 2 Torque Values All fittings must be tightened to their correct torque values See Appendix 1 in the rear of this manual for the correct torque specifications 7 3 One Way Valve NOTE The one way valve assembly should be dis assembled cleaned and the three o rings should be replaced at least annually Damaged and or corroded parts should be replaced A repair kit is availabl...

Page 80: ...the one way valve You may damage the valve if pliers are used CAUTION Do not allow any Teflon tape to cover the end of the adapter or to enter the one way valve Loose pieces of Teflon tape can interfere with the performance of the one way valve or the regulator and may block the diver s air supply This could lead to death through suffocation WARNING type and clean if necessary Clean in accordance ...

Page 81: ...used for a bearing surface to mount the side block A special gasket seals the air train cup to the helmet shell incisde the helmet RTV silicone rubber compound is used to form a gas tight seal between the side block and the exterior of the helmet shell 7 4 2 Side Block Assembly Removal Tools Required 7 16 11 16 and 7 8 inch Open End Wrenches 11 16 and 7 8 inch Open End Wrench Attachment on Torque ...

Page 82: ...one 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 Do not use a screwdriver or chisel to remove the sideblock as damage to the shell could result Be sure to peel or scrape the old silicone sealant away from both sealing surfaces before reas...

Page 83: ...efore the sealant has cured it could leak through the side block mounting stud hole screw hole or air flow hole This could lead to drowning WARNING also cause long term damage to body tis sue Read and follow all precautions listed on the silicone sealant tube and Material Safety Data Sheet WARNING Use silicone sealant in a well ventilated area Do not breathe the fumes from uncured silicone sealant...

Page 84: ... air properly the diver cannot use the free flow system as a source of breathing air This could lead to suffocation WARNING Avoid eye contact with ac etone This chemical is an irritant and may cause tissue damage WARNING WARNING Avoid skin contact with ac etone Wear rubber gloves Acetone can damage the nervous system A generous amount of silicone sealant must be evenly applied to the side block pr...

Page 85: ...rench The defogger valve components are disassembled as follows 1 First unscrew the lock nut and remove the spring control knob and washer 2 Next unscrew the bonnet Its o ring will come off with it The valve stem o ring and washer usually come out with the bonnet and can be pushed out of the bonnet once removed from the side block 3 If the stem remains in the side block body it can be lifted out a...

Page 86: ... Next install the new Teflon washer and new o ring onto the stem 3 Insert the proper end of the stem into the seat as sembly and turn clockwise until the seat lightly bot toms out Leave the stem in place 4 Lubricate the new o ring and install on the bonnet 5 Slide the bonnet over the stem and thread the bon Knob Side block Spring Seat Washer Locknut Bonnet Valve stem O ring Washer O ring Proper as...

Page 87: ...water solution followed by cleaning with a 50 50 dilute solution of white vinegar water Rinse with fresh water Clean all parts See the cleaning instructions in Section 6 3 2 2 Inspect the packing and washer for wear and re place if necessary Normally the packing will last a very long time and does not require replacement as long as the valve operates smoothly and does not leak To replace the packi...

Page 88: ...ve body from the side block the one way valve assembly must first be removed 6 If the emergency valve body is then removed clean and inspect the pipe thread and inspect for damaged threads cracking or distortion Replace the emer gency valve if any damage is present Re tape threads with Teflon tape 1 wraps start ing two threads back tighten using good engineering practice To reinstall the emergency...

Page 89: ...AY OVERSTRESS THE PART AND CAUSE THE PART TO FAIL It is NOT necessary to have the control knob for the emergency gas supply valve perfectly square i e at a 90 degree angle to the side block Any angle is ac ceptable provided that 1 the valve handle can be turned easily and 2 the diver can locate the handle easily a Attach supply whip from the EGS first stage to EGS helmet valve b Ensure the defogge...

Page 90: ...back and forth to aid removal 7 7 3 Inspection of Bent Tube Assembly Clean the bent tube in accordance with the cleaning procedures in Chapter 6 The o ring at the regulator end should be cleaned and inspected whenever the bent tube is removed Replace the bent tube if it is excessively scratched dented or compressed deeper than 1 8 inch If the helmet has been used for burning jobs carefully check f...

Page 91: ...demand regulator on your helmet is not maintained or adjusted properly The demand regulator must receive regular maintenance to assure the best performance possible However in the event the demand regulator is damaged there is always a backup supply of steady flow gas available from the defogger valve If the regulator does not breathe easily the diver can not work hard and will tire rapidly Simply...

Page 92: ...w starts When the button is fully depressed a strong surge of gas must be heard 5 If the purge button travels less than 1 16 or greater than 1 8 before free flow is heard the demand regula tor requires internal adjustment 7 8 2 Inspection of Regulator Body Interior Tools Required 1 4 inch Flat Blade Attachment on Torque Screwdriver 1 On the demand regulator remove the demand regu lator clamp by re...

Page 93: ... the washer and o ring NOTE If the spacer and the spring set are stuck this could indicate corrosion or possible saltwater intrusion into the adjustment tube and assembly or that the adjustment tube is bent The demand regulator should be removed from the helmet and cleaned and inspected per 6 3 General Cleaning Inspection Procedures on page 55 and 7 8 5 Demand Regulator Assembly Removal from Hel m...

Page 94: ...all the washer and the lightly lubricated o ring on the adjustment shaft 3 Slip the packing nut over the adjustment shaft fol lowed by the adjustment knob 4 Hold the shaft and rotate the knob until the pin Inspect the o ring washer holes line up Use the inlet valve holder from the regulator tool kit to accurately align these holes Using a small hammer drive the pin back into place until it is flus...

Page 95: ...ers are removed the same way 7 8 6 Disassembly of the SuperFlow 350 Demand Regulator Tools Required 1 4 inch Flat Blade Screwdriver on Torque Wrench 7 8 inch Open end Attachment on Torque Wrench 3 4 inch Open end Attachment on Torque Wrench 3 32 inch Punch 7 8 inch Open end Wrench Small O ring pick Small Ball Peen Hammer Sharp trim knife X acto KMDSI Tool Kit Part 525 620 Silicone Adhesive Dow Cor...

Page 96: ...ment knob drive out the roll pin using a 3 32 punch Use a block of wood with a 1 4 hole drilled through it to support the knob Position the knob so the roll pin is over the hole The adjustment knob can be held against the wood block allowing the roll pin to be driven into the 1 4 hole 8 Remove the inlet nipple from the regulator body The o ring should be replaced if a scheduled overhaul is being p...

Page 97: ...e the fumes from uncured silicone sealant These fumes are dangerous and can cause uncon sciousness They can also cause long term damage to body tis Slight bends in the spokes may be removed by pressing with a thumb The exhaust valve seating area should be free of dirt and corrosion to ensure the valve can lay flat and seal properly The exhaust flange may be replaced if it is damaged NEVER lubricat...

Page 98: ...ct assembly 1 Install the exhaust flange gasket and screws onto the regulator body Use Loctite 222 to secure the Align the flange and the gasket Apply a drop of threadlocker to the screws Install and tighten the two screws that hold the flange in position WARNING The gasket that sits between the regulator exhaust flange and regulator body must be in place Without this flange the regu lator will le...

Page 99: ...all the retaining pin in the adjustment knob regulator body First place the washer then 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 CAUTION Be sure that the washer and spacer that are installed on the inlet valve shaft are in stalled in the corre...

Page 100: ...nut to 40 inch pounds 14 Rotate the adjustment knob in i e clockwise several turns then recheck the torque one more time Ensure the adjustment shaft rotates smoothly and there is no binding Screw clockwise the adjustment knob all the way in towards the regulator body and let sit for 24 hours 15 Stretch the Tri Valve main exhaust body onto the exhaust flange of the regulator Rotate as needed so the...

Page 101: ... bent tube assembly onto the inlet nipple 1 to 2 threads Ensure that the Teflon ring is in place and engage the bent tube nut to the side block fully until it is hand tight You may need to gently rock the regulator body and or the bent tube to fully engage side block nut Next fully engage clockwise the large nut on the bent tube into the regulator inlet until hand tight This will ensure the nut is...

Page 102: ...o retain the whisker properly The exhaust valves must be correctly installed in the exhaust valve inserts or they will not seal correctly This could lead to a backflow of water into the hel met which could expose the diver to any contaminants that are in the surrounding water Depending on the contaminants this could lead to serious personal injury or death WARNING The exhaust valve inserts must be...

Page 103: ...gency WARNING Special note on whisker clamps There is no left or right whisker clamp Both clamps are identical If the clamps are not oriented correctly it will be very difficult to tighten the screws that secure them There is also a good possibility that the clamp will come off of the whisker reducing the effectiveness of the exhaust system in keeping the breathing system dry Whisker Assembly Deta...

Page 104: ...ee flow just stops and there is 1 16 inch 1 5 mm to 1 8 inch 3 0 mm of free play at the end of the lever 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 actuat...

Page 105: ...3 adjustment is necessary and the special KMDSI tool kit is not available proceed as follows 1 Remove the regulator clamp cover and diaphragm 2 Adjust the regulator adjustment knob all the way in finger tight only 3 Pressurize the regulator to between 135 150 p s i g 8 5 10 bar 4 Slowly back out on the adjustment knob until a slight free flow is heard and then rotate the adjust ment knob in clockw...

Page 106: ...f the regulator does not free flow slowly depress the purge button until a slight free flow develops The purge button should depress no further than 1 8 inch 3 0 mm before the regulator Press the cover over the diaphragm The nut must not be loosened more than 1 8 turn to lower the height of the lever If more adjustment is necessary the lever should be bent downward If the nut is loosened more than...

Page 107: ...river NOTE If there is low or no flow when the regulator is pressurized and the lever is very loose travels more than 1 8 inch at the roller end the nut must be tightened 1 Adjust demand regulator bias adjustment knob in i e clockwise 2 Ensure supply pressure is adjusted between 135 150 p s i g 9 3 10 3 bar 3 Back the demand regulator bias adjustment knob 98 out counterclockwise until a slight ste...

Page 108: ...alled when installing a new oral nasal mask Simply stretching the oral nasal mask over the nose block device can cause the oral nasal mask to tear CAUTION 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 6 Install the valve body in the oral nasal The valve MUST be on the inside of the oral n...

Page 109: ...ury or death 7 9 3 Oral Nasal Replacement 1 Snap the oral nasal over the regulator mount nut 2 Reinstall the microphone Exploded view of the Tri Valve exhaust system To remove the Tri Valve exhaust from the helmet you must first cut the tie wrap that secures the exhaust main body to the regulator 3 Reinstall the nose block device See Chapter 8 for complete instructions on reinstalling the nose blo...

Page 110: ...e surrounding water Depending on the contaminants this could lead to serious personal injury or death WARNING The exhaust valve inserts must be in stalled in the correct orientation in exhaust main body If the inserts are in stalled backwards the diver will be unable to exhale This could lead to suffocation and death WARNING To allow access to the two exhaust valves in the whisker wings you must f...

Page 111: ...hat are in the surrounding water Depending on the contaminants this could lead to serious personal injury or death WARNING 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 edge of the nut that holds them Do...

Page 112: ... are installed into and which way they face when mounted in the body They MUST be reinstalled facing the same way If you exhale into the regulator the valves must open 4 Install a new exhaust valve into each whisker ex haust 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 inserts assembly m...

Page 113: ... through the hole in the hub of the spokes until it pops into its seating area 5 Trim the excess tail off the end of the exhaust valve that protrudes into the interior of the regulator 6 Reinstall the diaphragm cover clamp and clamp screw 7 10 3 Tri Valve Assembly Installation 1 The Tri Valve main body opening mates to the regulator exhaust flange This opening needs to be worked onto the regulator...

Page 114: ...his will ensure the nut is bottomed on the shoulder on the bent tube Do not tighten further 8 Loosen the jam nut on the regulator inlet counter clockwise and engage the jam nut fully to the large nut on the bent tube Using a 7 8 open end wrench hold the large nut on the regulator end of the bent tube and tighten the jam nut against it using a torque wrench with a 7 8 adapter to 40 inch pounds 9 Re...

Page 115: ...hould be replaced at the slightest sign of deterioration or aging of the rubber Simply grasp the valve and pull to remove The water dump valve on the SuperLite 27 is protected by the water purge deflector shown here The water purge deflector is removed by cutting the tie wrap that holds it in place The water dump valve should be replaced at least annually Exhaust valve Water Purge Deflector Water ...

Page 116: ...event sealing when re installed 2 Once the valve body is removed inspect the valve to see if it is worn If so it should be replaced 3 To replace the purge valve hold the purge valve body with one hand and cut the stem from the exist ing valve 4 Install a new valve in the body by snapping it into the purge valve body 7 11 4 Purge Valve Body Installation 1 The purge valve body simply snaps into its ...

Page 117: ...ulti Purpose sealant 1 Apply silicone sealant Dow Corning RTV 732 Multi Purpose sealant to the base of the exhaust body Take care not to block the opening for the main exhaust valve 2 Position the water dump exhaust body on the helmet shell Note orientation of body Install the screws and using a torque screwdriver tighten the screws to 12 inch pounds of torque Wipe off any excess sealant Make sure...

Page 118: ...ink if available Magnifying glass New valve body o ring 7 12 2 Overpressure Relief Valve Disassembly and Cleaning Do not use cleaning solvents i e min eral spirits bleach etc when cleaning the relief bleed valve The use of clean ing solvents may lead to failure of the relief bleed valve WARNING 1 Turn off the gas supply to the first stage regulator then bleed off any remaining pressure Remove the ...

Page 119: ... oxygen or mixed gas containing more than 23 oxygen by volume for lift checking the relief bleed valve The use of oxygen or mixed gas in a high pressure supply system not designed and cleaned for oxygen service can result in a fire or explosion causing serious injury or death WARNING NOTE The relief bleeder valve is lift checked and or adjusted using an adjustable first stage regulator equipped wi...

Page 120: ...ter 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 pops open and will not stop flowing secure the air supply valve and allow the valve to reseat Try the procedure again ensuring that the supply valve is only ...

Page 121: ...I recommended cleaning sanitizing solutions and procedures see 6 3 General Cleaning Inspection Procedures on page 55 8 2 Helmet Shell Inspection The helmet shell is constructed using hand laid fi berglass cloth carbon fiber mat and strands im pregnated with polyester resin It is extremely du rable but can be damaged Helmets that have suffered damage can often be re paired but repairs to the helmet...

Page 122: ...ubber can also be glued onto this pad 8 3 2 Nose Block Device Replacement 1 Prior to reassembly lubricate the two O rings 2 Slide the shaft through oral nasal mask in the hel met shell 3 Place both O rings on the shaft followed by the packing 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 ...

Page 123: ...tainer screws Position the handle on the helmet 3 Pry up at the front of the handle to break loose the RTV 8 4 2 Handle Replacement 1 Clean off all the old RTV silicone sealant re maining on the handle and the helmet shell and screw hole 2 Place a liberal amount of RTV Dow Corning RTV 732 or equivalent Multi Purpose sealant on the rear mount surface of the handle and in the mount screw hole in the...

Page 124: ...nt Acetone may be used for this pur pose Use a wooden wedge and the mallet to break the seal between the weight and the helmet shell DO NOT USE A SCREWDRIVER OR CHISEL TO REMOVE THE WEIGHT This could damage the helmet shell requiring expensive repair Do not use a screwdriver or similar sharp instrument to remove the weights as it will damage the fiberglass finish Use only wooden wedges under corne...

Page 125: ...ng helmet 8 4 5 Diamond Weight Removal Tools Required NOTE This weight is optional The standard SuperLite 27 configuration does not include this weight Flat Blade Torque Screwdriver Rubber Mallet Wooden Wedge 1 To remove the diamond weight first unscrew and remove the two screws and washers on the inside of the helmet 2 Use a wooden wedge and a mallet to break the seal between the weight and the h...

Page 126: ... it to shatter upon impact from any strong blow If the face port fails underwater the helmet will flood and drowning may result WARNING 8 5 2 Face Port and Nose Block Device Removal Tools Required 7 16 Open end Wrench 1 4 Flat Blade Attachment on Torque Screwdriver Slip Joint Pliers and a Rag or cloth NOTE Wrap a rag around the nose block knob while re moving to prevent chrome damage when turning ...

Page 127: ...y available There are no equivalent O rings manu factured by other vendors 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 flooding WARNING 2 Lightly lubricate the O ring with Christo Lube lubricant and replace in the helmet shell 3 Place the face port into the helmet shell making sure the O ring has been lightly lubricated and...

Page 128: ...have been damaged or become loose requir ing replacing Replacement of inserts should only be completed by an authorized trained KMDSI technician that has received certification in insert replacement Minor fiberglass and gel coat repairs must only be completed by technicians that have re ceived fiberglass and gel coat training and certifica tion by KMDSI 7 Install the nose block device from the int...

Page 129: ...ace ports An aftermarket face port s thickness or out er periphery may be incorrect and cause the helmet to flood It could also be made of inferior materials causing it to fail This could result in serious injury or death WARNING 8 5 4 Special Note Regarding Ports NOTE There are two different face ports available for KMDSI helmets and masks One port specifically fits the KMB 28 Band Mask The other...

Page 130: ...KMDSI neoprene neck dams come in a variety of sizes Be sure to obtain the right size neck dam for your neck A neck dam that is too tight will be very uncom fortable and can cause you to pass out WARNING New neck dams are supplied with no holes punched in them for the mounting screws As the screws are inserted and tightened they cut their own holes in the neck dam Before starting installation note ...

Page 131: ...eps them from binding in the neoprene on instal lation 7 Insert the Allen head screws into the aligned holes on either side of the pull strap groove and start the screws You must apply enough pressure to pen etrate the neoprene Once the threads engage con tinue tightening the screws three turns 8 Use the punch to align the two screw holes at the base of the tongue on the stepped ring and start the...

Page 132: ...e stepped ring Use a sharp razor to start the cut Once the cut is started pull on the neoprene and maintain tension on it as you continue cutting The cutting edge of the blade should follow the outside rim of the split rings The point of the blade should be directed inside against the corner where the top of the stepped ring meets the step You must have a clean cut with no loose strips of neoprene...

Page 133: ...ps of the neck dam mounting screws lightly with silicone lubricant This will pre vent them from grabbing and twisting the rubber Center the split rings by pressing on the dam and feeling the inside edge of the stepped ring and the split rings Install the split rings inside the trimmed outer lip of the neck dam The neck dam stepped ring and split rings MUST be properly aligned in order to get the s...

Page 134: ... 4 inch 6 0 mm off the neck dam at a time trying it on after each trim Trim latex neck dams with the largest sharpest scissors available Never dive with a neck dam that is too tight A neck dam that is too tight could cause the diver to pass out due to pres sure on the carotid artery in the neck This could lead to severe personal injury or death WARNING Use a sharp razor blade to trim the excess la...

Page 135: ...n Strap Removal Tools Required Phillips screwdriver The chin strap must be replaced as a complete unit 1 Remove the two screws that secure the chin strap to the helmet shell Clean any sealant or debris from the holes 2 Remove the worn chin strap and discard 8 8 2 Chin Strap Replacement 1 Using a syringe inject silicone sealant into the holes that secure the chin strap 2 Install the two screws that...

Page 136: ...cial compound and has unique di mensions It is a softer durometer O ring than is commonly available There are no equivalent O rings manufactured by other vendors This O ring must be re placed with a KMDSI O ring Failure to do so could lead to seal failure and helmet flooding This could lead to drowning WARNING The strap should be oriented so that the tail pulls towards the right side of the helmet...

Page 137: ...f service able used pins are returned to the dealer and for warded to KMDSI 8 11 1 Removal of Sealed Pull Pins Tools Required 9 64 Hex Key on Torque Screwdriver 1 Unscrew the hex head screws from the helmet ring on the base of the helmet 2 Remove the sealed pull pins by pulling them out of the helmet ring 3 Return the pins to your authorized dealer for re placement The sealed pull pins must be ser...

Page 138: ...f the swing tongue catch 2 Remove the spring spacer Take care not to lose the Teflon washer that is attached to the inside of the swing tongue catch If it comes loose it must be glued back in place A quick dry rubber cement works well 3 Remove the screw from the left side of the swing tongue catch 4 Remove the washer and the spacer The swing tongue catch should disengage from the spring now 5 If t...

Page 139: ...the spacer fits through the hole in the swing catch and no binding occurs 5 Place the looped end of the spring on the top side of the helmet ring and insert the screw through it 6 Tighten all three screws to 20 inch pounds 2 25 Newton Meters of torque 7 Test the function of the swing catch Also test prior to diving with the system to ensure proper op eration Make sure you have not lost the Teflon ...

Page 140: ...e locking collar is damaged through careless handling it may need to be replaced 1 Use the open end wrench and torque wrench to remove the bolt from the collar 2 Slide the bolt out of the hinge Take care not to lose the two Teflon washers that sit between the locking collar and the rear hinge mounts on the hel met ring 3 Turn the sealed pull pins until they are disen gaged and lift the locking col...

Page 141: ... Unscrew the two screws that hold the neck pad Take care not to lose the T washers or adjustment nuts 3 Slide the neck pad off the locking collar 4 If the neck pad needs replacement remove and save the screws T washers and adjustment nuts for reuse Exploded view of the locking collar assembly Hinge bolt Nut Locking collar Neck pad Adjustment nut Washer Screw Washer T washer Teflon Washer Washer Pr...

Page 142: ...e on the bot tom of the helmet ring but do not close the catch mechanism 7 Insert the bolt through one of the washers and through the locking collar hinge just far enough so that the tip of the hinge pin shows at the first bolt hole on the locking collar hinge 8 Slide one of the Teflon washers between the locking collar and hinge block on the rear of the hel met ring 9 Push the bolt through the op...

Page 143: ...ver 8 14 2 Chin Cushion 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 The head cushion foam is easily replaceable The chin cushion Note If the head moves the helmet should follow A loose fitting head cushion will cause poor oral nasal mask fit resulting ...

Page 144: ...the helmet shell for inspection and disassembly 1 The rubber front cover is removed first the rear cover is next removed The protector is now free 2 Check the wire connections They should be sol id 3 Check the mylar diaphragm If the mylar is torn or loose replace the entire unit preferably with a corrosion resistant chrome plated mylar speaker Part 515 008 Although cardboard speakers are available...

Page 145: ...or Remove the O ring 5 The entire communications assembly can be re placed with a spare assembly for the most rapid turnaround 8 15 4 Replacement of Communications Assembly 1 Install the O ring on the communications mod ule 2 Carefully push the communications module through the opening in the helmet shell The com munications posts or waterproof connector assem bly if present should be pointed towa...

Page 146: ...ule 4 Lift the terminal lugs out of the communications module Note the position of the terminal wires 5 Install the terminals for the earphones Note that the wires must go on separate terminals as before 8 15 7 Waterproof Connector SuperLite 27 helmets are supplied either with a waterproof connector or an optional set of termi nal posts The waterproof connector is subject to failure if the helmet ...

Page 147: ...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 washers through the open ing on the terminal lugs in the connector and ear phone and microphone 5 Thread the screws into the communications module 6 Tighten the screws until snug Do not overtight en 7 Install the r...

Page 148: ...l rights reserved Document 130115001 SuperLite 27 Installing the white wire Installing the red wire Installing the red microphone wire Installing the white microphone wire Installing the right earphone wires Installing the left earphone wires ...

Page 149: ...e the nuts the wiring harness and washers from the communications posts 6 Remove the communications posts from the module 7 Remove all traces of silicone sealant from the communications module Use a 3 4 inch wrench to unscrew the waterproof connector Pull the connector out of the module 8 15 9 2 Communications Post Replacement 1 Apply fresh RTV silicone sealant to the base of the communications po...

Page 150: ...et shell per 8 15 4 Replacement of Communi cations Assembly on page 129 Use a wrench to tighten the binding post nuts Use good ventilation when using RTV seal ant Fumes from this material may irritate your lungs Read and follow the directions in the MSDS before using this material CAUTION Wear eye protection when using RTV sealant This material may irritate your eyes Read and follow the directions...

Page 151: ... and severe heat loss through the respiration process For this reason KMDSI recommends installing the hot water shroud when diving in waters colder than 40 F 4 C Water supply to the shroud assembly should be at least 1 gallon 3 7 liters per minute at a minimum temperatureof105 F 42 C Whendivingoperations areconductedduringseverecoldsurfacetemperatures a hot water shroud should be used to prevent i...

Page 152: ...VCflangeintheotherendofthe corrugated tube 1 4 of the flange should still show 10 Attach the side block end of the bent tube to the side block assembly Using the torque wrench and 11 16 attachment tighten to 100 inch lbs 11 3 Newton Meters if the regulator end of the bent tube was loosened torque the jam nut to 40 inch lbs 4 5 Newton Meters 11 Slide the PVC flange up towards the side block and ins...

Page 153: ... until the valve stem is flush with the lock nut face 16 Reinstall the emergency valve knob spring and nut Tighten the locknut with a flat blade screwdriver until the valve stem is flush with the lock nut face 17 The completed installation should appear as pictured here Install the second PVC flange in the side block shroud tube Pull the corrugated tube over the PVC flange at the sideblock Fasten ...

Page 154: ... plug 2 Check the O ring on the low pressure whip to be sure it is present and in good condition Carefully screw the low pressure whip into the side block 3 Tighten fitting to the specifications provided by the dry suit manufacturer Do not overtighten 4 Pressurize helmet and test connection for leaks Removing the plug from the side block When using the low pressure port on the side block for attac...

Page 155: ...theweldlensmountears 3 With the shield facing out from the helmet or Install the screws through the mount ears Remove the two plug screws from the port retainer Tighten the weld lens assembly mask install and tighten the two mount screws into the port retainer 4 Tighten the two lock nuts on the ends of the hinge studssothattheweldinglensassemblycanbeflipped up but will not fall down from its own w...

Page 156: ...female connector should be equipped with a sleeve lock that must be properly aligned before the hose can be disengaged One end of the hose with the connector attaches to the emergency valve assembly while the other end of the hose with its mating connector attaches to any of the standard low pressure ports on the KMDSI SuperFlow first stage regulator or any high perfor mance regulator used for the...

Page 157: ... 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 158: ...w handle 20 2 25 57b 530 078 Screw diamond weight 20 2 25 60 530 045 Screw handle 12 1 3 61a 530 062 Screw port weight 20 2 25 62 530 070 Screw port weight 20 2 25 66 530 317 Nut air train 35 4 69 530 317 Nut air train 15 1 6 70 530 050 Screw sideblock 20 2 25 71 530 032 Screw water dump body 12 1 3 79 530 052 Screw port plug 20 2 25 80 530 035 Screw port retainer 12 1 3 85 550 062 Knob nose block...

Page 159: ...d 35 4 Note on Torque Specifications Note 1 Use Teflon tape for one to one and a half wraps starting two threads back from the pipe thread end of the fitting to avoid getting Teflon tape in the valve Tighten pipe thread using good engineering practices Checklist Maintenance and Pre Dive Inspections For the most current check lists helmet maintenance procedures and pre dive inspections please check...

Page 160: ...t necessarily call out that all O rings and normal consumable items will be replaced The manual is written in this way so that if an assembly compo nent or part is being inspected or disturbed between normal intervals it is acceptable to reuse O rings and components providing they pass a visual inspection When conducting annual or scheduled overhauls all O rings should be replaced The side block s...

Page 161: ...contaminated with oils and other petroleum or chemical contaminants 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 Fluorolube KMDSI highly recom mends using Christo Lube and uses Christo Lube during the assembly of all KMDSI gas train compo nents Regardless ...

Page 162: ...he surface When underwater inhalation and exhalation resistive ef fort increases due to the density of the breathing 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 163: ...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 15 2 52 188 64 226 36 8 00 1...

Page 164: ...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 49 BAR 40 212 65 7 42 296 97 356 36 12 59 50 175 53 6 30 315 15 378 18 13 36 62 5 137 42 5 15 321 97 386 36 13 65 75 108 33 4 27 320 45 384 55 13 58 220 PSIG 15 18 BAR 40 220 67 7 67 306 67 368 00 13 00 50 182 56 6 52 325 76 390 91 13 81 62 5 147 45 5 45 340 91...

Page 165: ...4 280 73 9 92 50 123 37 4 73 236 36 283 64 10 02 62 5 110 33 4 33 270 83 325 00 11 48 75 83 25 3 52 263 64 316 36 11 17 150 PSIG 10 35 BAR 40 172 52 6 21 248 48 298 18 10 53 50 137 41 5 15 257 58 309 09 10 92 62 5 115 35 4 48 280 30 336 36 11 88 75 93 28 3 82 286 36 343 64 12 14 160 PSIG 11 04 BAR 40 185 56 6 61 264 24 317 09 11 20 50 147 45 5 45 272 73 327 27 11 56 62 5 130 40 4 94 308 71 370 45 ...

Page 166: ...02 61 7 12 356 06 427 27 15 09 62 5 170 51 6 15 384 47 461 36 16 30 75 148 45 5 48 411 36 493 64 17 44 Appendix 3 Table 4 SuperFlow SuperFlow 350 Regulator High Pressure Regulated Source Depth Regulator Setting Surface Gauge in P S I G Regulator Setting Surface Gauge in BAR FSW MSW Minimum P S I G Maximum P S I G Minimum Bar Maximum Bar 0 60 0 18 150 225 10 3 15 5 61 100 19 30 200 250 13 8 17 2 10...

Page 167: ...d 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 minimum RMV of 62 5 This method can still be used The old method used the for...

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Kirby Morgan SuperLite 27, Operation And Maintenance Manual

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