Kirby Band Masks User Manual

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Page 1

WARNING

Kirby Morgan® Models 18 & 28 Band Masks

Operations and Maintenance Manual

KMDSI Part # 100-002

™

Kirby Morgan Dive Systems, Inc.

1430 Jason Way

Santa Maria, CA 93455, USA

Telephone (805) 928-7772, FAX (805) 928-0342

E-Mail: KMDSI@KirbyMorgan.com, Web Site: www.KirbyMorgan.com

Manual prepared by KMDSI, Marine Marketing and Consulting, and Dive Lab, Inc.

NOTE: This manual is the most current for the Kirby Morgan 18 & 28 BandMasks®. It is page dated August 2010. Future changes will be shown on page III and the changed pages will carry the date of change. Previous manuals may not reﬂect these updates.

Diving with compressed breathing gas is a hazardous activity. Even if you do everything right there is always the danger that you may be killed or injured. No piece of diving equipment can prevent the possibility that you may be killed or injured any time you enter the water.

The Kirby Morgan 18 & 28 BandMasks® meet or exceed all performance and testing requirements of all government and non-government testing agencies throughout the world. They are CE approved. They are approved for use on all commercial and military work underwater. Only Kirby Morgan masks and helmets have achieved the CR (Commercial Rated) mark, the highest United States of America rating.

Kirby Morgan, SuperLite®, BandMask®, BandMask®, KMB, KMB-BandMask®, DSI, Diving 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 trademark/trade dress protected.

© Copyright 1970-2010 Kirby Morgan Dive Systems, Inc. All rights reserved. This manual is made available for the express use of owner of this Kirby Morgan product. No part of this manual may be reproduced, stored in any retrieval system, or transmitted, or used in any form or by any means, whether graphic, electronic, mechanical, photocopy, or otherwise by technology known or unknown, without the prior written permission of Kirby Morgan Dive Systems, Inc.

Document Number 100720002, August 2010

Page 2

Kirby Morgan® BandMasks® 18 & 28

Warranty Information

Kirby Morgan Dive Systems, Inc. warrants every new mask, helmet, or KMAC Air Control System to be free from defects in workmanship for a period of three hundred sixty ﬁve (365) days from date of purchase. This warranty covers all metal, ﬁberglass, and plastic parts. This warranty does NOT cover rubber parts, communications components, or headliners. In addition, due to the electrolytic nature of underwater cutting and welding, chrome plating cannot be warranted when the diver engages in these activities.

Should any part become defective, contact the nearest authorized KMDSI dealer. If there is no dealer in your area, contact KMDSI directly at (805) 928-7772. You must have a return authorization from KMDSI prior to the return of any item, Upon approval from KMDSI, return the defective 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 properly serviced and/or maintained according to the appropriate KMDSI manual. In addition, the user is responsible to ensure that all product updates as recommended by KMDSI have been performed.

3) Unauthorized modiﬁcations have been made to the product.

4) The product has been abused or subjected to conditions which are unusual or exceed the

product’s intended service.

NOTE: Be sure to complete the enclosed warranty card and return it to KMDSI immediately. No

warranty claims will be honored without a satisfactorily completed warranty card on ﬁle at KMDSI.

Page 3

®®

Location Number Order No. Description

1 510-509 Head Harness (Spider) 2 525-740 KMB Hood Assembly 3 545-015 Nose Block Device 510-575 Nose Block Pad 4 520-020 Valve Body 5 510-550 Valve, Oral Nasal 6 530-060 Screw ( 18 only) 7* 510-490 O-Ring (18 only) 510-211 O-Ring (28 & pre '99 18) 8* 550-081 Regulator Mount Nut (18 only) 550-038 Regulator Mount Nut

(28 & pre '99 18)

9 510-747 Oral Nasal Mask 10 515-0 05 Earphone, Right 11 515-006 Earphone, Left 510-542 Earphone Cover set 515-008 Speaker 520-0 15 Speaker Protector 12 515-009 Microphone 13 515-030 Communications Set 14 520 -051 Comfort Insert (18 only) 15 530-095 Screw 16 545-007 Top Band 17* 520 -056 Mask, Fiberglass (18 only) 520 -055 Mask, Fiberglass (18 only, pre '99) 520-125 Mask,Frame (

28, 1"

)

520-096 Mask,Frame (⅞") 18 530-535 Washer 19 530 -415 Washer 20 530-317 Nut 21 545-016 Air Train 21a 510-762 Air Train Gasket KMB 18 ONLY 22 530-317 Nut 23 530-535 Washer 24 545-065 Standoff (28 only) 25 530-050 Screw 26 510-260 O-Ring 27 520 -004 Face Port (18 only) 520-128 Face Port (28 & pre 1979 18's only) 28 560 -070 Port Retainer 28n 550-116 Nose Block Guide 29 530-052 Screw, Port Plug 30 530-035 Screw 31 510-010 O-Ring 32 510-008 O-Ring 33 555-180 Packing Nut 34 550-062 Knob, Nose Block 35 525-752 Tri-Valve™ Exhaust (35a-35i) 35a 510-786 Starboard Whisker™ 35b 510-787 Port Whisker™ 35c 510-761 Tri-Valve Exhaust Main Body 35d 520-200 Whisker™ Exhaust Valve Insert 35e 510-776 Exhaust Valve 35f 520-042 Tie Wrap 35g 520-118 Tri/Quad Valve Whisker Clamp 35h 530-008 Brass Screw 35i 530-009 Brass Nut 36 550-061 Spacer 37 540 -015 Plate 38 530-045 Screw 39* 545-080 Reg. Body, SuperFlow 350 (18 only) 545-022 Regulator Body

(28 pre 2004& pre '99 18 only)

40 550-060 Piston 41 535-807 Spring Set 42 550-059 Spacer 43 550-057 Shaft

Location Number Order No. Description

44 520 -032 Washer 45 510-011 O-Ring 46 550-055 Packing Nut 47 550-053 Knob, Adjustment 48 530-601 Retaining Pin 49 530-030 Screw 50 545-020 Clamp 51 545-018 Cover Assembly 51a 535-905 Retaining Clip 51b 540-055 Cover 51c 535-810 Spring, Purge Button 51d 520-017 Purge Button 51e* 520-078 Purge Button Sticker (18 only) 520-077 Purge Button Sticker

(28 & pre '99 18)

52 510-553 Diaphragm 53 530-303 Nut 54 550-052 Spacer 55 545-038 Roller Lever 56 530-506 Washer 57* 530-505 Washer 58* 535-804 Spring

(pre '04 28 & pre '99 18)

59 545-026 Inlet Valve 60 510-014 O-Ring 61a 550-046 Inlet Nipple, "A" 61b 550-048 Inlet Nipple, "B" 61c 550-050 Jam Nut, "B" 62 510-552 Exhaust Valve 62a 540-122 Exaust Flange, Chrome 62b 510-401 Gasket 62c 530-020 Screw 63a 505-026 Demand Regulator Assem. 18 "A" (⅞") 63b* 505-027 Demand Reg Assem."B"

(28 pre '05 & pre '99 18)

(⅞")

505-069 Demand Reg Assem. 350 18 "B",28 (1") 63c 505-028 Reg Adjustment Assem. 64 530-021 Screw 65 545-024 Exhaust Cover (18) 545-041 Exhaust Cover (28) 66 510-561 Main Exhaust Valve 67 550-063 Exhaust Body (18 only) 68 545-009 Bottom Band 69 530-035 Screw (18 only) 70 550-040 Nut 71 530-308 Hex Nut 72 530-525 Washer 73 515 -035 Communications Post 74 510 -481 O-Ring 75 550-043 Plug 76 555-175 Packing Gland

77 520-113 Ferrule Set 78 555-178 Packing Nut 79 515-045 W.P. Connector, Male (4 pin) 79a 505-047 W.P Connector Assem. complt. 80 515-049 Terminal 81 515-061 Terminal Block 82 550-019 Locknut 83 535-802 Spring 84 520-524 Knob, control 85 520 -030 Washer 86 550-020 Bonnet 87 510-015 O-Ring 88 520 -031 Washer 89 510-010 O-Ring 90 550-022 Valve Stem 91 550-023 Seat Assem.

Kirby Morgan 18 A/B & 28 Band Mask

Location Number Order No. Description

92 550-024 Stud - Side Block 93a 550-026 Side Block - "A" N/A 93b 550-029 Side Block - "B" 94 550-140 Emergency Valve Body 95 550-138 Stem 96 540-095 Washer 97 520 -024 Packing 98 550-091 Packing Nut 99 520-525 Knob, Control 100 535-802 Spring 101 550-019 Locknut 102 505-070 Emergency Valve Assembly 103 555-195 One-Way Valve 104 555-117 Adapter, Brass, 1/4" NPT/0 105 Seat 106 Wiper 107 O-Ring 108 O-Ring 109 Poppet 110 Spring

Order

Complete

see

Loc. # 103

111 Body 112 510-483 O-Ring 113 505-060 One-Way Valve Assembly 114 550-095 L.P. Plug, w/O-ring 114b 310-003 O-Ring 115a 510-011 O-Ring 115b 520-033 O-Ring, Teﬂon 116 555-154 Bent tube Assembly 117a 510-010 O-Ring 117b 510-012 O-Ring 118a 555-152 Regulator Hose w/O-Rings 118b 555-155 Bent Tube Assem. w/O-Rings 119a 505-022 "A" Side Block Assem. Complt.-N/A 119b 505-024 "B" Side Block Assem. Complt. 120 540-175 Bottom BandKeeper® Attachment Plate 120a 540-182 Bottom BandKeeper® Mount 121 530-073 Screw 122a 540- 171 Top BandKeeper® Mount 122b 540-179 Top BandKeeper® Attachment Plate 122c 530-073 Screw 123 530-040 Screw 124 530-062 Screw 525-620 Tool Kit (not shown)

For

Replacement

Parts

Order

Kit

#525-330

Use only Kirby Morgan original replacement parts. The use of other manufacturer's parts will interfere with the performance characteristics of your life support equipment and may jeopardize your safety. Additionally, any substitutions will void any warranties offered by KMDSI. When ordering spares, always insist on Kirby Morgan original parts.

Following publication of this booklet, certain changes in standard equipment, options, prices and the like may have occurred which would not be included in these pages. Your Authorized KMDSI dealer is your best source

for up-to-date information on any of these products. © Kirby Morgan Dive Systems, Inc. reserves the right to change product speciﬁcations at any time without incurring obligations.

Kirby Morgan Dive Systems, Inc.® 1430 Jason Way, Santa Maria, CA 93455

Phone: 805/928-7772 Fax: 805/928-0342

www.KirbyMorgan.com e-mail: kmdsi@KirbyMorgan.com

Product Changes

Page 4

Kirby Morgan

28n

93a

93b

100

101

102

103

113

114b

114

112

111

110

109

104

105

108

106

107

115b

116

117b

115a

117a

118b

118a

119a

119b

79a

120

121

123

122c

122b

122a

124

21a

120a

Note: “21a” not needed for the KMB 28

63c

61a

61c

61b

63a

63b

51a

51b

51c

51e

51d

62a

62b

62c

35f

35b

35d

35e

35g

35h

35i

35c

35a

Kirby Morgan 18 A/B & 28 Band Mask

Kirby Morgan Dive Systems, Inc.® 1430 Jason Way, Santa Maria, CA 93455

www.KirbyMorgan.com e-mail: kmdsi@KirbyMorgan.com

Phone: 805/928-7772 Fax: 805/928-0342

As of January 1, 1999, all KMB 18B's are manufactured with

the large tube SuperFlow 350 Regulators, part number 505-069, and a new frame part number 520-056. The large tube regulator cannot be retroﬁtted into pre '99 KMB 18B's without the purchase of a new frame. Small tube ﬁberglass frames, Part number 520-055, are available as replacement parts (see 17)

Page 5

Kirby Morgan® BandMasks® 18 & 28

Record Of Changes

It is the responsibility of the owner of this product to register their ownership with Kirby Morgan Dive Systems, Inc., by sending the warranty card provided. This card is to establish registration for any necessary warranty work and as a means of communication that allows KMDSI to contact the user regarding this product. The user must notify KMDSI of any change of address by the user or sale of the product.

All changes or revisions to this manual must be recorded in this document to ensure that the manual is up to date.

Change Number Date Description of Change

1 05/21/2008 Reworded: Section 2.1 Product Speciﬁcations, 2.2.1 SuperFlow

350 Demand Regulators, 2.2.2 SuperFlow® 450 Performance, 2.7 Operational Speciﬁcations & Limitations, Page 25 changed email address, Two warnings at the bottom of page 26, Page 27 changed email address and Page 41 changed size of text box to accommodate missing part number

Added: Appendix 3 and 4

and SuperFlow®

Removed: Tables 1 and 2 from chapter 2

2 08/20/2008 Page III Removed page number column.

Added: Last paragraph to chapter 5 on page 65. Heading changed. Moved: Chapter 5 into two columns. Changed: Section 7.8.8 Reassembly of the SuperFlow 350 Demand Regulator to eliminate washer and spring text. Section 7.10.2.2 Regulator Exhaust Valve Replacement, step 2 switching tie wraps for whisker clamps. Page 65 Various text changes Page 66 Added Whisker Clamp Replacement Kit: Part # 525-032 to second column.

3 11/05/2008 Table of contents redesign

Page 148 Various torque speciﬁcation updates

4 03/23/2009 Page 40 Section 3.6.1 Step 8: Changed 13 kg cm to 1.3 Newton Meters.

Page 71 Section 6.4.5 2nd Paragraph: Changed 28 kg cm to 2.94 Newton Meters. Page 75 Section 7.3.2: Changed 270 kg cm to 17 Newton Meters. Page 76 Section 7.3.2 Step 7: Changed 270 kg cm to 17 Newton Meters. Page 80 Section 7.4.4 Step 7: Changed 40 Inch Pounds to 15 Inch Pounds. Page 88 Section 7.7.4 Step 8: Changed 150 Inch Pounds to 75 Inch Pounds. Page 122 Section 8.4.3 Step 6: Changed 14 Inch Pounds to 12 Inch Pounds. Page 138 Section 9.2.1 Step 10: Changed 112 kg cm to 11.3 and 4.5 Newton Meters. Page 145 Added 122c to Torque Specs

5 11/18/2009 Chapter 2: addition of CE conforming criteria

6 03/30/2010 Updated images of whisker wings

7 07/20/2010 Added wiring diagram to chapter 8.

Page 6

Kirby Morgan® BandMasks® 18 & 28

WARNING

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 be injured or killed any time you enter the water. We do not herein make any effort to teach the principles of diving. The information in this manual is intended for users of Kirby Morgan masks and persons that maintain or service Kirby Morgan masks.

Page 7

Kirby Morgan® BandMasks® 18 & 28

Table Of Contents

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II

Record Of Changes Denition of Signal Words Used in this Manual

Chapter 1 General Information KMDSI Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Introduction

1.2 Full-Face Masks and Manifolds

1.3 Kirby Morgan Diving Helmets

Chapter 2 Description & Operational Specications

Kirby Morgan 18 & 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Product Specications

2.2 Regulator Performance

2.2.1 SuperFlow® and SuperFlow® 350 Demand Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2.2 SuperFlow® 450 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3 Cage Code

2.4 CR Standards

2.5 CE Certication

2.5.1 CE Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.5.2 Notifying Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.6 Risks in Decompression Diving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.7 Operational Specications & Limitations

2.8 Overview of the KMB18 & KMB28

2.9 Detailed Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.9.1 Mask Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.9.2 Gas Flow Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.9.3 Main Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.9.4 Hood and Face Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.9.5 Hood and Face Seal Retainer Bands and Band Keepers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.9.6 Head Harness or “Spider” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.9.7 Reducing Carbon Dioxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.9.8 Equalizing the Middle Ear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.9.9 Face Port or Viewing Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.9.10 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.9.11 Use of Bail-Out System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.10 Accessories

2.10.1 Eye Protection for Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.10.2 Hot Water Shroud for SuperFlow 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.10.3 Special Regulator Tools for SuperFlow 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.10.4 Hard Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.11 Helmet Transport And Storage

2.11.1 One BandMask

2.11.2 Two BandMasks

2.11.3 Helmet Carrying Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.12 Use of Kirby Morgan Original Replacement Parts

Chapter 3 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.1 Introduction

3.2 Design Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Page 8

Kirby Morgan® BandMasks® 18 & 28

3.3 First Use of Your Kirby Morgan Diving Mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.4 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.5 Custom Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.6 Pre Dress-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.6.1 Pre-Dive Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.7 Preparing the Mask for Diving

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.7.1 Clean Face Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.7.2 Check Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.7.3 Check Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.7.4 One Way Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.7.5 Sealing Integrity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.8 Emergency Gas System (EGS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.9 Setting Up to Dive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.9.1 Flushing Out the Umbilical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.9.2 Connecting the Umbilical to the Mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.9.3 Opening the Breathing Gas Supply to the Mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.9.4 Fogging Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.9.5 Donning the Mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.9.6 Testing the Breathing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.10 Diving Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.10.1 Standing By to Dive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.10.2 Attaching the Umbilical to the Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.10.3 Diver Dons Mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.10.4 Diver Check Gas Flow Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.10.5 Communications Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.10.6 Diver Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.10.7 Water Entry and Descent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.10.8 Adjust Regulator for Low Work Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.11 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.11.1 Flooding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.11.2 Inhalation Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.11.3 Gas Flow Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.11.4 Demand Regulator Free Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.12 Post Dive Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.12.1 Removing the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.12.2 Removing the Mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.12.3 Mask Storage Between Dives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Chapter 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.1 General

4.2 Communication Malfunction

4.3 One Way Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.4 Side Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.5 Water Leakage Into BandMask

4.6 Demand Regulator Malfunction

4.7 Emergency Gas Supply Valve

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Chapter 5 Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.1 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.1.1 Daily Pre-Dive Maintenance A2.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.1.2 Daily Post Dive Maintenance A2.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.1.3 Supervisors Equipment Checks A2.4 and A2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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5.2 Monthly Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.3 Yearly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.3.1 Overhaul/Inspection Checklist A2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Chapter 6 General Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6.1 Introduction

6.2 Required tools, Cleaning Agents, Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6.2.1 Component and Parts Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

6.2.2 Component and Parts Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

6.2.3 Teon® Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.2.4 RTV Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.2.5 Thread Locker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.3 General Cleaning & Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

6.3.1 O-Ring Removal/Inspection/Cleaning and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6.3.2 General Cleaning Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6.3.2.1 Soap Solution for General Cleaning and Leak Detector Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6.3.2.2 Acidic Cleaning Solution and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6.3.2.3 Germicidal Cleaning Solutions and Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6.4 Daily Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.4.1 Post Dive Gear Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.4.2 Hood and Band Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.4.3 Hood, Bands and Band Keeper Attachment Plates Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.4.4 Additional Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

6.4.5 Reinstalling the Hood and Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6.4.6 Note on discontinued Old Style Hoods - (#510-510) Pre "band keeper" model . . . . . . . . . . . . . 64

6.5 Monthly Maintenance (or between jobs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

6.5.1 Communications Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

6.5.2 Lubricate Nose Block O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6.5.3 Inspect the Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Chapter 7 Breathing System Maintenance and Repairs . . . . . . . . . . . . . . . . . . . . . . . 67

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.2 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.3 One Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.3.1 Disassembly Of The One Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.3.2 Reassembly of the One Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

7.4 Side Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.4.2 Side Block Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.4.3 Separating the Side Block Assembly from the Mask Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.4.4 Side Block Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

7.4.5 Hose Assembly (KMB-18A only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7.4.5.1 Hose Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7.4.5.2 Hose Assembly Inspection “A style Side Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7.4.5.3 O-ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7.4.5.4 Hose Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7.5 Defogger Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

7.5.1 Disassembly of the Defogger Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

7.5.2 Cleaning and Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

7.5.3 Reassembly of the Defogger Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

7.6 Emergency Valve Assembly

7.6.1 Disassembly of the Emergency Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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7.6.2 Cleaning and Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

7.6.3 Reassembly of Emergency Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

7.7 Bent Tube Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

7.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

7.7.2 Removal of the Bent Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

7.7.3 Inspection of Bent Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

7.7.4 Reinstallation of the Bent Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

7.8 Demand Regulator SuperFlow 350

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

7.8.1 Demand Regulator Test for Correct Adjustment, Fully Assembled . . . . . . . . . . . . . . . . . . . . . . . . . . 82

7.8.2 Inspection of Regulator Body Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

7.8.3 Demand Regulator Bias Adjustment Servicing, Demand Regulator on the Mask . . . . . . . . . . . . 83

7.8.4 Reassembly of Adjustment System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

7.8.5 Demand Regulator Assembly Removal from Mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7.8.6 Disassembly of the SuperFlow 350 Demand Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

7.8.7 Inspection of Demand Regulator Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

7.8.8 Reassembly of the SuperFlow 350 Demand Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

7.8.9 Tuning the SuperFlow 350 Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

7.8.10 Regulator Steady Flows When Pressured Up: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

7.8.11 Regulator has Low or No Flow When Pressurized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

7.8.12 Unexplained Demand Regulator Free Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

7.9 Oral/Nasal Mask

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

7.9.1 Oral/Nasal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

7.9.2 Inspection of Oral/Nasal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

7.9.3 Oral/Nasal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

7.10 Tri-Valve™ Exhaust Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

7.10.1 Tri-Valve™ Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

7.10.2 Tri-Valve™ Exhaust Valve & Regulator Exhaust Valve Replacement . . . . . . . . . . . . . . . . . . . . . . 102

7.10.2.1 Tri-Valve™ Exhaust Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

7.10.2.2 Regulator Exhaust Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

7.10.3 Tri-Valve™ Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

7.11 Exhaust Valve Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

7.12 Overpressure Relief / Bleed Valve Overhaul Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

7.12.1 Overpressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

7.12.2 Overpressure Relief Valve Disassembly and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

7.12.3 Overpressure Relief Valve Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

7.12.4 Overpressure Relief Valve Lift Check/Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Chapter 8 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

8.1 General

8.2 Mask Frame Inspection

8.3 Nose Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

8.3.1 Nose Block Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

8.3.2 Nose Block Device Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

8.4 Face Port

8.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

8.4.2 Face Port and Nose Block Device Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

8.4.3 Face Port and Nose Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

8.4.4 Special Note Regarding Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

8.5 Hood and Band Keeper Removal and Replacement

8.5.1 Hood, Bands and Band Keeper Attachment Plates Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

8.5.2 Band Keeper Mount Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Page 11

Kirby Morgan® BandMasks® 18 & 28

8.5.3 Inspect / Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

8.5.4 Hood, Bands and Band Keeper Attachment Plates Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

8.6 Replacing the Face Seal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

8.6.1 Removing the Old Face Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

8.6.2 Pre-Coat the Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

8.6.3 Installing the Face Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

8.7 Communications System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

8.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

8.7.2 Earphone Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

8.7.3 Microphone Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

8.7.4 Earphone Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

8.7.5 Waterproof Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

8.7.5.1 Waterproof Connector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

8.7.5.2 Connector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

8.7.6 Communications Posts

8.7.6.1 Communications Post Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

8.7.6.2 Communications Post Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Chapter 9 Accessories for the Kirby Morgan BandMasks

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

. . . . . . . . . . . . . . . . . 131

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

9.2 Hot Water Shroud

9.2.1 Hot Water Shroud Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

9.3 Low Pressure Inator Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

9.3.1 Installation of the Low Pressure Inator Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

9.4 Weld Lens Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

9.4.1 Weld Lens Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

9.5 Weld Shield Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

9.5.1 Weld Shield Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

9.6 Use of Quick Disconnect

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

9.7 Hard Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

9.7.1 Hard Shell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

9.7.2 Hard Shell Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Table of Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Appendix 1: Torque Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Checklist, Maintenance, and Pre-Dive Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Appendix A2 Maintenance and Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . 142

Appendix 3 Supply Pressure Requirements & Tables . . . . . . . . . . . . . . . . . . . . . . . . . 144

Appendix 3 Table 1 Work Rate Expressed as Respiratory Minute Volume (RMV)* Appendix 3 Table 2 Compressor Supply Table SuperFlow and SuperFlow 350 Appendix 3 Table 3 SuperFlow Table Supply Pressure Requirements

450 SS Balanced Regulator Low Pressure Compressor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Appendix 3 Table 4 SuperFlow® / SuperFlow® 350 Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

High Pressure Regulated Source Appendix 3 Table 5 Supply Pressure Guidelines REX SuperFlow

450 Stainless Steel Balanced Regulators High Pressure Regulated Source

Supply Pressure Guidelines

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Regulator / KM-47 / KM-77 / and

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

. . . . . . . . . 145

. . . . . . . . . . . . 145

Appendix 4 Standard Kirby Morgan Surface Supply Pressure Formula -

Old Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Page 12

Kirby Morgan® BandMasks® 18 & 28

CAUTION

DANGER

WARNING

Denition of Signal Words Used in this Manual

For your protection, pay particular attention to items identiﬁed by signal words in this manual. These terms are identiﬁed as, CAUTION, WARNING and DANGER. It is especially important for you to read and understand these sections.

This word indicates an imminently hazardous situation, which if not avoided, could result in death or serious injury.

This word indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

This word indicates a potentially hazardous situation, which if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

If English is not your native language and you have any difﬁculty understanding the language of any warnings as they appear in the manual, please have them translated.

Este é um aviso importante. Queira mandá-lo traduzir.

Este es un aviso importante. Sirvase mandario 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 mask, 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 comprehensive and factual

as possible. We reserve the right however, to make changes at any time, without notice, in prices, colors, materials, equipment, speciﬁcations, models and availability. Since some information may have been updated since the time of printing, please contact your local KMDSI dealer if you have any questions. Periodically KMDSI Operations and Maintenance Manuals are reviewed. Any updates/changes will be posted on the KMDSI website and may be downloaded for insertion/correction.

Important Safety Information:

This Kirby Morgan diving mask is intended for use by trained divers who have successfully completed a recognized training course in surface supplied diving.

Page 13

Kirby Morgan® BandMasks® 18 & 28

WARNING

Follow all the instructions in this manual carefully and heed all safety precautions. Improper use of this diving mask could result in serious injury or death.

Kirby Morgan Dive Systems, Inc. (KMDSI) warns all divers who use the Kirby Morgan diving mask to be sure to use only KMDSI original parts from a KMDSI authorized dealer. Although other parts, O-rings and ttings may appear to t on Kirby Morgan diving masks, they may not be manufactured to the same standards maintained by KMDSI. The use of any parts other than KMDSI original parts may lead to equipment failure and accidents.

Diving in waters that are chemically, biologically, or radiologically contaminated is extremely hazardous. Although some Kirby Morgan diving masks may be adapted for use in some contaminated environments, special training, equipment, and procedures are necessary. Do not dive in a contaminated environment unless you have been thoroughly trained and equipped for this type of diving.

Read this manual before using or maintaining the mask, even if you have experience with other diving masks. If you have purchased the mask new from 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 mask to another diver, be sure

this manual accompanies the mask 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.

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 mask was completely checked and should be ready to dive as it was shipped from the factory. However, it is always the diver’s responsibility to check all the components of the mask prior to diving.

Any and all berglass repairs done to this mask MUST be done by a KMDSI factory trained repair facility. Painting is not recommended by KMDSI. Furthermore, many diving companies will not allow painted masks to be used because painting can mask previous berglass damage. KMDSI certied technicians are not responsible for certifying masks free from damage during annual overhauls.

Mask shells can be re-gel coated by authorized/certied KMDSI trained technicians that have received berglass training by KMDSI. Masks that are to be painted for cosmetic purposes, should be rst, certied free of berglass damage by an authorized KMDSI technician certied in berglass repair. A log entry should be made in the mask log that the mask was free of damage prior to painting. Keep in mind other KMDSI technician can refuse to work on mask shells that have previously been painted or repaired by non KMDSI certied persons.

This manual is supplied to the original purchaser of this mask. If you have any questions about the use of the mask or you need another copy of this manual, Part Number 100-002, contact KMDSI or your nearest KMDSI dealer or it may be downloaded free from the KMDSI website at www.KirbyMorgan.com.

Page 14

Kirby Morgan® BandMasks® 18 & 28

WARNING

If you have any questions regarding the use, maintenance, or operation of this mask, contact KMDSI at (805) 9287772, fax: (805) 928-0342, or e-mail: kmdsi@kirbymorgan.com.

Kirby Morgan masks and helmets are cleaned and lubricated for oxygen service when they come from the factory. However, if the mask is used with an oil lubricated air compressor, contamination with hydrocarbons may result. If the breathing system in the mask is exposed to hydrocarbons, it must be cleaned for oxygen service and lubricated with oxygen safe lubricants before using it again with breathing mixtures containing a high percentage of oxygen. If this is not done, res and explosions may result, exposing the user to serious personal injury or death.

Components requiring lubrication, should only be lubricated with oxygen compatible lubricants such as Christo

, Fluorolube®, or Krytox®.. Lubricants must be used sparingly and should not be mixed with other lubricants.

Lube

KMDSI helmets and masks are intended for underwater use only and should only be

used by qualied divers that have received proper training in the use of this type of equipment. KMDSI helmets and masks should not be used or worn without the appropriate life support systems, such as air or gas supplies and support personnel as described in this manual.

KMDSI helmets and masks should never be used for motor sport racing, aviation /

space craft use, or for chemical warfare use. The mask 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 mask should not be used by persons under the inuence of drugs or alcohol. Furthermore, infants, children, or persons under the age of 18 should never wear KMDSI helmets and masks. Failure to pay heed to the above could result in serious injury or death.

Never use the mask without rst completing all pre-dive maintenance and set up proce-

dures.

Do not use KMDSI helmets or masks in currents exceeding 3.0 knots Use in currents

greater than 3 knots may allow water to enter the exhaust valve, possibly causing regulator ooding. This could lead to drowning.

Surface-supplied diving can be a strenuous activity. Most Kirby Morgan masks weigh in excess of 12 pounds. KMDSI recommends that persons with a previous neck or back injury seek professional medical approval prior to engaging in surface supplied diving operations using any Kirby Morgan mask. Use of any Kirby Morgan mask with a preexisting physical/medical condition may result in death or serious injury.

Page 15

Kirby Morgan® BandMasks® 18 & 28

The information contained in this manual is intended to aid the user in optimizing the performance of this mask. The application of some of this information will 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.

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 rules and regulations 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 mask, contact KMDSI (805) 928-7772 or at kmdsi@ kirbymorgan.com or Dive Lab Inc. (850) 235-2715 or at Divelab@aol.com

Page 16

Kirby Morgan® BandMasks® 18 & 28

Hood

Sideblock

Emergency Gas

Supply Valve

Steady

FlowValve

Mask Frame

Spider

Band Keeper

Port Retainer

Oral/Nasal Mask

Comfort Insert

18 ONLY

Non-Return Valve

Bent Tube

The Kirby Morgan BandMask

SuperFlow 350 Regulator

Tri-Valve Whisker Wing

Regulator Adjustment

Knob

™

Page 17

Kirby Morgan® BandMasks® 18 & 28

STOP!

BEFORE GOING FURTHER-

This manual will refer to location numbers in specic drawings, or in the exploded view, which is in the back of this manual. These numbers are called “location” numbers. They are used to nd the referred to parts in the drawings in this manual only. They are not the part number. Next to the exploded drawing is a list of the “location” numbers that match the Kirby Morgan part numbers along with the name of the part. Always check the part number when ordering to make sure it is correct. When ordering, always specify the helmet model number and serial number as well.

Chapter 1

General Information KMDSI Products

1.1 Introduction

The Kirby Morgan Corporation was started in 1965. The copper and brass “Heavy Gear” or “Standard Dress” helmets were the ﬁrst helmets manufactured by the company. Over the years Kirby Morgan designed, manufactured and sold many different helmets and masks for commercial divers.

Staying active in commercial diving has contributed to the successful design innovations of KMDSI products. This may be the primary reason for the acceptance of our designs by professional divers.

Bev Morgan has designed more than ﬁfty-seven diving helmets and over 40 diving masks. All employees of KMDSI participate as part of the Kirby Morgan design team. It would not be possible for us to supply the commercial, military, scientiﬁc, and public service diving industries with our equipment, without the team of people that make up Kirby Morgan Dive Systems, Inc. (KMDSI)

We feel it is important for the reader to understand that we at KMDSI consider ourselves as only part of the process along 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 organization administrators and their supporting personnel has contributed to the current state of the art of diving.

Each piece of gear we manufacture has in it some of the thinking of those who have gone before us. To all those people who gave something of themselves to the men and women who work underwater, we express a thank you.

We have a strong commitment to providing the best diving equipment and service possible. This thinking has been the policy of Kirby Morgan Dive Systems,

Bev Morgan, Chairman of the Board

Kirby Morgan Dive Systems, Inc.

Inc. and we will continue to take this approach to our work.

Our extensive dealer network makes it easy to obtain genuine Kirby Morgan replacement parts, as well as technical assistance worldwide.

KMDSI has always concentrated on designing and manufacturing diving equipment that allows most repairs, inspections, and all routine maintenance to be performed by the user. Most routine preventative and corrective maintenance can be accomplished by the user utilizing this manual, the KMDSI Tool Kit (P/N 525-620) and common hand tools. Technician training is available through Dive Lab Inc. Information can be obtained on line at www.divelab.com or by telephone at 850-235-2715.

Page 18

Kirby Morgan® BandMasks® 18 & 28

™

1.2 Full-Face Masks and Manifolds

KMB® 18 A/B

approved and ™ marked

The EXO Full Face Mask is designed for both surface supplied and scuba diving. By enclosing the divers eyes, nose and mouth, the EXO permits nearly normal speech when used in conjunction with most wireless, and all hard wire underwater communication systems.

The EXO BR (BALANCED REGULATOR) shown here is designed to meet or exceed recommended performance goals in both scuba and surface supplied modes and is

approved. It meets and surpasses

European standards for regulator performance.

The KMB 18B BandMask® 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 KMB 28B feature the new Tri-Valve™ Exhaust System.

The KMB 28B BandMask

(not shown) is very similar to the KMB 18, with many parts on the KMB 18B being interchangeable with the KMB 28B. The major difference between the 18 and 28 is the material of the mask frame itself. The KMB 18 has a ﬁberglass frame (yellow) while the KMB 28B frame is an extremely durable injection molded plastic (black).

Other differences include:

1) The main exhaust body of the KMB 28 is part of the frame itself and uses a #545-041 main exhaust cover

2) no comfort insert is required on the 28

3) the face ports for the 18 and the 28 differ slightly in size.

EXO® BR

approved and ™ marked

The Balanced Regulator helps reduce the work of breathing for the diver by balancing the intermediate air pressure against the valve sealing pressure inside the regulator. This enables the regulator to instantly adjust to changes in line pressure. The balanced regulator is adjustable for a wide range of intermediate pressures between 90 PSIG – 250 over ambient pressure (6.2 – 17 bar).

Both models have a modular communications design that permits rapid and simple maintenance. The optional Hard Shell provides surfaces for mounting lights, cameras etc.

Both the KMB 18 and KMB 28 are

approved.

Page 19

SuperMask M-48

™

w/ Scuba Pod

Kirby Morgan® BandMasks® 18 & 28

KMACS-5

w/ No Communications

approved and ™ marked

The SuperMask M-48 is an innovative new design in a full-face mask. It provides the diver with all the comfort of a full-face mask with the convenience of changeable second stage regulators as well as the ability to use a snorkel without having to remove the mask.

The mask is comprised of two major components, the mask frame and the interchangeable lower pod. The removable lower pod is a feature unique to the SuperMask full-face mask. When diving, the pod is easily removed and replaced on the mask, providing the diver the capability to buddy-breathe, snorkel, use an octopus or perform an “in water” gas switch.

With the pod sealed to the mask, the ﬂexible, silicone pod cover allows the diver to quickly place the regulator mouthpiece into the mouth or dive with it free of the mouth for communications. With the mouthpiece in, the regulator may be used without the pod being sealed to the mask.

KMACS-5

w/ Communications

The Kirby Morgan Air Control System-5 (KMACS) is a lightweight, portable control box for use in surface 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 high-pressure air and supplies low pressure through the umbilical to the diver’s breathing system.

High pressure yokes permit U.S. standard scuba cylinders or DIN equipped cylinders to be used. Lowpressure air supply ﬁttings allow for a compressor to be used as the primary air source.

The mask may also be used surface supplied when used with the proper accessories. We are currently developing several different pod conﬁgurations for both open circuit and rebreather use. For further information, see the Frequently Asked Questions (FAQ) area on

our web site at www.KirbyMorgan.

com/FullFaceMasks/M48.html.

A complete pneumo system with dual reading gauges (both US Standard and Metric) is provided for each diver’s air, as well as a shut-off/bleed system that uses two high-pressure feed lines which allows changing of used cylinders without interruption of the diving operation. Optional shut off valves allow the isolation of each diver’s air supply.

The Communication Set is a multipurpose intercommunication system that provides reliable and clear communications between a topside operator (tender) and one or more surface-supported divers, recompression chambers, or other submersible systems.

SuperMask M-48

w/ Rebreather pod

marked

Page 20

Kirby Morgan® BandMasks® 18 & 28

1.3 Kirby Morgan Diving Helmets

All Kirby Morgan diving helmets and masks are manufactured by Kirby Morgan Dive Systems, Inc. (KMDSI). Each step of the manufacturing process is carefully controlled to assure the customer of a high quality, durable helmet that will function properly for many years.

There are eight models of Kirby Morgan diving helmets currently in production. They are the SuperLite 17B, (MK-21- U.S. Navy version), SuperLite the SuperLite 37SS, 47, 57, and 77. All are

The SuperLite

27, and Kirby Morgan models 37,

-17 A/B was ﬁrst developed in 1975

™

marked.

and quickly set a new standard for diving helmet design. Many large and small commercial diving companies, military organizations, scientiﬁc divers, and public safety divers are successfully using this design around the world. This helmet is

marked.

17C

The SL-17 A/B helmet system consists primarily of two major components: the neck dam/yoke assembly, and the helmet. To don the helmet, the diver ﬁrst slips the angled neck dam with the attached yoke over 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 seals

the neck dam to the helmet but also secures the front of the yoke, fastening the helmet to the diver’s head.

The SuperLite

-17A/B shares many common breath-

ing system parts with all Kirby Morgan helmets and masks. The breathing system was man-tested to 1600 FSW by the University of Pennsylvania and approved by the U.S. Navy for surface-supplied diving to 190 FSW with air and 300 FSW with mixed gas. It surpasses all requirements of all governing agencies and it is approved for commercial diving through out the world.

SuperLite® 17A/B

approved and ™ marked approved and ™ marked

Yoke and Latch Catch

Assembly

™

Kirby Morgan

Neck Pad and

Sealed Pull Pins.

Page 21

Other features that are common to all Kirby Morgan

™

helmets include:

* Face port and retainer ring * Communications components * Oral/nasal mask * Nose block device * Air train defogger

Kirby Morgan® BandMasks® 18 & 28

The Kirby Morgan

37 Commercial Diver’s Helmet

represents what we at Kirby Morgan consider to be a turning point in modern diving helmet design. The helmet consists of two major assemblies: the helmet shell/helmet ring assembly and the neck dam/neck ring assembly.

The helmet comes with the large tube SuperFlow 350 adjustable demand regulator which provides an easier breathing gas ﬂow during peak work output. A quick change communications module is available with either bare wire posts or a waterproof connector.

The helmet ring houses the sealed pull pins and provides protection for the bottom end of the helmet. The diver is also provided with an internally adjustable chin support. This custom ﬁt and balance seats the helmet comfortably for long periods of time even when working in the face down position.

The SuperLite

27® Commercial Diver’s Helmet has

all the same features of the KM37 on a smaller, low volume shell design. This helmet is often preferred by persons with smaller heads.

SuperLite

approved and ™ marked

Kirby Morgan® 47

The chrome plated machined brass helmet neck ring houses the 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

The Kirby Morgan® 47 offers the ultimate in a high performance breathing regulator. This helmet has an entirely new breathing system, oral nasal mask, and water ejection system. The REX with it’s fully adjustable balanced piston is a breakthrough design that exceeds the requirements of all government or other testing agencies.

approved and ™ marked

Demand Valve,

with either bare wire posts or a waterproof connector, allows for easy, efﬁcient maintenance of the helmets communications.

It has the best work-of-breathing performance when compared to ANY other commercial diving helmet. The Kirby Morgan 47 Dive Helmet has been tested

The helmet also features the SuperFlow 350 large tube adjustable demand regulator. The helmet is available in the umbilical over the shoulder, “B”

and meets or exceeds European CE requirements and is fully commercially rated. In all other respects, this helmet is nearly identical to the Kirby Morgan 37.

conﬁguration only.

Page 22

Kirby Morgan® BandMasks® 18 & 28

™

marked

The Kirby Morgan® 57 helmet features our revolutionary new SuperFlow 450 Stainless Balanced Regulator. It's machined from a stainless steel casting for the ultimate in performance and reliability.

Like all KMDSI regulators on our helmets and Band Masks

, we use only regulators that are speciﬁcally 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 gas you need at heavy work loads. This commercially rated fully diver adjustable regulator delivers all the breathing gas you might require for the most demanding work underwater.

The Kirby Morgan

57 also includes our Quad-

Valve™ Exhaust System. It's recommended for diving in biologically contaminated water, when you're properly trained and equipped, using recommended procedures. This new exhaust has exceptionally low exhalation resistance that you must experience to appreciate.

approved and ™ marked

The Kirby Morgan® 77 represents the ﬁrst in a new generation of stainless steel diving helmets that provide an alternative for the diver who prefers a metal helmet. The helmet features our new stainless steel

REX

regulator, which offers the best performance

of any other Kirby Morgan system.

It has the best work-of-breathing performance when compared to ANY other commercial diving helmet. The Kirby Morgan 77 Dive Helmet has been tested and meets or exceeds European CE requirements and is fully commercially rated.

The advantages of this all stainless steel helmet include the following:

• No reﬁnishing required if the surface is scratched or gouged.

• Faster production of helmets for customer delivery.

• Elimination of threaded inserts for securing the port retainer to the helmet shell.

B WARNING

• No need to remove the handle to remove the port retainer.

Before attempting any diving in any type of contaminated water, a complete diving and topside course in hazardous materials emergencies

• One piece sideblock includes both the free-ﬂow valve and the Emergency Gas System valve.

should be completed. The divers and the topside team must be properly

• The helmet ring is an integral part of the helmet.

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.

Page 23

Kirby Morgan® BandMasks® 18 & 28

approved and ™ marked

The Kirby Morgan

37SS features an all stainless

steel shell, as well as a stainless sideblock, helmet ring, bent tube, handle, and other key components. The SuperFlow 350 is standard on this helmet.

The Kirby Morgan 37SS features a quick change communications module, available with either bare wire posts or a waterproof connector, and allows for easy, 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 gouged

• Elimination of threaded inserts for securing port retainer to helmet shell

Page 24

Page 25

Kirby Morgan® BandMasks® 18 & 28

WARNING

Chapter 2

Description & Operational Specications

Kirby Morgan 18 & 28

This manual is our effort to explain the operation, maintenance and use of the KMB 18 & 28. We do not herein make any effort to teach the principles of diving. It is our assumption the reader is a qualied diver. We highly recommend that all divers should train, under controlled conditions, in the use of any model of commercial diving mask that they have not previously used or trained in, prior to use on the job, until they have mastered the skills required to use their mask correctly.

This section includes detailed descriptions of the Kirby Morgan 18 and 28, as well as important operational speciﬁcations. Most, but not all, parts are interchangeable between these two masks.

2.1 Product Specications

Weight: KMB 18 - 13.63 pounds KMB 28 - 12.73 pounds Mask Frame KMB 18: Fiberglass, polyester resin, polyester gel coat, carbon ﬁber Mask Frame KMB 28: Xenoy Control Knobs: ABS plastic Lens: Clear polycarbonate Hood: Neoprene. O-Rings: Buna-N

The recommended lubrication type for breathing gas mixtures containing oxygen percentages greater than 50% is Christo Lube Halocarbon

. Helmet gas train components being used with gas mixtures containing less than 50% oxygen can be lubricated with food grade silicone grease such as Dow Corning can be used in waters at water temperatures as low as 34° F (1°C).

thermoplastic

, Krytox®, Tribolube® and

111. The BandMask®

2.2 Regulator Performance

2.2.1 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 BandMasks

. 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 regulator can be used on the SL-27, KM-37 and KMB-18/28 BandMasks

. Breathing performance is greatly affected by the support equipment used, as well as the supply pressure to the helmet or mask.

2.2.2 SuperFlow® 450 Performance

The SuperFlow

450 is an all Stainless Steel regulator of a balanced design that offers a slightly higher degree of breathing performance and extreme breathing rates, more than the non balanced SuperFlow regulator.

2.3 Cage Code

The cage code for identifying KMDSI products for U.S. government purposes is 58366.

2.4 CR Standards

Never use aerosol-propelled sprays near the face port of any Kirby Morgan diving mask. The propellant used in these aerosols can invisibly damage the face port and cause it to shatter on impact from any strong blow. If the face port fails underwater, injury or death may result.

If you have any questions regarding proper set-up, operation, or maintenance of your Kirby Morgan 18 or 28, contact KMDSI (850) 928-7772 or at kmdsi@ KirbyMorgan.com or Dive Lab Inc. (850) 235-2715 or at Divelab@aol.com

Kirby Morgan masks and helmets meet or exceed all standards established by Dive Lab of Panama City, Florida, and are CR (Commercially Rated) marked.

Page 26

Kirby Morgan® BandMasks® 18 & 28

2.5 CE Certication

The BandMask® has been tested and conforms to the performance requirements as set forth in Annex II of Directive 89/686/EEC and, as far as applicable, the EN 250:2000, EN 250/A1:2006 and EN 153331:2008 (Class C). It is fully CE marked with demand regulator SuperFlow 690 and P/N 510-747.

350 and oral nasals P/N 510-

CAUTION

The user cannot:

• remove the mark from the frame of the BandMask®;

• modify or counterfeit the data reported on the mark.

Category of PPE: III

WARNING

The BandMask® has been tested with air and CE certicates for use with air up to 50 meters. Compressed air must been compliant with the EN 12021. All the tables reporting the technical data and the pressure of use are relative to compressed air.

2.5.1 CE Marking

On the frame of the BandMask ﬁxed.

EN250:2000 EN250/A1:2006

EN15333-1:2008 CLASS C

BAND MASK MODEL:

YEAR OF PRODUCTION:

CE Mark

In the mark the data reported are the following:

the CE mark is af-

KIRBY MORGAN

DIVE SYSTEMS, INC.

1430 Jason Way,

Santa Maria, CA 93455

0496

CAUTION

The mark must be visible and legible throughout the life of the PPE. If the mark deteriorates or is not legible the user should contact the manufacturer.

2.5.2 Notifying Body

The Notiﬁed Body is DNV- MODULO UNO S.c.a.r.l. Address: Via Courgnè, n.21 10156 Torino Identiﬁcation number: 0496.

2.6 Risks in Decompression Diving

Decompression diving always presents the diver with additional risks.

WARNING

Decompression diving always involves the risk of decompression sickness. Omitted decompression due to a loss of the breathing gas supply or other accidents can cause serious injury or death. Use of a Kirby Morgan mask or helmet cannot prevent this type of injury.

1. The name and the address of the manufacturer;

2. Harmonized reference standard: EN 250:2000, EN 250/A1:2006 and EN 15333-1;

2.7 Operational Specications & Limitations

-Umbilical minimum I.D. 3/8” (9.5 mm) of not more than two sections, total length not to exceed 600 feet

3. CLASS C = NO protection;

4. PPE model;

5. Serial number (stamp on the BandMask

6. The year of production;

7. CE marking:

;

8. Notifying Body number

frame);

(183m).

The KMB 18 and 28 meet or exceed all requirements of NPD, Health and Safety, (U.K.), United States Navy, ADCI United States and is CR rated by Dive Lab, Panama City, Fla., USA.

Every model of KMDSI helmets and masks undergo extensive type testing to fully document the performance capability and required supply pressures when using various umbilical and pressure combinations. All users should take the time to become knowledgeable on supply requirements to insure proper performance and for the comfort and safety of the diver.

Page 27

Kirby Morgan® BandMasks® 18 & 28

Recommended overbottom (OB)gas supply pressure for best performance at depths are calculated by the formula (fsw x 0.445) + recommended p.s.i g.

The required supply pressures for the KMB 18 and 28 equipped with either the SuperFlow SuperFlow

450 regulators are listed in the appropri-

350 or

ate supply pressure tables in Appendix 3.

WARNING

The demand regulator and side block assemblies have a maximum design pressure of 250 psig (15.5 bar) over the ambient pressure, higher pressures could lead to component failure resulting in serious injury.

The supply pressures listed in the supply tables were derived by breathing simulator trials. There are two tables used for the SuperFlow regulators and two separate tables for the SuperFlow

and SuperFlow® 350

450 regulator. It is important that users understand how to use the tables. For further information on supply requirements for the KMB 18 and 28 or any Kirby Morgan helmet or mask check the Kirby Morgan website at www.kirbymorgan.com.

WARNING

When the BandMask® is used for air diving in countries that conform to C.E. regulations it must be used to a maximum depth of 164fsw (50msw). I.A.W. EN 15333-1.

-Temperature limitations: Use at water temperatures below 33 ºF (1 ºC) requires use of hot water shroud (P/N 525-100) and hot water.

NOTE The Hot Water Shroud (Part #525-100) in conjunction with hot water to the diver should be used whenever diving operations are conducted using HEO (15.56°C) for the comfort of the diver. KMDSI further recommends that the shroud be used in conjunction with hot water to 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.

at water temperatures less than 60°F

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 refrigeration effect of breathing air pressure reduction, and the addition of moisture from the divers exhalation coming in contact with the topside air temperature. If diving where the water temperature is 33°F (1°C) or warmer but the topside air temperature is below freezing, 32°F (0°C) icing of the demand regulator is possible. To help eliminate the possibility of freezing on the surface, warm water should be run over the exterior of the demand regulator prior to water entry, if the hot water system is not used.

The umbilical assembly should be composed of good quality diving hose that meets industry standards. Generally, gas hose will be married to the communications wire, pneumofathometer hose, and strength member in a manner that will allow the strength member to receive all the strain. There are also good quality umbilicals available that are assembled at the factory using a twisted method which does not require marrying. Regardless of the system used, the umbilical is the diver’s life line and should always be of excellent quality and maintained carefully.

If you have any questions regarding proper set-up, operation, or maintenance of your KMB 18 or 28 contact KMDSI (850) 928-7772 or at kmdsi@KirbyMorgan.com or Dive Lab Inc. (850) 235-2715 or at Divelab@aol.com

WARNING

Gas systems used to supply Kirby Morgan helmets and masks must be capable of supplying gas to the diver at the required pressure and ow rates as stated in the operational specications. The use of unregulated gas sources is extremely dangerous.

The use of standard SCUBA type regulators is unacceptable, as there are no provisions for adjusting the intermediate pressure to the diver. Only proven systems that allow for varying the gas supply pressure to the diver should be used for umbilical diving.

Page 28

Kirby Morgan® BandMasks® 18 & 28

WARNING

2.8 Overview of the KMB18 & KMB28

All Kirby Morgan diving masks are manufactured by hand. Each step of the manufacturing process is carefully controlled to assure the customer a high quality, durable mask that will function properly.

The mask is a rugged full-face mask that was speciﬁcally designed for commercial diving to allow a working diver to swim as easily as possible.

These masks feature the SuperFlow 350 large tube adjustable demand regulator which provides superb breathing gas ﬂow during peak work output.

Both the KMB 18 and 28 are conﬁgured to receive the umbilical over the shoulder.

Both masks use the Tri-Valve™ Exhaust system to provide an exceptionally dry breathing regulator. However, these masks are not recommended for con-

taminated water diving. Hooded face masks should NOT be used for diving in contaminated water situations. Water can leak past the face seal and expose the diver to contaminants.

The Kirby Morgan BandMask Morgan BandMask® KMB 28 compare as follows:

1) The face port (or view port) on the KMB 18 remains unchanged in shape from the SuperLite®-17A/B. The face port in the KMB 28 is a slightly different size than the KMB 18.

2) The main exhaust body is molded into the mask frame in the KMB 28.

3) The exhaust covers on the two masks are slightly different.

4) There is a vacuum formed comfort insert in the KMB 18.

5) The air train in the KMB 28 requires a special standoff for proper mounting of the side block.

6) The side block and bent tube assembly that transports air/gas to the demand regulator from the side block are the same on both masks and on most Kirby Morgan helmets.

KMB 18 and the Kirby

Before attempting any diving in any type of contaminated water, a complete 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 Tri-Valve™ exhaust works well during jetting operations. It has been found that the use of a TriValve™ assembly can help in the prevention of inversion of the exhaust valve during heavy jetting operations.

Communications are available in either bare wire posts or with a waterproof connector, and allows for easy, efﬁcient maintenance of the communications in the mask. The KMB 18 and 28 incorporate the same communications components used in all other Kirby Morgan helmets.

The face ports for the KMB 18 and KMB 28 are not interchangeable. Do not attempt to use a face port from a KMB 28 in a KMB 18.

Although the port will t into the mask frame, it will not seal properly. This will lead to continuous leakage of the mask and could cause a rapid depletion of the diver’s breathing gas as they attempt to clear the mask.

Never use a third party face port. Its thickness or shape may be incorrect and cause it to ood. It could also be made of inferior materials causing it to fail. This could be fatal.

Page 29

When diving in heavy current (i.e. exceed-

CAUTION

ing 3 knots) the single exhaust system on all KMDSI masks/helmets could allow water to enter, due to turbulence/eddying. It is important for the user/diver to take excessive currents into consideration. The Tri-Valve Exhaust

system will help prevent water intrusion when diving in heavy currents, up to 5 knots. Unlike the old double exhaust, the Tri-Valve does not limit the diving depth.

Many of the breathing system components on these masks are also compatible with the Kirby Morgan helmets. This helps reduce the inventory of spare parts that must be carried by commercial diving companies.

Kirby Morgan® BandMasks® 18 & 28

Page 30

Kirby Morgan® BandMasks® 18 & 28

WARNING

2.9 Detailed Description

2.9.1 Mask Frame

The mask frame on the KMB 18 is fabricated of noncorrosive, rigid ﬁberglass which will not carry an electrical charge. The mask frame on the KMB 28 is made from Xenoy not carry an electrical charge.

The mask frame is the central structure for mounting all the components that make up the complete mask. It is designed to allow easy replacement of parts when necessary. Any repair to the mask frame must be done at an approved KMDSI repair center.

2.9.2 Gas Flow Systems

The main gas supply ﬂow from the umbilical enters the system at the adapter and ﬂows through the one way valve to the interior of the side block . The one way valve or “non-return” is a very important component.

EGS Gas Supply

Main Gas Supply

, a thermoplastic that also will

Gas Flow To Air Train

The emergency gas comes from a tank of compressed gas worn by the diver. It enters the system through the Emergency Gas valve when the diver turns the control knob on. The ﬂow then enters the side block .

Both sources of gas ﬂow through the same passage in the side block body to three exits. One exit is always open to supply gas to the demand regulator assembly . The second exit is to the defogger valve (also known as the free-ﬂow or steady-ﬂow valve) assembly. The third is to the port on the side block to connect a dry suit inﬂator hose.

Never connect the main gas supply hose from the diving station/umbilical to the emergency valve. There is no one way valve in the emergency gas valve. If this mistake is made, any break in the supply hose could possibly result in a “squeeze”. This could result in serious injury or death.

The side block on the mask is drilled and tapped to accept low-pressure inﬂator hoses. This allows the diver the capability to inﬂate variable volume dry suits. It is tapped with a 3/8-24 thread oriﬁce, standard for American ﬁrst stage scuba regulator’s low-pressure auxiliary ﬁttings.

Auxiliary L.P. Port

Gas Flow To Regulator

The one way valve prevents the ﬂow of gas out of the helmet to the umbilical in the event of a sudden lowering of pressure in the umbilical. This can happen due to an accidental break in the hose or a ﬁtting near the surface. Not only would the emergency gas be lost if the one way valve failed (concurrent with a hose or ﬁtting break on deck), but the diver could suffer from a serious “squeeze” that could cause injury or death.

Although we have selected the valve for its reliability and quality, inspection and maintenance of this valve must be done regularly. It is very easy to disassemble and inspect. (A rebuild kit for this valve is Part #525-330).

The one way valve must be tested daily, prior to the commencement of diving operations. Failure of one way valve could cause serious injury or death. Follow the procedures for testing the valve in this manual.

The port is shipped plugged at delivery. This inﬂation capability does not signiﬁcantly interfere in any way with the breathing characteristics of the regulator during normal use providing a limiting hose is used. When using a dry suit inﬂation hose, the hose should be equipped with a ﬂow restrictor (P/N 555-210) to limit ﬂow in the event the hose ruptures or is severed.

Side block

Install inflator hose here

Plug

Bent tube

Low pressure hoses may be connected to the side block.

Stud

O-ring

Page 31

WARNING

The side block inator port is intended

WARNING

for dry suits only. When using the side block low-pressure inflator port, only good quality hoses and ttings should be used and must incorporate an in-line ow restrictor to reduce gas ow in the event of hose failure. Any hose or tting failure in this arrangement will subject the diver to a decreased air supply. Do not use the side block inator port for any purpose other than attaching a dry suit hose.

The KMDSI Restrictor Adaptor, KMDSI Part #555-210.

When using the side block low pressure inator port, the diver should only use high quality hoses with an integrated ow restrictor or a KMDSI ow restrictor PN# 555-210. All hoses must have an in-line restrictor to reduce the gas ow in the event of hose failure.

Do not use fitting adapters. Standard adapters do not provide an adequate ow restriction. The use of many off-the- shelf adapters on the side block assembly could expose the low pressure hose ttings to excessive stress. Any failure of an ination hose will subject the diver to a decreased supply pressure.

Kirby Morgan® BandMasks® 18 & 28

The diver can control the ﬂow of gas through the defogger system with the control knob for either emergency breathing (backups) or to ﬂush water that may have entered the mask. The gas enters the mask and ﬂows through the air train which directs the gas onto the face port to help eliminate or clear fogging that forms on the port from the diver’s warm breath.

The gas ﬂow continues out through the water dump (main exhaust) valve, or into the oral nasal mask by means of the oral/nasal valve. The diver can breathe from this ﬂow of gas if the demand regulator malfunctions. The gas then ﬂows through the oral nasal valve, through the oral nasal, into the regulator and out through the regulator exhaust. Flow continues into the exhaust main body of the Tri-Valve

™

exhaust. From there it can exit through either of the exhaust valves and out through the whiskers.

With normal breathing as the diver inhales the helmet and demand regulator body go slightly negative drawing the diaphragm down against the roller lever opening the inlet valve and starting gas ﬂow. The gas ﬂow continues to match the diver’s inhalation as the rate increases, peaks and then ebbs and stops when the diver exhales. The supply gas stays off as the exhalation gas passes out through the exhaust valves and Tri-valve whisker into the water. The Tri-Valve whisker helps deﬂect the bubbles away from the face port to keep the view clear.

Adjustment Knob Adjustment Shaft

O-ring

Retaining Pin

Spacer

Regulator Body

The SuperFlow 350 Demand Regulator

Inlet Valve

O-ring

Inlet Nipple

Jam Nut

Exhaust Valve

Gasket

Screws

Exhaust Flange

Piston

Spacer

Roller Lever

Washer

Diaphragm

Nut

Cover

Washer

Spring Set

Retaining Clip

Purge Button Spring

Packing Nut

Screw

Clamp

Purge Button Sticker

Purge Button

Page 32

Kirby Morgan® BandMasks® 18 & 28

WARNING

flange

Diving a KMDSI helmet or BandMask® with a bias setting greater than that just necessary to keep the demand valve from free owing increases the work of breathing and reduces the diver’s ability to perform heavy work.

All KMDSI Helmets and BandMasks® are equipped with a multi-turn demand regulator adjustment knob. This adjustment knob allows the diver to make corrections to compensate for a wide range of incoming gas supply pressures.

The adjustment knob operates by simply increasing or decreasing the amount of spring bias tension on the demand regulator inlet valve. The adjustment knob has a range of approximately 13 turns from full in to full out. The intent of this bias adjustment device is strictly to allow the diver to make adjustments for variations in umbilical supply pressure.

be adjusted by the diver to be at the easiest breathing setting at all times. The exact number of turns required is dependent on the supply pressure.

The Tri-Valve exhaust system is now standard equipment for the KM 18 and 28. This superior exhaust system has exceptionally low exhalation resistance, and helps to keep the mask free of contaminants in polluted water.

The Tri-Valve™ is designed to couple the regulator exhaust with the BandMask

main exhaust and route them into a single plenum chamber, mounted between the regulator body and main exhaust body. The exhaust gas then must pass through either one of two (or both) exhaust valves that are part of the bubble deﬂector (whisker). By having an exhaust valve in both sides of the bubble deﬂector, exhalation resistance is minimized, while still helping to maintain the isolation of the main BandMask

and

regulator exhaust valves.

This adjustment device is not intended as a minimummaximum device. Minimum and maximum applies to supply pressure only. The adjustment knob should

Exhaust main body

Exhaust body

Exhaust valve

Whisker clamp

Tri-Valve Exhaust System

Exhaust valve insert

Kidney plate

Exhaust Main Cover

Whisker

Exhaust valve

Exhaust

Page 33

FEATURES OF THE KMB 18 AND 28

Band Keepers help to ensure the

top and bottom bands that secure the hood remain in the exact position required.

Steady Flow Valve provides an ad-

ditional ﬂow of air into the helmet for ventilation and defogging. The air/gas ﬂow is through the air train, across the faceplate into the oral nasal mask.

Kirby Morgan® BandMasks® 18 & 28

Spider is adjustable to provide the ﬁt required to maintain a good seal without causing jaw fatigue.

Air Train diffuses the incoming

breathing air/gas onto the face plate to defog the lens.

Emergency Gas Supply Valve

provides the emergency breathing gas to the diver.

Gas Supply Non-Return Valve prevents loss of gas

pressure in the event of umbilical damage, preventing a “squeeze”.

Silicone Oral Nasal Mask is

made of a superior silicone material which is hypo-allergenic and has a longer work life than latex. It also provides attach-

ing the optional eyeglass kit,

KMDSI part number 525-775

with oral nasal and 525-776

without oral nasal.

Nose Block Device al-

lows the diver to block the nose to equalize the ears.

SuperFlow 350®

Demand Regulator

provides adjustable, easy

breathing for hard work.

Communications System can be either

bare wire posts as shown or a waterproof connector. The waterproof type is recommended when a “round robin” or diver/tender both mics “on” communications system is used.

Neoprene Hood & Face Seal provides warmth without the weight of a hard shell.

Tri-Valve™ Exhaust System

The Patents Pending Tri-Valve™ Exhaust System has less breathing resistance than the older single valve exhaust while providing an extremely dry hat. The entire exhaust system and Whiskers™ are made of a chemical resistant compound and are quite robust.

Page 34

Kirby Morgan® BandMasks® 18 & 28

Main Exhaust Body

Main Exhaust Valve

The rubber mushroom valve is designed to present a resistance to the ﬂow of exhaust gasses. This is necessary to prevent the demand regulator from turning on a steady ﬂow when the diaphragm is positioned lower than the main exhaust during a dive. The diver does not encounter this resistance as they exhaust out of the regulator exhaust.

2.9.4 Hood and Face Seal

The hood and face seal is fabricated from foam neoprene and open cell foam. The open cell foam forms a comfortable cushion that pushes the sealing surface of the foam neoprene against the diver’s face. This is what keeps the water away from the diver’s face.

Main Exhaust Cover

2.9.3 Main Exhaust System

The main exhaust system is located at the bottom of the mask frame. Breathing gas exiting through this valve automatically purges water from the interior of the mask. This happens naturally because the valve is the lowest part of the mask during normal working or swimming conditions. The cover may be removed by unscrewing the two screws. Removal of the cover permits access to the rubber mushroom valve. The main exhaust body on the KMB 18 is held in place by three screws. (Note: The main exhaust body is molded directly into the mask frame on the KMB 28.)

The hood incorporates built-in pockets that are open to the interior of the mask frame. These pockets retain the earphones. It is very easy to remove the earphones for maintenance.

If the standard hood does not ﬁt your head comfortably, other sizes are available from your KMDSI dealer.

2.9.5 Hood and Face Seal Retainer Bands and Band Keepers

The top band and the bottom bands ﬁt around the hood and face seal combination, and clamp it ﬁrmly to the mask frame. Two screws tighten these bands in place.

Comfort Insert

Top Band

Bottom Band Keeper Mount

Top Band Keeper Attachment Plate

Hood and

Spider

The spider, hood, bands, and band keeper system.

Face Seal

Bottom Band

Bottom Band Keeper Attachment Plate

Top Band Keeper Mount

Page 35

The patent pending Band Keepers™ coupled with the

WARNING

redesigned hood, not only prevent any separation of the hood from the mask but also make it impossible for the bands to separate from the mask. Five spider “hooks” consisting of stainless steel posts welded to the retainer bands are located on the top and bottom bands. The top band has three stainless steel posts. The bottom band has two stainless steel posts.

The bands must be tightened properly or the mask frame may separate from the hood and face seal. If this happens the diver can drown and death may result.

2.9.6 Head Harness or “Spider”

The ﬁve legged head harness or “spider” is a simple and convenient method of keeping the mask in place against the diver’s face. The multiple holes in each leg allow adjustment to ﬁt any size head.

Kirby Morgan® BandMasks® 18 & 28

It will be more comfortable if the lower rear or neck area of the spider is as low as possible on the diver’s neck. If this lower portion of the spider is too high, it will cause the face seal to push up on the chin causing discomfort.

Page 36

Kirby Morgan® BandMasks® 18 & 28

WARNING

2.9.7 Reducing Carbon Dioxide

It is important to reduce the volume of air/gas space that the diver is breathing through. Carbon dioxide (CO

) can build up if proper ﬂushing does not occur.

A rubber oral nasal mask is located inside the mask to ﬁt over the diver’s nose and mouth. The oral nasal attaches to the regulator mount nut. This separates the breathing gas ﬂow from the larger gas space on the interior of the mask, and this in turn reduces carbon dioxide buildup.

Always be sure the oral nasal valve is properly mounted in the oral nasal mask. If the valve is mounted improperly or is absent this can lead to a higher CO the mask. A higher CO ziness, nausea, headaches, shortness of breath, or blackout.

level can cause diz-

level inside

Do not confuse the oral/nasal valve with the main exhaust valve. They are not the same thickness. The main exhaust valve is much thicker.

Using the main exhaust valve in the oral nasal valve body will restrict the air ow to the diver. Using the oral nasal valve in the main exhaust could cause water to leak into the mask. This could lead to drowning.

2.9.8 Equalizing the Middle Ear

A nose block device allows the diver to block their nose to provide an overpressure in their middle ear for equalization. The blocking pad on the inside of the oral nasal mask is attached to a shaft which passes through a packing gland to the outside of the mask. A knob attached to the end of the shaft can be pushed in to slide the pad under the diver’s nose.

Equalizing Device

Oral/Nasal Valve

Regulator Mount Nut

When not needed, the knob is pulled out so the pad does not rub under the diver’s nose. The pad may also be turned upside down (to provide more clearance under the diver’s nose) by rotating the shaft.

Oral/Nasal Mask

Equalizing Knob

Regulator Body

The oral/nasal mask helps to reduce carbon dioxide.

Page 37

Mask Frame

O-ring

Port

Port Retainer

Port screw

Port Plug

2.9.9 Face Port or Viewing Lens

WARNING

The face port or viewing lens is extremely strong clear polycarbonate plastic which is easily removable for replacement of the lens. An O-ring, located under the lens, seals the lens to the mask frame.

Kirby Morgan® BandMasks® 18 & 28

The port retainer screws must be tightened to proper torque specications per the instructions in this manual. See Appendix 1 for proper torque specications. Do not over tighten. This could lead to port failure and mask ooding. Drowning could result.

The face port is held in position by the port retainer.

2.9.10 Communications

In the KMB 18 & 28, both earphones and microphone are wired in parallel to the communications terminal block.

Kirby Morgan uses only high quality speakers and microphones in its communication system, to help ensure the clearest possible communications.

Earphone

Microphone

Oral/nasal mask

Terminal block

The earphones slide into pockets in the hood, while the microphone sits in a pocket in the oral/nasal mask.

Plug

Terminal

Binding post

Waterproof Connector

Packing Gland

Page 38

Kirby Morgan® BandMasks® 18 & 28

CAUTION

WARNING

2.9.11 Use of Bail-Out System

Kirby Morgan strongly recommends the use of an Emergency Gas System (bail-out system) on every dive. The diver should be equipped with a emergency gas system sufﬁcient to allow the diver to ascend to the surface without making an emergency ascent, or transit to a safe place, i.e. stage or bell where umbilical supply can be restored.

Emergency swimming ascents without breathing gas are extremely dangerous. This type of ascent can lead to lung overexpansion injuries and/or decompression sickness.

The Emergency Gas System should consist of a cylinder of an appropriate size for the water depth, ﬁrst stage regulator with whip, and an overpressure-relief valve ﬁtted on the ﬁrst stage. The diver wears this assembly on their back on a harness and the whip is connected to the Emergency Valve on the mask.

Your emergency air/gas supply on a deep mixed-gas dive is extremely limited. All divers must be aware of exactly how long their bailout bottle will last at depth. For example, a diver breathing one cubic foot of air a minute at the surface will use a 50 cubic foot bailout bottle in approximately 7 minutes at 198 FSW while at rest.

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 various relief pressures.

The diver should always be equipped with an emergency gas system, including an appropriate size cylinder, regulator, over-pressure relief valve, and whip. This system is normally mounted on the diver’s harness.

Page 39

Kirby Morgan® BandMasks® 18 & 28

CAUTION

2.10 Accessories

2.10.1 Eye Protection for Welding

The Welding Lens assembly (Part #525-403) or the new Weld Shield Assembly (Part #525-400) may be installed on the port retainer using the predrilled and tapped holes that are provided. These holes are plugged with blanking screws when a new mask is shipped from our plant.

The weld lenses are standard 2 × 4 ½ inches or 4 ½ × 5 ½, identical to the lenses used in topside welding hoods. They may be replaced quickly without tools.

2.10.2 Hot Water Shroud for SuperFlow 350

KMDSI manufactures a hot water shroud kit for the KMB 18&28. The shroud completely encases the side block, bent tube assembly, and demand regulator to provide efﬁcient gas heating for especially deep or cold dives. Heating the diver’s breathing gas is especially important in cold water or when breathing mixtures of helium and oxygen.

Be sure to use only the mount screws provided with the weld lens assembly. Longer screws can damage the port retainer mounting inserts and cause the face port

O-ring to leak.

The KMDSI Welding Lens for the Kirby Morgan 18&28 (KMDSI Part #525-403)

The KMDSI Weld Shield Assembly (KMDSI Part #525-

400)

Page 40

Kirby Morgan® BandMasks® 18 & 28

2.10.3 Special Regulator Tools for SuperFlow 350

Five special tools are available for internal adjustment of the demand regulator assembly; the inlet valve holder, regulator adjustment wrench, socket wrench, castle wrench and regulator mount socket wrench. These three wrenches make regulator adjustment much easier. The tools come in a convenient sized pouch with instructions. (Part #525-620). This tool kit now ships standard with every Kirby Morgan mask and helmet equipped with the SuperFlow 350 regulator.

The Kirby Morgan Hard Shell, Part #520-010

2.11 Helmet Transport And Storage

• The kind of package is a cardboard box with

Kraft paper packaging to stabilize the BandMask®;

The weight of the box is usually:

• For 1 BandMask

• For 2 BandMasks The package dimension are:

• For 1 BandMask® is 12 × 10 × 12 inches (305 ×

254 × 305 mm);

• For 2 BandMasks® is 23 × 15 × 16 inches (584 ×

381 × 406 mm);

• The BandMasks® are sent to dealers by plane

and truck. Depending on how the dealer wants it sent.

is 14.2 pounds (6.44 Kg);

is 28.4 pounds (12.9 Kg);

The Regulator Tool Kit, Part #525-620.

WARNING

Without correct, regular maintenance, your mask will not function properly. A poorly functioning mask can cause a fatal accident.

2.10.4 Hard Shell

The Hard Shell is an accessory that helps to protect the diver’s head from small lightweight items that may be dropped from the surface, or when the diver is working in a tight space and bumps their head.

The hard shell cannot protect the diver from head injuries due to heavy objects striking the hard shell, or from neck injuries.

2.11.1 One BandMask

Packaging Step 1

Page 41

Kirby Morgan® BandMasks® 18 & 28

Packaging Step 2

Packaging Step 4

Packaging Step 3

Packaging Step 5

Page 42

Kirby Morgan® BandMasks® 18 & 28

Packaging Step 2

Packaging Step 6

2.11.2 Two BandMasks

Packaging Step 1

Packaging Step 3

Packaging Step 4

2.11.3 Helmet Carrying Bag

To help protect your KMB 18 or 28, the mask carrying bag should be used to transport and store your mask between jobs.

Page 43

The KMDSI Helmet Bag, Part #500-901.

The KMDSI bag is made from extra heavy duty, black, ripstop nylon. The bottom of the bag is padded for additional protection. Grommeted drain holes allow the bag to breathe. The bag is also equipped with large carrying straps and side pockets. The bag is not intended for shipping your helmet as air cargo.

Kirby Morgan® BandMasks® 18 & 28

2.12 Use of Kirby Morgan Original Replacement Parts

Users of Kirby Morgan life support equipment are cautioned to always use Kirby Morgan original replacement parts. Parts manufactured by third party companies can cause accidents.

Look for the Kirby Morgan logo on Kirby Morgan products. This is your assurance that you are getting genuine Kirby Morgan replacement parts.

Page 44

Page 45

Kirby Morgan® BandMasks® 18 & 28

WARNING

Chapter 3

Operating Instructions

This manual is our effort to explain the operation, maintenance and use of the KMB 18 and 28. We do not herein make any effort to teach the principles of diving. It is our assumption the reader is a qualied diver. We highly recommend that all divers should train, under controlled conditions, in the use of any model of commercial diving mask or helmet that they have not previously used or trained in, prior to use on the job.

3.1 Introduction

This section provides advice on how to use the KMB 18 and 28. The use of these diving masks will vary with the type of work and environmental conditions. The basic procedures of donning and removing these masks will be similar for every job.

A proper training program in a calm, clear body of water should be undertaken. If the diver has not used the KMB 18 or 28 before, they must not dive with these masks without proper training.

However, divers that are familiar and trained in the use of previous Kirby Morgan masks; i.e., KMB 8, 9, 10, 18, the Navy MK. 1 mask, Navy MK. 21 helmet, or the Navy Mk. 22 mask or the SuperLite will ﬁnd that all Kirby Morgan diving helmets and masks have the breathing system controls located in the same position. The operation of this mask will also be similar. The diver must be tended at the surface at all times by a trained, qualiﬁed commercial diving tender.

helmets,

The umbilical is the diver’s lifeline to the diving control station.

Kirby Morgan commercial diving helmets and BandMasks for use with a self contained gas supply (scuba). There is no provision for surface swimming once the scuba air supply is depleted. This could lead to suffocation or drowning, which could be fatal.

are not intended

3.2 Design Purpose

All Kirby Morgan commercial diving BandMasks® and helmets are designed for use with an umbilical.

The umbilical is usually composed of at least a gas or air supply hose and communication wire, assembled with waterproof tape (and in some umbilicals twisted 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 the strain. This will help reduce the possibility of umbilical and umbilical ﬁtting fatigue and possible failure.

The diver must be tended at the surface at all times by a trained, qualiﬁed commercial diving tender.

Page 46

Kirby Morgan® BandMasks® 18 & 28

WARNING

The diving control station can be at the surface, in a diving bell, or in a submerged habitat. The diving control station is the center of the air/gas supply, communications with the diver, and diving procedures. The station can be as simple as a tender with a set of “phones” (communication ampliﬁer), or as complex as a control van in the midst of a saturation system.

Decompression diving always involves the risk of decompression sickness. Omitted decompression due to loss of gas supply or other accidents can cause serious injury or death. The use of a Kirby Morgan helmet or full-face mask cannot prevent this type of injury.

KMDSI manufactures a complete Air Control System, the KMACS 5™ with integrated communications and pneumofathometer. This portable system can be operated on either a high pressure air supply or on a low pressure compressor. The Air Control System has a specially designed high pressure regulator that reduces high pressure air and provides an adequate ﬂow to support divers to a depth of 130 fsw (40 msw)

When using a high-pressure console, for maximum breathing performance it is desirable to maintain an over bottom supply pressure of 150-165 p.s.i.g. (10.2 bar) when diving to depths of 100 fsw (30 msw), and 175-200 p.s.i.g. (11.2-13.6 bar) over bottom when diving to depths in excess of 100 fsw (30 msw). With the many different gas supply console conﬁgurations in use, it is important to ensure that the gas supply system used, is capable of supplying the mask with the necessary pressure and ﬂow of gas to allow the diver to work safely and efﬁciently. See Table 1 in Section 2.5 as a guide to supply pressure requirements.

When using a low-pressure compressor (200-225 p.s.i.) follow the recommendations in Table 2 in Section 2.5 for optimum performance.

The demand regulator and side block components are designed to work with pressures as low as 90 psig (6.2 bar) over bottom when diving to depths of 60 fsw or shallower, and as high as 225 psig (16 bar) O.B. when diving deeper. This wide operating range allows ﬂexibility when using various gas supply systems.

High pressure supply regulators and associated piping systems for surface supplied diving with Kirby Morgan helmets and masks must be capable of delivering a minimum of 4.5 acfm to the diver at depth. Only systems that can deliver the required gas ow should be used.

Page 47

Kirby Morgan® BandMasks® 18 & 28

WARNING

3.3 First Use of Your Kirby Morgan Diving Mask

When you ﬁrst receive your Kirby Morgan diving mask, carefully unpack it and examine it for any damage that may have occurred during shipment. Use the inspection sheet provided to ensure that no damage has occurred. The purchaser must contact the freight carrier and/or the KMDSI dealer if the mask has been damaged in shipment.

Be sure to complete the enclosed warranty card and return it to KMDSI immediately. No warranty claims will be honored without a correctly com-

pleted warranty card on ﬁle at KMDSI.

KMDSI must have your current address to ensure that you receive all safety notices and other important information concerning the mask. Please notify KMDSI of any change of address.

3.6 Pre Dress-In Procedure

Before dressing in for a dive, inspection of the mask systems must be made to be sure they are in proper working 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 recommended daily maintenance.

3.6.1 Pre-Dive Visual Inspection

Visually inspect the exterior and interior of the mask.

1) The demand regulator cover assembly should not be dented and the purge button must work.

2) The hood and face seal must not be torn or punctured. The hood must be in good condition with no tears or rips. The face seal must be properly glued to the hood. If it is not, or there are tears in the face seal this will cause the regulator to free ﬂow.

3) The spider must be in good condition. The rubber must not be torn or cracked.

3.4 Adjustment

Unlike our helmets, which have a neck dam that must be sized for the individual diver’s neck, the Kirby Morgan BandMasks to ﬁt most divers. No special pre-dive adjustment must be made other than securing the spider with the proper tension for the diver’s head.

are designed to be adjustable

3.5 Custom Hood

For divers with smaller heads, a custom made hood can be specially ordered. Contact your Kirby Morgan dealer for more information on this product.

The spider must be in good condition. If it is worn or cracked it could fail during the dive. This could cause the mask to ood or come off the diver’s head. This could lead to drowning.

There must be no holes in the face seal. If there are any holes in the face seal the demand regulator will free-ow. This could lead to rapid depletion of the air supply. Death could result.

4) Inspect the bent tube that supplies breathing gas to the regulator. There must be no dents or kinks in the assembly.

5) Inspect the face port. It must be in good condition.

6) ) Check the inside of the BandMask communications wires are hooked up and there are no loose nuts. Check the wire lugs to make sure they are not touching each other. This would cause a short (no communications).

. Be sure the

7) Inspect the oral/nasal mask. Make sure it is on the regulator mount nut properly and the valve is installed properly.

Page 48

Kirby Morgan® BandMasks® 18 & 28

WARNING

8) Check the screws on the port retainer. They must be adjusted to the proper torque setting (12 inch pounds (1.3 Newton Meters)) per the speciﬁcations in Appendix 1 of this manual. Binder head screws are used in this application for their self locking characteristics. Overtightening may strip out the threaded inserts in the mask frame.

All parts on the Kirby Morgan 18 and 28 must be adjusted to their proper torque specications. See Appendix 1 for a complete listing of torque specications for each part. Failure to adjust parts to the recommended specications could lead to BandMask could be fatal.

failure and accidents. This

Never use RTV to glue on the port retainer or to hold the threaded inserts in the mask if they are loose. If the RTV fails it could cause the mask to ood and lead to drowning. This could be fatal.

9) Check the mask frame to be sure that it is not cracked or damaged.

Consult the checklists at www.kirbymorgan.com and for the most recent pre-dive checks for your mask.

Page 49

Kirby Morgan® BandMasks® 18 & 28

WARNING

3.7 Preparing the Mask for Diving

3.7.1 Clean Face Port

Thoroughly clean the face port with a soft cloth and a mild liquid soap solution. DO NOT USE ANY AEROSOL SPRAYS ON THE POLYCARBONATE PORT!

Never use any aerosol propelled sprays near the face port of a Kirby Morgan mask or helmet. The propellant used in these aerosols

can invisibly damage the polycarbonate face port and cause it to shatter upon impact from any strong blow. If the face port fails underwater the helmet will ood and drowning may result.

3.7.2 Check Moving Parts

Check all moving parts, such as the regulator adjustment knob, the defogger control knob, emergency (EGS) knob, and the nose block device knob to ensure smooth and proper operation.

3.7.3 Check Communications

Check the communications system for proper operation. Put the mask on and talk to an assistant on the ampliﬁer. If you are by yourself, using 2 wire communications, with the mask off take the mask near the ampliﬁer and tap on each earphone and the microphone, listening to the taps on the ampliﬁer/ speaker. If using 4 wire, you will need to talk into the ampliﬁer/speaker feeling the vibration on each earphone and tap the microphone with your ﬁngertips and listen for the taps.

Communications must be tested prior to every dive.

All moving parts must be tested before the diver enters the water.

3.7.4 One Way Valve Check

The one way valve must be tested daily, prior to commencement of diving operations.

1) Prior to attaching the umbilical, close the emergency valve knob, attach and pressure up the emergency

Connect the bail-out to the emergency gas supply valve.

Page 50

Kirby Morgan® BandMasks® 18 & 28

WARNING

hose. Shut off the defogger control knob and screw in the adjustment knob on the regulator all the way.

2) With the emergency hose pressurized, turn on the emergency valve knob. If any gas escapes out the end of the adapter, the one way valve is faulty and must be rebuilt or replaced. A one way valve repair kit is available to rebuild these valves (Part # 525-330). valve repair kit is available for rebuilding these valves (Part # 525-330).

Never dive if the one way valve is not operating properly. If the hose or breathing gas/air tting breaks near the surface a serious injury could result to the diver’s lungs and/or eyes. In extreme cases this could be fatal. The one way valve must be tested daily prior to the commencement of diving operations.

3.7.5 Sealing Integrity Check

If there is any doubt whether or not the BandMask is sealing properly, perform the following test prior to diving.

Turn the supply gas off at the dive control system and bleed the umbilical. Pull the nose block device knob (34) all the way out, away from the mask. Have the diver install the mask on their face, but do not fasten the hood. Do not fasten the head harness (spider). With the mask held ﬁrmly against their face, there must be a suction on the diver’s face when they inhale. This will indicate that the mask is forming a good seal. If there is any leakage the diver must not dive until the source of the leakage has been found and corrected.

Checking the one way valve. With the bail-out bottle connected to the emergency valve, no gas should escape through the one-way valve when the EGS valve and cylinder valve are opened.

The mask should be checked for a proper seal prior to every dive.

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WARNING

3.8 Emergency Gas System (EGS)

If the diver’s main gas supply fails, the diver must have another source of gas that will enable them to return to the dive station or to a point where a normal 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.

Most commercial divers wear a harness (separate from the weight belt) that is used for several purposes. The harness is ﬁtted with large metal rings (usually brass or stainless steel). The umbilical is hooked into one of these rings to keep any strain off the mask. In addition, the rings on the harness are used to hang tools and 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.

Do not dive without a diver worn Emergency Gas System. If the main gas supply is lost, you will have nothing to breathe and may drown.

a cloth enclosure into which the tank ﬁts. The entire tank, valve, and regulator are enclosed in fabric. This helps to prevent snagging.

The diving harness

must have a provi-

sion for attaching the

emergency gas supply

and a place to attach

the diver’s umbili-

cal.

When determining the size of the emergency gas cylinder to use, several factors must be considered. The divers depth, the length of time the diver may be without the main gas supply, and the gas consumption rate. Regardless of the cylinder used, it should be of sufﬁcient volume to allow the diver to ascend at a normal rate or transit to a point where a normal gas supply can be reestablished.

Diver donning a complete bail-out system.

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 incorporate

Never dive without attaching the umbilical to some type of harness or clip on the diver’s body. Never allow the umbilical to pull on the mask directly or the diver could suffer a neck injury.

European C.E. ONLY

In European countries that have adopted C.E. certiﬁcation, 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).

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Kirby Morgan® BandMasks® 18 & 28

WARNING

The emergency air/gas tank must be ﬁtted with a good quality ﬁrst sage regulator with an intermediate pressure set between 125 psig-165 psig. The ﬁrst stage should be equipped with an overpressure relief valve set between 180-200 psig.

The KMDSI SuperFlow (Part #305-161) is a high quality ﬁrst stage. These regulators reduce the tank pressure to approximately 145 p.s.i.g. (9.9 bar). Other quality high performance Scuba regulators may also be used. Connect the ﬁrst stage hose with a set of quick disconnecting locking sleeves to the emergency valve assembly located on the side block.

A standard Scuba submersible pressure gauge must be connected to the high pressure port on the rst stage so that the diver can monitor their emergency supply.

First Stage Scuba regulator

An over-pressure relief valve must be installed on the ﬁrst stage used for the Emergency Gas Supply.

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 lowpressure EGS hose and the Emergency Valve. This could cause the low-pressure hose to burst resulting in the complete loss of the EGS system.

Use a good quality ﬁrst stage for your emergency gas supply.

The ﬁrst stage regulator must have at least two low pressure ports. One port is used for the connector hose to the emergency valve and the second is used to install an overpressure relief valve (Part #200-

017). The relief must be adjusted to start lifting at approximately 20 p.s.i.g. (1.4 bar) above the regulator intermediate setting. If the ﬁrst stage develops a leak,

the full pressure of the tank could be placed on the low pressure hose. This could cause the hose to burst. The overpressure relief valve will bleed off any leak.

Make sure the emergency valve knob is turned off, otherwise the emergency gas supply will be used up without the diver’s knowledge. Once the emergency supply hose is connected, the tank valve is turned on to pressurize the hose. In the event of 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.

Never connect the main gas supply hose from the diving control station to the Emergency Gas valve assembly (EGS). If this is done there is no one way valve protection for the diver in the event of damage to the umbilical or related equipment. The diver could be exposed to a serious “squeeze”. This can result in serious personal injury or death.

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There are several possible ways to conﬁgure your emergency gas system, although at KMDSI we only recommend one method. The conﬁguration we recommend is as follows: Cylinder Valve Open - EGS Valve on Helmet Closed This is the only method that we recommend. The advantages of this method are as follows:

• You only need to open one valve to activate your emergency supply.

• There is little danger of ﬂooding your ﬁrst stage regulator and ruining it.

Possible Emergency Gas Supply Cylinder & EGS Valve Configurations

Configuration Cylinder Valve EGS Valve Advantages/Disadvantages

Configuration 1 On Off Advantages (Regulator pressurized) • One valve to open

• First stage won’t nomally 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 (Regulator pressurized then Off • No loss of cylinder gas if then cylinder valve hose or regulator leaks closed) Disadvantages

• Two valves to open in emergency

• Slow leak on long dive may result in flooded 1st stage

• If dive depth exceeds pressure in first stage, first stage will flood

Configuration 4* Off Off Advantages

• No use of cylinder gas unless emergency occurs Disadvantages

• Regulator will flood and need service daily

• Two valves to open in * Requires ability to reach cylinder emergency valve without difficulty

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Kirby Morgan® BandMasks® 18 & 28

WARNING

There are risks with each method of conﬁguring your bail-out system. There is a risk that if you have the bail-out bottle on and the emergency valve on the mask closed, that the emergency gas could be lost if the hose or the ﬁrst stage itself develops a leak. However, KMDSI believes that this method poses the least amount of risk for the diver.

It is reasonable to assume that if the ﬁrst stage regulator and interface hoses are maintained and serviced on a regular interval, the chances of a leak are slim. The U.S. Army and Navy make it mandatory that the bail out cylinder is open and helmet emergency valve is shut.

Probably the most serious problem with any of the other possible conﬁgurations is that the ﬁrst stage will almost certainly ﬂood if it is not pressurized while you are underwater.

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 unknowingly being lost due to either a 1st stage failure or EGS hose failure.

KMDSI strongly recommends never diving with the EGS cylinder valve shut. The reasoning behind this is twofold. First, with the EGS cylinder valve open, gas is immediately available in the event of topside gas interruption via the EGS valve on the side block simply by opening it. Secondly, and most importantly, if the EGS regulator (1st stage) is not pressurized, during descent it is possible that sea water will leak through the rst stage intermediate circuit and regulator, causing failure of the EGS regulator and resulting in possible injury or death.

Always be sure to check the pressure in your bail-out bottle before you dive.

If the regulator ﬂoods and is not promptly serviced, it will not perform properly when you need it in an emergency. As a diver, you always must decide how much risk and what types of risk you are willing to expose yourself to when you dive. It’s up to each individual to make an informed choice regarding how to conﬁgure your bail-out system. We cannot make this choice for you.

KMDSI strongly recommends the use of a submersible pressure gauge with every bail-out system. Not only does this make it very easy to check your emergency 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 when you periodically check the gauge during your dive and will be able to take appropriate action.

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Kirby Morgan® BandMasks® 18 & 28

WARNING

3.9 Setting Up to Dive

3.9.1 Flushing Out the Umbilical

Before connecting the umbilical to the mask, the umbilical must be ﬂushed out to remove any dirt, moisture, or other debris. Connect the topside umbilical end to the topside diver control console. Ensure there is no pressure in the divers umbilical.

Carefully uncap the mask end of the umbilical and hold securely while pointing in a safe direction, then slowly bring up gas pressure to approximately 25-40 p.s.i.g. (1.7-2.7 bar). Allow the gas to ﬂow for at least 15 seconds. If it is not going to be used immediately, the umbilical should be recapped.

3.9.2 Connecting the Umbilical to the Mask

When you connect the hose to the mask be sure to use a wrench to hold the adapter, or inlet ﬁtting, and a second wrench to turn the swivel ﬁtting on the hose. If this is not done, the adapter will turn inside the one way valve. If this happens repeatedly the threads will wear and the valve will need to be replaced.

The connection between the hose and the mask must only be made up “snug”. Excessive force will deform and ruin the adapter. A second wrench must be used when the mask 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 communications, take extra care in handling these pieces. To connect the male and female parts, align the large pin on the male connector with the colored indicator mark on the female connector. Press the two connec-

If the one way valve or the adapter is loosened this will allow breathing gas to leak out of the breathing system. This could also result in a loss of all pressure to the mask, leaving the diver with nothing to breathe.

The waterproof connectors must be handled carefully to avoid damage.

Tape the connectors together with a bit of electrical tape to help ensure they stay together during the dive.

Use two wrenches to connect the umbilical to the mask.

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Kirby Morgan® BandMasks® 18 & 28

tors together until you hear a distinct “pop”. Do not twist the connectors. Tape the two connectors with 2 or 3 wraps of electrical tape to prevent them from pulling apart.

To separate the connectors remove the tape, grasp each of the 2 connectors at the thickest part, place your thumbs against each other, and push apart against your thumbs until the connectors are disconnected.

Do not twist the connectors. Do not pull them apart by pulling on the thin part of the wires.

If using communications with bare wire posts, make certain the posts move freely enough to apply full compression on the umbilical communication wire. Also make sure the posts and wire are free of corrosion.

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3.9.3 Opening the Breathing Gas Supply to

WARNING

the Mask

Prior to turning on the air supply for the mask, check to see that the free ﬂow valve is closed and the regulator adjustment knob is all the way in.

Bring up the gas supply pressure to between 135-150 p.s.i.g. (9.3-10.2 bar) then slowly back out on the mask demand regulator adjustment knob counterclockwise until a slight free ﬂow develops. Once a free-ﬂow develops, turn the adjustment knob back in clockwise until the free-ﬂow just stops.

To properly check the breathing system you must seal the face seal against your face. The best way to do this is to completely don the mask.

Kirby Morgan® BandMasks® 18 & 28

Never use any aerosol propelled sprays near the face port of any Kirby Morgan helmet or BandM ask

The propellant used

in these aerosols can invisibly damage the polycarbonate face port and cause it to shatter upon impact from any strong blow. If the face port fails underwater the mask or helmet will ood and drowning may result.

The regulator adjustment knob should be screwed all the way in before opening the breathing gas supply to the mask.

Apply a thin ﬁlm of soap to the lens to help prevent fogging.

3.9.4 Fogging Prevention

A thin ﬁlm of anti-fogging solution may be applied to the interior of the polycarbonate 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.

3.9.5 Donning the Mask

All donning procedures must be done by the diver until they are thoroughly at home with the mask. This will train for familiarity. However, the tender must be present to assist the diver and check to ensure that the diver has properly donned their equipment. It is impossible for the diver to see whether they are

The diver should use a solution which has been found

properly dressed in once the mask is on their head.

satisfactory in the past. However, do not use an aero- sol spray on the polycarbonate lens. The propellants in some aerosol dispensers cause damage to the lens.

With the diver holding the mask, the tender should now connect the quick disconnect ﬁttings for the bailout supply. Open the regulator adjustment knob

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Kirby Morgan® BandMasks® 18 & 28

and the defogger control knob for a steady ﬂow from both just prior to the diver dressing into the mask.

To prepare the mask for donning by yourself, close the zipper until only the last six inches are open. Fasten every “leg” of the spider (1) except the one on the bottom left.

Pick the mask up with both hands and fold the spider over the front of the mask. Pull the hood onto your head and close the zipper, taking care not to catch your hair in the zipper. You will need to support the mask with your right hand as you do this. Use your left hand to close the zipper. While you continue to support the mask with your right hand, use your left hand to fasten the remaining leg of the spider to your left. As a standby diver, it is essential for you to be able to don your mask yourself during an emergency.

For most divers, the mask is most comfortable when the spider is adjusted so that the top three legs of the spider are tighter than the bottom two. If you have an “average” size head, the adjustment most divers ﬁnd comfortable is three holes back from the edge of the top three legs of the spider, and two holes back from

You must be capable of donning, adjusting, and removing the mask by yourself.

Your tender should always be available to assist you when you are donning the mask. The tender should be able to see if any of your gear is not mounted correctly.

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Kirby Morgan® BandMasks® 18 & 28

WARNING

The tender must always be present to assist the diver while dressing and whenever the diver has their mask on their head while they are out of the water. It is difficult for the diver to walk while they are dressed in and they can stumble and fall, resulting in serious personal injury.

the edge of the outermost two legs of the spider. You may ﬁnd a different adjustment to be more comfortable depending on the size of your head.

The mask should feel comfortably snug against your face out of the water. There will be some compression of the face seal when it is adjusted properly. While the weight of the mask is heavy out of the water, it will be almost unnoticeable underwater.

Your tender may assist you in donning your mask if you prefer. In this case, the procedure is the same as donning by yourself, except that your tender will close the zipper on the hood and fasten the spider. You will still need to support the weight of the mask while your tender fastens you in.

To help keep the bib of your hood from ﬂoating up, you tuck the bib of the hood under your harness.

Never dive without attaching the umbilical to some type of harness or clip on the diver’s body. Never allow the umbilical to pull on the mask directly or the diver could suffer a neck injury.

3.9.6 Testing the Breathing System

Test the defogger system by turning on and off the defogger control knob. The regulator should be adjusted by turning the adjustment knob out until a slight steady ﬂow starts, then back in until the ﬂow just stops.

Next, the demand regulator system is checked for proper function: breathe in and out. Inhalation and exhalation effort should be nearly unnoticeable. Press in on the purge button in the regulator cover. This should produce a strong burst of breathing gas.

It is the responsibility of the diving supervisor to always ensure that all pre-dive checks have been properly conducted, prior to allowing the diver to enter the water. Consult the Dive Lab web site (www.divelab. com) for the most current pre-dive checks.

The bib of the hood should be tucked under the harness.

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Kirby Morgan® BandMasks® 18 & 28

3.10 Diving Procedures

3.10.1 Standing By to Dive

If you are the standby diver, the mask itself will be the last thing put on before you enter the water. You should have your weights, ﬁns, and gloves on, your umbilical should already be attached to your harness, and all you should need to do is don the mask and slip over the side, in the event you need to go to the assistance of another diver.

3.10.2 Attaching the Umbilical to the Harness

The umbilical must be hooked to the diver’s harness by means of a suitable clip that is bound to the umbilical. Some divers and companies prefer a quick release clip and 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 mask.

is being used, make sure it is hinged up all the way if the diver is making a jump entry. (We do not recommend jump entries.) A quick overall inspection by the tender is done and the diver is given the OK.

3.10.7 Water Entry and Descent

The tender must make sure there is a sufﬁcient length of umbilical clear if the diver is using a jump entry. There must be no chance of the umbilical hanging up when the diver jumps. Also, the defogger valve should be turned on to overpressure the mask to prevent the possibility of water pressure from inverting the mask exhaust valve when hitting the water.

The diver must report to the surface immediately after the entry. It is a good policy to descend 10 or 20 FSW (3-6 MSW), pause and check the regulator adjustment knob to ensure adjustment for the least breathing resistance.

The purpose of this adjustment knob is to allow the diver the ability to compensate for variations in umbilical supply pressure. This adjustment device operates by simply increasing or decreasing the amount of spring bias tension on the demand regulator inlet valve.

The umbilical must be attached to the diver’s harness to avoid a direct pull on the mask.

3.10.3 Diver Dons Mask

The diver dons the mask as per “3.9.5 Donning the Mask” on page 41.

3.10.4 Diver Check Gas Flow Systems

The diver must test the breathing system themselves as the tender ﬁnishes dressing them. The diver should operate the defogger valve, the demand regulator, and the purge button to assure themself of proper operation before entering the water.

3.10.5 Communications Check

The communications system, sending and receiving, should be checked again at this point.

3.10.6 Diver Ready

The diver is now ready to enter the water. They should be assisted to the water if needed. If a welding lens

This adjustment device is not intended as a minimummaximum 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 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.

Then the diver checks in with the surface before descending to the job. If a closed bell is being used, the diver enters the water from the bell and pauses for a short time outside the trunk until they are sure all systems are operating properly.

During the descent the communications must be checked again and the diver supply pressure should be adjusted as necessary to maintain the required over-bottom pressure. It may be necessary for the diver to readjust the demand regulator by means of the adjustment knob once at the work site to compensate for the variation in umbilical supply pressure. Once the diver has entered the water, the diving supervisor must conduct all appropriate checks to ensure that the mask is functioning properly while the

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Kirby Morgan® BandMasks® 18 & 28

WARNING

diver is submerged. These checks must be conducted prior to committing the diver to depth. See the Dive Lab web site at www.divelab.com for all appropriate in-water checks.

3.10.8 Adjust Regulator for Low Work Rates

At very low work rates, such as when the diver is resting, or during in-water decompression, the diver’s respiratory rate 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 mask exhaust to adequately wash out carbon dioxide (CO

In order to ensure that carbon dioxide does not accumulate in the mask, divers who are at rest underwater should screw the regulator adjustment knob “out,” i.e., away from the regulator, until a slight steady ﬂow occurs and the regulator can be heard to hiss. This will help to eliminate any excess carbon dioxide from the mask.

Excess carbon dioxide (CO2) is dangerous. Too much carbon dioxide in the diver’s breathing system can cause the diver to feel that they cannot breathe for comfort. In extreme circumstances, carbon dioxide can cause unconsciousness. This could lead to suffocation and death.

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Kirby Morgan® BandMasks® 18 & 28

DANGER

WARNING

3.11 Emergency Procedures

3.11.1 Flooding

In the event of partial or complete ﬂooding, the diver may clear the mask quickly by tilting the mask down and activating the defogger control knob or, if the regulator has taken on water, by pressing in on the manual purge button in the center of the regulator cover.

The water dump valve is located under the regulator. By placing this valve in the lowest position on the mask, water will exit more easily.

After clearing, cautiously check for additional ﬂooding. If the mask continues to take on water, return to the diving station, swimming with the water dump valve positioned at the lowest part of the mask: that is with the diver’s face forward and slightly tilted down. Keep the free ﬂow knob on. This increases the air/gas pressure slightly inside the mask and keeps the water out. Any incoming water is automatically purged.

3.11.2 Inhalation Resistance

If breathing becomes difﬁcult, adjust the demand regulator adjustment knob, for easier breathing by rotating the adjustment knob counter clockwise. If the breathing does not get noticeably better, press the purge button in the regulator cover. If a surge of gas does not ﬂow with this action, open the emergency valve.

If the ﬂow is noticeably better, immediately notify topside that you are on emergency gas. Insure your umbilical is clear and return to the stage or descent line. The diver should stay in communication with topside personnel and make preparations to abort the dive. The console operator should check to ensure the supply pressure to the diver is at the proper pressure.

remove the mask if needed. Never ditch the mask underwater unless conditions absolutely require that.

3.11.4 Demand Regulator Free Flow

If the demand regulator free ﬂows, adjust the knob in (clockwise) until it stops. If the free ﬂow cannot be stopped, the dive should be aborted. Even if there is no serious problem to the diver, the dive should be aborted and the problem with the regulator corrected

Rapid ascent is dangerous. It can lead to air embolism or decompression sickness. Air/gas embolism can cause immediate loss of consciousness and/or death. Even on a no decompression dive, a rapid ascent may cause decompression sickness. A diver must only make a rapid ascent when they are in immediate danger of death by drowning or asphyxiation.

Ditching the mask underwater must be avoided. If the diver ditches the mask underwater they will not be able to see. In many instances, even if the air supply is interrupted, topside will be able to get it back on line quickly. Do not ditch the mask underwater unless you are completely out of breathing gas and it is impossible to return to the surface due to entanglement of your equipment or similar circumstances.

3.11.3 Gas Flow Stops

A stop of ﬂow in the demand regulator usually indicates 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 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 insure your umbilical is clear and return to the diving station using the emergency breathing supply. Avoid making a rapid ascent if at all possible.

Once at the surface, or inside the bell, the diver may

Never remove a diving mask or helmet while you are in the stage. If you fall out of the stage with the mask or helmet off but still attached to your harness it may be very difficult to swim. Drowning may result.

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3.12 Post Dive Procedures

3.12.1 Removing the Equipment

After the diver is well clear of the water they may remove the mask. If the diver is working out of a stage they must not remove the mask until the stage is on deck.

3.12.2 Removing the Mask

Pull the nose block device knob away from your face before you start to remove the mask. A good tender will be prepared to help the diver with the removal of the mask as required.

Kirby Morgan® BandMasks® 18 & 28

After the diver is well clear of the water they may remove the BandMask of a stage they must not remove the BandMask

. If the diver is working out

until

the stage is on deck.

The diver can shed the BandMask® by ﬁrst releasing the bottom two Spyder straps then grasp the bottom of the mask with both hands and pushing out and up. The mask can be removed in the event of an emergency in this way even if the zipper is closed and the spider is in place.

Under normal circumstances, the diver should support the weight of the mask as the tender opens the zipper on the hood and unfastens the spider.

It is recommended that during normal diving operations that only the left side of the spider be opened. Complete removal is not necessary. This will help prevent loss of the spider.

Turn the emergency gas supply off at the tank. The emergency gas supply hose may be disconnected while the diver leaves the BandMask

on, or while they hold it after removal. The quick disconnect makes this procedure very easy. The tender should then unfasten the umbilical from the harness and take the BandMask

from the diver and set it aside. The

diver’s harness and bailout bottle is then removed.

You must be able to remove the mask by yourself.

If the BandMask® is not going to be used for a period of time, the hood must be removed and the earphone

The tender should be ready to assist the diver if needed.

covers removed. These parts must be dried before storage. When the BandMask the diver is ready to leave the job, the BandMask

is completely dry, or

must be stored in the carrying bag to protect it. KMDSI’s mask bag, Part Number 500-901, is designed for this purpose.

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Kirby Morgan® BandMasks® 18 & 28

3.12.3 Mask Storage Between Dives

The mask should be maintained per the daily maintenance section in Chapter 5.

If the mask is not going to be used for a period of time, the hood should be removed. The hood should be dried and replaced on the mask before storage. The regulator adjustment knob should be unscrewed all the way out (counterclockwise) until the next dive. When the mask is completely dry, or the diver is ready to leave the job, the mask should be stored in the carrying bag to protect it.

When the umbilical and emergency gas supply are disconnected, the gas ﬁttings on the mask must be capped to prevent any foreign matter from entering the breathing system.

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Kirby Morgan® BandMasks® 18 & 28

Chapter 4

Troubleshooting

4.1 General

Kirby Morgan BandMasks® are highly reliable life support equipment which should not malfunction if proper preventative maintenance procedures are followed. Most problems encountered in using the BandMask be easily remedied. The following information covers most potential operating difﬁculties.

4.2 Communication Malfunction Symptoms Probable Cause Remedy

can

No sound at either com box or BandMask

Communications weak or broken up.

Communications only work when wire is wiggled back and forth.

Communications only work when connector is wiggled back and forth.

Diver speech weak or can’t be heard.

Communications box not on. Activate switch and adjust

volume.

Com mu nic at i o ns i n cor r ect ly hooked up.

Communications not hooked up. Plug into terminals.

Communicator not functional. Replace communicator.

Broken/damaged communications wire

Battery Dead Recharge

Terminals in communications module corroded.

Battery weak. Recharge.

Loose wire. Clean and repair.

Break in diver’s communication wire.

Break in waterproof connector. If connector is suspect, remove from

Microphone in BandMask damaged.

dead or

Switch terminal wires.

Check continuity replace wire or umbilical.

Clean terminals with wire brush. Terminals should be bright, shiny metal.

Splice wire if damage is minor. Replace wire if damage is major.

line and test line for integrity prior to replacing connector.

Replace microphone as per manual.

4.3 One Way Valve Malfunction Symptoms Probable Cause Remedy

One way valve allows back-ﬂow. Foreign matter in valve. Disassemble valve, clean and

rebuild. Replace if needed.

One way valve doesn’t ﬂow any gas. Foreign matter in valve. Disassemble valve, clean and

rebuild. Replace if needed.

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Kirby Morgan® BandMasks® 18 & 28

4.4 Side Valve Malfunction Symptoms Probable Cause Remedy

Defogger can’t be shut off. Band-

Mask

free ﬂows through defogger.

Seat assembly damaged or debris under seat.

Clean and/or replace seat assembly.

Sideblock damaged by debris Replace sideblock.

Defogger valve will not ﬂow gas. No air in umbilical. Turn air on to diver’s supply topside.

Foreign matter in side block or one way valve.

Disassemble side block one way valve and clean.

Defogger valve knob hard to turn. Valve stem bent. Replace valve stem.

4.5 Water Leakage Into BandMask

Symptoms Probable Cause Remedy

Water leakage into BandMask®. Exhaust valve damaged or stuck

open.

Communications module O-ring extruded or damaged.

Communications module not properly tightened.

Communications module damaged.

Seat or replace valve.

Replace o-ring.

Tighten module mount nut.

Replace.

Binding posts or connector seal damaged.

Diaphragm damaged or not seated properly. Seat or replace diaphragm.

Remove posts, clean and reseal with RTV sealant.

Seat or replace diaphragm.

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Kirby Morgan® BandMasks® 18 & 28

4.6 Demand Regulator Malfunction Symptoms Probable Cause Remedy

Regulator continuously free ﬂows. Adjustment knob not screwed in. Screw in adjustment knob.

Bent tube damaged causing misalignment of adjustment nipple.

Supply pressure too high. Adjust supply pressure lower than

Regulator out of adjustment. Adjust regulator

Regulator is hard breathing. Adjustment knob screwed too far in. Screw adjustment knob out.

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-

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

Check the inlet nipple and soft seat. Replace as necessary.

225 p.s.i. over ambient.

mum required for depth.

adjust.

4.7 Emergency Gas Supply Valve Symptoms Probable Cause Remedy

Bail-out bottle drained without diver opening EGS valve

Knob difﬁcult to turn. Stem bent. Replace stem.

Valve will not ﬂow gas. Foreign matter in valve. Disassemble, clean, and

Stem fails to seat in valve body. Replace EGS valve body.

Debris under seat causing leakage. Service valve.

Leaking over-pressure relief valve on bail-out regulator.

Leaking bail-out regulator on bottle. Service regulator.

Leak in supply line 1st stage Service regulator.

Stripped control knob. Replace knob.

Service valve.

reassemble.

Page 68

Page 69

Kirby Morgan® BandMasks® 18 & 28

Chapter 5

Inspection and Maintenance

5.1 Routine Maintenance

Routine and preventative maintenance is critical and must be done on a regular basis. All parts and components of the mask have a useful service life and eventually will require replacement. Some items, when properly maintained, can go many years before replacement becomes necessary. Each mask should have a logbook that tracks the usage, maintenance and repairs.

It is essential to safety of the user that a routine and periodic schedule of maintenance, inspection, and testing be carried out. Masks should be inspected predive on a daily basis. Masks in continuous use around the clock should be rotated out every 24 hours and have a daily pre-dive inspection performed. Post dive cleaning and inspections should be completed each time mask use is ﬁnished for the day. To minimize the spread of germs, sanitizing should be performed after use, and in between use by different divers. Sanitizing procedures and recommended solutions are described and explained in the General preventative section of each KMDSI helmet and mask manual. If the user is in doubt about the serviceability or has questions in general, please contact your local KMDSI authorized repair facility or KMDSI at Tel. 805-928-7772. Check the Dive Lab website at www.divelab.com for the most up-to-date maintenance procedures.

KMDSI Maintenance Checklist are located on the KMDSI and Dive Lab websites. The checklists are intended for all helmet and mask models. There are also checklists for the KMB-18/28 BandMasks which are done up the same as the helmet checklists.

A2.1. All SL and KM helmets (all models) Recom-

mended Annual Maintenance Inspection and

Overhaul A2.2. Monthly Maintenance A2.3. Daily Set-Up and Functional Checklist A2.4. Supervisor’s Equipment Checks Prior to Entry A2.5. Supervisor’s Equipment Checks In-Water A2.6. Post Dive Cleaning

5.1.1 Daily Pre-Dive Maintenance A2.3

The helmets and masks should be set up in accordance with the Daily Set-Up and Function Checklist A2.3. The checklist can 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 Post Dive Maintenance A2.6

The helmets and masks should be cleaned in accordance with the A2.4 checklist The checklist can be laminated placed on a clipboard and checked off with a grease pencil. Completion should be logged in both the supervisor’s log, and the helmet or mask log book. The daily pre-dive is minimum daily checks KMDSI recommends. The daily post-dive may be modiﬁed to suit the needs of the user providing the basic intent of the checklist is being completed in a manner consistent with the original intent.

5.1.3 Supervisors Equipment Checks A2.4 and A2.5

These checks should be conducted by the diving supervisor or by persons designated by the supervisor in accordance with company policy.

5.2 Monthly Maintenance

A monthly inspection should be performed IAW the A2.2 checklist on a monthly or as directed by the A2.2 and / or anytime serviceability of the helmet or mask is in doubt. Helmets or masks used in contaminated waters or for welding, burning, and jetting operations will require service and inspection more frequently. If a situation arises that casts any doubt as to the serviceability of a part or component it should be replaced.

Use the appropriate manual for the model helmet or mask being serviced.

5.3 Yearly Maintenance

5.3.1 Overhaul/Inspection Checklist A2.1

The A2.1 checklist procedure fulﬁlls all requirements for complete inspection. The checklist should be performed at least annually and or more often if daily and monthly inspections reveal signs of excessive corrosion, contamination, improper operation or signs of damage or if the helmet log shows the unit had previously been used in a questionable environment. The daily and monthly inspections will determine the necessity for overhaul with greater accuracy than simply placing a number of hours on the overhaul

Page 70

Kirby Morgan® BandMasks® 18 & 28

schedule. All O-ring’s, exhaust valves, and soft goods should be replaced at least once a year. In between overhauls the soft goods can be cleaned inspect and reused providing a careful inspection reveals no damage or deterioration. Again, logged questionable previous diving environments will be determining factor as well. The A2.1 checklist should be ﬁlled out and retained in the maintenance ﬁles and provides an excellent record of maintenance. All maintenance should be annotated in the helmet log.

The Overhaul Checklist Procedure A2.1 is intended to aid persons performing routine overhauls of KMDSI SuperLite

Helmets and BandMasks®. 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 completed. Speciﬁc detailed procedures for each section of this checklist can be found in the Operations and Maintenance Manuals. This checklist when completed should be retained in the equipment maintenance ﬁles and the helmet or mask log book should be updated. The checklist’s are intended to be used for all models of KMDSI SuperLite Helmets and BandMasks BandMask

manuals can be downloaded free at www.

. All KMDSI helmet and

and KM

kirbymorgan.com.

Page 71

Chapter 6

General Preventative Maintenance

6.1 Introduction

This section covers the preventative maintenance necessary on the Kirby Morgan 18 & 28 diver’s masks. A mask that is kept clean and in good repair will offer far better service to the user. This mask 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 repairs and face port inserts. 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 their mask in top working condition. 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 Kirby Morgan masks and helmets:

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 screwdriver 7/64 inch Allen wrench driver 9/64 inch Allen wrench driver 5/32 inch Allen wrench driver

Kirby Morgan® BandMasks® 18 & 28

Tools required to do proper maintenance on Kirby Morgan masks and helmets.

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 2 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 wraps: Part # 520-042 Silicone lubricant Loctite #320, 400, 600 wet/dry sandpaper rubbing compound automotive wax clean rags

A specialized tool kit including the torque wrenches, crows feet adapters, intermediate pressure gage and other specialty tools are available individually or as a complete kit from Dive Lab Inc. for more information contact Dive Lab at www.divelab.com.

222 Thread locker

Page 72

Kirby Morgan® BandMasks® 18 & 28

WARNING

6.2.1 Component and Parts Cleaning

The mask and components should only be cleaned using a mild solution of dishwashing soap such as JOY ™ or Dawn ™ hand dishwashing soap.

Parts that have corrosion should be washed and scrubbed with a nylon bristle brush and then soaked in a solution of 50% white vinegar and water for 30-60 minutes followed by a light brushing and a good fresh water rinse. Hoods and rubber components should be cleaned using a mild soapy solution followed by a good rinsing and air-dried.

DO NOT use hair dryers or high heat to dry the rubber components, high temperatures will severely reduce their serviceability. To clean parts heavily encrusted with salt we recommend a dilute solution of white vinegar and a toothbrush.

6.2.2 Component and Parts Lubrication

All masks are lubricated at KMDSI with Christo

Lube

. Masks used for air diving or with gas mixtures containing less than 50 % oxygen can be lubricated with food grade silicone such as Dow Corning

111

or equivalent.

Do not use aerosol lubricants! Many aerosol propellants will damage plastic. Avoid lubricant contact with plastic parts.

All parts on Kirby Morgan masks and helmets must be adjusted to their proper torque specications. See Appendix 1 for a complete listing of torque specications for each part. Failure to adjust parts to the recommended specications could lead to helmet failure and accidents. This could be fatal.

Never use any aerosol

Silicone Spray

propelled sprays near the face port of Kirby Morga n ma sks and helmets. The propellent used in these aerosols can invisibly damage

the polycarbonate face port and cause it to shatter upon impact from any strong blow. If the face port fails underwater the mask will ood and drowning may result.

Kirby Morgan masks and helmets are cleaned for oxygen service when they are asse mbled at the factory. If the user intends to use this helmet for such service,

the mask or helme t must not be used with an oil lubricated compressor and proper procedures for diving with mixtures containing high partial pressures of oxygen must be followed.

On ly lu b ric an t s s u ch as K r ytox Fl uor olu be

, or Chr is to l ub e™ are

acceptable for oxygen service. Care must be taken to avoid contamination of gas system components with hydrocarbons when air is used as a breathing medium. Contamination with hydrocarbons can lead to fire or explosions when they make contact with high oxygen partial pressures. This can lead to serious personal injury or death.

NOTE: All parts on the mask that require lubrication

must be lubricated sparingly with the appropriate lubr icant. DO NOT USE AEROSOL SPRAY LUBRICANTS. Many aerosol propellants will damage plastic. Avoid lubricant contact with plastic parts/components.

Food grade silicone lubricant on all non-gas transporting components is acceptable. KMDSI recommends Dow Corning

111 or equivalent. KMDSI strongly recommends using Christo Lube ™ for aIl gas system lubrication. If the mask is intended to be used with breathing mixtures greater than 50% oxygen, it should be cleaned for oxygen service, and components requiring lubrication should be lubricated with a suitable oxygen compatible lubricant such as Christo-Lube Krytox

Halocarbon Fluorolube® or

Silicone lubricant is not recommended for helmets used with oxygen. (Avoid mixing lubricants to preclude incompatibility)

Page 73

WARNING

CAUTION

6.2.3 Teon

Tape

All pipe thread ﬁttings used on our masks require sealing with Teﬂon SEALANT. When installing Teﬂon

tape. DO NOT USE LIQUID

tape on pipe threads, apply the tape starting two threads back from the end of the ﬁtting.

Apply the tape in a clockwise direction under tension. 1½ wraps is all that is needed. Applying more than 1½ wraps of tape is not recommended. The use of more than 1½ wraps could cause excess Teﬂon

tape to travel into the breathing system.

Do not allow any excess Teon

tape to cover the end of the pipe thread ttings. Loose pieces of Teon

tape can interfere with the performance of breathing system components and may block the diver's air supply. This could lead to death through suffocation.

Kirby Morgan® BandMasks® 18 & 28

Wear eye protection when using RTV sealant. This material may irritate your eyes. Read and follow the directi ons in the MSDS before using this material.

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. This is a medium strength thread locker that will allow parts to be disassembled when needed.

Threads should be clean and dry prior to applying thread locker. Ensure that all excess thread locker has been removed. Allow thread locker to cure for at least 3 hours prior to using the component.

6.2.4 RTV Sealant

Certain components used in KMDSI helmets and masks use RTV adhesive / sealant to provide bonding and sealing. KMDSI recommends Dow Corning

™ RTV 732 multi purpose sealant. When sealant is applied the user must use care to insure excess sealant is wiped clean so as not to interfere with other components. Sealant should be allowed to cure for 24 hours before equipment is used.

Use good ventilation w h e n u s i n g R T V sealant. Fumes from th i s m a te r i a l m a y irri tate your lungs. Read and follow the d i re c t i o n s in th e MSDS before using this material.

Wear hand protection when using RTV seala nt. This material may irritate your skin. Read and follow the direc tion s in the MSDS before using this material

Use good ventilation when using Loctite

. Fu m e s f r o m t h i s material may irritate your lungs. Read and follow the directions in the MSDS before using this material.

Wear hand protection when using Loctite

. This material may irritate your skin. Read and follow the directions in the MSDS before using this material

Wear eye protection when using Loctite

. This material may irritate your eyes. Read and follow the directions in the MSDS before using this material.

Page 74

Kirby Morgan® BandMasks® 18 & 28

WARNING

6.3 General Cleaning & Inspection Procedures

Each diver must establish their own minimum standards for the care of their mask. We offer recommendations here with the suggestion that the diver establish for themselves what is necessary to provide a good working unit. Use of the mask in fresh water will require a timetable for maintenance procedures different from that when the mask is used in salt water.

Using the mask in sea water while jetting in sand will necessitate increased maintenance. Use of the mask in a heavy oil and/or chemical environment may make it necessary to replace rubber parts to assure proper function. Regardless, all helmets and masks should be disassembled, cleaned and inspected at least once a year. All o-rings should be replaced at least once a year.

NOTE: Certain fuel oils and/or chemicals will cause premature degradation of soft goods and seals by making them become soft, swell or break down. Upon exiting the contaminant, KMDSI recommends a thorough external decontamination/washing of the mask assembly as soon as feasibly possible, followed by a vigilant inspection of the interior of the mask to ensure that no contaminant has entered.

Wear eye protection to prevent cleaning and germicidal cleansing solutions from contacting eyes. If contact occurs, rinse

eyes with copious amounts of water and consult medical help immediately.

Cleanliness is imperative in maintaining and handling the Kirby Morgan masks and helmets. All tools, parts, and components must be kept free of oil, lubricant, rust, and other contamination. Foreign substances within an assembly may result in equipment failure and possible injury or death to personnel.

Different brands of lubricant should never be mixed. Ensure all old lubricant is removed prior to applying new lubricant.

Pay particular attention to the following parts prior to re-use; whisker, demand regulator diaphragm, demand regulator exhaust valve, exhaust valve, Tri-Valve Exhaust Valve(s), communications post(s) or communications connector assembly, and neck dam.

If in doubt about the serviceability of a part,

repair or replace it immediately. Use only Genuine Kirby Morgan replacement parts. The use of unauthorized parts may result in injury or death to the user.

Do not use solvents or bleach for cleaning. These agents are toxic and use of them may result in injury or death to personnel and damage to equipment.

Page 75

Kirby Morgan® BandMasks® 18 & 28

6.3.1 O-Ring Removal/Inspection/Cleaning and Lubrication

Strict cleanliness and proper lubrication are extremely important during o-ring installation. Comply with the following instructions to ensure proper installation:

NOTE: Ensure all parts are clean throughout the assembly procedure. Dirt or loose particles in the o-ring groove can cause leaks in the seal and damage to the o-ring, reducing its life. During cleaning of equipment, carefully clean o-ring grooves, using a soft bristle brush and liquid soap solution.

O-Ring Removal:

Do not use screwdrivers or metal picks to remove o-rings. When possible, only use ﬁngers to remove o-rings. If an o-ring ﬁts too tightly in its groove to be removed using the ﬁngers, use the appropriate tool from an o-ring removal kit (brass pick). You can also use the corner of a plastic credit card or tooth pick.

A plastic cable tie makes an effective O-Ring removal tool. Use of an appropriate tool helps prevent scratching the o-ring groove, which can cause leakage or premature failure of the seal.

free of dirt, rust particles, lubricant and oil and other contaminants as viewed by the unaided eye.

Sanitizing is deﬁned as eliminating germs and microorganisms. Sanitizing should be accomplished post use or prior to use by another user. KMDSI recommends sanitizing be accomplished any time the unit is to be used by another person during the mission or operation.

NOTE: The sanitizing procedure should be accomplished if possible between uses by different users during the same operation.

6.3.2.1 Soap Solution for General Cleaning and Leak Detector Use

Maintenance procedures include cleaning with a general-purpose soap solution of a mild diluted hand dishwashing soap such as Joy

or Palmolive®. Cleaning solution is prepared by mixing approximately one teaspoon of soap to 1/2 gallon of warm fresh water. This solution may also be used as a leak detector solution. Place all parts and components in a clean washbasin or sink and immerse in soap solution.

O-Ring Inspection:

If during routine corrective maintenance o-rings are to be reused, only reuse o-rings that pass a visual inspection. Inspect for deformities or compression set, hardening or brittleness, nicks or cuts, pits or blisters, 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 must be replaced whenever scheduled overhauls are being completed. During routine repairs or maintenance in between overhauls, o-rings and soft goods may be reused after cleaning provided a careful inspection reveals no wear or damage.

Place the o-rings in a cleaning basin, cover with a mild liquid soap solution, and brush gently with a soft bristle brush to remove all traces of old lubricant and contamination. Rinse cleaned o-rings with fresh water and wipe clean with lint-free cloths, then allow to air dry, carefully inspect for cracking, cuts, abrasions and deformities. Replace o-rings if any damage is found or suspected.

6.3.2 General Cleaning Guidelines

Cleaning and sanitizing of Kirby Morgan masks and helmets should be accomplished upon completion of use and/or prior to storage. Clean is deﬁned as

Allow parts/components to soak for at least ﬁve minutes, and then scrub using a nylon brush. Carefully brush all surfaces, paying close attention to o-ring grooves and threaded surfaces ensuring all lubricants are removed. Regardless of the soap used, all components must be thoroughly rinsed post cleaning to remove all traces of soap.

6.3.2.2 Acidic Cleaning Solution and Procedures

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 an 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 components, it will be best to replace the components.

6.3.2.3 Germicidal Cleaning Solutions and Procedure

The BandMask

has been tested and conforms to the

performance requirements as set forth in EN15333-1

§6.9-6.11. Sanitizing of the oral-nasal mask/regulator of Kirby Morgan masks and helmets is accomplished using one of four approved germicidal cleansing solutions. There are four examples of solutions shown below, along with the necessary ordering information and mixing instructions.

Page 76

Kirby Morgan® BandMasks® 18 & 28

CAUTION

1. SaniZide Plus: P/N: 34805 (spray) or 34810

(gallon), Ready to use; do not dilute. SAFETEC of America, Inc 1055 E. Delavan Ave. Buffalo, NY 14215 USA 1-800-456-7077

2. Advance TBE: P/N: AD160 (spray) or AD1128

(gallon), Infection Control Technology ): Ready to use. Infection Control Technology 1751 So. Redwood Rd. Woodscross, UT 84087 USA 1-800-551-0735

3. Bi-Arrest 2: P/N: BP201 (4 ounces) or BP 222

(32 ounces), Infection Control Technology. Mix two pumps of the concentrate with 16 ounces of fresh water. Infection Control Technology 1751 So. Redwood Rd. Woodscross, UT 84087 USA 1-800-551-0735

Germicidal cleansing solutions must be carefully diluted if required in accordance with the manufacturer’s recommendation. If solution is not of the recommended strength, it will not act as an effective disinfectant. Failure to thoroughly rinse germicidal cleansing solution from diving equipment may result in lung irritation and/or long-term degradation of rubber and silicone components of this equipment.

4. Condence Plus: P/N: 10009971 (32 ounces)

Mix one ounce of concentrate with one gallon of fresh water. Mine Safety Appliances, 1-800-MSA-2222

Sanitizing Procedure:

Unless otherwise directed, use the following procedure to disinfect the KMB-18 or 28 oral-nasal mask/ regulator:

1) Wet or immerse all components to be sanitized. Allow components to stay in contact with the solution 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 potable water.

NOTE: The purpose of this procedure is to sanitize the components exposed to each of the divers. KMDSI recommends sanitizing be performed daily, in between use by different divers, after each use, or when future use is anticipated within the mission (job) period. KMDSI deﬁnes “A mission is deﬁned as use of Kirby Morgan masks and helmets over a seven-day period.”

Page 77

Kirby Morgan® BandMasks® 18 & 28

WARNING

6.4 Daily Maintenance Procedures

The following steps must be performed daily at the completion of diving operations.

6.4.1 Post Dive Gear Breakdown

1) Disconnect the mask from the diving hose and EGS cylinder. Make sure the air is off and the breathing system of the mask is unpressurized. To vent the system, open the defogger valve knob and Emergency gas valve knob until all gas ﬂow stops.

2) Place a protective cap over both the air inlet and the emergency valve inlet to prevent foreign matter from entering the valves.

3) Remove the hood as per the next section of this manual.

6.4.2 Hood and Band Removal

The hood must be removed at the end of each diving day so it can be rinsed and dried. If the hood is not removed, so that it and the mask will dry, mold will grow inside the mask. This can be hazardous to your health.

Tools Needed:

- Flat Blade Screwdriver

- Torque Screwdriver w/Flat Blade & Philips Attachments

6.4.3 Hood, Bands and Band Keeper Attachment Plates Removal

1) Remove the top and bottom band keeper attachment plates by removing the screws that mount them.

2) Remove the band adjustment screws from the bands.

3) Remove the earphones from the pockets in the hood and remove the hood.

Cover the air inlet and emergency gas valve openings with dust caps when not in use.

Never disconnect any hose from the mask unless all gas has been vented from the hose rst. If the hose is disconnected with pressure in the line the ttings may be damaged. In addition, the hose can whip about causing injury to anyone standing nearby.

4) Rinse the hood both inside and out. Be sure it is completely dry before reinstalling it on the mask.

You must remove the screws that hold both the top and bottom band keepers before you can remove the screws on the bands themselves.

Page 78

Kirby Morgan® BandMasks® 18 & 28

WARNING

Hood

Mask Frame

Bottom Band

Top Band

Band Adjustment Screw

Bottom Band Keeper Mount

Top Band Keeper Attachment Plate

Top Band Keeper Mount

Bottom Band Keeper Attachment Plate

This drawing illustrates the relationship between the hood, bands, band keepers, mask frame, and port retainer.

and the regulator. This could be hazardous to your health.

Port Retainer

If the hood is not removed afte r d ivi ng an d t he mask is allowed to stay wet, mold can grow in the inside of the mask, particularly the oral nasal

It is not necessary to remove the bands from the hood if you are only rinsing the hood and not replacing the bands.

Page 79

Uncover the earphones so they may dry.

Kirby Morgan® BandMasks® 18 & 28

6.4.4 Additional Daily Maintenance

1) Remove the earphone covers from the earphones so they can dry completely.

2) Rinse the mask thoroughly with fresh water. Turn the defogger valve knob, emergency valve knob, and regulator adjustment knob while rinsing to prevent salt from accumulating under these valves.

3) Remove the regulator clamp, regulator cover, and diaphragm. Carefully clean the regulator body, diaphragm and cover. Do not depress the purge button while rinsing the regulator as this action will permit foreign matter back into the inlet valve and seat.

4) Screw the demand regulator adjustment knob all the way out. This will prolong the life of the inlet valve seat and keep the internal adjustment correct.

5) Lubricate the shaft of the nose block device with silicone lubricant.

The mask should be rinsed thoroughly with fresh water.

Nose block device

Oral/Nasal Mask

Mask frame

O-ring

6) When the hood and face seal are both dry, reinstall the hood. If the hood has not dried by the time you must dive again, it may be reinstalled at this time.

Be sure to check the Dive Lab website for the most up-to-date maintenance checklist.

Viewport (lens)

Packing nut

Port Retainer

Knob

The shaft of the nose block device needs regular lubrication with silicone lubricant.

Page 80

Kirby Morgan® BandMasks® 18 & 28

6.4.5 Reinstalling the Hood and Bands

Tools Needed:

- Torque Screwdriver w/Flat Blade & Phillips Attachments

Generally speaking, a used hood will take a “set” and show the signs of compression from the bands. This set will correspond to the depression in the mask frame where the bands compress the hood.

The screws holding the bands should be tightened to "26" inch pounds ("2.94" Newton Meters) of torque. As hoods age and the cells of the neoprene break down it will be possible to tighten the bands to the point where the bands almost touch.

1) Thread the band adjustment screws onto the bands only 2 - 3 turns.

2) Place the mask frame face down on a clean work surface and install the earphones into the earphone pockets in the hood.

4) Using a large Phillips screwdriver lightly snug the band adjustment screws onto the mask frame for the moment. Tighten the band adjustment screws equally on each side checking the position of the hood and bands as you tighten.

5) Reinstall the top and bottom band keeper attachment plates over the posts on the bands.

6) Thread and tighten the screws that secure the band keeper attachment plates to their respective band keeper mounts.

6.4.6 Note on discontinued Old Style Hoods - (#510-510) Pre "band keeper" model

Prior to the band keeper style of hood, when the hood is properly installed, the front edge of the hood must protrude a minimum of 1/4 to 1/2 inch (6.0-12.0 mm) from beneath the bands all the way around the mask.

3) Slip the hood and bands onto the mask frame until they are both correctly positioned and centered.

Note: On KMB-28’s it may be necessary to place the Adjustment Block part of the Band between the Side Block and the Mask Frame ﬁrst before sliding the other side of the Hood onto the Mask Frame.

KMDSI recommends switching any mask without the BandKeeper system to incorporate this system. It is a more secure method of hood attachment.

Mount the hood onto the mask frame.

Page 81

Kirby Morgan® BandMasks® 18 & 28

Earphone

Microphone

Oral/nasal mask

Terminal block

Binding post

Waterproof Connector

Plug

Terminal

Packing Gland

6.5 Monthly Maintenance (or between jobs)

NOTE: By deﬁnition “Monthly” is the minimum recommended maintenance that should be performed at least once a month with the mask in continuous use, (used for more than 20 diving days a month) or at least every two months with the mask used less than 10 diving days a month. Appendix A2.2 should also be performed any time the serviceability of the mask is in question.”

6.5.1 Communications Inspection

Visually inspect the earphones, microphone, wires, lugs, and communications posts if installed. Test each component for proper operation. 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.

Visually inspect and test the components of the com system on a regular basis.

Page 82

Kirby Morgan® BandMasks® 18 & 28

Mask Frame

Exhaust Body

Exhaust Valve

Exhaust Cover

6.5.2 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 the packing nut just to the point where the nose block device will still slide, but requires a ﬁrm push or pull.

2) Test the nose block shaft to ensure that it will still slide freely at this time. If it does not, loosen or tighten the packing nut just enough to permit the shaft to slide properly.

6.5.3 Inspect the Exhaust Valve

1) Remove the exhaust cover from the exhaust body by removing the two screws.

2) Inspect the exhaust valve for cracks or tears, replace if needed. Lubricate the valve with a small amount of silicone lubricant. Rub the lubricant into the valve thoroughly leaving no excess lubricant to collect sand or other debris. Replace the cover and replace the screws.

NOTE: The KMB 18 and 28 have different exhaust covers and should not be exchanged.

Lubricate the nose block device o-rings regularly to help ensure that the device shaft will slide properly. It's not necessary to remove the knob, but you do have to loosen the packing nut so that the o-rings are exposed.

The exhaust valve must be lubricated regularly.

Page 83

Kirby Morgan® BandMasks® 18 & 28

CAUTION

WARNING

Chapter 7

Breathing System Maintenance and Repairs

7.1 Introduction

This chapter covers the maintenance and repair of all components of the breathing system. The breathing system includes the one way valve, the emergency valve, the side block, the bent tube assembly, the demand regulator, and the oral/nasal mask.

The breathing system on all Kirby Morgan helmets and masks is simple and highly reliable. The fact that they can continue to operate when the components are not in a well-maintained condition can cause divers to become complacent about maintenance.

Your life depends on the correct function of this equipment!

While Kirby Morgan helmets and masks are simple to maintain, like any type of life support equipment, they do require regular periodic maintenance to function properly.

All parts disassembled should be thoroughly cleaned using the methods described in Chapter 6 Section

6.3. Components that require the use of lubricants, sealing and thread locking compounds should also be serviced.

Most fasteners have a torque value. It is imperative that all fasteners which have a torque value be tightened to the torque speciﬁcations as outlined by the procedure, or as listed in the table in the rear of this manual. If in doubt as to the proper torque setting, contact your local authorized repair facility or KMDSI.

7.3 One Way Valve

NOTE: The one-way valve assembly should be disassembled, 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, KMDSI Part #525-330.

Do not use pliers on the main body of the one way valve. You may damage the valve if pliers are used.

7.3.1 Disassembly Of The One Way Valve

Tools Required: Soft Jaw Vise 1 inch Open End Wrench Attachment on Torque Wrench (If no vise is available use a backup 1 inch open end wrench)

To disassemble and inspect the one way valve as-

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.

Overtightening a part may lead to part failure and improper operation of Kirby Morgan life support apparatus. Undertightening a part may cause the part to come loose and may also lead to improper operation of the equipment. Either situation may lead to personal injury or death.

sembly:

1) The one way valve assembly must be removed from the side block. Use the open end wrench to remove it.

2) After the one way valve has been removed, use two wrenches or hold the hex part of the body in a soft jaw vise while removing the seat with a wrench.

As the seat is removed, the wiper and the O-ring slide out in place in a groove on the seat. The poppet and the poppet O-ring usually come out in the seat being followed by the spring.

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Kirby Morgan® BandMasks® 18 & 28

CAUTION

WARNING

Adapter

Seat

Wiper O-ring Spring

O-ring

Correct assembly order of the one way valve.

Use two wrenches or hold the hex part of the body in a vise while removing or turning the seat with a wrench. Do not use pliers on the main body of the oneway valve. You may damage the valve if pliers are used.

Body

Poppet

O-ring

5) Be careful to wipe the poppet and poppet O-ring thoroughly, removing nearly all silicone to prevent foreign materials from sticking to these components.

6) Replace the spring.

7.3.2 Reassembly of the One Way Valve

The only functional part remaining in the valve body is a non-moving, pressed-in cage. The function of the cage is to contain the poppet during high gas ﬂows.

Do not attempt to move or remove the cage that sits inside the non-return (oneway) valve. Any attempt to remove this part can cause the non-return valve to fail, which can lead to serious personal injury or death.

3) Inspect the body interior for foreign matter of any type and clean, if necessary. Clean in accordance with the KMDSI cleaning instructions. If corrosion is present, clean using the acidic solution as outlined in the KMDSI cleaning procedures.

4) Inspect the seat, wiper, O-ring, poppet O-ring and poppet for wear, replace if necessary. Be sure each part is clean and all components are lightly lubricated with the appropriate lubricant.

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.

A repair kit is available for replacement parts, (Part #525-330). The one-way valve overhaul kit is also included in the KMB 18/28 soft goods overhaul kit (P/N 525-358). All O-rings should be replaced during normal/annual overhauls.

Tighten the non-return (one-way valve) in the sideblock to 150 inch lbs. (17 Newton Meters) with a torque wrench.

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WARNING

4) Tighten the seat to 150 inch lbs. (17 Newton Meters) with a torque wrench while holding the body in a soft jaw vise or wrench.

Kirby Morgan® BandMasks® 18 & 28

5) If the adapter has been removed, it must be cleaned and wrapped with Teﬂon

tape.

6) Test the operation of the valve.

7) Place the new O-ring on the end of the one way valve assembly and reinstall the valve assembly in the side block. Tighten to 150 inch lbs. (17 Newton Meters.) with a torque wrench.

Do not allow any Teon

tape to cover the end of the adapter, or to enter the one-way valve. Loose pieces of Teon

tape can interfere with the performance of the oneway valve or the regulator and may block the diver’s air supply. This could lead to death through suffocation.

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Kirby Morgan® BandMasks® 18 & 28

7.4 Side Block Assembly

7.4.1 General

The side block should be overhauled at least annually, or whenever components show signs of wear, damage or do not function smoothly or properly. Minimum replacement components during overhaul includes all O-rings. A repair kit is available for replacement parts, KMDSI Part #525-311

The side block does not require removal from the mask each time an overhaul is being conducted providing inspection of the internal passages does not reveal contamination or excessive corrosion. However, the side block should be completely removed at least every three years of active use to ensure fasteners are not corroded or frozen.

The side block assembly is held in place on the mask frame by a stud, ﬂat washer, lock washer, nut, and a machine screw. The screw does some securing but its main function is to prevent rotation of the side block. The stud also extends into the interior of the mask frame far enough to secure the air train by means of a 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. A special gasket seals the air train cup to the mask frame inside the mask. RTV silicone rubber compound is used to form a gas tight seal between the side block and the exterior of the mask frame.

Loosening the bent tube from the side block.

4) The side block assembly is ready to start removal.

7.4.3 Separating the Side Block Assembly from the Mask Frame

Tools Required: Putty Knife, 7/16 inch Open End Wrench 1/4 inch Flat Blade Stubby Screwdriver

1) Removal of the side block assembly requires removing the air train.

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 Wrench 1/4 inch Flat Blade Stubby Screwdriver

The bent tube assembly must be entirely removed before removal of the side block assembly is started.

1) Completely unscrew the bent tube assembly nut from the side block.

2) Using two wrenches, hold the nut at the regulator end of the bent tube assembly with the ﬁrst wrench. With the other wrench, loosen the jam nut by turning the wrench DOWN.

3) Unscrew the bent tube nut until it comes free, then pull the bent tube assembly straight out of the regulator inlet nipple.

Removing the air train.

Page 87

A thin putty knife can be pushed between the side

Stud

Washer

block and the mask frame

2) Remove the nut and washer, air train, and air train gasket.

Kirby Morgan® BandMasks® 18 & 28

NOTE: The alignment screw is located in a recess in the ﬁberglass next to the stud. This recess may be ﬁlled with RTV in older masks. The RTV must be scraped free to reveal the screw.

5) The side block assembly is now unfastened, but held in place 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 mask frame. A thin putty knife can be pushed between the side block and the mask frame 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 reassembling. Acetone helps remove this, but must be used sparingly since it will also remove the ﬂat black ﬁnish inside the mask.

6) If you plan to rebuild the side block assembly, it should be done at this time, while the side block is off the mask. Overhaul the defogger valve and emergency valve in accordance with the section in this chapter. Overhaul the one-way valve in accordance with the section in this chapter.

3) The stud nut is removed next, with the lock washer and ﬂat washer.

4) Next, the screw is removed.

Side block

Seat

O-ring

Plug

O-ring

Bent tube

O-ring

Valve stem

O-ring

Washer

O-ring

Bonnet

Knob

Spring

Locknut

Components of the Side Block

Page 88

Kirby Morgan® BandMasks® 18 & 28

WARNING

7.4.4 Side Block Assembly Replacement

If a new side block is being installed, make sure it aligns correctly in the holes of the mask frame before applying RTV silicone sealant.

1) Silicone sealant must be applied to the side block prior to installation on the mask frame. Use only Dow Corning

Care must be taken to avoid sealant entering the air opening in the side block. Be sure to remove all excess silicone sealant before it sets up. Acetone can be used to dissolve uncured sealant on the KMB 18 ONLY. A wooden tongue depressor or similar device is recommended to remove the silicone sealant on a KMB 28.

RTV 732 Multi Purpose sealant.

Use silicone sealant in a well ventilated area. Do not breathe the fumes from uncured silicone sealant. These fumes are dangerous and can cause uncon-

sciousness. They can also cause long term damage to body tissue. Read and follow all precautions listed on the silicone sealant tube and Material Safety Data Sheet.

DO NOT BLOCK

✘

A small amount of silicone sealant must be evenly applied to the side block prior to installation on the mask frame. Use only Dow Corning

AIR OPENING!

RTV 732 Multi Purpose sealant or equivalent.

Relationship between the mask frame and the B sideblock.

Stud

Side block

Apply silicone sealant to these areas

✓

Air Train

Air Train Gasket

The air train is mounted on the stud that is threaded into the sideblock.

Knob

O-ring

Bent tube

O-ring

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WARNING

Avoid contacting the plastic components with acetone. Acetone can melt the components

•

CORROSIVE

Do not dive the helmet until the sealant has had time to cure. Check the directions on the tube of sealant for curing time. If the mask goes into the water before the sealant has cured it could leak through the side block mounting stud hole, screw hole, or air ow hole. This could lead to drowning.

2) Thread the screw through the mask frame and lightly tighten into the side block body.

resulting in equipment failure. This could lead to drowning and possible death.

Kirby Morgan® BandMasks® 18 & 28

6) Slip the air train over the stud. Align the air train with the upper edge of the view port opening in the mask frame.

7) Place the washer on the stud and tighten the nut until the washer lays ﬂush on the air train, 15 inch pounds. DO NOT OVERTIGHTEN.

8) Test the side block prior to diving to ensure that no silicone sealant is blocking the air ﬂow to the mask. If it is, it must be cleaned out prior to diving.

Avoid breathing fumes from acetone and use in a well ventilated area. Breathing fumes can lead to nervous system damage, unconsciousness, and death.

3) Slide the ﬂat washer and the lock washer onto the stud. Run the stud nut down the stud and tighten. Tighten to 50 inch pounds (5.65 Newton meters). DO NOT OVERTIGHTEN.

4) Tighten the screw to the correct torque, 20 inch pounds.

5) Install the air train gasket on the air train cup that is held in position by the stud and nut. The gasket has a cut-out to accept the tube of the air train and a plug designed to cover the head of the alignment screw that helps to maintain the correct position for the side block.

The air train gasket forms a seal between the air train and the interior mask frame.

Avoid eye contact with acetone. This chemical is an irritant and may cause tissue damage.

Avoid skin contact with acetone. Wear rubber gloves. Acetone can damage the nervous system.

If silicone sealant is blocking the air ow into the mask it must be cleaned out. If it is not cleaned out, the diver may not be able to properly defog the mask or clear a ooded mask quickly. In addition, if the demand regulator is not delivering air properly, the diver cannot use the free ow system as a source of breathing air. This could lead to suffocation.

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Kirby Morgan® BandMasks® 18 & 28

7.4.5 Hose Assembly (KMB-18A only)

The hose assembly provides for breathing gas ﬂow from the Side Block Assembly to the regulator for the KMB-18A. Both ends of the hose assembly disconnect for complete removal.

The block itself is no longer available, but replacement hoses, O-rings, and valve components are still available. The block was discontinued in 2005. If your “A” block is damaged, your helmet can be converted to a “B” sideblock with only a few additional parts.

Regardless of the hose condition it must be replaced at least every two years and O-rings should be replaced at least annually.

“A” Side Block

7.4.5.2 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: KMDSI recommends the hose assembly be replaced at least every two (2) years even if the condition appears good.

o-ring

Stud

o-ring

Hose

7.4.5.1 Hose Assembly Removal

Tools Required: 9/16 inch Open-end Wrench 11/16 inch Open-end Wrench 13/16 inch Open-end Wrench O-ring Removal Tool Torque wrench

1) Loosen the hose assembly at the regulator end ﬁrst, while holding the regulator inlet nipple with a second wrench.

2) Disconnect the hose from the inlet nipple.

3) Loosen the hose at the side block connection.

4) Disconnect the hose from the side block.

The hose and O-rings must be inspected on a regular basis.

7.4.5.3 O-ring Replacement

1) Remove the O-ring from the side block end of the hose assembly by pinching it with your ﬁngers and sliding it up the threaded end of the assembly. Install a new O-ring that has been lightly lubricated.

2) To remove the O-ring on the regulator end of the hose, you will need to use an O-ring pick made of brass or plastic. Care must be taken not to scratch or damage the sealing surface on the hose ﬁtting when removing the O-ring. If the ﬁtting is gouged it will leak breathing gas.

7.4.5.4 Hose Assembly Replacement

1) Thread the hose assembly into the side block and tighten with a wrench.

2) Install the hose assembly ﬁtting onto the end of the regulator inlet nipple. Tighten the ﬁtting while holding the nipple with a second wrench.

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Kirby Morgan® BandMasks® 18 & 28

7.5 Defogger Valve

7.5.1 Disassembly of the Defogger Valve

Tools Required: 3/8 inch Slotted Flat Blade Screwdriver 13/16 inch Open End Attachment on Torque Wrench

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

Remove the defogger control knob.

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 after the bonnet is removed.

4) The seat assembly can be unscrewed from the side block body with the stem or a screwdriver.

7.5.2 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 Teﬂon tion, and replace if necessary. Damage such as a rough face or cuts to the seat indicate it must be replaced.

3) The Teﬂon if worn.

4) Be sure to place a light coating of silicone grease on all internal moving parts, O-rings, and washers. However, do not lubricate the Teﬂon attract dust and debris.

seat for wear and/or contamina-

washer and O-ring must be replaced

seat, as this will

The valve stem usually comes out with the bonnet.

The seat should be removed for inspection.

50%

Clean all the metal parts to remove salts.

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Kirby Morgan® BandMasks® 18 & 28

7.5.3 Reassembly of the Defogger Valve

Tools Required: 3/8 inch Slotted Flat Blade Screwdriver 13/16” Open End Attachment on Torque Wrench Minimum mandatory replacement parts during overhaul: Washers, O-rings

1) Screw in the new seat assembly until it is even with the front of the side block body.

2) Next, install the new Teﬂon O-ring onto the stem.

3) Insert the proper end of the stem into the seat assembly and turn clockwise until the seat lightly bottoms 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 bonnet into the side block.

washer and new

indication of a bent stem that must be replaced. Replace the knob and or stem if the ﬁt allows the valve to rotate loosely more than 1/8

8) Install the spring and locknut. Tighten on the locknut until it is ﬂush with the knob.

of a turn.

6) Tighten the bonnet with a torque wrench to 100 inch lbs.

7) Place the new Teﬂon 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.

Binding (or “hard spots”) in the rotation could be an

washer and the control knob

Seat

Valve

Side

stem

block

O-ring

Washer

O-ring

Bonnet

Knob

Spring

Washer

Proper assembly of the defogger valve.

Locknut

Page 93

7.6 Emergency Valve Assembly

The emergency valve assembly is not built into the side block. It is a separate component that can be removed and replaced, or disassembled in place on the side block assembly. The Emergency valve control

knob is not interchangeable with the defogger valve control knob.

7.6.1 Disassembly of the Emergency Valve

Tools Required: 11/16 inch Open End Wrench 1 inch Open-end Wrench Torque Wrench Attachments & Torque Wrench 3/8 inch Slotted Flat Blade Screwdriver Soft Jaw Vise Lubricant

Teﬂon Normal minimum overhaul replacement parts: Non

Tape

Kirby Morgan® BandMasks® 18 & 28

Remove the valve stem.

7.6.2 Cleaning and Lubricating

1) Clean all the metal parts in a soap and 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.

1) Remove the lock nut, spring, and knob.

2) Undo the packing nut. When the packing nut is free of the threads of the emergency valve body, back out the stem until it is free of the emergency valve body.

3) Remove the packing nut, packing, and washer from the stem.

Remove the lock nut, spring and knob.

2) Inspect the packing and washer for wear and replace 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 packing place the packing 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.

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, and/or rounded ﬂats that engage the control knob. Also inspect the shaft to ensure the conical seat surface is smooth and free of corrosion or damage.

4) Check the seat in the emergency valve body for wear or unevenness, galling and corrosion. To clean up the seat surface use a pencil eraser to buff the surface. Inspect all threaded surfaces for damage. Replace the emergency valve body if any damage is found.

Undo the packing nut.

Inspect the packing and washer.

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Kirby Morgan® BandMasks® 18 & 28

Valve Body

5) To remove the emergency valve body from the side block the one way valve assembly must ﬁrst be removed.

6) If the emergency valve body is removed, clean and inspect the pipe thread and inspect for damaged threads, cracking or distortion. Replace the emergency valve if any damage is present.

Re-tape threads with Teﬂon

tape, 1½ wraps starting two threads back. Tighten using good engineering practice. Reinstall the emergency valve body into the side block before installing the one way valve assembly.

7.6.3 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 lightly lubricate the stem shaft and threads..

NOTE: There are two different packings and washers supplied in the kit, 525-311, for rebuilding both the older style and the newer high ﬂow emergency gas valve. Match the removed packing and washers to the new ones supplied and discard the others.

3) Holding these components in place on the stem, screw the stem into the emergency gas valve body.

4) Rotate the stem until it is seated all the way in then, back it out 1/2 turn.

Installing the valve stem in the emergency valve.

5) T

hread the packing nut onto the emergency valve

body. Run the nut in and tighten slightly with a wrench.

6) Inspect the emergency gas valve knob for wear and damage. Ensure the ﬂats that engage the valve stem shaft are not rounded, cracked or damaged. The valve knob should not have rotational play greater than 1/16th of a turn.

NOTE: This knob is not interchangeable with the defogger valve knob.

7) Place the emergency gas valve knob onto the stem and rotate the stem all the way out, then back again. The rotation must be smooth. If “hard spots” or unevenness are felt during the rotation, the stem may be bent and could need replacement.

8) Tighten the packing nut with a torque wrench to

The components of the emergency valve.

Packing

Knob

Lock nut

Valve Stem

Washer

Packing nut

Spring

Page 95

50 inch pounds after seating.

WARNING

9) Place the spring, and locknut onto the stem securing the knob.

10) Tighten the locknut until its top is ﬂush with the top of the knob. The assembly is now complete and ready for testing.

NOTE: If the valve was removed from the side block, testing of the emergency gas valve is easily accomplished by attaching the valve, by itself, in the shut position, on to the intermediate whip of the ﬁrst stage. Pressurize to a minimum 135 p.s.i.g. (9.3 bar) using the EGS Cylinder and drop it into a bucket of clean water a minimum 30 seconds to check for leaks.

11) Before installing any pipe sealant, 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.

Kirby Morgan® BandMasks® 18 & 28

Hand tighten the valve, then continue an additional 1½ to 2 turns with a wrench keeping in mind the proper alignment of the control knob to the side block. Also, there should be at least one male thread visible. Check to be certain the valve is tight by trying to loosen the ﬁt by hand.

DO NOT TIGHTEN TH

AN NECESSARY!

THE VALVE BODY TIGHTER

OVER TIGHTENING MAY 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 acceptable provided that 1) the valve handle can be turned easily and 2) the diver can locate the handle easily.

a) Attach the supply whip from the EGS ﬁrst stage to EGS mask valve.

If the emergency valve body or assembly is being replaced with new parts, check for the 2 thread make-up. Within ± ¼ turn is OK. If there is less make up, then the threads may need to be chased with a ¼" NPT tap to obtain the proper make up. If tapping is required, the bent tube assembly, the one way valve assembly and steady ﬂow (defogger valve) components must all be removed and the side block body must be thoroughly cleaned to remove any loose particles. If this process is deemed necessary, contact Dive Lab or Kirby Morgan ﬁrst.

12) Before installing the valve assembly, wrap the pipe threads with 1½ turns of Teﬂon

tape starting after the ﬁrst thread. The amount of tape used should be based on what is found in the ﬁt check. Apply the tape with slight tension to allow the tape to ﬁll into the threads. Use only Teﬂon

tape.

Do not use any sealant on pipe threads on Kirby Morgan products other than Teon

tape or other approved sealants. Other sealants may not be oxy-

gen compatible and may lead to re or explosions which may cause severe personal injury or death.

b) Ensure the defogger valve knob is open and the EGS Valve is shut.

c) Pressurize EGS Valve to a minimum of 135 p.s.i.g. (9.3 bar) using the EGS cylinder as supply. Allow system pressure to stabilize , and then shut the EGS supply cylinder valve. Note time and ﬁnal stabilized system pressure.

d) Perform the leak check for minimum of ﬁve minutes, using a mild soap solution. Ensure there is no gas ﬂowing or pressure drop in the system. There should be no visible signs of external leakage if the valve is operating properly.

A leaking Emergency Gas Valve assembly can cause the diver to exhaust their entire EGS (bailout) without their knowledge. This may lead the diver to mistakenly assume their EGS supply is available when it is not. This could lead to panic or drowning in an emergency. Any worn or damaged components must be replaced.

Page 96

Kirby Morgan® BandMasks® 18 & 28

7.7 Bent Tube Assembly

7.7.1 General

The bent tube assembly provides breathing gas ﬂow from the side block assembly to the regulator assembly. Both ends of the bent tube assembly disconnect for complete removal. The O-ring and the Teﬂon O-ring should be replaced during normal overhauls or any 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 KMDSI procedures prior to inspection for reuse.

7.7.2 Removal of the Bent Tube Assembly

Tools Required: 11/16 inch Open-end Attachment on Torque Wrench 7/8 inch Open-end Attachment on Torque Wrench 7/8 inch Open-end Wrench

1) Always start removal at the side block end. The free swiveling mount nut on this end of the bent tube can be unthreaded completely and can slide down the tube.

Loosening the jam nut.

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.

Always start removal at the side block end.

2) The inlet nipple has a jam nut that locks the mount nut in place. With one wrench, hold the bent tube mount nut. With another wrench, turn DOWN the jam nut, backing it away from the mount nut. The mount nut can then be rotated until free of the regulator inlet nipple threads. It can be pushed up the bent tube.

Replace the bent tube if it is excessively scratched dented or compressed deeper than 1/8 inch. If the mask has been used for burning jobs, carefully check for erosion of the metal or severe corrosion. Replace if any erosion is present or integrity is in question. Keep in mind the bent tube is a critical component that routs breathing gas to the mask systems.

3) With the two mount nuts free; the bent tube assembly can be pulled straight out of the regulator inlet nipple. The bent tube assembly can be rotated back and forth to aid removal.

Replace the O-ring on the bent tube if it is worn or damaged.

Page 97

Kirby Morgan® BandMasks® 18 & 28

7.7.4 Reinstallation of the Bent Tube Assembly

Tools Required: 11/16 inch Open-end Torque Wrench Attachment 7/8 inch Open-end Torque Wrench Attachment 7/8 inch Open-end Wrench 1 3/8” socket Normal minimum replacement parts during overhaul: O-ring, Teﬂon

ring

If a new bent tube is being installed or the side block has been removed, refer to the section on sideblock replacement for installation instructions.

1) Loosen the regulator mount nut using the 1 3/8” socket several turns.

2) Lightly lubricate the bent tube O-ring and install in the O-ring groove at the regulator end of the bent tube, then install new Teﬂon

O-ring at the side block end.

3) Push the O-ring end of the bent tube assembly into the regulator inlet nipple. Slide it in until the side block end is aligned with the threads for the mount nut.

4) Be sure the new Teﬂon® O-ring is in place on the side block end of the bent tube then engage the threads to the side block and hand tighten.

5) Start the “regulator to bent tube” mount nut onto the inlet nipple of the demand regulator and run it up by hand as far as it will go.

NOTE: Run the mount nut up on the inlet nipple and hand tight only.

6) Using a torque wrench, tighten the bent tube assembly nut onto the side block to (100 inch lbs).

7.8 Demand Regulator SuperFlow 350

While the regulator systems on all Kirby Morgan helmets and masks are simple and highly reliable, the breathing resistance will increase if the demand regulator on your mask 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 cannot work hard and will tire rapidly. Simply put: If the demand regulator does not work properly the diver cannot work properly. This makes the maintenance of the demand regulator assembly essential.

For the gas inlet valve and adjustment system to operate properly, the components in the demand regulator MUST be in good condition and MUST be periodically adjusted internally.

Four (4) special tools, the inlet valve holder (Part #525-616), the regulator adjustment wrench (Part #525-611), the socket wrench (Part #525-612), and the castle wrench (Part #525-618) should be used to work on the regulator whenever possible.

Disassembly, assembly, and adjustment can be done without these tools, but the work is much easier and the adjustment is better if these tools are used. The above 4 tools are available together along with a tool pouch. The “Tool Kit with Pouch” is Part #525-620. This kit is included with every new Kirby Morgan helmet and BandMask

350.

equipped with the SuperFlow

7) Hold the mount nut on the end of the bent tube with a wrench and tighten the jam nut against it with a torque wrench to 40 inch pounds.

8) Torque the regulator mount nut to 75 inch lbs.

Tool Kit with pouch - Part #525-620.

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Kirby Morgan® BandMasks® 18 & 28

WARNING

7.8.1 Demand Regulator Test for Correct Adjustment, Fully Assembled

To maintain optimum performance of the demand regulator, it should be checked for proper function and adjustment prior to commencement of diving each diving day.

Check the regulator for adjustment and proper function with the assembly complete, and supplied with a breathing gas supply pressure of 135 to 150 p.s.i.g.

NOTE: 135 to 150 p.s.i.g. over ambient is the standard supply pressure to be used when adjusting all KMDSI helmet and band-mask demand regulators. See Chapter 2 for tables that list the proper supply pressures for speciﬁc depths.

NOTE: When storing the mask for any length of time, ensure that the regulator adjustment knob is turned “out” fully counterclockwise to avoid stressing the bias springs. This will prolong the life of both the inlet valve, seat, and bias springs.

1) Ensure the supply pressure is properly adjusted to 135 to 150 p.s.i.g.

2) Rotate the adjustment knob out counterclockwise slowly, until a slight steady ﬂow develops.

3) Slowly rotate the adjustment knob in clockwise, until the free ﬂow stops. Lightly depress the purge button several times to ensure the gas ﬂow has stopped.

4) Lightly depress the purge button. There should be between 1/16” and 1/8” free travel in the button before gas ﬂow 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 regulator 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 regulator clamp by removing the clamp screw.

Remove the demand regulator clamp.

2) Lift off the demand regulator cover and diaphragm.

3) Clean the diaphragm with the soap solution, per Section 6.3 and wipe dry. Inspect the diaphragm for holes, tears or any signs of deterioration by holding it up to a white light and stretching and pulling. Check for a good bond between the metal disc and the silicone membrane. Replace diaphragm if any doubt exists.

4) Inspect the interior of the demand regulator body for damage, corrosion and cleanliness. Clean the interior of the regulator body if necessary per Section 6.3.

NOTE: If adjustment is necessary as described in

7.8.1 Demand Regulator Test for Correct Adjustment, Fully Assembled step 5 on page 82. Don NOT install diaphragm, cover and ring. Adjust as per section 7.8.9 Tuning the SuperFlow 350 Regulator on page 95.

5) Reinstall the diaphragm, cover, and clamp. Tighten

Use only replacement diaphragms manufactured by Kirby Morgan. Use of other diaphragms may degrade performance and may cause increased breathing resistance. This can lead to fatigue and the inability to work at full capacity.

Page 99

the clamp screw to the recommended torque of 12 inch pounds using a torque screwdriver.

NOTE: Older regulator clamps, when properly torqued, had a gap of approximately 1/32” to 1/16” between the interior retaining clamp surfaces when fully tightened. All new clamps when properly torqued, have little or no gap between the interior retaining clamp surfaces.

7.8.3 Demand Regulator Bias Adjustment Servicing, Demand Regulator on the Mask

Note: This procedure should be used when replacing the O-ring on the adjustment shaft and or cleaning and lubricating the shaft threads during ﬁeld repairs with the demand regulator on the mask. Start at the adjustment knob end of the regulator:

Tools Required: 3/4 inch Open-end Wrench Attachment on Torque Wrench 3/32 inch Pin Punch & Small Block of Wood Ball-Peen Hammer Regulator Adjustment Tool Kit, Part #525-620 Torque Wrench

Kirby Morgan® BandMasks® 18 & 28

1) Unscrew the adjustment knob until it stops and a wrench can be placed on the nut. If the knob wobbles as you turn it, or is extremely hard to turn, the shaft

Screw the regulator adjustment knob out for removal.

is bent and needs to be replaced

2) Loosen the nut, then rotate the adjustment knob counterclockwise until the adjustment knob and the adjustment shaft are free, then remove the spacer, springs, and piston. At this point the threads can be cleaned and lubricated as well as the adjustment shaft.

3) Punch out the roll pin using a 3/32 pin punch. Use a block of wood with a 1/4” hole drilled through it to

Remove the spacer, spring set, and piston.

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.

4) Remove the adjustment knob, 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 mask and cleaned and inspected, per KMDSI recommended procedures.

5) Carefully inspect all parts for corrosion, paying particular attention to threaded surfaces and the spring set. Clean and lightly lubricate parts per Chapter 6.

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Kirby Morgan® BandMasks® 18 & 28

Adjustment

Regulator bo

NOTE: Carefully inspect the adjustment shaft to ensure it is straight. Check for damaged threads. Replace the adjustment shaft if any damage is found. Replace the O-ring.

NOTE: If the inside of the adjustment tube is corroded, this indicates saltwater intrusion into the adjustment tube and assembly. The demand regulator requires removal from the mask and cleaning per KMDSI recommended procedures.

6) Replace the O-ring on the adjustment shaft.

7) Replace washer.

8) Inspect the inside of the adjustment tube on the regulator body to be sure there is no corrosion and the adjustment assembly can travel freely. Ensure the alignment tube is not bent or misaligned from impact.

7.8.4 Reassembly of Adjustment System

Tools Required:

3/4 inch Open-end Wrench Attachment on Torque Wrench Silicone grease, or oxygen compatible grease if used for oxygen service.

1) Lightly lubricate the piston and spacer and place the piston back in the regulator adjustment tube, followed by the spring set, and spacer.

2) Lightly lubricate the adjustment shaft end and threads, install the washer and the lightly lubricated O-ring on the adjustment shaft.

3) Slip the packing nut over the adjustment shaft followed by the adjustment knob.

4) Hold the shaft and rotate the knob until the pin 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 ﬂush with the surface of the adjustment knob.

Inspect the O-ring & washer.

Adjustment shaft

Spacer

Piston

5) Screw the adjustment shaft clockwise back into the regulator body leaving enough packing nut exposed to get the wrench on it.

knob

Retaining pin

Packing nut

Components of the SuperFlow 350 Adjustment System

Kirby Band Masks User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual