Kirby Band Masks User Manual

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

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.

®®

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

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)

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.

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.

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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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

Kirby Morgan® BandMasks® 18 & 28

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

Kirby Morgan® BandMasks® 18 & 28

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

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

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.

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.

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.

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

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

™

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.

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.

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

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.

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.

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.

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

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.

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.

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.

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.

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

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

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Kirby Band Masks User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual