E-Mail: KMDSI@KirbyMorgan.com, Web Site:www.KirbyMorgan.com
Manual prepared by KMDSI, and Dive Lab, Inc.
NOTE: This manual is the most current for the Kirby Morgan® 37SS Helmet. It is page dated March 2013. Future
changes will be shown on page III and the changed pages will carry the date of change. Previous manuals may not
reect these updates.
B WARNING
Diving with compressed breathing gas is a hazardous activity. Even if you do everything right there is always the danger that you may be killed or injured. No piece of
diving equipment can prevent the possibility that you may be killed or injured any time
you enter the water.
The Kirby Morgan® 37SS diving helmet meets or exceeds all performance and testing requirements of
all government and non-government testing agencies throughout the world. Only Kirby Morgan masks
and helmets have achieved the Dive Lab®, CR (Commercial Rated) mark.
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
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 130318002
Warranty Information Kirby Morgan
Warranty Information
Kirby Morgan Dive Systems, Inc. warrants every new mask, helmet, or KMAC Air Control System
to be free from defects in workmanship for a period of three hundred sixty ve (365) days from date
of purchase. This warranty covers all metal, berglass, and plastic parts. This warranty does NOT
cover rubber parts, communications components, or headliners. In addition, due to the electrolytic
nature of underwater cutting and welding, chrome plating cannot be warranted when the diver engages in these activities.
Should any part become defective, contact the nearest authorized KMDSI dealer. If there is no
dealer in your area, contact KMDSI directly at (805) 928-7772. You must have a return authorization from KMDSI prior to the return of any item, Upon approval from KMDSI, return the defective part, freight prepaid, to the KMDSI plant. The part will be repaired or replaced at no charge as
deemed necessary by KMDSI.
This warranty becomes null and void if:
1) The product is not registered with KMDSI within ten (10) days of purchase.
2) The product has not been properly serviced and/or maintained according to the appropriate
KMDSI manual. In addition, the user is responsible to ensure that all product updates as
recommended by KMDSI have been performed.
3) Unauthorized modications 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.
®
37SS
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 le at KMDSI.
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 provides 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 NumberDateDescription of Change
104/28/2010Updated regulator tool kit image on rst page of chapter 6, pg. 51. Removed
Loctite® 262 from same page. Removed Loctite 262 from section "6.2.5
Thread Locker." Removed Loctite 262 from the following caption on page 78
of chapter 7: "The adapter for the EGS valve should be removed periodically to
inspect the o-ring and to make cleaning of the side block interior easier. Note
the stud which is used to mount the side block is fastened with Loctite® 222.
This is a dealer serviceable item only." Updated chapter 4.
209/27/2010Updated warranty information and chapter 1 images.
302/07/2011Updated earphones throughout manual
406/14/2011Changed 61 meters to 67 meters in Appendix 3 Table 3 SuperFlow® 350 Regu-
lator High Pressure Regulated Source
510/17/2011Updated CE Identication Number to 2049 and corrected area code for Santa
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. The information in this manual is intended for users of Kirby Morgan helmets and persons that maintain or service Kirby Morgan helmets.
Warranty Information �������������������������������������������������������������������������������� II
Record Of Changes �������������������������������������������������������������������������������� III
Denition of Signal Words Used in this Manual ������������������������������������������������� XI
Chapter 1 General Information KMDSI Products ����������������������������������� 1
2.2 CE Certication ���������������������������������������������������������������������������������� 9
2�2�1 CE Marking ���������������������������������������������������������������������������������� 9
2�2�2 Notied Body ������������������������������������������������������������������������������� 10
3.4.1.7 Adding Earphone Holes to the Head Cushion ������������������������������������������������ 28
®
37SS
3�4�2 Head Cushion Foam Spacer (HCFS) �������������������������������������������������������� 28
3.4.2.1 Installation of Head Cushion Foam Spacer (HCFS) �������������������������������������������� 28
3.4.2.2 Donning the Head Cushion Foam Spacer (HCFS) ��������������������������������������������� 31
3.4.2.3 Maintenance of the Head Cushion Foam Spacer (HCFS) �������������������������������������� 32
3.4.2.4 Stufng the Head Cushion Foam Spacer (HCFS) ���������������������������������������������32
3�4�3 Trimming the Neck Dam �������������������������������������������������������������������� 32
3�4�4 Adjusting the Neck Pad ��������������������������������������������������������������������� 34
3.5 Pre Dress-In Procedure ������������������������������������������������������������������������ 34
3.6 Preparing the Helmet for Diving���������������������������������������������������������������35
3�6�1 Clean Face Port ���������������������������������������������������������������������������� 35
3�6�2 Check Moving Parts ������������������������������������������������������������������������ 35
3�6�3 Check Communications �������������������������������������������������������������������� 35
3�6�4 One Way Valve Check ���������������������������������������������������������������������� 35
3.7 Emergency Gas System (EGS) ���������������������������������������������������������������� 38
3.8 Setting Up to Dive ������������������������������������������������������������������������������ 42
3�8�1 Flushing Out the Umbilical ������������������������������������������������������������������ 42
3�8�2 Connecting the Umbilical to the Helmet ���������������������������������������������������� 42
3�8�3 Opening the Breathing Gas Supply to the Helmet�������������������������������������������43
3�8�4 Fogging Prevention �������������������������������������������������������������������������43
3�8�5 Donning The Kirby Morgan Helmet ���������������������������������������������������������44
3�8�6 Testing the Breathing System ��������������������������������������������������������������� 46
3�8�7 Sealing Integrity Check ��������������������������������������������������������������������� 47
3�8�8 Adjust Regulator for Low Work Rates �������������������������������������������������������48
3.9 Removing the Helmet �������������������������������������������������������������������������� 48
3.12 Post Dive Procedures ������������������������������������������������������������������������50
3�12�1 Removing the Equipment ������������������������������������������������������������������ 50
3�12�2 Removing the Helmet ��������������������������������������������������������������������� 50
3�12�3 Storage of the Helmet Between Dives ����������������������������������������������������� 51
7.3 One Way Valve ���������������������������������������������������������������������������������� 73
7�3�1 Disassembly Of The One Way Valve �������������������������������������������������������� 73
7�3�2 Reassembly of the One Way Valve ���������������������������������������������������������� 74
7.4 Side Block Assembly���������������������������������������������������������������������������75
7�4�1 General ������������������������������������������������������������������������������������� 75
7�4�2 Removal of the Bent Tube ������������������������������������������������������������������ 75
7�4�3 Separating the Side Block Assembly from the Helmet Shell ��������������������������������76
7�4�4 Side Block Assembly Replacement ��������������������������������������������������������� 78
7�5�1 Disassembly of the Defogger Valve ���������������������������������������������������������79
7�5�2 Cleaning and Lubricating ������������������������������������������������������������������� 82
7�5�3 Reassembly of the Defogger Valve ����������������������������������������������������������82
7.6 Emergency Gas System Valve Assembly ����������������������������������������������������84
7�6�1 Disassembly of the Emergency Valve ������������������������������������������������������� 84
7�6�2 Cleaning and Lubricating ������������������������������������������������������������������� 86
7�6�3 Reassembly of Emergency Valve ����������������������������������������������������������� 86
7.7 Bent Tube Assembly ��������������������������������������������������������������������������� 89
7�7�1 General ������������������������������������������������������������������������������������� 89
7�7�2 Removal of the Bent Tube Assembly �������������������������������������������������������� 89
7�7�3 Inspection of Bent Tube Assembly ���������������������������������������������������������� 90
7�7�4 Reinstallation of the Bent Tube Assembly ��������������������������������������������������� 90
7�8�1 General Regulator Information �������������������������������������������������������������� 91
7�8�2 SuperFlow® 350 Demand Regulator Test for Correct Adjustment, Fully Assembled ��������� 91
7�8�3 Inspection of SuperFlow® 350 Regulator Body Interior ������������������������������������� 92
7�8�4 SuperFlow® 350 Demand Regulator Bias Adjustment Servicing, Demand Regulator on the
Helmet �������������������������������������������������������������������������������������������� 92
7�8�5 Reassembly of the SuperFlow® 350 Regulator Adjustment System ������������������������� 94
7.9 Regulator & Exhaust System Overhaul ������������������������������������������������������� 95
7�9�1 Pod System and Regulator Removal �������������������������������������������������������� 95
7�9�2 Removal of Water Dump Components ������������������������������������������������������97
7�9�3 Removal of Regulator Alone ���������������������������������������������������������������� 97
7.13 Reassembly of the SuperFlow® 350 Demand Regulator �������������������������������� 101
7�13�1 Tuning the SuperFlow® 350 Regulator ��������������������������������������������������� 107
7�13�2 SuperFlow® 350 Regulator Steady Flows When Pressured Up: Special Tools Used (No
8.5 Face Port �������������������������������������������������������������������������������������� 125
8�5�1 General ����������������������������������������������������������������������������������� 125
8�5�2 Face Port, Port Retainer, and Nose Block Device Removal ������������������������������� 126
8�5�3 Face Port, Port Retainer and Nose Block Replacement ����������������������������������� 127
8�5�4 Special Note Regarding Face Ports ������������������������������������������������������� 129
8�5�5 Port Retainer ������������������������������������������������������������������������������ 130
8.6 Neck Dam ������������������������������������������������������������������������������������ 130
8�6�1 Removal of the Neck Dam ���������������������������������������������������������������� 130
8�6�2 Neoprene Neck Dam Replacement ������������������������������������������������������� 130
8�6�3 Latex Neck Dam Replacement ������������������������������������������������������������ 133
8�6�4 Trimming a Latex Neck Seal �������������������������������������������������������������� 134
8.7 Neck Dam Pull Strap ������������������������������������������������������������������������� 135
8�7�1 Neck Dam Pull Strap Removal ������������������������������������������������������������ 135
8�7�2 Neck Dam Pull Strap Replacement ������������������������������������������������������� 135
8.8 Snap Tabs, Chin Strap, and Earphone Retainers ������������������������������������������ 135
8�12�1 Disassembly of the Swing Tongue Catch ������������������������������������������������ 140
8�12�2 Reassembly of the Swing Tongue Catch ������������������������������������������������� 141
Appendix 4 Standard Kirby Morgan Surface Supply Pressure Formula Old Method ��������������������������������������������������������������������������������������� 167
Kirby Morgan® 37SS Denition of Signal Words Used in this Manual
Denition of Signal Words Used in this Manual
For your protection, pay particular attention to items identied by signal words in this manual. These terms are
identied as, CAUTION, WARNING and DANGER. It is especially important for you to read and understand
these sections.
B DANGER
This word indicates an imminently hazardous situation, which if not avoided, could
result in death or serious injury.
B WARNING
This word indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.
B 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.
NOTICE
This word is used to address practices not related to personal injury.
If English is not your native language and you have any difculty understanding the language of any warnings
as they appear in the manual, please have them translated.
B WARNING
Este é um aviso importante. Queira mandá-lo traduzir.
B WARNING
Este es un aviso importante. Sirvase mandario traducir.
B WARNING
Quest è un avviso importante. Tradurlo.
B WARNING
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) 9287772 or by Email at kmdsi@kirbymorgan.com or Dive Lab Inc. (850) 235-2715 or at divelab@divelab.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, materi-
als, equipment, specications, models and availability. Since some information may have been updated since
Denition of Signal Words Used in this Manual Kirby Morgan
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.
®
37SS
B 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.
B WARNING
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 au-
thorized 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.
B WARNING
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.
B WARNING
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. Use Dive Lab checklist A2.3 found on the web at
www.divelab.com.
B WARNING
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.
Important Safety Information: This Kirby Morgan 37SS diving helmet is intended for use by trained divers
who have successfully completed a recognized training course in surface supplied diving
Kirby Morgan® 37SS Denition of Signal Words Used in this Manual
B WARNING
KMDSI helmets and masks are intended for underwater use only and should only be
used by qualied 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.
B WARNING
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 un-
der the inuence 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.
B WARNING
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.
B WARNING
Surface-supplied diving can be a strenuous activity. The Kirby Morgan 37SS 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 Kirby Morgan 37SS. Use of the Kirby Morgan 37SS with a preexisting physical/medical condition may result in death or serious injury.
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.
If you have any questions regarding the use, maintenance, or operation of this helmet, contact KMDSI at (805)
928-7772, fax: (805) 928-0342, or e-mail: info@kirbymorgan.com.
Components requiring lubrication, should only be lubricated with oxygen compatible lubricants such as
Christo-Lube®, Fluorolube®, or Krytox®. Lubricants must be used sparingly and should not be mixed with
other lubricants.
B 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.
Denition of Signal Words Used in this Manual Kirby Morgan
®
37SS
B WARNING
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.
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 asso-
ciated equipment. Many countries have specic laws and rules regarding commercial diving. It is important
for the user to understand the rules, regulations, and philosophy imposed by the governing, regulating bodies
whenever using commercial diving equipment.
Whenever KMDSI helmets or masks are used in European Countries, which have adopted the C.E. certication
programs, they must only be used with C.E. certied components. Diving operations should only be conducted
within the limits of the operational specications, and in accordance with the rules and regulations established
by the governing authority in the specic 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
B WARNING
Some of the procedures shown in this manual are for illustration purposes only. When
using chemicals or materials that require the use of hand or eye protection, always
wear the appropriate personnel protective equipment. Failure to use personnel protective gear may result in serious personal injury.
This manual will refer to location numbers in specific drawings, or in the exploded view, which is
in the back of this manual. These numbers are called “location” numbers. They are used to find 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 rst 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, scientic, 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 525-768) 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.
Chapter 1 - Full-Face Masks and Manifolds Kirby Morgan
C
O
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37SS
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 hardwire 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 berglass. 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 berglass 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.
Kirby Morgan® 37SS Chapter 1 - Full-Face Masks and Manifolds
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KMACS-5
w/ No Communications
SuperMask M-48
w/ Scuba Pod
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 exible, 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 rst 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 ttings 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 congurations for
both open circuit and rebreather use. For further
information, see the Frequently Asked Questions
(FAQ) area on
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.
marked
Chapter 1 - Kirby Morgan Diving Helmets Kirby Morgan
®
37SS
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 six Models of Kirby Morgan diving helmets
currently in production. They are the SuperLite®-17B,
(MK-21- U.S. Navy version), the SuperLite® 27, and
Kirby Morgan models 37, 47, 57, and 77. All are ™
marked.
The SuperLite®-17 A/B was rst developed in 1975
and quickly set a new standard for diving helmet
design. Many large and small commercial diving
companies, military organizations, scientic divers,
and public safety divers are successfully using this
design around the world. This helmet is marked.
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 rst slips
the angled neck dam with the attached yoke over his
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.
Kirby Morgan® 37SS Chapter 1 - Kirby Morgan Diving Helmets
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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 SuperLite® 27 Commercial Diver’s Helmet
represents what we at Kirby Morgan consider to be a
turning point in modern diving helmet design. With 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 t.
The quick-change communications module, available
with either bare wire posts or a waterproof connector,
allows for easy, efcient 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”
conguration only.
The Kirby Morgan 37 Commercial Diver’s Helmet
has all the same features of the SL-27 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 ow 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 t and balance seats the
helmet comfortably for long periods of time even
when working in the face down position.
SuperLite® 27
approved and ™ marked
Kirby Morgan® 47
®
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
(patents pending), 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.
Chapter 1 - Kirby Morgan Diving Helmets Kirby Morgan
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Kirby Morgan® 77
Kirby Morgan® 57
™
marked
®
®
®
37SS
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 specically
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 rst 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 renishing required if the surface is scratched
or gouged.
• Faster production of helmets for customer delivery.
B WARNING
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.
• Elimination of threaded inserts for securing the port
retainer to the helmet shell.
• No need to remove the handle to remove the port
retainer.
• One piece sideblock includes both the free-ow
valve and the Emergency Gas System valve.
• The helmet ring is an integral part of the helmet.
Kirby Morgan® 37SS Chapter 1 - Kirby Morgan Diving Helmets
®
approved and ™ marked
The Kirby Morgan® 37SS features an all stainless
steel shell, as well as a stainless sideblock, helmet
ring, bent tube, handle, and other key components.
The SuperFlow® 350 is standard on this helmet.
The Kirby Morgan 37SS features a quick change
communications module, available with either bare
wire posts or a waterproof connector, and allows
for easy, efcient maintenance of the helmet's communications.
The advantages of this stainless steel helmet include
the following:
• Rugged helmet shell and other components
• No renishing required if the surface is scratched
or gouged
• Elimination of threaded inserts for securing port
retainer to helmet shell
Description & Operational Specications Kirby Morgan 37SS
B WARNING
This manual is our effort to explain the operation, maintenance and use of the Kirby Morgan
helmet. We do not herein make any effort to teach the principles of diving. It is our assumption
the reader is a qualified 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, until they have mastered the skills required
to use their helmet correctly. Kirby Morgan helmets are intended for professional use only and
are not intended for recreation use by persons not trained in surface supplied procedures and
practices.
This section includes detailed descriptions of the
Kirby Morgan 37SS, as well as important operational
specications. This helmet shares some, but not all,
parts with the Kirby Morgan 77.
2.1 CR Marking
The helmet meets or exceeds all standards established
by Dive Lab of Panama City, Florida, and is CR
(Commercially Rated) rated with the SuperFlow®
350 non balanced regulator.
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The helmet has been tested with air
and CE certicates for use with air up
to 50 meters. Compressed air must be
compliant with the EN 12021.
All the tables reporting the technical
data and the pressure of use are relative to compressed air.
2.2.1 CE Marking
On the frame of the helmet the CE mark is afxed.
EN250:2000
EN250/A1:2006
EN15333-1:2008
CLASS B
HELMET MODEL:
YEAR OF PRODUCTION:
B WARNING
KIRBY MORGAN
DIVE SYSTEMS, INC.
1430 Jason Way,
Santa Maria, CA 93455
2.2 CE Certification
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® 350 and oral nasals P/N 510690 and P/N 510-747.
2. harmonized reference standard: EN 250:2000,
EN 250/A1:2006 and EN 15333-1;
3. Helmet model;
4. the year of production;
5. CE marking: ;
6. number of notied body.
Chapter 2 - Product SpecicationsKirby Morgan
KirbyMorgan.com or Dive Lab Inc. (850) 235-2715
B CAUTION
The user cannot:
• remove the mark from the frame of
the helmet;
• modify or counterfeit the data reported on the mark.
B CAUTION
The mark must be visible and legible
throughout the life of the PPE. If the
mark deteriorates or is not legible the
user should contact the manufacturer.
or at Divelab@aol.com. There are also detailed
checklists for the set-up and maintenance of your
helmet on the Dive Lab web site at www.divelab.com.
2.4 Regulator Performance
2.4.1 SuperFlow® 350 Demand Regulators
The SuperFlow® 350 non balanced regulator is the
standard demand regulator found on the SL-27,
KM-37 and KMB 18/28 Band Masks. NOTE: Pre
Sep. 2004 KMB 28 plastic frames will only except
the smaller mount tube found on the SuperFlow®
(non 350) regulator. The SuperFlow® 350 is fully
CE marked and CR rated.
®
37SS
2.2.2 Notified Body
The Notifying Body is Eurons-Modulo Uno
S.p.A.
Address: Via Cuorgne,
21-10156 Torino,
ITALY
Identication number: 0477.
2.3 Product Specifications
Weight: KM 37SS - 30.96 pounds
Helmet Shell: Stainless steel
Regulator Body - Chrome Plated Brass
Control Knobs: Polyurethane
Lens: Clear polycarbonate
Neck Dam: Neoprene. Optional latex neck dam
available.
O-Rings: Buna-N
Head Cushion: Nylon bag lled with #4 Polyester
foam
Recommended Lubricants: Dow Corning® MS4
Silicone Lubricant. Christolube, Krytox®, and Halocarbon® are also acceptable.
2.4.2 Minimum Operating Temperature
The KM-37SS can be used in waters at water temperatures as low as 34 degrees Fahrenheit (1 degree
Celsius) without the use of a hot water shroud and
hot water to prevent freezing. However it is strongly
recommended that the hot water shroud be used for
the comfort of the diver. At the time of this writing
a specic part number hot water shroud is not available for the KM-37SS however work is underway
to produce one.
B WARNING
Diving in cold water, i.e., at temperatures below 50 degrees F, may subject
the diver to severe respiratory heat
loss. This may lead to a decrease in
body core temperature also known
as “hypothermia.” Hypothermia is
extremely dangerous and can lead to
a loss of reasoning ability, decreased
manual dexterity, uncontrollable shivering, unconsciousness, and death.
B WARNING
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.
If you have any questions regarding proper set-up,
operation, or maintenance of your Kirby Morgan
helmet contact KMDSI (805) 928-7772 or at kmdsi@
The cage code for identifying KMDSI products for
U.S. government purposes is 58366.
2.6 Operational Specifications &
Limitations
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 KM-37SS
equipped with the SuperFlow® 350 regulator is listed in
the appropriate supply pressure tables in "Appendix 3
Supply Pressure Requirements & Tables" on page
164.
B WARNING
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.
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 KM-37SS® or any Kirby Morgan
helmet or mask check the Kirby Morgan website at
www.kirbymorgan.com.
-Umbilical minimum I.D. 3/8” (9.5 mm) of not more
than two sections, total length not to exceed 600 feet
(183m).
Decompression diving always involves
the risk of decompression sickness.
Omitted decompression due to a loss
of the breathing gas supply or other
accidents can cause serious injury or
death. Use of a Kirby Morgan helmet
or mask cannot prevent this type of
injury.
2.6.1 Using a High-Pressure Breathing Gas
Supply
High pressure (HP) control consoles are capable of
suppling air or mix gas at pressures and volumes
much greater than low pressure air compressors, and
are often preferred by military and and scientic divers. HP air systems are often used as back up supply
for LP compressor diving.
When using HP air or mix gas systems, The regulator is normally loaded to 100-150 psig on the surface
and increased to the bottom setting as the diver descends or when the diver reaches the bottom. During
ascend the pressure is reduced to between 100-150
p.s.i.g. once the diver is shallower than 100 feet. A
high-pressure gas supply is typically used under the
following conditions:
B DANGER
The umbilical assembly should be composed of good
quality diving hose that meets industry standards.
Generally, gas hose will be married to the communications wire, pneumofathometer hose, and strength
member in a manner that will allow the strength
member to receive all the strain.
There are also good quality umbilicals available that
are assembled at the factory using a twisted method
which does not require marrying. Regardless of the
system used, the umbilical is the diver’s life line and
should always be of excellent quality and maintained
carefully.
If you have any questions regarding proper set-up,
operation, or maintenance of your Kirby Morgan
helmet contact KMDSI (805) 928-7772 or at kmdsi@
KirbyMorgan.com or Dive Lab Inc. (850) 235-2715
or at Divelab@aol.com.
• When the work load exceeds the capabilities of the
compressor to supply a sufcient volume and pressure of breathing gas, regardless of the depth.
• When the diver is using pre-mixed gas.
• As a back-up for a low-pressure compressor
• Any time a high-pressure supply is available
The regulator is loaded as the diver increasingly
descends and unloaded as the diver returns to the
surface. If the diver experiences a free-ow with his
regulator, when the bias adjustment knob is properly
set and the regulator has been maintained correctly,
the pressure setting on the high-pressure regulator
setting may be too high and may need to be decreased.
For recommended pressures when using a highpressure breathing gas supply and dome loaded
regulator see Appendix Table 3. Generally speaking,
the topside regulator should be set at 140 p.s.i.g. over
bottom pressure for optimum regulator performance.
during peak work output. This is the same regulator
B WARNING
The demand regulator
and side block assemblies have a maximum
design pressure of 225
p.s.i.g. (15.5 bar) overbottom. Higher pressures could lead to
component failure and
serious personal injury.
B WARNING
Gas systems used to supply Kirby
Morgan helmets and masks must
be capable of supplying gas to the
diver at the required pressure and
ow rates as stated in the operational
specications. The use of unregulated
gas sources is extremely dangerous.
The use of standard SCUBA type
regulators is unacceptable, as there
are no provisions for adjusting the intermediate pressure to the diver. Only
proven systems that allow for varying
the gas supply pressure to the diver
should be used for umbilical diving.
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.
Development of the KM 37SS was started in 2005.
The goal was to bring together all of the top design
elements of the various Kirby Morgan helmets and
then rene the mix into what we at KMDSI consider
to be among the best in current diving helmet design. The KM 37SS takes some of the proven design
features of our world famous SuperLite® 17 A/B and
blends in many of the advanced design features of the
SuperLite® 27. Add in a stainless shell and sideblock
and you have a superb diving helmet. Exemplifying
our adherence to the highest quality and proven superior work performance, the KM 37SS is another
outstanding helmet from Kirby Morgan.
The KM 37SS incorporates the innovative locking
system and communications system of the SuperLite®
27 onto a larger KM 37 size stainless steel shell. The
37SS features the SuperFlow® adjustable demand
regulator which provides superb breathing gas ow
used on the KM 37.
The helmet consists of two pieces: the helmet shell/
helmet ring and the neck dam/neck ring assembly.
The machined helmet ring houses the sealed pull
pins and locking collar, and provides protection for
the bottom end of the helmet. The adjustable neck
pad on the locking collar, in combination with the
internal chin strap and adjustable head cushion, gives
the diver a secure, custom tailored t in the helmet.
The superior t and balance makes the helmet sit
comfortably for long periods of time even when
working in the face down position.
A quick change communications module, available
in either bare wire posts or a waterproof connector,
allows for easy, efcient maintenance of the communications in the helmet.
The KM 37SS has the SuperFlow® Quad exhaust
system, which is recommended for diving in contaminated water.
B WARNING
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.
Other helmet features which are common to the KM
37SS and other KMDSI helmets include:
Many of the breathing system components on these
helmets are also compatible with the KMB 18B and
28B full-face masks. 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 following is a general description of the features of the
KM 37SS.
1) The face port (or view port) area remains unchanged from the SuperLite®-17B.
2) The helmet is cast as a single piece and nished
using computer controlled machinery. The bottom
helmet ring receives the neck dam ring which seals
to the helmet with an O-ring. The seal is very air/water tight. The metal bottom of the KM 37SS is quite
durable in normal use, but care should be taken not
to drag the helmet bottom on the deck.
3) The neck dam on the KM 37SS is sandwiched
between the neck dam rings, securely holding it in
place. Replacement neck dams install easily. Latex
or foam neoprene neck dams are available.
4) When the neck dam/neck ring is locked into place
on the helmet, it is located up inside the protective
helmet ring (that the neck ring O-ring seals to) which
protects the neck ring and neck dam from side impact
damage during the dive.
5) The neck dam design (latex or neoprene foam)
helps position the helmet correctly. Replacement neck
dams should only be genuine KMDSI/Kirby Morgan
neck dams to assure proper operation and comfort.
An internal adjustable chin strap helps to secure the
diver’s head in the helmet.
6) The locking collar design holds the neck ring in
the sealed position. The O-ring seal is continuous
once the neck ring enters the helmet ring.
7) Attached to the locking collar is an adjustable
neck pad that should be adjusted to the diver prior
to diving. This will improve the t and performance
of the KM 37SS.
8) A system of two sealed pull pin locks is on the
KM 37SS. One lock is located on each side of the
helmet. The spring and sliding shaft of these locks
are inside an O-ring sealed main body. The interior
of the main body is lled with silicone uid. No ne
Spring**
Nut**
Washer**
Knob**
O-ring**
Bonnet**
O-ring**
Washer**
Adapter For
EGS Supply
Valve Seat**
Valve Stem**
L.P. Plug
Sideblock Body
L.P. Plug
Stud
Valve Stem*
Valve Seat*
Bent Tube
Adapter
O-ring*
Washer*
Bonnet*
O-ring*
Washer*
Knob*
Spring*
Nut*
** Components Of EGS Valve* Components Of Free-Flow Valve
Components of the EGS valve and free-ow valve. (Rebuild with kit #525-313)
ditional ow of air into the helmet for
ventilation and defogging. The air/gas
ow is through the air train, across the
faceplate into the oral nasal mask.
Emergency Gas Supply
Valve provides the emergen-
cy breathing gas to the diver.
Handle
Carrying point and provides attachment of accessories.
Silicone Oral Nasal Mask is made of
a superior silicone material which is hypoallergenic and has a longer work life than
latex.
Air Train diffuses the incoming
breathing air/gas onto the face plate
to defog the lens.
Nose Block Device
allows the diver to
block the nose to equalize the ears.
Gas Supply NonReturn Valve pre-
vents loss of gas pressure in the event of
umbilical damage, preventing a “squeeze”.
Positive-Lock® Latch System
The latch catches consist of two spring
loaded sealed pull pins which are pulled
forward to release the locking collar and
neck dam system. Even when the latches
are released, the neck dam maintains a
positive seal and will not allow the seal
to be broken until the locking collar
can be either bare wire posts as shown or a
waterproof connector. The waterproof type
is recommended when a “round robin” or
diver/tender both mics “on” communications
system is used.
SuperFlow® Regulator
This all metal, fully
adjustable, Commercial Rated™ demand
regulator provides easy
breathing and excellent
performance with low
pressure compressors
for the connection of dry
suits and buoyancy compensators.
Neck Dam Swing Catch
The Swing Catch rotates out of
the way to allow the neck dam
assembly to be unsealed from the
helmet. This simplies getting out
of the helmet.
Chapter 2 - General DescriptionKirby Morgan
sand or other debris can reach the interior of these
locks to interfere with their operation.
2.8 General Description
2.8.1 Helmet Shell
9) 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 cell foam inside.
The helmet shell and neck ring is fabricated of 316L
stainless steel as a one piece assembly. 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
B CAUTION
repair to the helmet shell must be done at an approved
KMDSI repair center.
The 17B head cushion should not be
used in the KM 37SS because the design of the head cushions is different.
Only genuine Kirby Morgan KM 37SS
head cushions should be used to assure proper operation and comfort.
2.8.2 Gas Flow Systems
The main gas supply ow from the umbilical enters
the system at the adapter and ows through the one
way valve to the interior of the side block. The one
way valve or “non-return” is a very important com-
10) The handle that is tted to the top of the helmet
can be used for mounting brackets for lights, TV
cameras, etc. Removal of the handle is quick and easy
and does not require sealing it to the helmet shell.
11) The communications system is a modular, quick
change design.
12) The unique design of the Quad-Valve™ helps keep
exhalation resistance low while maintaining excellent
watertight integrity.
ponent.
The one way valve prevents the ow of gas out of
the helmet to the umbilical in the event of a sudden
lowering of pressure in the umbilical. This can happen due to an accidental break in the hose or a tting
near the surface. Not only would the emergency gas
be lost if the one way valve failed (concurrent with
a hose or tting break on deck), but the diver could
suffer from a serious “squeeze” that could cause
injury or death.
®
37SS
Inlet Nipple
Jam Nut
Regulator Body
O-ring
Washer
Inlet Valve
Valve Seat
Exhaust Valve
Exhaust Flange
Gasket
Washer
Roller Lever
Nut
Spacer
Piston
Spring Set
Spring Set
Diaphragm
Shaft
Spacer
Cover
Packing Nut
Adjustment Knob
Exploded view of the SuperFlow® 350 regulator. (Rebuild with kit #525-310)