Kirby SuperLite User Manual

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WARNING

SuperLite® 17B Helmet

Operations and Maintenance Manual

KMDSI Part # 100-001

™

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 Marine Marketing and Consulting, Dive Lab, Inc., and KMDSI.

NOTE: This manual is the most current for the SuperLite® 17B Helmet. 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 SuperLite®-17A/B helmet is CE Approved and meets or exceeds all performance and testing requirements of all government and non-government testing agencies throughout the world. It is approved for use on all commercial and military work underwater.

Kirby Morgan, SuperLite®, BandMask, Band Mask, KMB, KMB-Band Mask, 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 design and trade dress protected.

© Copyright 1970-2010 Kirby Morgan Dive Systems, Inc. All rights reserved. This manual is made available for the express use of the 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 100720003

SuperLite® 17B

Warranty Information

Kirby Morgan Dive Systems, Inc. warrants every new mask, helmet, or KMACS 5 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 head cushions. 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 x 229. 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.

®®

SuperLite® 17 A/B Helmet

Location # Part # Description

1 510-521 Head Cushion

510-523 Replacement Foam 2 510-533 Drawstring Neck Dam 3 Neck Clamp

(Order Comp. see #7) 4 530-317 Nut 5 530-415 Washer 6 530-320 Nut, Lock 7 505-055 Neck Clamp Assembly 8-13 not used 14 505-008 Neck Clamp Yoke Assembly Comp. 15 530-066 Screw 16 530-601 Retaining Pin 17 550-255 Knob 18 535-900 Safety Pin 19 560-051 Latch Catch Body 20 535-808 Spring 21 550-257 Plunger 22 505-010 Latch Catch Assem., Pull Pin 23 530-034 17B Hinge Bolt, Electropolished 24 560-026 Hinge 25 530-028 Nut 26 540-157 Rear Hinge Tab, Electropolished 27 530-406 Washer 28 530-025 Screw 29 530-080 Screw 30 530-530 Washer 31 520-117 Urethane Yoke

520-060 Fiberglass Yoke 32 550-019 Locknut 33 535-802 Spring 34 520-524 Knob, Control 35 520-030 Washer 36 550-020 Bonnet 37 510-015 O-ring 38 520-031 Washer 39 510-010 O-ring 40 550-022 Valve Stem 41 550-023 Seat Assembly 42 550-024 Stud 43a 550-026 A Side Block 43b 550-029 B Side Block 44a 510-011 O-ring 44b 520-033 O-ring (teﬂon) 45b 555-154 Bent Tube Assembly 46a 510-010 O-ring 46b 510-012 O-ring 47a 555-152 Reg. Hose Assem. w/O-rings 47b 555-155 Bent Tube Assem. w/O-rings 48 550-095 L.P. Plug, w/O-ring 49 310-003 O-ring 50 550-140 Emergency Valve Body 51 550-138 Stem

Location # Part # Description

52 540-095 Washer 53 520-024 Packing 54 550-091 Packing Nut 55 520-525 Knob, Control 56 535-802 Spring 57 550-019 Locknut 58 505-070 Emergency Valve Assembly 59 510-483 O-ring 60 Body 61 Spring 62 Poppet 63 O-ring 64 O-ring 65 Wiper 66 Seat 67 555-117 Adapter, Brass, ¼" NPT/02 68 555-195 One-Way Valve 69 505-060 One-Way Valve Assem. 70a 505-022 “A” Side Block Assem. Complete 70b 505-024 “B” Side Block Assem. Complete 71 515-005 Earphone Right 72 515-006 Earphone Left

510-542 Earphone Cover set 515-008 Speaker

520-015 Speaker Protector 73 515-009 Microphone 74 515-030 Communications Set 75 560-023 Starboard Weight 75a 520-054 Visor 76 530-070 Screw 77 530-540 Washer 78 545-027 Snap Tab 79 530-078 Screw 80 510-446 O-ring 81 510-211 O-ring 82 550-038 Nut, Regulator Mount 83 510-747 Mask, Oral/Nasal (silicone) 84 510-550 Valve, Oral/Nasal Intake 85 520-020 Body, Oral/Nasal Intake Valve 86 545-015 Nose Block device

510-575 Nose Block Pad 87 530-090 Alignment Screw 88 550-339 Alignment Sleeve 89 560-005 Rear Weight 90 530-070 Screw 91 530-540 Washer 92 520-065 Helmet, Fiberglass 93 560-014 Handle 94 530-040 Screw 95 560-019 Port Weight 96 530-535 Washer 97 530-415 Washer 98 530-317 Nut

Order

Complete

see

Loc. # 68

For

Replacement

Parts

Order

Kit

#525-330

Location # Part # Description

99 545-016 Air Train 99a 510-762 Air Train Gasket 100 530-535 Washer 101 530-317 Nut 102 530-050 Screw 103 530-052 Screw, Port Plug Screw 104 530-035 Screw 105 510-010 O-ring 106 510-008 O-ring 107 555-180 Packing Nut 108 550-062 Knob, Nose Block 109 550-061 Spacer 110 540-015 Plate 111 530-045 Screw 112 545-022 Regulator Body 113 550-060 Piston 114 535-807 Spring Set 115 550-059 Spacer 116 550-057 Shaft 117 520-032 Washer 118 510-011 O-ring 119 550-055 Packing Nut 120 550-053 Knob, Adjustment 121 530-601 Retaining Pin 122 510-553 Diaphragm 123 545-018 Cover Assembly 123a 535-905 Retaining Clip 123b 540-055 Cover 123c 535-810 Spring, Purge Button 123d 520-017 Purge Button 123e 520-078 Purge Button Sticker 124 530-030 Screw 125 545-020 Clamp 126 530-303 Nut 127 550-052 Spacer 128 545-038 Roller Lever 129 530-506 Washer 130a 550-046 Inlet Nipple “A” 131b 550-050 Jam Nut “B” 132b 550-048 Inlet Nipple “B” 133 510-014 O-ring 134 545-026 Inlet Valve 134a 510-580 Valve Seat 134b 530-505 Washer 135 535-804 Spring 136 510-552 Exhaust Valve 137 505-026 Demand Reg. Assem. “A” 138a 505-027 Demand Reg. Assem. “B” 138b 505-028 Reg. Adjustment Knob Assem.

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

Location # Part # Description

139 510-554 Whisker™, Rubber (Pre 2004) 140 525-759 Quad-Valve™ Exhaust 140a 510-786 Starboard Whisker™ 140b 510-787 Port Whisker™ 140c 510-760 Quad Valve Exhaust Main Body 140d 520-200 Whisker™ Exhaust Valve Insert 140e 510-776 Exhaust Valve 140f 520-042 Tie Wrap 140g 520-118 Tri/Quad Valve Whisker Clamp 140h 530-008 Brass Screw 140i 530-009 Brass Nut 141 550-116 Nose Block Guide 142 560-070 Port Ret. Assembly 143 520-004 Face Port

520-128 Face Port, pre 1979 144 510-260 O-ring 145 550-040 Nut 146 530-308 Nut 147 530-525 Washer 148 540-054 Earphone Retainer 149 530-032 Screw 150 550-063 Exhaust Body 151 510-561 Exhaust Valve 152 530-021 Screw 152a 530-019 Screw, Quad Exhaust 152b 510-007 O-ring, Quad Exhaust Screw 153a 560-530 Exhaust Cover, Quad Exhaust 153b 520-042 Tie Wrap, Quad Exhaust 153c 510-033 O-ring, Quad Exhaust 154 515-061 Terminal Block 155 515-035 Communications Post 156 510-481 O-ring 157 550-043 Plug 158 515-049 Terminal 159 515-045 Waterproof Conn, Male 160 510-481 O-ring 161 555-175 Packing Gland 162 520-113 Ferrule Set 163 555-178 Packing Nut 164 505-047 W.P. Connector Assembly 165 505-130 Chin Strap 166 505-134 Strap Guide 167 505-138 Yoke Strap

525-620 Tool Kit (not shown)

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

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

75a

134b

165

167

166

164

163

137

138a

138b

109

110

111

140f

140b

140d

140e

140g

140h

140i

140c

140a

140

SuperLite® 17 A/B Helmet

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.

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

Following publication of this booklet, certain changes in standard equip-

Product Changes

ment, 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.

change product speciﬁcations at any time without incurring obligations.

SuperLite® 17B

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. Quantities marked in parenthesis.

Change Number Date Description of Change

1 05/28/2008 Reworded: 2.1 Product Speciﬁcations, 2.4 Operational Speciﬁcations & Limitations,

Warnings Corrected, 7.12.1 to the correct 7.16.1 and Table of Contents Updated.

Added: Appendix A2, 3 and 4

Moved: 2.4 Operational Speciﬁcations & Limitations, The SuperFlow Regulator Image Rotated and Scaled to ﬁt. Removed: Table 1 and Table 2 from chapter 2.

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

Page 16 First paragraph Part number added to Hard Shell. Page 17 Second paragraph 77 added to list of helmets. Chapter 1 rearranged and CE text added to KM-77 description. Pg 63 and 64 Chapter 5 made to two columns format and font changed to lower case instead of all caps. Page 65 Added Whisker Clamp Replacement Kit: Part # 525-032. Page 66 Corrected text to read “SL 17” instead of “KM 37 and 57” in 6.2, last sentence and photo caption. Page 102 step 17 corrected, "sssembly" to read "assembly." Page 173 Torque Speciﬁcation corrections. Page 174 Added note about thread locking compound.

3 03/13/2009 Page 75: Space added between 6.5.1 Quad.

Page 77: Removed grammatical error beneath image. Page 81: Corrected 40 inch pounds to 35 inch pounds in step 3. Lacquer thinner changed to acetone. Page 82: Corrected 40 inch pounds to 15 inch pounds in step 6. Lacquer thinner changed to acetone. Page 95: Corrected amount omitted inch pounds to 40 inch pounds in step 6. Page 105: Corrected 75 inch pounds to 100 inch pounds twice in step 18. Corrected 30 inch pounds to 40 inch pounds in step 22. Page 120: Corrected 75 inch pounds to 100 inch pounds in step 4. Page 122: Corrected 75 inch pounds to 100 inch pounds in step 8. Corrected 35 inch pounds to 40 inch pounds in step 9. Page 124: Removed step 11 and merged SPECIAL CARE text with step 10. Corrected 75 inch pounds to 100 inch pounds in step 16. Page 136: Corrected 35 inch pounds to 20 inch pounds in step 4. Page 140: Corrected 30 inch pounds to 20 inch pounds in step 3. Page 143: Corrected 35 inch pounds to 35-50 inch pounds in step 1. Page 152: Corrected 15 inch pounds to 20 inch pounds in step 5.

Demand

SuperLite® 17B

WARNING

Change Number Date Description of Change

3 (Continued) 03/13/2009 Page 154: Corrected 35 inch pounds to 25 inch pounds in step 5. Grammatical error,

"resuse" corrected to reuse in step 7. Corrected 35 inch pounds to 20 inch pounds in step 1 of section 8.10.1.2. Corrected 35 inch pounds to 20 inch pounds in step 3 of section 8.10.1.2. Page 175: Location #94's part number corrected from 530-045 to 530-040. Added location #'s 6, 107 and 152a.

4 07/23/2009 CE material added

5 10/05/2009 Changed location # 82's part number from 550-372 to 550-038 in the torque specs.

6 11/06/2009 Chapter 2: addition of CE conforming criteria.

7 04/19/2010 Updated images and diagrams with new whiskers.

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

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 helmets and persons that maintain or service Kirby Morgan helmets.

SuperLite® 17B

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 - SuperLite®-17B � � 9

2.1 CR Marking

2.2 CE Certication

2�2�1� CE Marking � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9

2�2�2� Notied Body � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10

2.3 Product Specications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10

2.4 Regulator Performance � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10

2.5 Cage Code � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10

2.6 Operational Specications & Limitations

2.7 Helmet Features

2.8 General Description � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13

2�8�1 Helmet Shell � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13

2�8�2 Gas Flow Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13

2�8�3 Emergency Gas Supply System (EGS) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 18

2�8�4 Helmet Attachment to the Diver � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 18

2�8�5 Sealing Arrangement � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 18

2�8�6 Reducing Carbon Dioxide � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 19

2�8�7 Communications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20

2�8�8 Equalizing the Middle Ear � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20

2�8�9 Face Port or Viewing Lens � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21

2�8�10 Latch Catch Assembly, Pull Pin � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21

2.9 Accessories � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21

2�9�1 Eye Protection for Welding � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21

2�9�2 Hot Water Shroud � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 22

2�9�3 Special Regulator Tools � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 22

2.10 Helmet Transport And Storage � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 23

2�10�1 Helmet Carrying Bag � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 24

2.11 Use of Kirby Morgan Original Replacement Parts

Chapter 3 Operating Instructions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 25

3.1 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 25

3.2 Design Purpose

3.3 First Use of Your Kirby Morgan Diving Helmet

3.4 Initial Adjustments to Your Helmet

3�4�1 Head Cushion � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 27

3�4�2 Adjusting the Neck Dam � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 28

3.5 Pre Dress-In Procedure

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � III

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SuperLite® 17B

3�5�1 Pre-Dive Visual Inspection � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 29

3.6 Preparing the Helmet for Diving� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 30

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3) You can also test the one-way valve by opening the steady-ow valve and attempting to suck air back through the one-way valve. This is also a good way to test. � � � � � � � � � � � � � � � � � � 30

3.7 Emergency Gas System (EGS) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 31

3.8 Setting Up to Dive

3�8�1 Flushing Out the Umbilical � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 35 3�8�2 Connecting the Umbilical to the Helmet � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 35 3�8�3 Opening the Breathing Gas Supply to the Helmet � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36 3�8�4 Fogging Prevention � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36 3�8�5 Donning The SuperLite®-17B � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 37 3�8�6 Testing the Breathing System � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 42 3�8�7 Sealing Integrity Check � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 42

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3�11�1 Removing the Equipment � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 45 3�11�2 Removing the Helmet � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 45 3�11�3 Storage of the Helmet Between Dives � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 46

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4.3 One Way Valve Malfunction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 47

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4.6 Demand Regulator Malfunction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 49

4.7 Emergency Gas Supply Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 49

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5.1 Routine Maintenance

5�1�1 Daily Pre-Dive Maintenance A2�3 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 51 5�1�2 Daily Post Dive Maintenance A2�6 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 51 5�1�3 Supervisors Equipment Checks A2�4 and A2�5 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 51

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5.2 Monthly Maintenance

5.3 Yearly Maintenance � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 51

5�3�1 Overhaul/Inspection Checklist A2�1 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 51

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6.1 Introduction

6.2 Required tools, Cleaning Agents, Lubrication � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 53

6�2�1 Component and Parts Cleaning � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 54

6�2�2 Component and Parts Lubrication � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 54

6�2�3 Teon® Tape � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 55

6�2�4 RTV Sealant � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 55

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6.3 General Cleaning & Inspection Procedures � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 55

6�3�1 O-Ring Removal/Inspection/Cleaning and Lubrication � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 56

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6�3�2�1 Mild Soap Solution for � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 57

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6.3.2.2 Acidic Cleaning Solution and Procedures � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 57

6.3.2.3 Germicidal Cleaning Solutions and Procedure � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 57

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6�5�1 Quad-Valve™ Exhaust System � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 61

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6�5�3 Steady Flow/Defogger Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 62

6�5�4 Bias Device Adjustable Section of Demand Regulator � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 62

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Chapter 7 Breathing System Maintenance and Repairs � � � � � � � � � � � � � � � � � � � � � � � 63

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7.2 One Way Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 63

7�2�1 Disassembly Of The One Way Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 63

7�2�2 Reassembly of the One Way Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 64

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7�3�3 Separating the Side Block Assembly from the Helmet Shell � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 66

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7�4�1 Disassembly of the Defogger Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 69

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7�4�3 Reassembly of the Defogger Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 70

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7�5�1 Disassembly of the Emergency Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 71

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7�5�4 Leak Testing the EGS Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 73

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SuperLite® 17B

7�6�2 Removal of the Bent Tube Assembly � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 74 7�6�3 Inspection of Bent Tube Assembly � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 75 7�6�4 Installation of the Bent Tube Assembly� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 75

7.7 Hose Assembly (SL-17A only) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 76

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7.8 SuperFlow

7�8�1 General Regulator Information � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 77 7�8�3 Inspection of SuperFlow® Regulator Body Interior � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 78

7�8�4 SuperFlow® Demand Regulator Bias Adjustment Servicing, Demand Regulator on the Helmet

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 79

7�8�5 Reassembly of the SuperFlow® Regulator Adjustment System� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 80 7�8�6 SuperFlow® Demand Regulator Removal from Helmet � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 81 7�8�7 Disassembly of the SuperFlow® Demand Regulator� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 82 7�8�8 Inspection of SuperFlow® Demand Regulator Parts � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 85 7�8�9 Reassembly of the SuperFlow® 350 Demand Regulator � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 87 7�8�10 Tuning the SuperFlow® Regulator � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 91

7.8.10.1 Important Notes on Regulator Adjustment � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 92

7�8�11 SuperFlow® Regulator Steady Flows When Pressured Up: Special Tools Used � � � � � � � � � � � � 93 7�8�12 Regulator Steady Flows When Pressured Up � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 95 7�8�13 Regulator has Low or No Flow When Pressurized � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 95 7�8�14 Unexplained Demand Regulator Free Flow � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 95

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7�9�1 Oral Nasal General Information � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 96 7�9�2 Oral Nasal Removal � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 96 7�9�3 Inspection of Oral Nasal � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 96 7�9�4 Oral Nasal Replacement � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 97

7.10 Quad-Valve™ Exhaust Assembly � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 98

7�10�1 Quad-Valve™ Assembly Removal � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 98 7�10�2 Quad-Valve™ Exhaust Valve Replacement � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 99 7�10�3 SuperFlow® Regulator Exhaust Valve Replacement � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 102 7�10�4 Quad-Valve™ Assembly Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 103

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7.12 Reinstalling the Quad-Valve™ Exhaust Assembly � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 105

7�13 Standard Old Style Single Exhaust Whisker PN# 510-554 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 106 7�13�1 Whisker Removal � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 106 7�13�2 Reinstalling the Whisker � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 107

7.14 Double Exhaust Whisker � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 108

7�14�1 Double Exhaust Whisker Cleaning and Overhaul, Whisker PN# 525-102 � � � � � � � � � � � � � � � � 108

7.15 Tri-Valve Exhaust Whisker � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 110

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7�15�1 Demand Regulator Assembly Removal � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 110

7�15�2 Replacing the Regulator Exhaust Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 110

7�15�3 Tri-Valve Exhaust Valve Replacement � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 111

7�15�4 Installing the Tri-Valve Exhaust System onto the Regulator � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 113

7.16 Overpressure Relief / Bleed Valve Overhaul Procedures

7�12�1 Overpressure Relief Valve � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 114

7�16�2 Overpressure Relief Valve Disassembly and Cleaning � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 114

7�16�3 Overpressure Relief Valve Reassembly � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 115

7�16�4 Overpressure Relief Valve Lift Check/Setting � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 115

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8.2 Yoke/Neck Clamp Assembly and Helmet Shell Inspection � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 117

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8.10 Neck Clamp/Yoke Assembly � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 138

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8.10.4.2 Four Hole Method of Attaching Neck Dam to Hinge Tab � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 146

8.10.4.3 Patch Method of Attaching Neck Dam to Hinge Tab � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 146

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8.11 O-Ring Seal Replacement

8.12 Head Cushion Foam Replacement

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9.3 Low Pressure Inator Hose Installation on the B Sideblock � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 153

9.4 Weld Lens & Weld Shield Assemblies � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 154

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Checklist, Maintenance, and Pre-Dive Inspections � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 163

Appendix A2 Maintenance and Inspection Procedures � � � � � � � � � � � � � � � � � � � � � � 164 Appendix 3 Supply Pressure Requirements & Tables � � � � � � � � � � � � � � � � � � � � � � � � � 166

Appendix 3 Table 1 Work Rate Expressed as Respiratory Minute Volume (RMV)* � � � � � � � � � 167 Appendix 3 Table 2 Compressor Supply Table SuperFlow® and SuperFlow® 350 � � � � � � � � � � 167 Appendix 3 Table 3 SuperFlow® 350 Regulator High Pressure Regulated Source � � � � � � � � � 169

Appendix 4 Standard Kirby Morgan Surface Supply Pressure Formula Old Method � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 169

SuperLite® 17B

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.

CAUTION

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 helmet, contact KMDSI (805) 928-7772 or by Email at info@KMDSI.com or Dive Lab Inc. (850) 235-2715 or at Divelab@aol.com

IMPORTANT: A word about this manual. We have tried to make this manual as 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 SuperLite successfully completed a recognized training course in surface supplied diving

17B diving helmet is intended for use by trained divers who have

SuperLite® 17B

WARNING

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

Kirby Morgan Dive Systems, Inc. (KMDSI) warns all divers who use Kirby Morgan diving helmets or masks 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 your Kirby Morgan diving helmet or mask, 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 Kirby Morgan diving helmets 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 helmet, even if you have experience with other diving helmets. If you have purchased the helmet 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 helmet to another diver,

be sure this manual accompanies the helmet and that the person reads and understands the manual. In addition to the manual a log book should be used to log all repairs, maintenance and use.

This helmet 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 helmet prior to diving.

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.

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

Helmet shells can be re-gel coated by authorized/certied KMDSI trained technicians that have received berglass training by KMDSI. Helmets 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 helmet log that the helmet was free of damage prior to painting. Keep in mind other KMDSI technicians can refuse to work on helmet shells that have previously been painted or repaired by non KMDSI certied persons.

SuperLite® 17B

WARNING

This manual is supplied to the original purchaser of this helmet. If you have any questions about the use of the helmet or you need another copy of this manual, contact KMDSI or your nearest KMDSI dealer. It may also be downloaded free from the KMDSI website at www.KirbyMorgan.com.

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 helmet must never be used by persons in poor physical condition, by persons with previous head, neck, or back injuries which could be aggravated by its use. The helmet should not be used by persons under the in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.

Do not use KMDSI masks or helmets 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. The SuperLite®-17B weighs approximately 30 lbs. KMDSI recommends that persons with a previous neck or back injury seek professional medical approval prior to engaging in surface supplied diving operations using the SuperLite®-17B. Use of the SuperLite®-17B with a pre-existing physical/ medical condition may result in death or serious injury.

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

Components requiring lubrication, should only be lubricated with oxygen compatible lubricants such as ChristoLube®®, Flourolube, or Krytox®. Lubricants must be used sparingly and should not be mixed with other lubricants.

The information contained in this manual is intended to aid the user in optimizing the performance of this helmet. 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.

SuperLite® 17B

WARNING

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

procedures. Failure to complete all pre-dive checks could result in helmet failure due to problems with the incorrect set-up of the equipment. This could lead to serious personal injury or death.

Always read the Material Safety Data Sheet (MSDS) for any chemical - adhesive, cleaning agent, or lubricant - used on your Kirby Morgan helmet. Some of these chemicals may cause serious bodily injury or death if used improperly or without the proper personal protective 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 helmet, contact KMDSI (805) 928-7772 or at KMDSI@KirbyMorgan.com or Dive Lab Inc. (850) 235-2715 or at Divelab@aol.com

SuperLite® 17B

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.

SuperLite® 17B

™

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 Band Mask frame is constructed of hand laid ﬁberglass. The head harness is a molded, strong tear resistant neoprene rubber.

The hood, which attaches to the mask frame with welded stainless steel bands, provides warmth for the divers head as well as pockets for the earphones. The communications connections can be either a male waterproof plug in type or bare wire posts. Both this mask and the KMB 28B feature the new Tri-Valve™ Exhaust System.

The KMB 28B Band Mask (not shown) is very simi- lar 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

SuperLite® 17B

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

SuperLite® 17B

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 37

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

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.

SuperLite® 17B

SuperLite

approved and ™ marked

Kirby Morgan 47

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.

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

The helmet also features the SuperFlow

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

approved and ™ marked

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 Demand Valve, with it’s fully adjustable balanced piston is a breakthrough design that exceeds the requirements of all government or other testing agencies.

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 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.

SuperLite® 17B

™

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 QuadValve™ 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 a stainless steel version of our new REX regulator, which offers the best performance of any 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.

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.

SuperLite® 17B

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

SuperLite® 17B

WARNING

CAUTION

WARNING

Chapter 2

Description & Operational Specications - SuperLite

This manual is our effort to explain the operation, maintenance and use of the SL 17. 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 commercial diving helmet that they have not previously used, or trained in, prior to use on the job.

-17B

This section includes a detailed description of the SuperLite

-17 as well as important operational

speciﬁcations.

2.1 CR Marking

The helmet meets or exceeds all standards established by Dive Lab of Panama City, Florida, and is CR (Commercially Rated) marked.

2.2 CE Certication

The helmet 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 B). It is fully CE marked with demand regulator SuperFlow and P/N 510-747.

Category of PPE: III

and oral nasals P/N 510-690

2.2.1. CE Marking

On the frame of the helmet the CE mark is afﬁxed.

EN250:2000 EN250/A1:2006

EN15333-1:2008 CLASS B

HELMET MODEL:

YEAR OF PRODUCTION:

CE Mark

KIRBY MORGAN

DIVE SYSTEMS, INC.

1430 Jason Way,

Santa Maria, CA 93455

0496

In the mark the data reported are the following:

1. the name and the address of the manufacturer;

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

3. PPE model;

4. the year of production;

5. CE marking:

;

6. number of notiﬁed body.

The user cannot:

• remove the mark from the frame of the helmet;

• modify or counterfeit the data reported on the mark.

The helmet 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 com-

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.

pressed air.

SuperLite® 17B

DANGER

WARNING

2.2.2. Notied 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 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 (183m).

2.3 Product Specications

Weight: 29.03 pounds Helmet Shell: Fiberglass, polyester resin, and carbon ﬁbers Control Knobs: Polyurethane Lens: Clear polycarbonate Neck Dam: Neoprene O-Rings: Buna-N Head Cushion: Nylon bag ﬁlled with #4 Polyester foam The recommended lubrication type for breathing gas mixtures containing oxygen percentages greater than 50% is Christo-Lube®®, Krytox Halocarbon. Helmet gas train components being used with gas mixtures containing less than 50% oxygen can be lubricated with food grade silicone lubricant such as Dow Corning

Never use aerosol-propelled sprays near the face port of any Kirby Morgan diving helmet. 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.

111.

, Tribolube® and

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.

The required supply pressures for the SL-17 equipped with the SuperFlow

350 regulators are listed in the

appropriate supply pressure tables in Appendix 3.

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

and SuperFlow® 350 regulators. It is important that users understand how to use the tables. For further information on supply requirements for the SL-17 or any Kirby Morgan helmet or mask check the Kirby Morgan website at www.kirbymorgan.com.

When the helmet 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.

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

2.4 Regulator Performance

-17

The demand regulator and side block assemblies have a maximum design pressure of 250 psig (17.2 bar) over the ambient pressure, higher pressures could lead to component failure resulting in serious injury.

The regulator on the SuperLite®-17B offers very good performance. The helmet has been tested at Dive Lab in Panama City, Florida, as well as by other the United States Navy’s Experimental Diving Unit and other independent testing laboratories.

2.5 Cage Code

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

Decompression diving always involves the

DANGER

WARNING

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 SL 17 cannot prevent this type of injury.

It is important for the user/diver to take excessive currents into consideration. The Quad-Valve™ Exhaust PN#525-759 is now standard on the SuperLite 17B. Unlike the old latex double exhaust, the quad system is not limited to a maximum depth of 150 FSW (46 msw) due to exhalation pressure.

-Temperature Limitations: Use at water temperatures below 33°F (1°C) requires the use of hot water shroud PN# 525-100 and hot water to help prevent icing of the demand regulator.

SuperLite® 17B

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.

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.

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

at water temperatures less than 60°F

(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. 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.

Only equipment certiﬁed and tested according to EN 250/E DIN 58 642 may be used with the SL 17 helmet when conducting diving operations in European EC compliant countries.

The 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.

2.7 Helmet Features

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

The SL 17 was developed in the late 1970s and it is still one of the most popular diving helmets in the world, a tribute to its timeless design.

The SL 17 incorporates an innovative locking system and the SuperFlow which provides an outstanding breathing gas ﬂow during peak work output.

The helmet consists of two pieces: the helmet shell/ helmet ring and the neck dam/yoke assembly. The head cushion and yoke gives the diver a secure ﬁt in the helmet. The ﬁt and balance seats the helmet comfortably for long periods of time even when working in the face down position.

adjustable demand regulator

SuperLite® 17B

WARNING

Port whisker wing

The Quad- Valve™ Exhaust is standard

equipment and recommended for

contaminated water diving.

Quad exhaust cover

Whisker clamp

Starboard whisker wing

Exhaust body

Exhaust valve

Whisker exhaust valve insert

Exhaust main body

Exhaust valve

The SL 17 is conﬁgured to receive the umbilical over the shoulder.

In the past, the optional Double Exhaust System (Part # 525-102) was available to reduce the possibility of back ﬂow of water and contaminants into the helmet. This system has been used successfully for diving in biologically contaminated environments for many years. To further reduce the possibility of water intrusion regardless of the exhaust system being used, the diver should avoid working in an inverted position.

The double exhaust was replaced by the QuadValve™ System. The unique design of the QuadValve™ helps keep exhalation resistance low while maintaining excellent watertight integrity.

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. For more information see the book “Diving in HighRisk Environments” by Steven M. Barsky.

SuperLite® 17B

CAUTION

lowing is a general description of the features of the SL 17.

When diving in heavy current (i.e. exceeding 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 Quad-Valve™ Exhaust system will help prevent water intrusion when diving in heavy currents. Unlike the old double exhaust, the Quad-Valve™ does not limit the diving depth.

The Quad-Valve™ exhaust system is now standard equipment for the SL 17. This superior exhaust system has exceptionally low exhalation resistance, and helps to keep the helmet free of contaminants in polluted water. The Quad-Valve™ isolates the breathing system from the surrounding water with a four valve, low breathing resistance design (Patents Pending).

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

1) The ﬁberglass shell face port (or view port) area remains unchanged. The side block and bent tube assembly that transports air/gas to the demand regulator from the side block are also the same. Most of the components in these areas are interchangeable between the 17B and models 27, 37, 47, and 57.

2) The neck dam on the SL 17 is secured by the neck clamp. Replacement neck dams install easily.

3) The head cushion attaches just inside the bottom of the helmet, keeping it in place when the diver dons the hat. The standard head cushion consists of a brushed nylon bag with an open cel polyester foam inside. Only genuine Kirby Morgan SL 17 head cushions should be used to ensure proper operation and comfort.

4) The handle that is ﬁtted to the top of the SL 17 and the port weight are areas that can be used as mounting brackets for lights, TV cameras, etc.

2.8 General Description

2.8.1 Helmet Shell

The helmet shell is fabricated of noncorrosive, rigid ﬁberglass which will not carry an electrical charge. This shell is the central structure for mounting all the components that make up the complete helmet. It is designed to allow easy replacement of parts when necessary. Any repair to the helmet shell must be done at an approved KMDSI repair center.

Other helmet features which are common to all KMDSI helmets include:

• the face port and retainer ring

• basic communications components

• the oral nasal mask

• the nose block device

• the air train

• most demand regulator components

Many of the breathing system components on these helmets are also compatible with the KMB 18B and 28B. This helps reduce the inventory of spare parts that must be carried by commercial diving companies.

Each step of the manufacturing process is carefully controlled to assure the customer of a high quality, durable helmet that will function properly. The fol-

2.8.2 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.

It prevents the ﬂow of gas out of the helmet to the umbilical in the event of a sudden lowering of pressure in the supply hose. This can happen due to an accidental break in the hose or a ﬁtting near the surface. Not only would the Auxiliary 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.

SuperLite® 17B

Defog Free Flow Valve Knob

Helmet Shell

Rear Weight

Sideblock

EGS Valve

Handle

Port Retainer

Oral Nasal Mask

Equalization Device

Non-Return Valve

Weight

Neck Dam

Neck Clamp Assembly

Quad-Valve™ Exhaust

(standard on all Kirby Morgan 37

helmets from 2005 on)

Regulator Adjustment Knob

Purge Button

Latch Catch Mechanism

™

The SuperLite® 17B helmet

SuperLite® 17B

WARNING

Adjustment knob

Regulator body

Diaphragm

Cover

Clamp

Inlet valve

Adjustment shaft

Packing nut

Piston

Spacer

Roller lever

Spacer

Nut

Inlet nipple “B”

Retaining pin

Spring

Washer

Inlet nipple “A”

Retaining clip

Jam Nut

Exhaust Valve

Washer

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).

Gas Flow To Air Train

Main Gas Supply

Gas Flow To Regulator

Auxiliary L.P. Port

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 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.

Returning to the side block assembly: the other passage for gas is to the demand regulator. It goes to a bent tube assembly that connects to the inlet nipple of the demand regulator. The ﬂow of gas in the demand regulator assembly is controlled by the inlet valve that supplies gas to the diver on inhalation “demand” only, and shuts off during the exhalation cycle.

The SuperFlow

demand regulator senses the start of the divers inhalation and opens the inlet valve, matching the diver’s need. The regulator continues to match the diver’s inhalation as the rate increases, peaks, then ebbs and stops.

When the diver exhales, the supply gas stays off as the exhalation gas ﬂows through the regulator body, out the regulator exhaust valve, through the Quad-Valve™ whiskers, and out into the water. The whiskers deﬂect the exhaust bubbles away from the face port to keep the diver’s view clear.

All KMDSI Helmets and Band Masks are equipped with a multi-turn demand regulator adjustment knob. This adjustment knob allows the diver to make corrections to compensate for a wide range of incoming gas supply pressures. See the section in this chapter

regarding appropriate supply pressures.

Both sources of gas ﬂow through the same passage in the side block body to two exits. One exit is always open to supply gas to the demand regulator assembly. The other exit is to the defogger valve (free-ﬂow valve) assembly.

The diver controls the ﬂow of gas through the defogger system with the control knob. The gas enters the helmet and ﬂows through the air train which directs the gas onto the face port to help eliminate or clear fogging of the faceplate that forms from the diver’s warm breath.

The ﬂow continues out through the water dump (helmet exhaust) valve, or into the oral nasal by means of the valve, then into the regulator and out through the regulator exhaust to the Quad-Valve™ whiskers. The diver can breathe from this ﬂow of gas if the demand regulator malfunctions.

The SuperFlow® Demand Regulator

SuperLite® 17B

DANGER

CAUTION

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

This adjustment device is not intended as a minimummaximum device. Minimum and maximum applies to supply pressure only. The adjustment knob should be adjusted by the diver to be at the easiest breathing setting at all times. The exact number of turns required is dependent on the supply pressure.

The regulator adjustment knob should be adjusted to the easiest breathing setting at all times. Adjusting the regulator further in than necessary to keep from freeowing increases breathing resistance.

The side block on the helmet 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.

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.

Diving a KMDSI helmet or BandMask

with a bias setting greater than that just necessary to keep the demand valve from free ﬂowing increases the work of breathing and reduces the diver’s ability to perform heavy work.

WARNING

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

Alignment Sleeve

SuperLite® 17B

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

Helmet Shell

Strap Guide

Hinge

Head Cushion

O-ring

Chin Strap

Neck Dam

Safety Pin

Neck Clamp

Latch Catch Body

Yoke

Rear

Yoke Strap

The Neck Dam and Neck Clamp Assembly

Hinge Tab

SuperLite® 17B

WARNING

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

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

2.8.3 Emergency Gas Supply System (EGS)

KMDSI strongly recommends that the working diver carry an independent supply of compressed gas (or air) ﬁtted with a ﬁrst stage regulator and hose that is connected to the inlet of the Emergency Gas Valve (EGV).

The KMDSI Overpressure Relief Valve, (part number 200-017) is fully adjustable and rebuildable and has been designed to relieve any over-pressurization of the ﬁrst stage regulator greater than the desired setting.

Every bailout (Emergency Gas System or EGS) ﬁrst stage regulator must be ﬁtted with an overpressure relief valve to prevent over pressurization of EGS L.P hose and possible total loss of emergency supply gas in event of regulator failure.

The over-pressure relief valve should

be installed on every ﬁrst stage used

for bailout.

KMDSI Part #200-017

NOTE: This valve can be adjusted for various relief pressures.

2.8.4 Helmet Attachment to the Diver

On the SuperLite

-17 A/B, the helmet shell has an O-ring seal around the base of the ﬁberglass rim. The helmet is held in place on the diver’s head by the yoke/neck clamp, which mounts on the diver’s neck and seals to the bottom rim of the helmet.

The adjustment of this clamp is critical to the safe use of the helmet. Periodic adjustments to the clamp MUST be made as the neck dam ages or if you convert to a dry suit mount. The adjustment should always be checked if the yoke clamp assembly is used on different helmets. YOU SHOULD NEVER HAVE TO FORCE THE CLAMP SHUT.

Do not dive unless the latch catch is properly engaged and the strap guide and yoke strap are in position. Failure to use these devices to properly secure the helmet on the diver’s head could lead to drowning, which may result in severe personal injury or death.

The head cushion is made from layers of open cell foam inserted in a head shaped nylon bag. Adding

Be sure the Emergency air/gas rst stage regulator is tted with a relief valve for over-pressurization of the emergency

or subtracting foam layers from the bag can adjust the ﬁt of the head cushion. The head cushion must be adjusted correctly for the helmet to ﬁt properly.

gas supply hose. A leaky rst stage can overpressure the hose resulting in hose rupture. This would cause a loss of the entire emergency gas supply, with possible serious injury or death.

2.8.5 Sealing Arrangement

The neck dam is available in several sizes and is fabricated in a cone shape. The neck dams on all SuperLite

-17A/Bs are made of foam neoprene.

The neck dam seals against the diver’s neck. The ﬁt of the neoprene neck dam may be made larger by trimming 1/4” off the circumference. Only trim a

SuperLite® 17B

WARNING

maximum of 1/4” at a time; trimming too much will result in a loose ﬁt.

NOTE: If you must trim the neck dam, be careful not to trim off too much material. The neck dam must t snugly. While it may be a slight bit uncomfortable out of the water, and may feel snug, once in the water the neck dam will loosen slightly.

Pulling the neck dam over the diver’s head can be difcult. Stretching (expanding) the seal and placing it part way over the head can help reduce the force needed to install the seal. Proper training is necessary to install the neck seal over the diver’s head and onto their neck. Although the possibility is very remote, injury may result if this procedure is not done properly. If a diver does not know how to don the neck dam, they must seek proper instruction before proceeding.

2.8.6 Reducing Carbon Dioxide

It is important to minimize the volume of air/gas space that the diver is breathing through. Carbon dioxide (CO2) can build up if proper ﬂushing does not occur. A silicone oral nasal mask is located inside the helmet that ﬁts over the diver’s nose and mouth.

Helmet shell

Handle

The face port is held in position by the port

retainer.

O-ring

Port retainer

Kidney plate

Port

Wing

SuperLite® 17B

WARNING

Equalizing Device

Oral/Nasal Mask

Valve Body

Regulator Mount Nut

O-ring

Oral/Nasal Valve

The oral nasal mask, valve, and equalizing device.

The oral nasal attaches to the regulator mount nut. This separates the breathing gas ﬂow from the rest of the dead-air space inside the helmet, subsequently reducing the potential for carbon dioxide buildup.

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

2.8.7 Communications

In the SL 17, both earphones and microphone are wired in parallel to the communications system. The communications can be equipped with either a waterproof connector, or binding posts for bare wire connection.

Electrical signals are sent to, and received from, the surface through the umbilical wires. An ampliﬁer boosts the signals to the desired volume for the surface and the diver.

2.8.8 Equalizing the Middle Ear

A nose block device allows the diver to block their nose to provide an overpressure in their middle ear for equalization. The blocking pad on the inside of the oral nasal mask is attached to a shaft which passes through a packing gland to the outside of the helmet.

level inside

level can cause

The yoke and latch catch assembly must work properly

together.

Neck Dam

Safety

Hinge

Neck Clamp

Latch Catch Body

Yoke

Rear Hinge Tab

SuperLite® 17B

DANGER

A knob attached to the end of the shaft can be pushed in to slide the pad under the diver’s nose.

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

2.8.9 Face Port or Viewing Lens

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

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

The Latch Catch is designed so that in the event that the pin is pulled and the yoke drops down, the neck clamp will remain closed. It’s like two separate locks.

Old latch catch assembly. This device should not be used any

longer.

2.8.10 Latch Catch Assembly, Pull Pin

The latch catch assembly includes the pull pin and safety pin. The purpose of this assembly is to ensure that the neck clamp assembly remains securely fastened around the base of the helmet, so the helmet remains on the diver. This arrangement functions in a similar manner to the old “dummy pin” on a heavy gear helmet.

All SuperLite

-17A/B & U.S. Navy MK-21 Mod. 0 & Mod. I Helmets sold by KMDSI now have the Pull Pin Latch Catch Assembly”, Part Number 505

-010 (brass) or 505-011 (chrome)on the helmet to lock the Yoke in position. The mounting system for the Pull Pin Latch Catch Assembly is identical to the old style Push Pin Latch Catch Assembly, # 505-015 which is now obsolete.

Each Pull Pin Latch Catch Assembly is shipped with a Safety Pin, Part Number 535-900 which we recommend be used when the user requires a two step release system on the helmet. It can be used with or without a cord attached to prevent loss of the Safety Pin when not in use. All Pull Pin Latch Catch Assemblies, P/N 505-010 or 505-011, which are sold as spare or replacement parts include this Safety Pin, P/N 535-900.

Current latch catch assembly with safety pin.

2.9 Accessories

2.9.1 Eye Protection for Welding

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

The weld lenses are standard 2 x 4 1/2 inches or 4 1/2 x 5 1/2, identical to the lenses used in topside welding hoods. They may be replaced quickly without tools.

SuperLite® 17B

CAUTION

The KMDSI Welding Lens for the SuperLite®-17 (KMDSI

Part #525-403)

The hot water shroud is recommended for deep mixed gas

diving.

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

face port O-ring to leak.

The KMDSI Weld Shield Assembly (KMDSI Part #525-400)

2.9.3 Special Regulator Tools

Four special tools are available for internal adjustment of the demand regulator assembly (105); the inlet valve holder, regulator adjustment wrench, socket wrench and castle wrench. These three wrenches make regulator adjustment much easier. The tools come in a convenient, wallet sized pouch with instructions. (Part #525-620). This tool kit ships standard with every Kirby Morgan helmet and band mask.

2.9.2 Hot Water Shroud

KMDSI manufactures a hot water shroud kit for the SL 17. The shroud completely encases the side block, bent tube assembly, and demand regulator to provide efﬁcient gas heating for especially deep or cold dives. Heating the diver’s breathing gas is es-

The Regulator Tool Kit, Part #525-620.

pecially important in cold water or when breathing mixtures of helium and oxygen.

2.10 Helmet Transport And Storage

• the kind of package is a cardboard box with air

ﬁlled pillows with styrofoam inserts to stabilize the helmet;

• the weight of the box is usually 40 pounds (18

Kg);

• the package dimension is 18 × 18 × 15 inches

(460 × 460 × 380 mm);

• one helmet is packed per box;

• the helmets are sent to dealers by plane and

truck. Depending on how the dealer wants it sent.

SuperLite® 17B

Packaging Step 3

Packaging Step 1

Packaging Step 2

Packaging Step 4

Packaging Step 5

SuperLite® 17B

Packaging Step 6

2.10.1 Helmet Carrying Bag

To help protect your SL 17, the helmet carrying bag should be used to transport and store your helmet between jobs.

Look for the Kirby Morgan logo on Kirby Morgan products.

This is your assurance that you are getting genuine Kirby

Morgan replacement parts.

The KMDSI Helmet Bag, Part #500-901.

The KMDSI bag is made from extra heavy duty, black, ripstop nylon. The bottom of the bag is padded for additional protection. Grommeted drain holes allow the bag to breathe. The bag is also equipped with large carrying straps and side pockets. The bag is not intended for shipping your helmet as air cargo. The part number for the bag is Part #500-901.

2.11 Use of Kirby Morgan Original Replacement Parts

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

SuperLite® 17B

WARNING

Chapter 3

Operating Instructions

This manual is our effort to explain the operation, maintenance and use of the SuperLite®-17B. 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 helmet that they have not previously used or trained in, prior to use on the job.

3.1 Introduction

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

A proper training program in a calm, clear body of water should be undertaken. If the diver has not used the SuperLite these helmets without proper training.

-17B. The use of these diving helmets will

-17B before, they must not dive with

Kirby Morgan diving helmets are not intended for use with a self contained gas supply (scuba). There is no provision for surface swimming once the scuba air supply is depleted. This could lead to suffocation or drowning, which could be fatal.

However, divers that are familiar and trained in the use of previous Kirby Morgan masks; i.e., KMB 8, 9, 10, 18, 28, the Navy MK. 1 mask, Navy MK. 21 helmet, or the Navy Mk. 22 mask, or other Kirby Morgan helmets, will ﬁnd that all Kirby Morgan diving helmets and masks have the breathing system controls located in the same position. The operation of this helmet will also be similar. The diver must be tended at the surface at all times by a trained, qualiﬁed commercial diving tender.

3.2 Design Purpose

All Kirby Morgan diving helmets are designed for use with an umbilical.

The umbilical is usually composed of at least a gas or air supply hose and communication wire, assembled with waterproof tape (and in some umbilicals wound similar to strands in a rope) to form a single unit. Some umbilicals also have included a hose for hot water, a pneumofathometer hose, and a strength member, such as a cable or strong line.

It is strongly recommended that the air/gas umbilical be married to a strength member in a manner that allows the strength member to receive the strain. This will help reduce the possibility of umbilical and umbilical ﬁtting fatigue and possible failure.

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

SuperLite® 17B

WARNING

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

The diver must be tended at the surface at all times by a trained, qualiﬁed commercial diving tender. Never dive without a qualiﬁed tender holding your diving hose.

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

Decompression diving always involves the risk of decompression sickness. Omitted decompression due to loss of gas supply or other accidents can cause serious injury or death. The use of the KM 37 or 57 cannot prevent this type of injury.

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

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

In countries that have adopted C.E. standards only C.E. certiﬁed supply systems and components may be used in conjunction with the helmet.

KMDSI manufactures a complete Air Control System, the KMACS 5™ with or without integrated communications as well as pneumofathometer. This portable system can be operated on either a high pressure air supply or on a low pressure compressor. The Air Control System has a specially designed high pressure regulator that reduces high pressure air and provides an adequate ﬂow to support divers to a depth of 130 FSW (40 msw)

The helmet demand regulator and side block assemblies have been designed to operate with a supply pressure from 90 p.s.i.g. (6.2 bar) over ambient pressure to 225 p.s.i.g. (16 bar) over ambient pressure. This wide operating range allows ﬂexibility when using various gas supply systems.

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

3.3 First Use of Your Kirby Morgan

WARNING

Diving Helmet

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

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

warranty card on ﬁle at KMDSI.

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

3.4 Initial Adjustments to Your Helmet

Before using the helmet for the ﬁrst time, it must be checked and adjusted for proper ﬁt. There are several adjustments that must be made to provide a more comfortable ﬁt when wearing the helmet.

3.4.1 Head Cushion

The ﬁt of the helmet is primarily determined by the layers of open cell foam that ﬁll the head cushion bag.

The center top/rear foam in the SuperLite very dense to reduce compression and spring-back. This reduces the tendency of the helmet to ride up when underwater. Do not replace this rigid foam with a soft foam. A softer foam is used on the sides and around the bottom of the head cushion.

-17B is

SuperLite® 17B

The head cushion must ﬁt properly. You can add or remove foam to adjust the ﬁt.

with scissors to provide a better ﬁt, or more foam can be added to give a tighter ﬁt.

The head cushion ﬁt is extremely important. A proper ﬁtting headliner keeps the nose and mouth securely in the oral nasal allowing a good seal and providing maximum regulator performance and CO2 washout.

On the SuperLite from the head cushion bag. The chin strap bolts directly to the helmet and is secured around the outside of the head cushion in the chin area. Ensure the chin strap is used.

If the chin strap is not fastened or positioned properly, the helmet can ﬂoat up on the diver’s head. This can make the helmet very uncomfortable and may pull

-17B there is a chin strap separate

The diver’s head can be moved forward into the oral nasal mask by adding layers of additional foam at the rear of the head cushion. The diver’s head can be moved up or down in the helmet by decreasing or increasing the foam pads at the top of the head cushion.

Usually, a diver with a small head will use all the foam that comes with a new hat. A diver with a larger head will need to remove a layer of foam in the center top and back of the head cushion. The foam may be cut

On older SuperLite®-17B helmets the chin strap is part of the head cushion. All helmets should be changed to have the chin strap bolt directly to the helmet.

Old style head cushions with chinstraps may be used, but the chin strap that is bolted to the helmet MUST be used. We recommend that the old head cushion chin strap be removed (i.e., cut off) to prevent confusion.

SuperLite® 17B

WARNING

CAUTION

WARNING

the oral nasal mask away from the face. Additionally, in the unlikely event the helmet was separated from the neck clamp/yoke assembly, the helmet will be retained.

3.4.2 Adjusting the Neck Dam

If your helmet is new, or any time you replace the neck dam, it must be adjusted to ﬁt you. New neck dams are cone shaped and will probably be too tight if not properly trimmed.

Trim the neck dam until it is still snug. (You can

Never dive with a neck dam that is too tight. A neck dam that is too tight could cause the diver to pass out due to pressure on the carotid artery in the neck. This could lead to severe personal injury or death.

also stretch it by sliding it over a SCUBA tank and allowing it to sit overnight.) If you still cannot get the proper ﬁt by stretching the neck dam, it must be trimmed further. Do not trim more than 1/4 inch at a time.

Avoid trimming neoprene neck dams too much. Neoprene neck dams will loosen over time as they are used and the cells of the foam neoprene break down. If you trim the neck dam too much it will be too loose and will leak. Trim the neck dam until it is snug, then stretch it before use.

Do not breathe the fumes from uncured neoprene cement. These fumes are dangerous and can cause unconsciousness. They can also cause long term damage to body

tissue. Read and follow all precautions listed on the neoprene cement can. Allow neoprene cement to cure for a minimum of 24 hours before using the helmet.

Trim the neck dam until it is still snug. Trim only a maximum of 1/4 inch off the circumference of the neck dam at a time. When you are done, the neck dam must be tight enough so that it does not leak. This may feel a bit snug out of the water, but will be more comfortable underwater once the neoprene compresses from increased pressure.

Trim the neck dam with the largest, sharpest scissors available, in order to make as few cuts as possible. There must be no jagged edges on the neck dam or it may eventually tear. Sew and/or glue the edge of the original seam to keep the stitching from unraveling.

As the neoprene neck dam ages, it will become looser, due to a natural breakdown of the cells. This is particularly true if the helmet is locked in and out of a bell or saturation system. As the neck dam becomes worn it will need replacement to ensure that it seals properly.

A neoprene neck dam that is too large may be tightened up by cutting a wedge out of the open end. Glue the cut back edges back together using wet suit cement, then sew the glued seam together. Be sure to

New neck dams must be adjusted so that they ﬁt properly.

allow the modiﬁcation to the neck dam 24 hours to dry and solvents to off gas.

3.5 Pre Dress-In Procedure

WARNING

Before dressing in for a dive, inspection of the helmet systems must be made to be sure it is in proper working order. This must be done well in advance of the dive so any problems can be ﬁxed without delaying the dive. The following steps are part of the recommended daily maintenance.

SuperLite® 17B

Binder head screws are used in this application for their self locking characteristics. Overtightening may strip out the threaded inserts in the helmet shell.

3.5.1 Pre-Dive Visual Inspection

Visually inspect the exterior and interior of the helmet.

1) The demand regulator cover assembly should not have excessive dents or dents deeper than 1/4”. The purge button must operate freely and should have no less than 1/16” and no more than 1/8” inward travel before gas ﬂow is heard.

There must be no holes in the neck dam. If there are any holes in the neck dam the helmet could leak or ood. In addition, the demand regulator will not operate properly. Drowning could result.

2) The neck dam must not be torn or punctured, and properly trimmed to ﬁt.

3) Inspect the O-ring on the bottom of the helmet shell. The O-ring must be in place and undamaged.

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

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

The O-ring on the base of the helmet shell on the SuperLite place and in good condition. Without a proper functioning O-ring the helmet will leak and possibly ood. Drowning could result.

10) Make sure the head cushion is properly fastened (snapped) inside the helmet to the snap tabs.

11) Make sure the chin strap is the new version that bolts directly inside the helmet with tab bolts. If the older system is used where the chin strap is part of the head cushion, replace it as soon as possible.

12) Make sure the strap guide and yoke strap that help secure the helmet are in place and in good condition.

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

-17B must be in

6) Be sure the communications wires are hooked up and tested.

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

8) Make sure the head cushion is properly fastened inside the helmet.

9) Check the screws on the port retainer . They must be adjusted to the proper torque setting speciﬁcations noted in Appendix 1 of this manual.

SuperLite® 17B

WARNING

3.6 Preparing the Helmet for Diving

3.6.1 Clean Face Port

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

3.6.2 Check Moving Parts

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

Inspect the yoke/neck clamp and latch catch mechanism. They must engage and disengage properly. If the Yoke/Neck Clamp Assembly has been used with a different helmet, it MUST be readjusted to ﬁt the current helmet.

3.6.3 Check Communications

Check the communications system for proper operation. Put the helmet on and talk to an assistant on the ampliﬁer. If you are by yourself, with the helmet off take the helmet near the ampliﬁer and tap on each earphone and the microphone, listening to the taps on the ampliﬁer/speaker.

Talk into the ampliﬁer/speaker feeling the vibration on each earphone and the microphone with your ﬁngertips. Check the ﬁt and tightness of the comm module mount nut.

3.6.4 One-Way Valve Check

The one-way valve must be tested daily, prior to commencement of diving operations. There are two ways to test the valve

1) Prior to attaching (or pressuring up) the umbilical, close the emergency valve knob, attach and pressure up the emergency hose. Shut off the defogger control knob and screw in the adjustment knob on the regulator all the way.

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

You can test the one-way valve either by attempting to suck air through the valve with the steady-ﬂow valve open, or by connecting the bail-out to the main supply (with the steady ﬂow and regulator adjustment closed) and opening the emergency valve to check for back-ﬂow.

3) You can also test the one-way valve by opening the steady-ﬂow valve and attempting to suck air back through the one-way valve. This is also a good way to test.

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

SuperLite® 17B

WARNING

3.7 Emergency Gas System (EGS)

If the diver’s main gas supply fails, the diver must have another source of gas that will enable them to return to the dive station or to a point where a normal gas supply can be reestablished. For this reason, an emergency gas supply (bailout) cylinder must be used on all dives. The bailout cylinder is normally worn on the back using a combination backpack and lifting harness.

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

lower rear or front, while larger tanks are usually mounted vertically in the center back similar to a Scuba diver’s tank. Some harness designs incorporate a cloth enclosure into which the tank ﬁts. The entire tank, valve, and regulator are enclosed in fabric. This helps to prevent snagging.

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

The diving harness

must have a provi-

sion for attaching the

emergency gas supply

and a place to attach

the diver’s umbili-

cal.

Diver donning a complete bail-out system.

Most commercial divers wear a harness (separate from the weight belt) that is used for several purposes. The harness is ﬁtted with large metal rings (usually brass or stainless steel).

The umbilical is hooked into one of these rings to keep any strain off the helmet. In addition, the rings on the harness are used to hang tools and other equipment. Usually the harness is also designed to provide a means of lifting an unconscious diver from the water. This harness is the best method of securing the emergency breathing gas to the diver.

A small tank can be mounted horizontally on the

The umbilical should always be attached to the harness to avoid a direct pull on the diver’s helmet.

SuperLite® 17B

WARNING

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

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

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

European C.E. ONLY

In European countries that have adopted C.E. certiﬁcation, only C.E. certiﬁed cylinders are allowed to be used and must have a minimum charged capacity available to the diver of 1400 N/l (50 scf). The emergency gas supply must only be ﬁtted with a KMDSI ﬁrst stage regulator and have a KMDSI over pressure relief valve installed (Part # 200-017).

pressure to less than 225 p.s.i.g. (16 bar) ambient diver pressure. The KMDSI SuperFlow

First Stage SCUBA regulator (Part #305-161) is an excellent device for this use.

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

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

The ﬁrst stage regulator must have at least two low pressure ports. One port is used for the connector hose to the emergency valve and the second is used to install an overpressure relief valve (Part #200-017). If the ﬁrst stage develops a leak, the full pressure of the tank could be placed on the low pressure hose. This could cause the hose to burst. The overpressure relief valve will bleed off any leak.

Make sure the emergency valve knob is turned off, otherwise the emergency gas supply will be used up without the diver’s knowledge. Once the emergency supply hose is connected, the tank valve is turned on to pressurize the hose. In the event of an emergency due to a loss of the main gas supply, the emergency valve knob located on the side block is turned on supplying gas to the side block assembly and the regulator.

The relief must be adjusted to start lifting at approximately 20 p.s.i.g. (1.4 bar) above the regulator intermediate setting. The purpose of the relief valve is to allow pressure to vent off in the event the ﬁrst stage regulator develops a leak or creeps. Without a pressure relief valve, the hose could rupture and the emergency gas supply would be lost.

The emergency air/gas tank must be ﬁtted with a good quality ﬁrst stage regulator to reduce the

Never dive without an over pressurization relief valve installed on the EGS regulator (1st stage). Without the relief valve if the EGS regulator develops an internal leak, or carries-away, the full pressure of the EGS cylinder would be placed on the low-pressure EGS hose and the Emergency Valve. This could cause the low-pressure hose to burst resulting in the complete loss of the EGS system.

SuperLite® 17B

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

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

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

Possible Emergency Gas Supply Cylinder & EGS Valve Configurations

Configuration Cylinder Valve EGS Valve Advantages/Disadvantages

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

• First stage won’t normally flood Disadvantages

• If hose or first stage leaks some or all EGS gas will be lost

Configuration 2* Off On Advantages (No pressure in • One valve to open regulator) • No loss of gas from cylinder if hose leaks or regulator leaks Disadvantages

• First stage will flood and must be serviced after each day of diving

Configuration 3* On momentarily Off Advantages (Regulator pressurized then Off • No loss of cylinder gas if then cylinder valve hose or regulator leaks closed) Disadvantages

• Two valves to open in emergency

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

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

Configuration 4* Off Off Advantages

• No use of cylinder gas unless emergency occurs Disadvantages

• Regulator will flood and need service daily

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

SuperLite® 17B

WARNING

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

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

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

Some divers, keep the EGS gas cylinder valve shut during the dive. Their rationale being; in the event of an emergency, they will simply open the EGS cylinder valve thus eliminating any EGS air/gas unknowingly being lost due to either a 1st stage failure or EGS hose failure.

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

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

KMDSI strongly recommends the use of a submersible pressure gauge with every bail-out system. Not only does this make it very easy to check your emergency gas pressure prior to diving, it also allows you, in most cases, to periodically check the pressure in your system while you dive. In this way, if you have a leak, you will probably ﬁgure it out and will be able to take appropriate action.

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

Never connect a high-pressure hose directly to the EGS valve assembly, as this will transmit the full pressure of the tank to the side block. The side block is not designed for high pressure and may burst. This may result in severe personal injury or death.

3.8 Setting Up to Dive

WARNING

3.8.1 Flushing Out the Umbilical

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

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

3.8.2 Connecting the Umbilical to the Helmet

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

SuperLite® 17B

Connecting the umbilical to the helmet.

The connection between the hose and the helmet must only be made up “snug”. Excessive force will deform and ruin the adapter. A second wrench must be used when the helmet is disconnected as well, otherwise the adapter and/or the one-way valve assembly may become loose and fail to make a seal.

If you are using waterproof connectors for your com-

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

munications, take extra care in handling these pieces. To connect the male and female parts, align the large pin on the male connector with the yellow mark on the female connector. Press the two connectors together until you hear a distinct “pop”. Do not twist the connectors. Tape the two connectors with a bit of electrical tape to prevent them from pulling apart.

Always use two wrenches to connect the umbilical to the adapter. Use the correct size wrenches whenever possible to avoid damage to the ﬁttings.

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

Connecting the waterproof connectors.

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

SuperLite® 17B

WARNING

3.8.3 Opening the Breathing Gas Supply to the Helmet

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

Slowly bring up the gas pressure to the helmet to 150 (10.2 bar). Slowly back out on the regulator adjustment knob until a slight free ﬂow develops, then turn the adjustment knob in (clockwise) until the free ﬂow just stops.

To properly check the breathing system you must completely don the helmet.

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

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

Make sure that the regulator adjustment knob is screwed in and the steady-ﬂow valve is closed before opening the air supply to the helmet.

3.8.4 Fogging Prevention

A thin ﬁlm of anti-fogging solution may be applied to the interior of the polycarbonate face port prior to the dive to help prevent fogging during the dive. A mild liquid dish washing soap, or other commercially available anti-fogging solutions, may be applied with a soft rag to the interior of the port.

The diver should use a solution which has been found satisfactory in the past. However, do not use an aerosol spray on the polycarbonate lens. The propellants in some aerosol dispensers cause damage to the lens.

SuperLite® 17B

WARNING

3.8.5 Donning The SuperLite

-17B

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

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

Pull the pull pin knob out, away from the helmet. While holding the knob out, lift the neck clamp handle up and out to release the tension on the clamp. Swing the handle forward, toward the front of the helmet. Slide the yoke/neck clamp assembly backwards away from the helmet until the rear hinge tab disengages from the alignment sleeve.

As a diver, to don the yoke assembly, hold the yoke/ neck clamp in your hands in front of your body. Swing the neck clamp assembly up towards your chest. Lift the entire unit over your head until the opening for the yoke is positioned at the back of your neck. Slide the yoke forward until it is centered on your neck.

Reach over your head and insert the four ﬁngers of each hand in the opening of the neck dam. Keep your thumbs on the outside of the neck dam. Spread the neck dam by pulling against the palms of each hand. Pull the neck dam over your head.

The tender must ensure the neck dam is turned so that the top edge is up and folded down (out) away from the diver’s neck.

Donning the yoke and neck dam.

If the yoke/neck clamp assembly is connected to the

Spread the neck dam and pull it over your head.

helmet, it must be removed before you can don the helmet. To release the neck clamp, you must ﬁrst remove the safety pin that engages the latch catch assembly.

SuperLite® 17B

CAUTION

Locate the ends of the chin strap before you put the helmet on your head.

Adjust the neck dam so that it is turned up and out.

The neck dam is always turned up against the diver’s neck. This is very important! With the neck

dam turned down, the helmet will vent air from the neck dam causing the regulator to free ﬂow. This will make the helmet very uncomfortable.

With the diver holding the helmet, the tender should now connect the quick disconnect ﬁttings for the bailout supply. Open the regulator adjustment knob and the defogger control knob for a steady ﬂow from both just prior to the diver dressing into the helmet.

The diver should place the helmet face port down and locate the tab on the end of the chin strap of the head cushion. Loosen the tab completely. Grab the base of the helmet with both hands while you hold the head cushion open. Lift the helmet over your head and carefully lower it.

Reach up inside the front of the helmet and tighten the chin strap until it is just snug. The chin strap tightens on the outside of the chin cushion. It does not sit against the diver’s chin directly.

Push your head into the rear of the helmet. Then, pull the helmet down and from side to side until it is comfortable on your head. Position the chin strap under your chin.

Spread the head cushion so that it is easier to don the helmet.

Pull the strap down and back towards the divers right until it is snug, but comfortable. Reach up inside the helmet and fasten the strap under the divers chin by attaching it to the Velcro tab on the right side of the head cushion.

Take care to prevent the end of the strap from becoming fastened between the helmet shell and the neck dam. Tucking the end into the helmet will ensure this. In particular, the tender should watch for this. Make sure the chin strap bolts directly to the helmet. If not,

Be sure to fasten the chin strap. If the chin strap is not fastened properly, the helmet will oat up on the diver’s head. This can make the helmet very uncomfortable.

SuperLite® 17B

WARNING

Close-up detail of hinge tab engaging alignment sleeve.

replace it at the earliest opportunity.

Lift the helmet over your head.

The rear hinge tab must engage the alignment sleeve.

Tilt your head back and push the entire yoke/neck clamp assembly backwards on your neck. This is to engage the hinge tab on the alignment sleeve. The front edge of the neck clamp should be under and past the front edge of the helmet. Keep your head tilted back, and lift the front of the helmet up with one hand.

The tender must locate the rear hinge tab on the back of the yoke. Lift the rear hinge tab out away from the helmet and up until it can slide over the alignment sleeve on the back of the helmet. Slide the tab over the sleeve.

If the hinge tab is not mounted on the alignment sleeve correctly, the yoke/neck clamp assembly could come off. Helmet ooding may occur. Drowning and death may result if the helmet oods.

SuperLite® 17B

The diver must hold the helmet down while the clamp is swung to their right to fully engage it against the bottom of the helmet. Note how the tender is supporting the clamp mechanism with their left hand.

The pull pin must properly engage the bail on the neck clamp.

The safety pin must be installed prior to every dive.

The tender next grasps the handle on the neck clamp assembly and swings it to the diver’s right. This action will open the clamp fully.

While the diver holds the helmet down, push up on the

The clamp is swung to the diver’s left. Once it passes “over-center” it will close easily,

neck clamp assembly until the clamp is completely seated against the bottom of the helmet. DO NOT USE THE HANDLE AS A LEVER TO LIFT THE CLAMP. This will damage the clamp mechanism.

KMDSI strongly recommends the utiliza-

WARNING

tion of the safety pin, Part # 535-900. This pin is inserted just below the cam-lock bail.

If a safety pin is not used, there is a possibility the clamp on the yoke latching system could be inadvertently opened during the course of the dive by unintentional depression of the plunger lock. Helmet ooding, drowning and death may result.

NOTE: KMDSI recommends that all old style “push style” pin latch catch assemblies be replaced with new Pull Pin Latch Catch part# 505-010. The old push pin latch catch assemblies are no longer available nor are replacement parts.

Additionally the pull type latch catch should also employ the use of the safety pin to avert accidental opening of the latch catch during diving operations. (Additional guidance is available by contacting Dive Lab Inc. at (850) 235-2715 or E-Mail DiveLab@ aol.com.)

SuperLite® 17B

The yoke strap is positioned underneath the handle on the helmet.

NOTE: If you are ready to dive, ensure the tender installs the safety pin before you enter the water.

While maintaining pressure on both the helmet and the clamp, swing the clamp handle to the diver’s left until it passes “over-center” and closes. Open the latch catch assembly by pulling out on the pull pin.

Lift up on the yoke assembly until the latch catch engages the bail on the neck clamp handle, and release the pull pin. The spring loaded pull pin should bottom in the latch catch assembly capturing the handle bail.

The helmet is now locked into place and the diver can test the breathing system properly.

If used, the yoke strap is now placed over the top of the helmet (but under the handle) and secured in place. The yoke strap is standard on all 17B helmets shipping after January 2004. It’s use is strongly recommended.

The loop on the adjustable end of the strap slides over the yoke on the diver's right side. Tighten the yoke strap by pulling down on the free end to help ensure the helmet stays on properly.

SuperLite® 17B

WARNING

3.8.6 Testing the Breathing System

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

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

Do not perform this test unless the diver and their tender are stationed immediately adjacent to the diver’s air manifold and you are certain the air is on to the manifold. If the diver is unable to ow air to the helmet, either through the umbilical or the bailout, they may not be able to remove the helmet easily.

To break the seal in this situation, the diver must put their hand between the neck dam and the neck, and pull the neck dam away from the neck. A tender must be standing by to assist the diver in removing the helmet if needed. Suffocation could result.

The diver must be satisﬁed that their helmet is working properly before they enter the water.

3.8.7 Sealing Integrity Check

If there is any doubt that the helmet is sealing properly, perform the following test prior to diving.

Turn the supply gas off at the dive control system and bleed the umbilical.

With the neck dam and yoke on the diver’s neck, the helmet is installed and the yoke is closed. When the diver attempts to inhale, a suction on the neck dam is formed, indicating they are achieving a good seal. The diver must then turn the air on immediately so that they can breathe. If the diver does not turn the air on they will not be able to breathe, unless the neck dam is pulled away from their neck.

To perform this test, the diver must have an assistant standing by. The assistant should be in control of the gas supply console in the event the diver needs air or they must be ready to lend a hand. The diver must be next to the dive control manifold so that the air may be turned on instantly, or the diver must be ready to run a hand between their neck and the sealing neck dam in order to pull the neck dam away from the neck to allow breathing.

WARNING

3.9 Diving Procedures

3.9.1 Standing By to Dive

The diver may wear the neck dam yoke assembly without discomfort if they are standing by to make a dive. However, the helmet itself must always be the last thing put on before the diver enters the water. Everything else must be ready to go before the diver puts the helmet on so they won’t have to support the weight of the helmet while out of the water.

3.9.2 Attaching the Umbilical to the Harness

The umbilical must now be hooked to the diver’s harness by means of a suitable clip that is bound to the umbilical. Some divers and companies prefer a quick release clip and others prefer a clip that is screwed together so the diver cannot easily remove it from their harness. The securing of the umbilical keeps the pull of the hose at the diver’s harness and not on the helmet.

SuperLite® 17B

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

3.9.3 Diver Dons Helmet

The diver dons the helmet as per this chapter.

3.9.4 Diver Check Gas Flow Systems

The diver must check out the breathing system themself as the tender ﬁnishes dressing them. Operate the defogger valve, the demand regulator, and the purge button to assure yourself of proper operation before entering the water.

3.9.5 Communications Check

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

The communications system must be functioning properly throughout the dive.

3.9.6 Diver Ready

The diver is now ready to enter the water. They should be assisted to the water if needed. If a welding lens is being used, make sure it is hinged up all the way if the diver is making a jump entry. We do not recom-

The umbilical must be properly attached to the diver’s harness.

mend jump entries. A quick overall inspection by the tender is done and the diver is given the OK.

SuperLite® 17B

3.9.7 Water Entry and Descent

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

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

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

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

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

3.10 Emergency Procedures

3.10.1 Flooding

In the event of partial or complete ﬂooding, the diver may clear the helmet quickly by tilting the helmet down and activating the defogger control knob. Pressing in on the manual purge button in the center of the regulator cover will evacuate water from the regulator, if any remains.

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

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

3.10.2 Inhalation Resistance

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

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

During the decent the communications must be checked again and the diver supply pressure should be adjusted as necessary to maintain the required over-bottom pressure. It may be necessary for the diver to readjust the demand regulator by means of the adjustment knob once at the work site to compensate for the variation in umbilical supply pressure.

3.10.3 Gas Flow Stops

A stop of ﬂow in the demand regulator usually indicates the main gas supply has stopped. The diver should ﬁrst open the emergency valve by turning the knob. If there is still no ﬂow from the demand regulator, the defogger valve knob should be opened. Keep in mind that if the defogger valve is left open, the bailout bottle will drain very quickly, particularly if the diver is deep.

DANGER

Immediately notify topside, check to insure your

WARNING

umbilical is clear and return to the diving station using the emergency breathing supply. Avoid making a rapid ascent if at all possible.

Once at the surface, or inside the bell, the diver may remove the helmet if needed. Never ditch the helmet underwater unless conditions absolutely require that.

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

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

SuperLite® 17B

3.10.4 Demand Regulator Free Flow

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

3.11 Post Dive Procedures

3.11.1 Removing the Equipment

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

3.11.2 Removing the Helmet

On the SuperLite remove the safety pin before you can remove the helmet. Slide the pin out and away from the latch catch. Release the yoke safety strap.

The tender should assist the diver by pulling out on the pull pin knob on the latch catch assembly. This will allow the let the yoke to fall away. Next grab the handle on the neck clamp assembly and pull outwards away from the helmet, until the handle is in front of the diver’s face. This action will break the seal of the neck dam around the base of the helmet and the neck dam and clamp will fall away from the bottom front of the helmet.

While having the diver tilt their head back, reach behind the back of the helmet and lift the rear hinge tab off the alignment sleeve in the back of the helmet.

When you’re wearing the helmet, once the neck clamp is open, you must reach underneath the front of the helmet and loosen the chin strap that holds the helmet in position. Then, lift the helmet over your head using both hands, one on either side of the helmet to support its weight.

-17 A/B, the tender must ﬁrst

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

SuperLite® 17B

WARNING

After the helmet is removed, the tender can take it from the diver and carefully lay it aside, on a soft surface, such as a coil of the umbilical.

Next, reach in and spread the neck dam, pulling against the sides of the neck dam with the palms of both hands. Lift the neck dam over your head. Slide the yoke backwards away from your neck to remove it.

The diver’s harness and EGS cylinder is then removed. The emergency gas supply hose may be disconnected while the diver leaves the helmet on or while they hold the hat after removal. The quick disconnect makes this procedure very easy.

3.11.3 Storage of the Helmet Between Dives

The helmet should be maintained per the daily maintenance section in Chapter 6. Also, check the Dive

Lab post dive checklist A2.4 at www.divelab.com.

If the helmet is not going to be used for a period of time, the head cushion, should be removed. The head cushion should be dried and replaced in the hat before storage. The regulator adjustment knob should be unscrewed all the way out (counterclockwise) until the next dive.

When the helmet is completely dry, or the diver is ready to leave the job, the helmet should be stored in the carrying bag to protect it.

If the head cushion becomes wet it may be dried out by removing it from the helmet, squeezing excess water out, and letting the head cushion hang dry or putting it in a clothes drier on air dry only.

Once you have removed the helmet, spread the neck dam to remove it.

Use only the air dry setting when drying head cushion foam in a drier. Use of a higher setting could cause the foam to melt or start a re.

SuperLite

17B

Chapter 4

Troubleshooting

4.1 General

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

4.2 Communication Malfunction Symptoms Probable Cause Remedy

No sound at either com box or helmet.

Communications weak or broken up.

Communications only work when wire is wiggled back and forth.

Communications only work when connector is wiggled back and forth.

Communications box not on. Activate switch and adjust

volume.

Communicat i ons i n c or r e c t ly hooked up.

Communications not hooked up. Plug into terminals.

Communicator not functional. Replace communicator.

Broken/damaged communications wire

Battery Dead Recharge / use alternate D.C. source.

Terminals in communications module corroded.

Battery weak. Recharge / use alternate D.C. source.

Loose wire. Clean and repair.

Break in diver’s communication wire.

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

Switch terminal wires.

Check continuity replace wire or umbilical.

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

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

line and test line for integrity prior to replacing connector.

Diver speech weak or can’t be heard.

Microphone in helmet dead or damaged.

Replace microphone as per manual.

4.3 One Way Valve Malfunction Symptoms Probable Cause Remedy

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

rebuild. Replace if needed.

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

rebuild. Replace if needed.

SuperLite

17B

4.4 Side Valve Malfunction Symptoms Probable Cause Remedy

Defogger can’t be shut off. Helmet free ﬂows through defogger.

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

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

Seat assembly damaged or debris under seat.

Sideblock damaged by debris Replace sideblock.

Foreign matter in side block or one way valve.

Clean and/or replace seat assembly. Check - clean side block seal area.

Disassemble side block one way valve and clean.

4.5 Water Leakage Into Helmet Symptoms Probable Cause Remedy

Water leakage into helmet. Exhaust valve damaged or stuck

open.

Binding posts or connector seal damaged.

Diaphragm damaged or not seated properly.

O-ring in neck dam ring damaged or missing.

Seat or replace valve.

Remove posts, clean and reseal with RTV sealant.

Seat or replace diaphragm.

Replace o-ring.

Port retainer screws loose. Tighten screws.

Neck dam torn or damaged. Replace neck dam.

Hair caught between o-ring and base of helmet.

Head cushion or chin strap caught under o-ring at neck dam.

Regulator assembled improperly. Check for proper assembly.

Remove hair from this space.

Clear cushion or dam

SuperLite

4.6 Demand Regulator Malfunction Symptoms Probable Cause Remedy

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

17B

Bent tube damaged causing misalignment of adjustment nipple.

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

Supply pressure too high. Adjust supply pressure lower than

225 p.s.i. over ambient.

Regulator out of adjustment. Adjust regulator

Regulator continuously free ﬂows when underwater only.

Neck dam turned down, or too large for divers neck.

Hair caught between o-ring and

Neck dam must be turned up. Replace neck dam with proper size.

Clean hair out.

base of helmet.

Neck dam torn. Repair or replace neck dam.

Poor seal in neck dam ring As-

Replace O-rings

sembly

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

Supply pressure too low. Increase supply pressure.

Regulator improperly set up.

Regulator does not supply gas. Gas supply pressure too low. Increase supply pressure to mini-

mum required for depth.

Regulator is out of adjustment. Adjust regulator

No gas in umbilical Turn diver’s gas supply on topside.

Blockage in breathing system. Disassemble regulator, clean, and

adjust.

4.7 Emergency Gas Supply Valve Symptoms Probable Cause Remedy

Bail-out bottle drained without diver opening EGS valve

Knob difﬁcult to turn. Stem bent. Replace stem.

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

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

Debris under sea causing leakage. Service valve.

Leaking over-pressure relief valve

Service valve.

on bail-out regulator.

Leaking bail-out regulator on bottle. Service regulator.

Leak in supply line 1st stage Service regulator.

reassemble.

Stripped control knob. Replace knob.

Chapter 5

Inspection and Maintenance

SuperLite

17B

5.1 Routine Maintenance

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

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

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

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

mended Annual Maintenance Inspection and

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

5.1.1 Daily Pre-Dive Maintenance A2.3

The helmets and masks should be set up in accordance with the Daily Set-Up and Function Checklist A2.3. The checklist can be laminated placed on a clipboard and checked off with a grease pencil. Completion

should be logged in both the supervisors log and the helmet or mask log book. The daily pre-dive is minimum daily checks KMDSI recommends. The daily pre dive may be modiﬁed to suit the needs of the user providing the basic intent of the checklist is being completed in a manner with the original intent.

5.1.2 Daily Post Dive Maintenance A2.6

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

5.1.3 Supervisors Equipment Checks A2.4 and A2.5

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

5.2 Monthly Maintenance

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

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

5.3 Yearly Maintenance

5.3.1 Overhaul/Inspection Checklist A2.1

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

SuperLite

17B

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

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

Helmets and Band Masks. The checklist should be used in conjunction with the applicable Operations and Maintenance Manual for the model helmet being serviced and is primarily intended to guide and document the maintenance as it is completed. Speciﬁc detailed procedures for each section of this checklist can be found in the Operations and Maintenance Manuals. This checklist when completed should be retained in the equipment maintenance ﬁles and the helmet or mask log book should be updated. The checklist’s are intended to be used for all models of KMDSI SuperLite

and KM Helmets and band masks. All KMDSI helmet and band mask manuals can be downloaded free at www.kirbymorgan.com.

Chapter 6

General Preventative Maintenance

6.1 Introduction

This section covers the preventative maintenance necessary on the SuperLite both A&B. A helmet that is kept clean and in good repair will offer far better service to the user. This helmet is designed for easy access to all areas for proper inspection and servicing. Numbers appearing in parenthesis below are “location” numbers that are used in the blow apart illustration at the rear of this manual.

6.2 Required tools, Cleaning Agents, Lubrication

All KMDSI helmets and masks are designed with the professional diver in mind. Most maintenance can be performed by the diver using common tools and this manual. There are some repairs however, that must be accomplished only by KMDSI authorized repair facilities. This includes ﬁberglass and helmet neck clamp repairs, and face port inserts. For technical assistance please telephone your nearest authorized dealer or call KMDSI at (805) 928-7772.

Every diver should carry sufﬁcient tools and spare parts to maintain their helmet in top working condition. It is very impor tant to use wrenches of the correct size rather than adjustable wrenches when possible. Adjustable wrenches tend to slip and can round the edges of soft brass parts. The following wrenches and tools are required to maintain the SL 17:

Torque wrench with the following attachments: 1 3/8 inch crows foot 7/16 inch open end wrench 9/16 inch open end wrench 5/8 inch open end wrench 11/16 inch open end wrench 3/4 inch open end wrench 13/16 inch open end wrench 7/8 inch open end wrench 1 inch open end wrench

Torque screwdriver and these attachments: 1/8, 1/4, and 3/8 inch ﬂat blade screwdrivers #2 Phillips blade screwdriver 7/64 inch Allen wrench driver 9/64 inch Allen wrench driver

-17 diver’s helmet, models

SuperLite® 17B

Tools required to do proper maintenance on the SL 17.

5/32 inch Allen wrench driver

Open end wrenches in the following sizes: 3/8 inch 7/16 inch 9/16 inch 3/4 inch 7/8 inch 1 inch

Two adjustable wrenches, 6 & 8 inches in length. 3/8 inch ﬂat blade screwdriver with a notch in the center of the tip. 1/4 inch ﬂat blade stubby screwdriver 2 needle nose pliers diagonal cutting pliers slip joint pliers 3/32 inch punch putty knife O-ring removal tool KMDSI regulator repair tools: Part #525-620 ball peen hammer Whisker Clamp Replacement Kit: Part # 525-032 tie wraps: Part # 520-042 Silicone lubricant Loctite #320, 400, 600 wet/dry sandpaper rubbing compound automotive wax

clean rags

222 Thread locker

SuperLite® 17B

WARNING

6.2.1 Component and Parts Cleaning

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

Parts that have corrosion should be washed and scrubbed with a nylon bristle brush and then soaked in a solution of 50% white vinegar and water for 3060 minutes followed by a light brushing and a good fresh water rinse. Helmet liners and rubber components should be cleaned using a mild soapy solution followed by a good rinsing and air-dried.

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

6.2.2 Component and Parts Lubrication

All helmets are lubricated at KMDSI with Christo-

Lube

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

111 or equivalent.

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

Never use any aero-

Silicone Spray

sol propelled sprays near the face port of Kirby Morgan helmets. The propellent used in these aerosols can invisibly damage the

Kirby Morgan diving helmets are lubricated for use with oxygen rich mixtures as they come from the factory.

Only lubricants such as

, Fluorolube®,

Tribolube

Kr ytox

or Christo-Lube® are acceptable for oxygen service. Care must be taken to avoid contamination of gas system components with hydrocarbons when air is used as a breathing medium. Contamination of Kirby Morgan masks and helmets with hydrocarbons can lead to re or explosions when this equipment makes contact with high oxygen partial pressures.

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

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

NOTE: All parts on the helmet that require

lubrication must be lubricated sparingly with the appropriate lubricant.

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

SuperLite® 17B

WARNING

6.2.3 Teon

Tape

All pipe thread ﬁttings used on our helmets, masks and components require sealing with Teﬂon

tape.

DO NOT USE LIQUID SEALANT. When installing Teﬂon

tape on pipe threads, apply the tape

starting two threads back from the end of the ﬁtting.

Apply the tape in a clockwise direction under tension.

/2 wraps is all that is needed. Applying more than

/2 wraps of tape is not recommended. The use of

more than 1

/2 wraps could cause excess Teﬂon® tape

to travel into the breathing system.

Do not allow any excess Teon® tape to cover the end of the pipe thread ttings. Loose pieces of Teon

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

6.3 General Cleaning & Inspection Procedures

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

Using the helmet in sea water while jetting in sand will necessitate increased maintenance. Use of the helmet in a heavy oil and/or chemical environment may make it necessary to replace rubber parts to assure proper function. Regardless, all helmets should be disassembled, (with the exception of the weights) cleaned and inspected for damage. All soft goods (o-rings, exhaust valves, and diaphragm) should be should be changed in accordance with the Dive Lab Checklist A2.1. Any parts that have excessive wear or corrosion should be replaced.

Use only thin Teon® tape to avoid damage to threads.

6.2.4 RTV Sealant

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

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

6.2.5 Thread Locker

KMDSI recommends Loctite

222 as the thread locking compound that should be used on components that call for a thread locker. Threads should be clean and dry prior to applying thread locker. Avoid Contact with Polycarbonate Plastics (Face Port)

Ensure that all excess thread locker has been removed. Allow thread locker to cure for at least 3 hours prior to using the component.

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

Pay particular attention to the following parts prior to re-use; the Quad-Valve™ assembly, demand regulator diaphragm, demand regulator exhaust valve, communications post(s) or communications connector assembly,

and neck dam.

If in doubt about the serviceability of a part,

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

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

SuperLite® 17B

WARNING

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

copious amounts of water and consult medical help immediately.

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

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

6.3.1 O-Ring Removal/Inspection/Cleaning and Lubrication

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

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

O-Ring Removal:

Do not use screwdrivers or hard metal picks to remove O-rings. When possible, only use ﬁngers to remove O-rings. If an O-ring ﬁts too tightly in its groove to be removed using the ﬁngers, use the appropriate tool from an O-ring removal kit (brass pick).

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

O-Ring Inspection:

If during routine corrective maintenance O-rings are to be reused, only reuse O-rings that pass a visual inspection. Inspect for deformities or compression set, hardening or brittleness, nicks or cuts, pits or blisters, or any other signs of damage. Cut and discard damaged O-rings and replace them with new ones.

O-Ring Reuse:

All O-rings and soft goods should be replaced whenever scheduled overhauls are being completed. During routine repairs or maintenance in between the overhauls, O-rings and soft goods may be reused after cleaning provided a careful inspection reveals no wear or damage.

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

6.3.2 General Cleaning Guidelines

Cleaning and sanitizing of the helmet should be accomplished upon completion of use and/or prior to storage. Clean is deﬁned as free of dirt, rust particles, lubricant and oil and other contaminants as viewed by the unaided eye.

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

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

Always sanitize the helmet prior to use by another person. Failure to do could result in the transmission of com m u nicable diseases, some of which

may cause long term disability or death.

6.3.2.1 Mild Soap Solution for General Cleaning and Leak Detector Use

Maintenance procedures include cleaning with a general-purpose solution of a mild diluted hand dishwashing soap such as Joy or Palmolive. Cleaning solution is prepared by mixing approximately one teaspoon of soap to 1/2 gallon of warm fresh water. This solution may also be used as a leak detector solution. Place all parts and components in a clean washbasin or sink and immerse in soap solution.

To properly sanitize the demand regulator between use by different divers, the regulator cover and diaphragm must be removed, as well as the oral nasal mask. These items must be submerged in sanitizing solution and agitated as directed in the sanitizing procedure. Use a spray bottle and spray the interior of the demand regulator with the sanitizing solution, too. Allow all parts to be wetted for a minimum of 10 minutes before thoroughly rinsing with fresh water.

SuperLite® 17B

6.3.2.3 Germicidal Cleaning Solutions and Procedure

Sanitizing of the oral-nasal mask/regulator of KM 37 is accomplished using one of four approved germicidal cleansing solutions. There are four examples of solutions shown below, along with the necessary ordering information and mixing instructions.

In almost all cases, germicidal solutions must be diluted. See the manufacturer's directions for use.

NOTE: Ensure helmet liner and cushion are removed prior to sanitizing the oral-nasal mask/ regulator.

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

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

The microphone and interior of the helmet should also be wiped down with a clean rag which has been dampened in sanitizing solution. Follow this after 10 minutes with a clean rag which has been dampened in fresh water.

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

After cleaning, allow the regulator, diaphragm, and cover to dry before reassembling.

6.3.2.2 Acidic Cleaning Solution and Procedures

Metal parts that have visible corrosion should ﬁrst be cleaned using the soap solution scrubbed with a nylon bristle brush, then soaked in a solution of 50% white vinegar and water for less than 60 minutes. They may also be placed in a ultrasonic sink followed by a light brushing and thorough rinsing with fresh water and air-dried. If corrosion is such that 50/50 vinegar will not clean components, it will be best to replace the components.

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

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

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

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

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

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

Sanitizing Procedure:

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

1) Wet or immerse all components to be sanitized. Allow components to stay in contact with the solution for at least 10 minutes.

SuperLite® 17B

CAUTION

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

2) If the solution appears to be drying, apply more solution to keep it wet for the full 10 minutes.

3) After 10 minutes, thoroughly rinse components under running potable water.

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

SuperLite® 17B

WARNING

6.4 Daily Maintenance

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

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

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

4) If the head cushion is wet, the chin cushion is probably wet, too. Like the head cushion, the chin cushion is fastened into the helmet with snaps. Remove it from the helmet, rinse it with fresh water, and allow it to dry.

5) Remove the earphones from the retainer clips. Avoid getting water on the oral nasal microphone and earphones. Remove the earphone covers from the earphones so they can dry completely.

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

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

3) If the head cushion is wet, remove it from the helmet and rinse it with fresh water. The head cushion is fastened into the helmet with snap tabs and pulls out easily. To ensure that the head cushion is dry for future use you may want to remove the head cushion foam. However, do not remove the foam unless it is absolutely necessary. The head cushion will dry properly without removing the foam.

Remove the foam for the head cushion if wet.

Uncover the earphones so they may dry.

Wash the microphone with a mild solution of soapy water, followed by a rinse with fresh water.

6) Wash the exterior of the helmet with a mild soapy

SuperLite® 17B

WARNING

water solution. Rinse the exterior of the helmet thoroughly with fresh water. Turn the defogger valve knob, emergency valve knob, and regulator adjustment knob while rinsing to prevent salt from accumulating under these valves.

7) Remove the regulator cover, clamp and diaphragm, and wash the interior of the regulator with a mild solution of soapy water. Run water through the air delivery tube located in the oral nasal.

Do not depress the purge button while rinsing the regulator as this action will permit foreign matter back into the inlet valve and seat.

8) Wash the interior of the helmet and oral nasal mask with a soapy water solution and rinse with fresh water.

9) Screw the demand regulator adjustment knob all the way out. This will prolong the life of the inlet valve seat and keep the internal adjustment correct. Close the emergency valve and steady ﬂow valves.

12) If the neck dam is damaged it should be replaced.

13) Operate the neck clamp and latch catch as you rinse these items with clean, fresh water.

14) Wipe all surfaces with a clean, dry towel to remove water droplets and allow to dry.

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

11) Rinse the neck dam assembly and allow to dry. Remove the O-ring from the bottom of the helmet, clean and lubricate.

Avoid patching a torn or punctured neck dam. If the patch comes off underwater the helmet could ood and/or cause the demand regulator to freeow. Serious injury, drowning or death may result. A damaged neck dam should be replaced.

The nose block O-rings must be regularly lubricated.

The neck clamp and latch catch must operate properly. They must be regularly inspected and serviced.

The o-ring on the base of the helmet must be in good condition.

6.5 Monthly Inspections

WARNING

6.5.1 Quad-Valve™ Exhaust System

The exhaust system on your helmet requires regular attention. It should be inspected and serviced every month.

1) Remove the whisker clamps (or tie wraps) that secure the whiskers.

2) Carefully cut the tie wrap that connects the Quad exhaust cover to the exhaust main body.

SuperLite® 17B

Use only KMDSI original replacement spares when repairing your helmet. 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 all warranties offered by KMDSI.

3) Remove the two screws that hold the Quad exhaust cover to the exhaust body.

4) Remove the Quad exhaust cover and inspect the exhaust valve.

Inspect the exhaust valve for cracks or tears, replace if needed. Lubricate the valve with a small amount of silicone lubricant. Rub the lubricant into the valve thoroughly leaving no excess lubricant to collect sand or other debris.

Port retainer

5) Reinstall the Quad exhaust cover so that it connects to the exhaust main body and the exhaust body.

6) Install the screws and tighten to "12" inch pounds.

7) Install the tie wrap that fastens the exhaust main body to the Quad exhaust cover and tighten until snug.

8) Install the whisker clamps properly and tighten. See Chapter 7 for this procedure.

Exhaust main body

Whisker clamp

Port wing

Tie wrap

Exhaust body

Water dump valve

Starboard wing

O-ring

Quad exhaust cover

Whisker exhaust valve insert

Exhaust valve

Regulator body

The Quad-Valve™ Exhaust System

Exhaust valve

Whisker spacer

Kidney plate

SuperLite® 17B

6.5.2 Emergency Valve Assembly

Without gas to the helmet, check “exercise” the Emergency Gas Supply valve ensuring the valve operates smoothly. Replacement/overhaul guidance will be found in Chapter 7 of this manual.

6.5.3 Steady Flow/Defogger Valve

Without gas to the helmet, check, i.e., “exercise” the Steadyﬂow/Defogger valve ensuring the valve operates smoothly. Replacement/overhaul guidance will be found in Chapter 7 of this manual.

6.5.4 Bias Device Adjustable Section of Demand Regulator

Remove the regulator cover clamp, cover and diaphragm and inspect the interior of the regulator body for corrosion and contamination. Carefully inspect the diaphragm for cuts, tears and deterioration. If any damage is present replace the diaphragm, per Chapter 7 of this manual.

Attach an air source to the umbilical adapter and set the supply pressure to between 135-150 p.s.i.g. (9.3-11.4 bar). Adjust the regulator knob out, until a slight free ﬂow develops, then, adjust in until the free ﬂow just stops and check the lever play. It should be between 1/16” – 1/8” (1.5 – 3.0 mm). Adjust if necessary, per Chapter 7. Reinstall the diaphragm, the cover and the clamp.

6.5.5 Neck Clamp and Yoke Assembly

Inspect the neck clamp and yoke assembly and test for proper operation per Chapter 8 of this manual.

6.5.6 Latch Catch Mechanism

Inspect the latch catch mechanism and test for proper operation per Chapter 8 of this manual.

Chapter 7

CAUTION

Breathing System Maintenance and Repairs

7.1 Introduction

This chapter covers the maintenance and repair of all components of the breathing system. The breathing system includes the one way valve, the emergency valve, the side block, the bent tube assembly, the demand regulator, and the oral nasal mask.

The breathing systems on all Kirby Morgan helmets and masks are simple and highly reliable. The fact that they can continue to operate when the components are not in a well-maintained condition can cause divers to become complacent about maintenance.

SuperLite® 17B

Never use pliers to work on the one way valve.

Your life depends on the correct function of this equipment!

While Kirby Morgan helmets and masks are simple to maintain, like any type of life support equipment, they do require regular periodic maintenance to function properly.

All parts disassembled should be thoroughly cleaned using the methods described in the Appendix in the rear of this manual. Components that require the use of lubricants, sealing and thread locking compounds should also be maintained.

Most fasteners have a torque value, it is imperative that all fasteners which have a torque value be tightened to the torque speciﬁcations as outlined by the procedure, or as listed in appendix 1. If in doubt as to the proper torque setting, contact your local authorized repair facility or KMDSI.

7.2 One Way Valve

NOTE: The one-way valve assembly should be disassembled, cleaned and the three O-rings should be replaced at least annually. Damaged and/or corroded parts should be replaced. A repair kit is available for

replacement parts (525-330).

Use two wrenches or hold the hex part of the body in a vise while removing or turning the seat with a wrench. Do not use pliers on the main body of the oneway valve. You may damage the valve if pliers are used.

(If no vise is available use a backup 1 inch open end wrench)

To disassemble and inspect the one way valve assembly:

1) The one way valve assembly must be removed from the side block. Use the open end wrench to remove it.

2) After the one way valve has been removed, use two wrenches or hold the hex part of the body in a soft jaw vise while removing the seat with a wrench.

As the seat is removed, the wiper and the O-ring will slide out in place in a groove on the seat. The poppet and the poppet O-ring usually come out in the seat being followed by the spring.

7.2.1 Disassembly Of The One Way Valve

Tools Required: Soft Jaw Vice 1 inch Open End Wrench Attachment on Torque Wrench

The only functional part remaining in the valve body is a non-moving, pressed-in cage. The function of the cage is to prevent the poppet O-ring from blowing out of place during high ﬂows. Do not attempt to remove the pressed in cage.

SuperLite® 17B

WARNING

Adapter

Seat

Wiper O-ring Spring

O-ring

Correct assembly order of the one way valve.

3) Inspect the body interior for foreign matter of any type and clean, if necessary. Clean in accordance with the cleaning instructions in Chapter 6. If corrosion is present, clean using the acidic solution as outlined in Chapter 6.

Body

Poppet

O-ring

4) Inspect the seat, wiper, O-ring, poppet O-ring and poppet for wear, replace if necessary. Be sure each part is clean and all components are lightly lubricated with the appropriate lubricant. A repair kit is available for replacement parts. (Part #525-330)

5) Be careful to wipe the poppet and poppet O-ring thoroughly, removing nearly all excess lubricant to prevent foreign materials from sticking to these components.

6) Replace the spring.

7.2.2 Reassembly of the One Way Valve

1) Slide the new O-ring over the poppet.

2) Insert the new spring into the valve body, followed by the poppet.

3) Next, install the new O-ring and new wiper on the seat. Thread the seat into the valve body.

4) Tighten the seat to 150 inch lbs. (17 Newton meters) with a torque wrench while holding the body in a soft jaw vice or wrench.

5) If the adapter has been removed, it must be cleaned and wrapped with Teﬂon

tape.

Tighten to 150 inch lbs. (17 Newton Meters) with a torque

wrench.

6) Test the operation of the valve.

7) Place the new O-ring on the end of the one way valve assembly and reinstall the valve assembly in the side block. Tighten to 150 inch lbs. (17 Newton Meters) with a torque wrench.

Do not allow any Teon® tape to cover the end of the adapter, or to enter the oneway valve. Loose pieces of Teon

tape can interfere with the performance of the one-way valve or the regulator and may block the diver’s air supply. This could lead to death through suffocation.

7.3 Side Block Assembly

7.3.1 General

The side block should be overhauled at least annually, or whenever components show signs of wear, damage or do not function smoothly or properly. Minimum replacement components during overhaul includes all O-rings. A repair kit is available for replacement parts (Part #525-311).

The side block does not require removal from the helmet each time an overhaul is being conducted providing inspection of the internal passages does not reveal contamination or excessive corrosion. However, the side block should be completely removed at least every three years of active use to ensure fasteners are not corroded or frozen.

The side block assembly is held in place on the helmet shell by a stud, ﬂat washer, lock washer, nut, and a machine screw. The screw does some securing but its main function is to prevent rotation of the side block. The stud also extends into the interior of the helmet shell far enough to secure the air train by means of the washer and nut.

SuperLite® 17B

Loosening the bent tube from the side block.

4) The side block assembly is ready to be separated from the helmet shell at this time.

The air train cup that ﬁts over the stud is made of soft brass and cannot be used for a bearing surface to mount the side block. RTV silicone rubber compound is used to form a gas tight seal between the side block and the exterior of the helmet shell.

7.3.2 Side Block Assembly Removal

Tools Required: 7/16,11/16, and 7/8 inch Open End Wrenches 11/16 and 7/8 inch Open End Wrench Attachment on Torque Wrench 1/4 inch Flat Blade Stubby Screwdriver

The bent tube assembly must be entirely removed before removal of the side block assembly is started.

1) Completely unscrew the bent tube assembly nut (14) from the side block.

2) Using two wrenches, hold the nut at the regulator end of the bent tube assembly with the ﬁrst wrench. With the other wrench, loosen the jam nut by turning the wrench DOWN.

Remove the bent tube assembly before removing the side

block.

3) Unscrew the bent tube nut until it comes free, then pull the bent tube assembly straight out of the regulator inlet nipple.

SuperLite® 17B

7.3.3 Separating the Side Block Assembly from the Helmet Shell

Tools Required: Putty Knife 7/16 inch Open End Wrench 1/4 inch Flat Blade Stubby Screwdriver

1) Removal of the side block assembly requires removing the air train.

A thin putty knife helps to remove the side block.

side block and the helmet shell to help free it.

You must remove the nut that secures the air train before you

can proceed in removing the side block.

2) Remove the nut and washer that secure the air train, then the air train and air train sealing gasket.

3) The stud nut is removed next, with the lock washer and ﬂat washer.

4) Next, the alignment screw is removed.

NOTE: The alignment screw is located in a recess in the ﬁberglass next to the stud. In older helmets without the air train gasket, this recess was normally ﬁlled with RTV. The RTV, if present, must be scraped free to reveal the screw.

Do not use a screwdriver or chisel to remove the sideblock as damage to the shell could result. Be

sure to peel or scrape the old silicone sealant away from both sealing surfaces before reassembling. Acetone helps remove this, but must be used sparingly since it will also remove the ﬂat black ﬁnish inside the helmet.

6) If you plan to rebuild the side block assembly, it should be done at this time, while the side block is off the helmet. Overhaul the defogger valve and emergency valve in accordance with this chapter. Overhaul the one-way valve in accordance with this chapter.

Air Train

Air Train Gasket

Alignment Screw

Stud

5) The side block assembly is now unfastened, but held in place by the rubber sealing compound (silicone sealant) that acts as a glue. It may be necessary to rock just slightly, or pry the side block from the helmet shell. A thin putty knife can be pushed between the

The air train fastens to the stud that connects the assembly to

Sideblock

the sideblock.

SuperLite® 17B

WARNING

Use silicone sealant in a well ventilated area. Do not breathe the fumes from uncured silicone sealant. These fumes are dangerous and can

cause unconsciousness. They can also cause long term damage to body tissue. Read and follow all precautions listed on the silicone sealant tube and Material Safety Data Sheet.

Do not dive the helmet until the sealant has had time to cure. Check the directions on the tube of sealant for curing time. If the helmet goes into the water before the sealant has cured it could leak through the side block mounting stud hole, screw hole, or air ow hole. This could lead to drowning.

If silicone sealant is blocking the air ow into the helmet it must be cleaned out. If it is not, the diver may not be able to properly defog the helmet or clear a ooded helmet quickly. In addition, if the demand regulator is not delivering air properly, the diver cannot use the free ow system as a source of breathing air. This could lead to suffocation.

Avoid breathing fumes from acetone and use in a well ventilated area. Breathing fumes can lead to nervous system damage, unconsciousness, and death.

✘

DO NOT BLOCK AIR OPENING!

Avoid eye contact with acetone. This chemical is an irritant and may cause tissue damage.

Apply silicone sealant to these areas

✓

A light application of silicone sealant must be applied to the side block prior to installation on the helmet shell. Use only Dow Corning® RTV 732 Multi Purpose sealant or equivalent.

SuperLite® 17B

WARNING

Engages the tube on the

7.3.4 Side Block Assembly Replacement

If a new side block is being installed, make sure it aligns correctly in the holes of the helmet shell by dry ﬁtting it before applying RTV silicone sealant.

1) A light application of silicone sealant must be applied to the side block prior to installation on the helmet shell. The sealant should surround the stud, alignment screw, and air inlet on the block. Use only Dow Corning

RTV 732 Multi Purpose sealant

or equivalent. This work must be done in a wellventilated area.

Care must be taken to avoid sealant entering the air opening in the side block. Be sure to remove all excess silicone sealant before it sets up. Acetone can be used to dissolve uncured sealant, after tightening.

2) Fit the side block to the helmet shell.

3) Thread the screw through the helmet shell and lightly tighten into the side block body.

Avoid skin contact with acetone. Wear rubber gloves. Acetone can damage the nervous system.

air train.

4) Slide the ﬂat washer and the lock washer onto the stud. Run the stud nut down the stud and tighten to 35 inch pounds (4 Newton meters). Do not overtighten!

5) Tighten the screw to the correct torque, 20 inch pounds. Clean off all excess silicone sealant. Acetone may be used for this purpose.

6) Place the air train gasket on the base of the air train. The knob on the base of the air train gasket is designed to cover the recessed hole where the screw that helps maintain the position of the air train is installed. Slip the air train over the stud. Align the air train with the upper edge of the view port opening in the helmet shell.

7) Place the washer on the stud and tighten the nut until the washer lays ﬂush on the air train, 15 inch pounds. Do not overtighten!

8) Test the side block prior to diving to ensure that no silicone sealant is blocking the air ﬂow to the helmet. If it is, it must be cleaned out prior to diving.

The air train gasket forms a seal between the air train and

the interior helmet shell.

SuperLite® 17B

7.4 Defogger Valve

7.4.1 Disassembly of the Defogger Valve

Tools Required: 3/8 inch Slotted Flat Blade Screwdriver 13/16 inch Open End Attachment on Torque Wrench

The defogger valve components are disassembled as follows:

1) First, unscrew the control knob lock nut and remove the spring, control knob, and washer.

Remove the defogger control knob.

2) Next, unscrew the bonnet. Its o-ring will come off with it. The valve stem, o-ring, and washer usually come out with the bonnet and can be pushed out of the bonnet once removed from the side block.

3) If the stem remains in the side block body it can be lifted out after the bonnet is removed.

4) The seat assembly can be unscrewed from the side block body with the stem or a screwdriver.

7.4.2 Cleaning and Lubricating

1) Clean all the metal ﬁrst in the soapy water solution and then in a 50/50 dilute solution of white vinegar/ water. Rinse in fresh water.

2) Check the Nylon seat for wear and/or contamination, and replace if necessary. Damage such as a rough face or cuts to the seat indicate it must be replaced.

3) The Teﬂon if worn.

4) Be sure to place a light coating of proper lubricant on all internal moving parts, O-rings, and washers. However, do not lubricate the Nylon seat, as this will attract dust and debris.

washer and O-ring must be replaced

The valve stem usually comes out with the bonnet.

5) Inspect the seat area inside the side block and replace the block if damaged.

50%

Clean all the metal parts to remove salts.

The seat should be removed for inspection.

Note: The procedures are the same for the “A” sideblock.

SuperLite® 17B

Stud

Spring

Washer

The Side Block assembly and it’s

associated parts.

Side block

Seat

O-ring

Plug

O-ring

Bent tube

7.4.3 Reassembly of the Defogger Valve

Tools Required: 3/8 inch Slotted Flat Blade Screwdriver 13/16” Open End Attachment on Torque Wrench Minimum recommended replacement parts during overhaul: Washers, O-rings

1) Screw in the new seat assembly until it is even with the front of the side block body.

O-ring

Valve stem

O-ring

Washer

O-ring

Bonnet

Knob

Locknut

Binding (or “hard spots”) in the rotation could be an indication of a bent stem that should be replaced. Replace the knob and or stem if the ﬁt allows the valve to rotate loosely more than 1/8

8) Install the new Teﬂon the spring, and locknut. Tighten the locknut until it is ﬂush with the knob.

of a turn.

washer, new knob, and

2) Next, install the Teﬂon the stem.

3) Insert the proper end of the stem into the seat assembly and turn clockwise until the seat lightly bottoms out. Leave the stem in place.

4) Lubricate the O-ring and install on the bonnet.

5) Slide the bonnet over the stem and thread the bonnet into the side block.

6) Tighten the bonnet with a torque wrench to 100 inch lbs.

7) Place the new Teﬂon on the stem and rotate the stem counterclockwise until the seat assembly tops out fully open. The control knob must turn smoothly without any binding.

washer and O-ring onto

washer and the control knob

Note: The procedures are the same for the “A” sideblock.

7.5 Emergency Valve Assembly

WARNING

The Emergency valve control knob is not interchangeable with the defogger valve control knob.

The control knob for the emergency valve and the defogger knob are not interchangeable. Use only the correct knob for the appropriate valve.

7.5.1 Disassembly of the Emergency Valve

Tools Required: 11/16 inch Open End Wrench 1 inch Open-end Wrench Torque Wrench Attachments & Torque Wrench 3/8 inch Slotted Flat Blade Screwdriver Soft Jaw Vice Lubricant

Teﬂon

1) Remove the lock nut, spring, and knob.

2) Undo the packing nut, and remove the packing, and washer.

Tape

SuperLite® 17B

Remove the valve stem.

3) When the packing nut is free of the threads of the emergency valve body, back out the stem until it is free of the emergency valve body.

7.5.2 Cleaning and Lubricating

1) Clean all the metal parts in a soap and water solution, followed by cleaning with a 50/50 dilute solution of white vinegar/water. Rinse with fresh water. Clean all parts. See the cleaning instructions in Chapter 6.

2) Inspect the packing and washer for wear and replace if necessary. Normally the packing will last a very long time and does not require replacement as long as the valve operates smoothly and does not leak. To replace the packing place the packing nut in a vise and carefully work the packing out with a small screw driver, taking care not to damage the threads of the packing nut. Replace the washer if needed.

3) Inspect the stem seat for unevenness or wear and replace if necessary. It must also be replaced if the stem is bent. Damage will include damaged threads, rounded ﬂats that engage the control knob. Also

Remove the lock nut, spring and knob.

inspect the shaft to ensure the conical seat surface is smooth and free of corrosion or damage.

Undo the packing nut. Inspect the packing and washer.

SuperLite® 17B

4) Check the seat in the emergency valve body for wear or unevenness, galling and corrosion. Check the seat on the emergency valve stem. To clean up the seat surface use a pencil eraser to buff the surface. Inspect all threaded surfaces for damage. Replace the emergency valve body if any damage is found.

5) To remove the emergency valve body from the side block the one way valve assembly must ﬁrst be removed.

6) If the emergency valve body is then removed, clean and inspect the pipe thread and inspect for damaged threads, cracking or distortion. Replace the emergency valve if any damage is present.

Re-tape threads with Teﬂon

tape, 1 ½ wraps starting two threads back, tighten using good engineering practice. To reinstall the emergency valve body onto the side block, the one-way valve assembly should not be installed.

7.5.3 Reassembly of Emergency Valve

1) Lightly lubricate the stem threads in the body as well as the bonnet threads.

2) Replace the washer and packing on the stem, then lightly lubricate the stem shaft and threads.

Installing the packing nut on the valve stem.

NOTE: There are two different packing (s) and washers supplied in the kit (525-311), for rebuilding both the older style and the newer high ﬂow emergency gas valve. Match the removed packing and washers to the new ones supplied and discard the others.

3) Holding these components in place on the stem, screw the stem into the emergency gas valve body.

4) Rotate the stem until it is seated all the way in then, back it out -1/2 turn.

5) T

hread the packing nut onto the emergency valve

body. Run the nut in and tighten slightly with a wrench.

Valve Body

Packing

Knob

Lock nut

Valve Stem

Washer

Packing nut

Spring

The emergency valve

WARNING

The control knob for the emergency valve

WARNING

and the defogger knob are not interchangeable. Use only the correct knob for the appropriate valve.

SuperLite® 17B

11) Before wrapping the threads with pipe tape, check the ﬁt of the valve assembly pipe threads to the mating threads of the side block. There should be 2 turns of hand make up before needing to use a wrench.

If there is less make up, call your nearest KMDSI dealer or Dive Lab for advice.

6) Inspect the emergency gas valve knob for wear and damage. Ensure the ﬂats that engage the valve stem shaft are not rounded, cracked or damaged. The valve knob should not have rotational play greater than  of a turn.

NOTE: This knob is not interchangeable with the defogger valve knob.

7) Place the emergency gas valve knob onto the stem and rotate the stem all the way out, then back again. The rotation must be smooth. If “hard spots” or unevenness are felt during the rotation, the stem may be bent and could need replacement.

8) Tighten the packing nut with a torque wrench until moderate resistance is felt when turning the knob. Torque to 50 inch pounds after seating.

9) Place the spring, and locknut onto the stem securing the knob.

10) Tighten the locknut until its top is ﬂush with the top of the knob. The assembly is now complete and ready for testing.

NOTE: At this time, with the valve separated from the sideblock, testing of the emergency gas valve is easily accomplished by attaching the valve, by itself in the shut position, on to the bail-out whip from the ﬁrst stage. Pressurized to a minimum 135 p.s.i.g. (9.3 bar) using the EGS Cylinder and dropping it into a bucket of clean water a minimum 30 seconds to check for leaks.

Use only thin Teon® tape when installing the Emergency Gas Supply valve in the side block. Thick tape can lead to thread damage, which may make it impossible to install the EGS valve in the side block properly. This could lead to a loss of breathing gas.

12) Before installing the valve assembly, wrap the pipe threads with 1 ½ turns of Teﬂon ﬁrst thread. Apply the tape with slight tension to allow the tape to ﬁll into the threads.

Hand tighten the valve, then continue an additional 1 ½ to 2 turns with a wrench keeping in mind the proper alignment of the control knob to the side block. Also, there should be at least one male thread visible. Check to be certain the valve is tight by trying to loosen the ﬁt by hand.

DO NOT TIGHTEN TH

AN NECESSARY! OVERSTRESS THE PART AND CAUSE THE PART TO FAIL.

It is NOT necessary to have the control knob for the emergency gas supply valve perfectly “square,” i.e., at a 90 degree angle to the side block. Any angle is acceptable provided that 1) the valve handle can be turned easily and 2) the diver can locate the handle easily.

7.5.4 Leak Testing the EGS Valve

1) Attach supply whip from the EGS ﬁrst stage to EGS helmet valve.

2) Ensure the defogger valve knob is open and the EGS Valve is shut.

A leaking Emergency Gas Valve assembly can cause the diver to exhaust their entire EGS (bailout) without their knowledge. This may lead the diver to mistakenly assume their EGS supply is available when it is not. This could lead to panic or drowning in an emergency. Any worn or damaged components must be replaced. A sub mersible press ure gauge should always be used with the EGS system to help minimize this risk.

THE VALVE BODY TIGHTER

OVER TIGHTENING MAY

tape starting after the

SuperLite® 17B

3) Pressurize EGS Valve to a minimum of 135 p.s.i.g. (9.3 bar) using the EGS cylinder as supply. Allow system pressure to stabilize, and then shut the EGS supply cylinder valve. Note time and ﬁnal stabilized system pressure.

4) Perform the leak check for minimum of ﬁve minutes, using the mild soapy solution, per Chapter 6. Ensure there is no gas ﬂowing or pressure drop in the system. There should be no visible signs of external leakage if the valve is operating properly.

7.6 Bent Tube Assembly

7.6.1 General

The bent tube assembly provides breathing gas ﬂow from the side block assembly to the regulator assembly. Both ends of the bent tube assembly disconnect for complete removal. The O-ring and the Teﬂon O-ring should be replaced during normal overhauls or any time these components are deemed unserviceable.

7/8 inch Open-end Attachment on Torque Wrench 7/8 inch Open-end Wrench

1) Always start removal of the bent tube at the side block end. The free swiveling mount nut on this end of the bent tube can be unthreaded completely and can slide down the tube.

2) The inlet nipple has a jam nut that locks the mount nut in place. With one wrench, hold the bent tube mount nut. With another wrench, turn DOWN the jam nut, backing it away from the mount nut. The mount nut can then be rotated until free of the regulator inlet nipple threads. It can be pushed up the bent tube.

3) With the two mount nuts free; the bent tube assembly can be pulled straight out of the regulator inlet nipple. The bent tube assembly can be rotated back and forth to aid removal.

These components do not require replacement during ﬁeld repairs providing a careful visual inspection does not reveal wear or damage. All soft goods should be carefully cleaned in accordance with Chapter 6 prior to inspection for reuse.

7.6.2 Removal of the Bent Tube Assembly

Tools Required: 11/16 inch Open-end Attachment on Torque Wrench

Always start removal at the side block end.

Loosening the jam nut.

7.6.3 Inspection of Bent Tube Assembly

WARNING

Clean the bent tube in accordance with Chapter 6. The O-ring at the regulator end should be cleaned and inspected whenever the bent tube is removed.

Replace the bent tube if it is excessively scratched dented or compressed deeper than 1/8 inch. If the helmet has been used for burning jobs, carefully check for erosion of the metal or severe corrosion. Replace if any erosion is present or integrity is in question. Keep in mind the bent tube is a critical component that routs breathing gas to the helmet systems.

7.6.4 Installation of the Bent Tube Assembly

Tools Required: 11/16 inch Open-end Torque Wrench Attachment 7/8 inch Open-end Torque Wrench Attachment 7/8 inch Open-end Wrench Normal minimum replacement parts during overhaul: O-ring, Teﬂon

ring

1) Lightly lubricate the bent tube O-ring and install in the O-ring groove at the regulator end of the bent tube, then install new Teﬂon

O-ring at the side block end.

2) Push the regulator end of the bent tube assembly into the inlet nipple. Slide it in until the side block end of the tube is aligned with the threads for the mount nut.

SuperLite® 17B

Replace the O-ring on the bent tube if it is worn or damaged.

Do not wrap the bent tube with tape, ropework, springs, hose wrap, or other items. This will prevent daily inspection of the bent tube. In addition, some of these items may trap moisture, which could lead to corrosion and failure of the bent tube.

If the tube fails, this could lead to a rapid depletion of the diver’s breathing gas supply. This could lead to serious personal injury or death.

3) Be sure the Teﬂon

O-ring is in place on the side block end of the bent tube, then engage the threads on the tube to the side block and hand tighten.

4) Start the “regulator to bent tube” mount nut onto the inlet nipple of the demand regulator and run it in by hand as far as it will go.

NOTE: Run the mount nut up on the inlet nipple hand tight only.

5) Using a torque wrench, tighten the bent tube assembly mount nut onto the side block to (100 inch lbs).

6) Hold the mount nut on the end of the bent tube with a wrench and tighten the jam nut against it with a torque wrench to 40 inch pounds.

SuperLite® 17B

7.7 Hose Assembly (SL-17A only)

The hose assembly provides for breathing gas ﬂow from the Side Block Assembly to the regulator for the SuperLite disconnect for complete removal.

The block itself is no longer available, but replacement hoses, o-rings, and valve components are still available. The block was discontinued in 2005. If your “A” block is damaged, your helmet can be converted to a “B” sideblock with only a few additional parts.

Regardless of the hose condition it must be replaced at least every two years and o-rings should be replaced at least annually.

-17A. Both ends of the hose assembly

“A” Side Block

7.7.2 Hose Assembly Inspection “A” style Side Block

Inspect the hose ﬁttings for slippage and thread damage.

Inspect the hose for gouges, cuts, blisters, abrasions or any obvious signs of damage or deterioration. If the hose is worn or damaged it must be replaced.

Inspect the o-rings. If they are worn or cracked they must be replaced. Replace the hose O-ring during overhauls and/or annually.

NOTE: KMDSI recommends the hose assembly be replaced at least every two (2) years even if the condition appears good.

o-ring

Stud

o-ring

Hose

7.7.1 Hose Assembly Removal

Tools Required: 9/16 inch Open-end Wrench 11/16 inch Open-end Wrench 13/16 inch Open-end Wrench O-ring Removal Tool Torque wrench

1) Loosen the hose assembly at the regulator end ﬁrst, while holding the regulator inlet nipple with a second wrench.

2) Disconnect the hose from the inlet nipple.

3) Loosen the hose at the side block connection.

The hose and o-rings must be inspected on a regular basis.

7.7.3 O-Ring Replacement

1) Remove the o-ring from the side block end of the hose assembly by pinching it with your ﬁngers and sliding it up the threaded end of the assembly. Install a new o-ring that has been lightly lubricated.

2) To remove the o-ring on the regulator end of the hose, you will need to use an o-ring pick made of brass or plastic. Care must be taken not to scratch or damage the sealing surface on the hose ﬁtting when removing the o-ring. If the ﬁtting is gouged it will leak breathing gas.

7.7.4 Hose Assembly Replacement

1) Thread the hose assembly into the side block and tighten with a wrench.

2) Install the hose assembly ﬁtting onto the end of the regulator inlet nipple. Tighten the ﬁtting while holding the nipple with a second wrench.

4) Disconnect the hose from the side block.

SuperLite® 17B

7.8 SuperFlow® Demand Regulator

7.8.1 General Regulator Information

While the regulator systems on all Kirby Morgan helmets are simple and highly reliable, the breathing resistance will increase if the demand regulator on your helmet is not maintained or adjusted properly. The demand regulator must receive regular maintenance to assure the best performance possible. However, in the event the demand regulator is damaged, there is always a backup supply of steady ﬂow gas available from the defogger valve.

If the regulator does not breathe easily, the diver cannot work hard and will tire rapidly. Simply put: If the demand regulator does not work properly the diver cannot work properly. This makes the maintenance of the demand regulator assembly essential.

For the gas inlet valve and adjustment system to operate properly, the components in the demand regulator MUST be in good condition and MUST be periodically inspected and adjusted.

Four special tools, the inlet valve holder (Part #525-

616), the regulator adjustment wrench (Part #525-611), the socket wrench (Part #525-612), and the castle wrench (Part #525-618) should be used to work on the SuperFlow

regulator whenever possible.

7.8.2 SuperFlow® Demand Regulator Test for Correct Adjustment, Fully Assembled

To maintain optimum performance of the demand regulator, it should be checked for proper function and adjustment prior to commencement of diving each diving day, in accordance with the KMDSI Daily Set Up and Functional Checklist. See the Dive Lab website (www.divelab.com) for the latest procedures for set-up.

Check the regulator for adjustment and proper function with the assembly complete, and supplied with a breathing gas supply pressure of 135 to 150 p.s.i.g.

NOTE: 135 to 150 p.s.i.g. over ambient is the standard supply pressure to be used when adjusting all KMDSI helmets and band-mask equipped with the SuperFlow

regulator. See Chapter 2 for recom-

mended pressures during use.

NOTE: When storing the helmet for any length of time, ensure that the regulator adjustment knob is turned “out” fully counterclockwise to avoid stressing the bias springs. This will prolong the life of both the inlet valve, seat, and bias springs.

1) Rotate the regulator adjustment knob in, towards the regulator body.

Disassembly, assembly, and adjustment can be done without these tools, but the work is much easier and the adjustment is better if these tools are used. The above 4 tools are available together along with a tool case. The “Tool Kit with Pouch” is Part #525-620. This kit is included with each new Kirby Morgan helmet that is equipped with the SuperFlow

Tool Kit with pouch - Part #525-620.

regulator.

2) Ensure the supply pressure is connected and properly adjusted to 135 to 150 p.s.i.g.

3) Turn on the gas supply.

Set the supply pressure to between 135 and 150 p.s.i. before

adjusting the regulator.

SuperLite® 17B

WARNING

The regulator should begin to free ﬂow once the adjustment

knob is screwed out several turns.

4) Rotate the adjustment knob out counterclockwise slowly, until a slight steady ﬂow develops.

5) Slowly rotate the adjustment knob in clockwise, until the free ﬂow stops. Lightly depress the purge button several times and ensure the gas ﬂow has stopped.

7.8.3 Inspection of SuperFlow

Regulator

Body Interior

Tools Required:

1/4 inch Flat Blade Attachment on Torque Screwdriver

1) Remove the demand regulator clamp by removing the clamp screw.

2) Lift off the regulator cover and diaphragm.

3) Clean the diaphragm with the soapy solution, per Chapter 6 and wipe dry. Inspect the diaphragm for holes, tears or any signs of deterioration by holding it up to a white light and stretching and pulling. Check for a good bond between the metal disc and the silicone. Replace diaphragm if any doubt exists.

4) Inspect the interior of the demand regulator body for damage, corrosion and cleanliness. Clean the interior of the regulator body if necessary.

5) Reinstall the diaphragm, cover, and clamp. Do not lubricate the diaphragm Tighten the clamp screw to the recommended torque to 12 inch pounds using a torque screwdriver.

6) Lightly depress the purge button. There should be between 1/16” and 1/8” free travel in the button before gas ﬂow starts. When the button is fully depressed, a strong surge of gas must be heard.

7) If the purge button travels less than 1/16” or greater than 1/8” before free ﬂow is heard, the demand regulator requires internal adjustment, per this chapter.

Remove the demand regulator clamp.

Use only replacement diaphragms manufactured by Kirby Morgan. Use of other diaphragms may degrade performance and may cause increased breathing resistance. This can lead to fatigue and the inability to work at full capacity.

SuperLite® 17B

NOTE: Older regulator clamps, when properly torqued, had a gap of approximately 1/32” to 1/16” between the retaining clamp surfaces when fully tightened. All new clamps when properly torqued, have little or no gap between the retaining clamp surfaces.

7.8.4 SuperFlow Adjustment Servicing, Demand Regulator on the Helmet

Note: This procedure should be used when replacing the O-ring on the adjustment shaft and or cleaning and lubricating the shaft threads during ﬁeld repairs of the demand regulator on the helmet. Start at the adjustment knob end of the regulator:

Tools Required: 3/4 inch Open-end Wrench Attachment on Torque Wrench 3/32 inch Punch & Small Block of Wood Ball-Peen Hammer Regulator Adjustment Tool Kit, Part #525-620 Torque Wrench

Demand Regulator Bias

2) Loosen the nut, then rotate the adjustment knob counterclockwise until the adjustment knob and the adjustment shaft are free.

3) Remove the spacer, springs, and piston. At this point the threads can be cleaned and lubricated as well as the adjustment shaft.

1) Unscrew the regulator adjustment knob until it stops. If the knob wobbles as you turn it, or is extremely hard to turn, the shaft is bent and needs to be replaced. Also check the alignment of the tubes in the regulator to make certain they are straight. If not, the regulator body may need to be replaced.

Adjustment shaft

Spacer

Regulator

Piston

body

Shake out the spacer, spring set, and piston.

Adjustment knob

Retaining pin

Packing nut

The regulator adjustment mechanism on the SuperLite®-17.

SuperLite® 17B

NOTE: If the inside of the adjustment tube is corroded, this indicates saltwater intrusion into the adjustment tube and assembly. The demand regulator requires removal from the helmet and cleaning per this Chapter.

Inspect the washer and o-ring.

4) Punch out the roll pin using a 3/32 punch. Use a block of wood with a 1/4” hole drilled through it to support the knob. Position the knob so the roll pin is over the hole. The adjustment knob can be held against the wood block allowing the roll pin to be driven into the 1/4” hole.

5) Remove the adjustment knob, the washer and O-ring.

NOTE: If the spacer and the spring set are stuck, this could indicate corrosion or possible saltwater intrusion into the adjustment tube and assembly, or that the adjustment tube is bent. The demand regulator should be removed from the helmet and cleaned and inspected, per this Chapter..

7.8.5 Reassembly of the SuperFlow

Regulator Adjustment System

Tools Required:

3/4 inch Open-end Wrench Attachment on Torque Wrench Silicone lubricant, or oxygen compatible lubricant if used for oxygen service.

1) Lightly lubricate the piston and spacer and place the piston back in the regulator adjustment tube, followed by the spring set, and spacer.

2) Lightly lubricate the adjustment shaft end and threads, install the washer and the lightly lubricated O-ring on the adjustment shaft.

3) Slip the packing nut over the adjustment shaft followed by the adjustment knob.

4) Hold the shaft and rotate the knob until the pin holes line up. Use the inlet valve holder from the regulator tool kit to accurately align these holes. Use the punch and wood block as described in previous step 4 on page 80 to reassemble. Using a small hammer drive the retaining pin back into place, until it is ﬂush with the surface of the adjustment knob.

6) Carefully inspect all parts for corrosion, paying particular attention to threaded surfaces and the spring set. Clean and lightly lubricate parts per the instructions in this chapter.

NOTE: Carefully inspect the adjustment shaft to ensure it is straight, Check for damaged threads. Replace the adjustment shaft if any damage is found. Replace the O-ring.

7) Replace washer.

5) Screw the adjustment knob assembly clockwise back into the regulator body leaving enough packing nut exposed to get the wrench on it.

NOTE: Ensure the adjustment shaft rotates smoothly.

6) Thread the packing nut onto the regulator body (81) and tighten with the 3/4” torque wrench to 40 inch pounds) after seating, turn the knob all the way in and all the way out making sure there is no interference.

8) Replace the O-ring.

9) Inspect the inside of the adjustment tube on the regulator body to be sure there is no corrosion and the adjustment assembly can travel freely. Ensure the alignment tube is not bent or misaligned from impact, and that the threads are clean.

SuperLite® 17B

7.8.6 SuperFlow

Demand Regulator

Removal from Helmet

Tools Required: Torque Wrench and 1 1/4 inch Socket 1/4 inch Flat Blade Attachment on Torque Screwdriver Torque Wrench and 11/16 Open-end Attachment Torque Wrench and 13/16 Open-end Attachment Torque Wrench and 7/8 inch Open-end Attachment 7/8 inch Open-end Wrench

1) To remove the regulator from the helmet, the bent tube should be disconnected ﬁrst. The bent tube assembly should be loosened at the side block and disconnected from the regulator. It may now be swiveled out of the way or completely removed.

2) Remove the whiskers from the port retainer by removing the screws. Take care not to lose the spacers or kidney plates.

3) Remove the nose block device per Chapter 8.

The regulator mount nut must be loosened with a wrench.

7) Now the regulator assembly can be pulled out of the helmet.

Remove the whiskers from the helmet.

8) The center section of the exhaust whisker wing, named the exhaust main body has a tie wrap holding it in place. Remove the tie wrap then stretch the body off the regulator exhaust ﬂange.

9) Older model double or single exhaust whiskers are removed similarly.

4) Remove the oral nasal mask.

5) The regulator mount nut is removed along with the sealing O-ring.

6) Cut the tie wrap that connects the regulator body to the Quad-Valve™ cover.

Remove the mount nut from the regulator.

SuperLite® 17B

7.8.7 Disassembly of the SuperFlow® Demand Regulator

Tools Required: 1/4 inch Flat Blade Screwdriver on Torque Wrench 7/8 inch Open-end Attachment on Torque Wrench 3/4 inch Open-end Attachment on Torque Wrench 3/32 inch Punch 7/8 inch Open-end Wrench Small O-ring pick Small Ball Peen Hammer Sharp Trim Knife (X-ACTO

) KMDSI Tool Kit Part #525-620 Silicone Adhesive Dow Corning

732 or equivalent Minimum Recommended Replacement Parts for Annual Overhaul: Inlet valve Soft Seat 510-580 Adjustment shaft O-ring 510-011 Adjustment Shaft Washer 520-032 Adjustment Nut 530-303 Diaphragm 510-553 Inlet Nipple O-ring 510-014 Exhaust valve 510-552

Remove the cover clamp from the regulator.

1) Remove the regulator cover clamp screw and clamp.

2) Remove the regulator cover and the diaphragm.

3) Adjustment knob removal is started by unscrewing the adjustment knob until it stops.

4) The packing nut is now exposed enough to use a wrench on it for removal. As the nut is backed off, unscrew the knob also.

5) The O-ring and washer will remain on the adjustment shaft.

6) Tilt the regulator so that the spacer, spring set, and piston fall out of the adjustment tube of the regulator.

NOTE: If the spacer and the spring set are stuck, this indicates possible corrosion or saltwater intrusion into the adjustment tube or the adjustment tube may be bent. The demand regulator requires removal from the helmet and cleaning per this Chapter and This occurs if the helmet were dropped on the adjustment knob or the diver hit the adjustment knob against a rigid object. Repairs must be made by a trained KMDSI technician.

Components to the regulator adjustment assembly.

7) On the adjustment knob, drive out the roll pin using a 3/32 punch. Use a block of wood with a 1/4 ” hole drilled through it to support the knob. Position the knob

The cotter pin must be driven out with a hammer and punch.

so the roll pin is over the hole.

Retaining

Packing

SuperLite® 17B

Clamp

nut

Cover

Adjustment

knob

Adjustment

shaft

Spacer

Diaphragm

Piston

Spring

Regulator

body

Retaining clip

Nut

Spacer

Roller lever

Regulator.

Washer

Blowapart drawing of the SuperFlow

Exhaust

Valve

Washer

Inlet valve

Inlet nipple

“A”

Inlet nipple “B”

Jam Nut

SuperLite® 17B

WARNING

The adjustment knob can be held against the wood block allowing the roll pin to be driven into the 1/4" hole.

8) Remove the inlet nipple from the regulator body. The O-ring should be replaced if a scheduled overhaul is being performed.

) Place the castle wrench in the inlet nipple side of the demand regulator over the soft seat of the inlet valve to prevent the inlet valve from rotating.

Install the socket wrench from the KMDSI Tool Kit (Part #525-620) through the adjustment tube and engage the adjustment nut on the inlet valve. Loosen and remove the adjustment nut by rotating the socket wrench counterclockwise.

10) Tilt the regulator and drop out the inlet valve and washer.

11) The spacer and lever will now fall out of the regulator body.

NOTE: Ensure that the washer comes out with the rest of the components.

12) Remove the exhaust valve from the exhaust ﬂange.

The Castle Wrench and inlet valve.

The inlet valve adjustment nut must never be reused. Reuse of the adjustment nut will not allow the regulator to maintain proper adjustment, or internal components could become dislodged casing the regulator function to fail. This could lead to drowning or death.

Kirby SuperLite User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual